WinGD X72 Maintenance Manual
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WinGD X72 Maintenance Manual

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Table of Contents

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Winterthur Gas & Diesel Ltd.
Winterthur Gas & Diesel AG
Winterthur Gas & Diesel S.A.
Schützenstrasse 3
P.O. Box 414, 8401
Winterthur, Switzerland
Maintenance Manual
Tel. +41 (0)52 264 8844
Fax +41 (0)52 264 8866
www.wingd.com
X72
Issue 002 2019-09

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Summary of Contents for WinGD X72

  • Page 1 Maintenance Manual Issue 002 2019-09 Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. +41 (0)52 264 8844 Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax +41 (0)52 264 8866 Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com...
  • Page 2 Information in this publication is subject to change without notice. NO LIABILITY, WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS INTENDED FOR INFORMATION PURPOSES ONLY. www.wingd.com...
  • Page 3 Modification Service Engine Documentation Summary for Maintenance Manual Page No. Modification Title Subject Page or (MM) Date Manual new exch. 2015 Maintenance Manual, Issue 2015 Date of publication 2015 3303-2/A2 2015 EAAD085741 Bottom End Bearing New document for engines with ELBA (New Support 94322A) 3303-3/A 2015 EAAD085741 Top End Bearing New document for engines with ELBA (New Support 94322A)

  • Page 4: Removal

    Subject Page or (MM) Date Manual new exch. Maintenance 2016-11 General All documents New engine brand WinGD X72 added Manual Update 0002-1/A1 2016-11 Update SCR Table of Contents New documents 2708-1/A2; 8155-1/A1 added 0330-1/A1 2016-11 EAAD086203 Clearance Table Guide shoe nominal dimension changed...
  • Page 5 Date of publication 2018-02 Group 0 2019-08 WinGD Input ToC Links to 5562-1/A2 and 5552-5/A1 corrected Group 5 2019-08 WinGD Input Supply Unit, Injection Links to 5562-1/A2 and 5552-5/A1 corrected and Exhaust Valve Control Date of publication 2019-08 9403-4A1 2019-08 WinDG input Hydraulic Pre- Pge 4: Cylinder cover Reset Jack/Round Nut turns changed.
  • Page 6 General Information Bedplate and Tie Rod Cylinder Liner and Cylinder Cover Crankshaft, Connecting Rod and Piston Driving Wheels and Shut-off Valve for Starting Air Supply Unit, Injection and Exhaust Valve Control Scavenge Air Receiver and Auxiliary Blower Cylinder Lubrication Piping, Exhaust Manifold, SCR Crank Angle Sensor Unit, Tools...

  • Page 7: Table Of Contents

    ......... . . 0803−1/A1 X72 / MM / 2015 Winterthur Gas & Diesel Ltd.

  • Page 8: General

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

  • Page 9: Group7

    Outside makes are, for example, such engine components, tools or devices which are not manufactured in accordance with production drawings from WinGD Ltd. The ”Maintenance Manual” is divided into the following main chapters: General guidelines for maintenance...
  • Page 10 Intentionally blank...

  • Page 11: Removal

    0002−1/A1 Maintenance Table of Contents Table of Contents General Information Group 0 For Particular Attention ..............0000−1/A1 Preface .
  • Page 12 0002−1/A1 Maintenance Table of Contents Cylinder Liner and Cylinder Cover Group 2 Cylinder Liner Measure the Bore ..............2124−1/A1 Removal and Installation .
  • Page 13 0002−1/A1 Maintenance Table of Contents Piston Removal and Installation ............. . 3403−1/A1 Disassemble and Assemble .
  • Page 14 0002−1/A1 Maintenance Table of Contents Piping Group 8 Exhaust Waste Gate (Low-Load Tuning) ..........8135−1/A1 SCR Valve −...
  • Page 15 0008−1/A1 Maintenance General Engine Numbering and Designations Turbocharger 1 Turbocharger 2 Auxiliary Auxiliary Blower 1 Blower 2 Cylinder Numbering DRIVING END FREE END Main Bearing Numbering Fig. 1 Thrust Bearing Pads Rail Unit FUEL EXHAUST SIDE SIDE Supply Unit Clockwise Counterclockwise Rotation Rotation...
  • Page 16 0008−1/A1 Maintenance flex Parts: Fuel Pump 1 Fuel Pump 2 Fuel Pump 3 Servo Oil Pump 2 Servo Oil Pump 1 WCH01190 Fig. 3 Crank Angle Sensor Unit Proximity Sensors II-II GEAR WHEEL DRIVING GEAR Fig. 4 CRANKSHAFT SUPPLY UNIT ZS5123C ZS5124C Fig.

  • Page 17: General Safety Precautions

    0011−1/A1 Maintenance General Guidelines for Maintenance Safety Measures and Warnings General ............General safety precautions .
  • Page 18 0011−1/A1 Maintenance Safety Measures and Warnings Precautionary measures before beginning of maintenance work Before starting any maintenance work on the engine (particularly on the running gear), take the following precautionary measures: Close the shut-off valves on the starting air bottles. Close all the shut-off valves in the control air supply unit, and open the drains on both air bottles until it is depressurized.
  • Page 19 0011−1/A1 Maintenance Safety Measures and Warnings Special safety measures Prior to turning the crankshaft with the turning gear, make sure and take notice: that no person is inside the engine and no loose parts, tools or devices can get jammed. bear in mind that the coupled propeller turns too (danger in surroundings).
  • Page 20 Used rubber rings must always be replaced by new ones when an overhaul of any engine component takes place; they must conform in dimension and quality to the WinGD specifications. The fitting of piston seal rings and rod seal rings requires the greatest of care to prevent damage, over expansion or deformation.
  • Page 21 0012−1/A1 Maintenance General Guidelines for Lifting Tools Wire Rope Slings, Span-sets, Eye Bolts, etc. General ............Attachment elements .
  • Page 22 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. Lifting capacity (for information purposes only): Lifting capacity [kg] Eye bolts & eye nuts, single-strand double-strand (45°) thread size 1200 1800 1290 3200 2300 4600 3300 6300 4500 8600 6100 11 500 8300 Note: The details listed in the table above are based on DIN 580 &...
  • Page 23 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. 2.4.1 Remarks on the use of RUD-eye bolts they must be completely screwed down, lying fully on the seating surfaces. they are hand-screwed with their own star-profile wrenches (do not use any ex- tension).
  • Page 24 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. 2.4.2 Remarks on the use of RUD-swivel lugs they must be completely screwed down, lying fully on the seating surfaces. they are hand-screwed with an open end wrench. Prior to loading the RUD-swivel lug adjust it in force direction (Fig.
  • Page 25 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. Attaching and disconnecting The following must be observed: Distribution of load: one strand carries the total of load weight two strands carry each one half of the load weight four strands carry each one quarter of the load weight if the load is distributed equally.
  • Page 26 Intentionally blank...
  • Page 27 0330−1/A1 Maintenance Clearance Table General ............Crankshaft and Thrust Bearing .

  • Page 28: Crankshaft And Thrust Bearing

    0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing WCH01221 Fig. 2 Fig. 1 2015 2/ 27 Winterthur Gas & Diesel Ltd.
  • Page 29 0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 1203 Thrust bearing 1224 − 0.5 Thrust bearing pad thickness − 0.6 Thrust bearing clearance axial (total) 0.8...1.3 Clearance between thrust pad and...

  • Page 30: Crankshaft And Main Bearing

    0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing Fig. 3 MAIN BEARING MAIN BEARING No. 2 AND FOLLOWING No. 1 Fig. 4 WCH01220 2015 4/ 27 Winterthur Gas & Diesel Ltd.
  • Page 31 0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 1132 Main bearing No. 1 Crankshaft outer ∅ − 0.09 Main bearing inner ∅ Bearing clearance vertical 0.4−0.7...

  • Page 32: Crosshead Guide

    0330−1/A1 Maintenance Clearance Table Crosshead Guide FUEL SIDE Fig. 5 WCH02888 2015 6/ 27 Winterthur Gas & Diesel Ltd.
  • Page 33 0330−1/A1 Maintenance Clearance Table Crosshead Guide Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3326 Crosshead guide + 0.25 Guide bar (column) transverse 1270 − 0.30 Guide shoe transverse 1270 −...

  • Page 34: Cylinder Liner

    0330−1/A1 Maintenance Clearance Table Cylinder Liner Fig. 6 Fig. 7 WCH02224 Fig. 8 2015 8/ 27 Winterthur Gas & Diesel Ltd.
  • Page 35 0330−1/A1 Maintenance Clearance Table Cylinder Liner Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 2130 Water guide jacket on cylinder cover + 0.30 Water guide jacket upper part Ø 1010 + 0.10 Clearance total...

  • Page 36: Piston Rod Gland

    0330−1/A1 Maintenance Clearance Table Piston Rod Gland Fig. 10 Fig. 11 Fig. 12 Fig. 13 99.7406 WCH02225 Fig. 9 2015 10/ 27 Winterthur Gas & Diesel Ltd.
  • Page 37 0330−1/A1 Maintenance Clearance Table Piston Rod Gland Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 2303 Piston rod gland Ring width radial min. 25 Ring width radial min. 20.20 Ring width radial min.

  • Page 38: Exhaust Valve

    0330−1/A1 Maintenance Clearance Table Exhaust Valve VALVE SPINDLE GUIDE BUSH 016.995/08 Fig. 15 016.994/08 Fig. 14 2015 12/ 27 Winterthur Gas & Diesel Ltd.

  • Page 39: Exhaust Valve

    0330−1/A1 Maintenance Clearance Table Exhaust Valve Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 2754 Valve spindle − 0.26 Spindle outer ∅ 69.50 − 0.29 2751 Guide bush + 0.030 Bore inner ∅...

  • Page 40: Top And Bottom End Bearings To Connecting Rod

    0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod Fig. 16 016.993/08 2015 14/ 27 Winterthur Gas & Diesel Ltd.
  • Page 41 0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3303 Top end bearing 3326 Crosshead pin outer ∅ − 0.08 Bearing inner ∅...

  • Page 42: Piston Cooling And Crosshead Lubricating Link

    0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubricating Link EXHAUST SIDE 016.996/08 Fig. 17 003.314/00 Fig. 18 2015 16/ 27 Winterthur Gas & Diesel Ltd.
  • Page 43 0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubricating Link Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3603 Piston cooling and crosshead lu- bricating link outer ∅ Bearing clearance radial 0.03−0.09 0.20...

  • Page 44: Piston And Piston Rings

    0330−1/A1 Maintenance Clearance Table Piston and Piston Rings 2015 18/ 27 Winterthur Gas & Diesel Ltd.
  • Page 45 0330−1/A1 Maintenance Clearance Table Piston and Piston Rings Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3406 Piston head − 0 Head (tapered part) outer ∅ 714.6 − 0.2 − 0 Head outer ∅...

  • Page 46: Driving Wheels For Supply Unit

    0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit INTERMEDIATE WHEEL FOR SUPPLY UNIT Fig. 19 INTERMEDIATE WHEEL FOR SERVO PUMP UNIT Fig. 21 WCH02228 Fig. 20 2015 20/ 27 Winterthur Gas & Diesel Ltd.
  • Page 47 0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 4103 Intermediate wheel Shaft outer ∅ Bearing clearance vertical *0.121 to 0.21 0.30 Axial clearance total 0.6−1.1...

  • Page 48: Fuel And Servo Pump Units

    0330−1/A1 Maintenance Clearance Table Fuel and Servo Pump Units FUEL PUMP UNIT Fig. 22 SERVO PUMP UNIT WCH02232 Fig. 23 2015 22/ 27 Winterthur Gas & Diesel Ltd.
  • Page 49 0330−1/A1 Maintenance Clearance Table Fuel and Servo Pump Units Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 5552 Fuel pump unit Gear Wheel outer ∅ − 0.025 Bearing clearance radial 0.153−0.237 0.33 Axial clearance...

  • Page 50: Fuel Pump

    0330−1/A1 Maintenance Clearance Table Fuel Pump PLUNGER & CYLINDER WCH02233 Fig. 25 WCH00832 Fig. 24 2015 24/ 27 Winterthur Gas & Diesel Ltd.
  • Page 51 0330−1/A1 Maintenance Clearance Table Fuel Pump Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 5556 Fuel pump Plunger (40, 42 and 44 mm) Clearance (plunger / cylinder) A−B radial 0.035−0.038 0.045 Clearance (plunger / cylinder) B−C radial...

  • Page 52: Integrated Electric Balancer

    0330−1/A1 Maintenance Clearance Table Integrated Electric Balancer I - I WCH03469 Fig. 26 2015−11 26/ 27 Winterthur Gas & Diesel Ltd.
  • Page 53 0330−1/A1 Maintenance Clearance Table Integrated Electric Balancer Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 7758 Bearing Bearing pin outer ∅ Bearing clearance radial 0.16−0.28 0.32 Axial clearance total 0.5−1.1 7758 Compensating shaft Tooth backlash*...
  • Page 54 Intentionally blank...

  • Page 55: Tightening Values Of Important Screwed Connections

    0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2015 1/ 11 Winterthur Gas & Diesel Ltd.
  • Page 56 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2015 2/ 11 Winterthur Gas & Diesel Ltd.
  • Page 57 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2015 3/ 11 Winterthur Gas & Diesel Ltd.
  • Page 58 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2015 4/ 11 Winterthur Gas & Diesel Ltd.
  • Page 59 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2015 5/ 11 Winterthur Gas & Diesel Ltd.
  • Page 60 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2015 6/ 11 Winterthur Gas & Diesel Ltd.
  • Page 61 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2015 7/ 11 Winterthur Gas & Diesel Ltd.

  • Page 62: 0352−1/A1

    0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 1500 (495) 20 Nm 45° 0.5 ±0.04 See on page 1 position 3 Or hand-tight with a spanner 1500 700 bar 1500 bar 1500 All screws All screws See on page 1 position 8 with 600 bar with 1500 bar Hydraulic jack Group 9710...
  • Page 63 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections G¼“ G¼“ 1500 1500 1250 MOLYKOTE PASTE G−N MOLYSLIP COPASLIP NEVER SEEZ NSBT On threads and contact surfaces On threads and contact surfaces On threads and contact surfaces NO ADDITIONAL LUBRICATION LUBRICATING OIL SAE 30 On threads and contact surfaces 2015 9/ 11...
  • Page 64 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections M33x2 G¼“ Secured with Loctite 2701 G¼“ G¼“ G¼“ G¼“ G¼“ MOLYKOTE PASTE G−N MOLYSLIP COPASLIP NEVER SEEZ NSBT8 On threads and contact surfaces On threads and contact surfaces On threads and contact surfaces NO ADDITIONAL LUBRICATION LUBRICATING OIL SAE 30 On threads and contact surfaces...
  • Page 65 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections MOLYKOTE PASTE G−N MOLYSLIP COPASLIP NEVER SEEZ NSBT8 On threads and contact surfaces On threads and contact surfaces On threads and contact surfaces NO ADDITIONAL LUBRICATION LUBRICATING OIL SAE 30 On threads and contact surfaces Designation: LUBRICATION OIL SAE 30 Designation:...
  • Page 66 Intentionally blank...
  • Page 67 0352−2/A1 Maintenance Torque Values and Elastic Stud Replacement Torque Values − Standard Screws and Elastic Studs Torque Values − Standard Screws We highly recommend the torque values given in the table below for aII standard metric screws of grade 8.8. This applies to all threaded connections not shown on page 0352−1.

  • Page 68: 0352−2/A1

    0352−2/A1 Maintenance Torque Values − Standard Screws and Elastic Studs Replacement of Elastic Studs Procedure Read the data in the manual of the jointing compound manufacturer. Remove the unserviceable elastic stud. Remove the grease and clean the sealing surfaces of the new elastic stud. Remove the grease and other unwanted material from the tap hole and the area where the elastic stud will be installed.
  • Page 69 0352−2/A1 Maintenance Torque Values − Standard Screws and Elastic Studs For the elastic studs installed in the valve cage, cylinder liner and cylinder jacket fill the area around the elastic stud with jointing compound (see Fig. 3). JOINTING COMPOUND SEALING SURFACES ELASTIC STUD Fig.
  • Page 70 Intentionally blank...
  • Page 71 0360−1/A1 Maintenance Masses (Weights) Individual Components per Piece in kg Group Component Design Main bearing cover (1st) 556 (410) 1115 1134 Main bearing shell 1224 Thrust bearing pad 1717 Casing (upper part) free end Casing (upper part) driving end 1720 Oil baffle, upper part Oil baffle, lower part 1903...
  • Page 72 0360−1/A1 Maintenance Individual Components per Piece in kg Group Component Design 3306 Connecting rod shaft 4095 3306 Bearing cover for bottom end 511−519 bearing with elastic studs 3310 Bearing shell for bottom end bearing 3312 Bearing cover for top end bearing 3315 Bearing shell for top end bearing 3326...

  • Page 73: 0360−1/A1

    0360−1/A1 Maintenance Individual Components per Piece in kg Group Component Design 6506 Turbocharger(MET) MET53MB 4100 MET60MB 4500 MET66MB 6500 MET71MB 8000 MET83MB 12500 6506 Turbocharger (ABB) A165−L 2000 A170−L 3000 A175−L 4900 A180−L 7000 A185−L 9000 A190−L 12000 A265−L 2700 A270−L 3000 A275−L...
  • Page 74 Intentionally blank...
  • Page 75 0380−1/A1 Maintenance Maintenance Schedule Inspection and Overhaul Intervals (Guidelines) Intervals & Lifetime Group Component Work to be carried out [operating hours] Lubricating oil − Laboratory analysis 3000 Main fuel and − Check filter elements − in particular for white lubricating oil metal particles (clean or replace filter as 3000 filters...

  • Page 76: Removal

    0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Intervals & Lifetime Group Component Work to be carried out [operating hours] − Friction type: Check pre−tension of screws and 1715−1 Engine stays remove corrosion marks from friction 6000 − 8000 elements, first time after sea trial −...
  • Page 77 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Intervals & Lifetime Group Component Work to be carried out [operating hours] − Check combustion space for damage and at each piston 2708−1 Cylinder cover wear removal engine lifetime − Estimated lifetime: Cylinder cover (remanufacturing as required) Injection valve...
  • Page 78 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Intervals & Lifetime Group Component Work to be carried out [operating hours] 108000 2751−4 − Estimated lifetime: Exhaust valve spindle (remanufacturing as required) 72000 − Exhaust valve seat (remanufacturing as required) − Measure crank deflection, always after the ship 3103−1 Crankshaft 6000...
  • Page 79 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Intervals & Lifetime Group Component Work to be carried out [operating hours] Guide shoe, 3326−1 − Check clearances 6000 − 8000 crosshead pin 18000 − 36000 3403−1 Piston − Remove and clean (condition based) −...
  • Page 80 − Clean the filter 6000 − Replace servo oil pump either with new one or 5551−1 Servo oil pump a pump overhauled by a WinGD Services 36000 workshop Servo oil pump − Check pinion and driving wheels to servo oil 5552−1...
  • Page 81 12000 Valve (FLV) running surface − Overhaul unit or replace it with a new item or a 24000 WinGD serviced item − Estimated Lifetime: Flow limiting valve 24000 Servo oil rail − Replace hoses (at least each 5 years) 30000 Exhaust valve 5612−1...
  • Page 82 Lubricating − Replace the lubricating pump with new item, or 7218−1 as necessary pump a pump overhauled by a WinGD workshop. Filter − Replace filter element before the cylinder as necessary replacement lubricating system − Estimated lifetime: Cylinder lubricating pump...
  • Page 83 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Intervals & Lifetime Group Component Work to be carried out [operating hours] Pressure − Compare and calibrate according to master 8135−1 gauges and 6000 − 8000 instruments pyrometers − Check fastenings at intervals if necessary, half yearly Pipe holders tighten the screws (first time after 100 Op.h.)
  • Page 84 Overhaul according to Maintenance Manual Genuine spare parts used Engine monitoring Engines according to specifications of WinGD Ltd. On the engine sectional drawings 0803−1, those parts are marked with group numbers, as they are found in the Maintenance Manual. 2016-01 10/ 10 Winterthur Gas &...
  • Page 85 0803−1/A1 Maintenance Engine Cross Section and Longitudinal Section Cross section 2728−1 2722−1 8460−1 8733−1 5562−1 5612−1 6420−1 4325−1 8447−1 6606−1 6545−1 3326−1 3326−2 6708−1 3301−1 3206−1 4103−1 4103−2 1112−1 WCH02248 Fig. 1: Cross Section 2015 1/ 2 Winterthur Gas & Diesel Ltd.
  • Page 86 0803−1/A1 Maintenance Engine Cross Section and Longitudinal Section Longitudinal section 2751−1 2708−1 2751−4 2708−3 2124−1 1903−1 2124−3 2138−1 3403−1 3403−4 3425−1 8752−1 2303−1 5556−1 9223−1 3326−1 5591−1 3326−2 3303−2 5581−1 3303−4 3140−1 4103−1 1132−1 1132−2 3103−1 1203−1 1224−1 3130−1 3130−2 WCH02249 Fig.
  • Page 87 ........1903−1/A1 X72 / MM / 2015 Winterthur Gas & Diesel Ltd.
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  • Page 89 1112−1/A1 Maintenance Bedplate and Thrust Bearing Foundation Bolts Checks Tools: 1 Feeler gauge 94122 2 Hydraulic distributors 94934A 1 Pre-tensioning jack 94145 1 HP hose 94935 1 HP oil pump 94931 General You must do a check of the tension of the foundation bolts (hold-down studs) at longer intervals e.g.

  • Page 90: Tension Check

    1112−1/A1 Maintenance Foundation Bolts − Check Tension Check Clean the threads of the foundation bolts (6, Fig.3) and the seating surfaces. Attach the pre-tensioning jack (94145, Fig.1) to the foundation bolt (6, Fig.3). Open the vent screw (1). Turn the foundation bolt (6) fully down until there is a small clearance, or no clearance between the foundation bolt and the nut (4).
  • Page 91 1132−1/A1 Maintenance Main Bearing Elastic Studs − Loosen and Apply Tension Tools: 2 Double pre-tensioning jacks 94114 4 Coupling elements 94934G 1 Feeler gauge 94122 3 HP hose 94935 1 Pressure gauge 94934A 1 Hydraulic unit 94942 1 Distributing piece 94934C Note: Always use the hydraulic double pre-tensioning jacks (94114, Fig.1) to loosen and apply tension to:...
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  • Page 93 1132−2/A1 Maintenance Main Bearing Main Bearing − Removal and Installation Tools: 1 Manual ratchet 94016-009 1 Turning-out device 94118B 2 Spur-geared chain block 94017-006 (wide bearing shell) 1 Chain (asymmetric) 94019A 1 Lifting plate 94119 1 Chain (symmetric) 94019B 1 Feeler gauge 94123 1 Eye bolt 94045-M48...
  • Page 94 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Covers No. 2 to No. 8 − Removal Tools − Installation Remove the oil pipe (1, Fig. 1) to the Fig. 1 main bearing cover (2). 94018C 94017−009 (H3) 94016−009 (H1) 94045−M48 94018B...
  • Page 95 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing 10) Install the lug (94116C, Fig. 4) on the main bearing cover (1). 94116C 11) Make sure that the thrust device Fig. 4 (94110, Fig. 5) is clean. WARNING Injury Hazard: Do not use the thrust device 94110 as a lifting device.
  • Page 96 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Cover − Removal Operate the manual ratchet (H1, Fig. to lift the main bearing cover (4). CAUTION 94117 Damage Hazard: Use the 94116C roller support 94117 only as shown with a maximum angle of the manual ratchet chain at 45°...
  • Page 97 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Cover No. 1 − Removal Remove the covers (2 and 3, Fig. 11). Loosen the elastic studs (5) and remove their nuts according to 1132−1. Remove oil pipe 4 from main bearing cover (Fig.
  • Page 98 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Shell − Removal Hydraulic Jacks − Installation WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel or in the engine. CAUTION Damage Hazard: Do not remove two adjacent main bearing shells at the same time.

  • Page 99: Removal

    1132−2/A1 Maintenance Main Bearing − Removal and Installation 11) If the value of the lateral bearing clearance is more than 0.1 mm, lower the crankshaft and do step a) to step c): Install the hydraulic jacks (94936) in position where the lateral bearing clearance is smaller.
  • Page 100 1132−2/A1 Maintenance Main Bearing − Removal and Installation Operate the spur-geared chain block (94017-006, Fig. 17) to turn the bearing shell (1) as shown in Fig. 18 Fig. 94017−006 Note: If the bearing shell (1) does not move, the lifting plate (94119, Fig.
  • Page 101 1132−2/A1 Maintenance Main Bearing − Removal and Installation Bearing Shell No. 2 to No. 8 − Removal 94143 94117 Note: The bearing cover and the top main bearing shell are removed. Note: The crank is at the exhaust side at TDC.
  • Page 102 1132−2/A1 Maintenance Main Bearing − Removal and Installation 10) Operate the manual ratchet (94016−009, Fig. 22) to move the bottom bearing shell until the chain hook is adjacent to the roller support (94117). 94117 94016−009 Fig. 22 11) Attach the lifting tool (94116A) to the 94116A bearing shell (1, Fig.
  • Page 103 1132−2/A1 Maintenance Main Bearing − Removal and Installation 94017−006 17) Attach the second spur-geared chain block (94017−006, Fig. 25) to the gallery and the lifting tool (94116A) 18) Operate the spur-geared chain blocks (94017−006) to move the bearing shell to the fuel side as shown. 94116A Fig.
  • Page 104 Damage to the bearing shell will occur. If the running marks are not symmetrical (axial or radial), speak to, or send a message to WinGD. Replace the bearing shells if necessary. Do an inspection of the surface of the bearing pin. If necessary, repair the surfaces that have scratches.
  • Page 105 1132−2/A1 Maintenance Main Bearing − Removal and Installation Note: To prevent bearing shell movement into the bearing girder, hold the bearing shell and move it slowly into the bearing girder (on fuel side) at the rope ends. Carefully move the bearing shell into the bearing girder (on the fuel side). Carefully put the Allen screws into the bearing shell.
  • Page 106 1132−2/A1 Maintenance Main Bearing − Removal and Installation 14) After each installation of a new bearing shell, measure the crank deflection, refer to 3103−1. 15) Do a check of an oil supply to the main bearing. Main Bearing − Lubrication After an overhaul of the bearing shells, more lubricant can be added to prevent damage to the surface of the bearing shells.
  • Page 107 1203−1/A1 Maintenance Thrust Bearing Axial Clearance Check Tools: 1 Inside micrometer 94101 Procedure One Start the engine in the direction AHEAD to move the crankshaft fully forward. Stop the engine. Put the dial gauge 8 in position on the oil baffle (top part) (9, Fig.
  • Page 108 1203−1/A1 Maintenance Checking the Axial Clearance Procedure Two Start the engine in the direction AHEAD to move the crankshaft fully forward. The crankshaft must touch the thrust pads (3, Fig. Stop the engine. Make sure that the crankshaft does not move.
  • Page 109 1224−1/A1 Maintenance Thrust Bearing Thrust Bearing Pads − Removal and Installation Tools: 1 Manual ratchet 94016-009 (H3) 1 Eye bolt 94045-M16 2 Spur-geared chain block 94017-006 (H1, H2) 1 Carrier 94155 2 Shackle 94018A 1 Link 94321 1 Eye bolt 94045-M12 Preparation Read the data in...
  • Page 110 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation Removal Remove and discard the lockwire from the three bolts (9, Fig. 2) on the arbor supports (3, 7) of the applicable thrust pads (5). Remove the bolts (9) from the arbor support (3 or 7) of the applicable thrust pads. Attach the eye bolt (94045-M12) to the arbor support (3 or 7).
  • Page 111 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation Install the carrier (94155) on the gear wheel (12) as shown. Remove the temperature sensors (8, Fig. 10) Attach the eye bolt (94045−M12) to the thrust pad (5, Fig. WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or inside the engine.
  • Page 112 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation 14) Remove the chain block and eye bolt. 15) Install the three bolts (9, Fig. Fig. 2) to the arbor support (3). 16) Lock the bolts (9, Fig. 3) with wire as shown. WCH02338 Lockwire Fig.
  • Page 113 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation Completion Install the cover (2, Fig. Remove all tools and equipment from the work area. 2015 5/ 5 Winterthur Gas & Diesel Ltd.
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  • Page 115 1715−1/A1 Maintenance Engine Stays with Friction Shims Pre-tension Checks Tools: 1 Feeler gauge 94122 2 Hydr. distributors 94934A 1 Pre-tensioning jack 94145 1 HP hose 94935 1 HP oil pump 94931 General The engine stays (see Fig.1) are related to the design of the ship. The engine stays are installed as follows: Four engine stays are installed on the exhaust side, or the fuel side.
  • Page 116 1715−1/A1 Maintenance Engine Stays with Friction Shims: Pre-tension Checks Pre-tension Checks Clean the threads of the bolts (2, Fig.1) and the seating surfaces. Apply Molykote paste G to the threads of the bolts (2). Refer to 9403−2 and 9403−4. Attach the pre-tensioning jack and the applicable equipment as shown in Fig.
  • Page 117 1715−1/A2 Maintenance Hydraulic Engine Stays Oil Pressure Checks General Two hydraulic engine stays (1, Fig. 1) are installed on the exhaust side and two on the fuel side of the engine. The vibration dampening is done inside the accumulator body by a gas (nitrogen) filled bladder surrounded with oil.
  • Page 118 1715−1/A2 Maintenance Oil Pressure Checks WCH02339 ENGINE SIDE WCH00915 Fig. 1 Fig. 1 Key 1 Hydraulic engine stays 5 Rod 2 Accumulator body (bladder inside) 6 Plug ⅜ inch NPT 3 Pressure gauge 7 Ball valve 4 Damping control valve 8 Hydraulic cylinder 2015 2/ 2...

  • Page 119: General

    1903−1/A1 Maintenance Tie Rod Pre-tension Checks and Tie Rod Replacement Tools: 1 Feeler gauge 94122 1 Pressure gauge 94934A 2 Pre-tensioning jacks 94180 3 HP hoses 94935 1 Connection block 94934 1 Hydraulic unit 94942 General We recommend that you check the tension of all the tie rods one year after commissioning.

  • Page 120: Removal

    1903−1/A1 Maintenance Pre-tension Checks and Tie Rod Replacement Tie Rods − Replacement Preparation Remove protection cover (5, Fig. from all tie rods. Clean the surface of the intermediate ring (2). Refer to 9403−4, then attach the two pre-tensioning jacks (94180) to two tie rods (4) that are opposite each other (e.g.
  • Page 121 1903−1/A1 Maintenance Pre-tension Checks and Tie Rod Replacement Tensioning Note: Start with the tie rods in the middle of the engine a−a, then b−b etc). 1500 bar Put the two pre-tensioning jacks (94180, Fig. 3) on the tie rods (4). 100 bar Apply a tension of 100 bar, refer to 9403−4.
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  • Page 123: Cylinder Liner And Cylinder Cover Group

    ..........2751−4/A1 X72 / MM / 2016−11 Winterthur Gas & Diesel Ltd.
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  • Page 125: Measure The Bore

    2124−1/A1 Maintenance Cylinder Liner Measure the Bore Tools: 1 Inside micrometer 94101 1 Ladder 94224 1 Gauge 94225 Measure the the cylinder liner before you remove a piston. 94224 Remove the cylinder cover, (refer to 2708−1). WARNING Danger: Gas Hazard. Poisonous gas can stay in the cylinder liner.
  • Page 126 2124−1/A1 Maintenance Measure the Bore Put the gauge (94225) in position on the top face of the cylinder liner (1) in line with the longitudinal axis of the engine. Make sure that the top hole (A) is above the ridge in the non-running surface of the cylinder liner (1, Fig.

  • Page 127: Removal And Installation

    2124−2/A1 Maintenance Cylinder Liner Removal and Installation Tools: 1 Manual ratchets 94016−009 1 Sling 94202K 2 Manual ratchets 94016−031 1 Lifting tool 94215 1 Lifting tool 94210 1 Assembly tool 94345E Preparation ............Cylinder Liner −...
  • Page 128 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting 94201 Lifting Tool − Install Put the two flange couplings (17, Fig. 2) in position on the cylinder liner. Tighten the five screws (22) in each flange coupling. Put the lifting tool (94201) in position on top of the cylinder liner.
  • Page 129 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Cylinder Liner − Installation Install the lifting tool (94201), refer to the procedure in paragraph 2.1. Clean the seating surfaces (SS) on the cylinder liner (2) and cylinder jacket (1, Fig. Carefully lower the cylinder liner (2) almost on to the cylinder jacket (1).
  • Page 130 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Water Guide Jacket − Removal 94201 Remove the cylinder liner, refer to paragraph to paragraph 2.2. Remove the lifting tool (94201) together with the flanges (17) from the cylinder liner (see paragraph 2.3). 94018A Attach the eye bolts (4) to the water guide jacket (3).
  • Page 131 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Water Guide Jacket − Installation 94201 Install the insulation bandage, refer to paragraph 7. Make sure that all O-rings are in perfect condition and properly installed. Apply oil to the O-rings. 94018A Attach the lifting tool (94201) to the cylinder liner (see paragraph 2.3).
  • Page 132 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Insulation Bandage − 94210 Removal Remove the cylinder liner (see paragraphs to 2.2). Remove the water guide jacket (see paragraph 4). Use the assembly tool (94345E) to remove all the tension springs (21, Fig.
  • Page 133 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Cylinder Liner − Safe 94292K Storage Make sure that the water guide jacket is removed (refer to paragraph 4). Step 1 Step 2 Make sure that the insulation bandage is removed (refer to paragraph 5). Install the lifting tool (94210) on the cylinder liner (see paragraph 2.1).
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  • Page 135: Remove Unwanted Material, Dress The Lubricating Grooves And Scavenge Ports

    2124−3/A1 Maintenance Cylinder Liner Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports Tools: 1 Grinding device 94299 General During operation, the cylinder liner becomes worn and an edge of unwanted material collects immediately above the location where the top piston ring movement stops. Also, the lubricating grooves decrease in depth and the corner radii of the scavenge ports become smaller.
  • Page 136 2124−3/A1 Maintenance Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports 94299 WCH02352 Unwanted Material r = 8.0 mm 2.0 mm to 3.0 mm 1.0 mm Piston Fig. 1 2015 2/ 4 Winterthur Gas & Diesel Ltd.
  • Page 137 2124−3/A1 Maintenance Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports Lubricating Grooves CAUTION Damage Hazard: Make sure that you keep the initial shape of the lubricating grooves when you remove sharp edges. If the depth of the lubricating grooves (1, Fig.

  • Page 138: 2124−3/A1

    2124−3/A1 Maintenance Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports II - II ROUNDED EDGES WCH02350 WCH02350 Fig. 3 WCH02350 After the repair is completed, fully clean the lubricating grooves and the bore of the cylinder liner. Remove unwanted particles, which may have passed into the scavenge space through the ports.
  • Page 139 2138−1/A2 Maintenance Lubricating Quill Removal and Installation Tools: 1 HP oil pump 94931 1 Connection nipple (G¼ inch) 94934I 1 Hydraulic distributor 94934H 1 HP hose 94935 (with pressure gauge 1 Dismantling tool 94213 0 bar to 25 bar) General If it is not necessary to remove the cylinder liner (1, Fig.

  • Page 140: 2138−1/A2

    2138−1/A2 Maintenance Lubricating Quill Nozzle Tip − Replace Remove the two bolts (2, Fig. 2) and the plate (1) from the distance sleeve (3). Put the distance sleeve (3) on (5) of the lubricating quill. Attach the plate (1) to the nozzle tip (4). Engage the collar on the plate with the recess on the lubricating quill (5).
  • Page 141 2138−1/A2 Maintenance Lubricating Quill Lubricating Quill − Function Check General You do a function check to make sure that the non-return valve (3, Fig. 3) operates correctly. The pressure that opens the non-return valve is 5.0 bar. During the function check, keep the lubricating quill (2) in a horizontal position. For the function check, use an oil with a viscosity as given in the specifications that follow: SAE 50 at 40_C (approx.
  • Page 142 2138−1/A2 Maintenance Lubricating Quill Installation CAUTION Damage Hazard: The surfaces of the cylinder liner and the nozzle tip make a metallic seal. The seat angles in the cylinder liner and on the nozzle tip are different. Do not use a gasket between the cylinder liner and the nozzle tip, or damage to the equipment can occur.
  • Page 143 2138−1/A2 Maintenance Lubricating Quill Tighten the nuts (10) of the union. Step a) to step c) is only necessary if the cylinder liner was installed. Remove the protection from the eight pipes (5). Connect the eight pipes (5). Attach the two holders (3) to the eight pipes (5). Bleed the oil pipes (9) (refer to 7218−1, paragraph 3.2).
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  • Page 145 2303−1/A1 Maintenance Piston Rod Gland Replace, Assembling, Wear Measurement Tools: 2 Working platforms 94142 1 Distance piece (11 mm) 94231C 2 Working supports 94143 1 Distance piece (9 mm) 94231D 2 Distance holders 94230 2 Spring assembly tool 94233 1 Clamp ring (2-parts) 94231A 1 Piston supporting device 94350...

  • Page 146: Procedure One

    2303−1/A1 Maintenance Replace, Assembling, Wear Measurement Procedure One Piston rod gland − removal CAUTION You must prevent an unwanted movement of the crankshaft when you do the procedure. Use the turning gear to turn the piston to BDC. Attach the two distance holders 94230 to the piston rod 2 (see Fig.

  • Page 147: Piston Rod Gland − Disassemble

    2303−1/A1 Maintenance Replace, Assembling, Wear Measurement Piston rod gland − disassemble Remove the four screws (3) (see Fig. 4). Remove the O-Rings (5). Push the two parts of the housing (2) away from the piston rod. Remove the two parts of the housing (2).
  • Page 148 2303−1/A1 Maintenance Replace, Assembling, Wear Measurement II - II WCH02292 I - I Fig. 6 Fig. 6: Gland Box, Overview 1 Cylinder Block 6 Inner Bolt M16x100 2 Gland box housing, 2-part 7 Outer Bolt M16x100 3 Bolt M12x55 8 Locking Plate 4 Dowel Pins 9 Spring Dowel Pin 5 Support...

  • Page 149: Piston Rod Gland − Assemble

    2303−1/A1 Maintenance Replace, Assembling, Wear Measurement Piston rod gland − assemble Attach the two parts of the clamp ring 94231A to the piston rod (see Fig. Put the three parts of the ring support (15) and the scraper rings (16) on the clamp ring 94231A.
  • Page 150 2303−1/A1 Maintenance 14) Put the two parts of the distance piece 94231B (12 mm height) on the gaskets 12, 14 (see Fig. 15) Put the four parts of the gaskets 12, 13 on the distance piece 94231B. Make sure that there is an equal distance between the four parts. 16) Make sure that all horizontal spring dowel pins 18 and the vertical spring dowel pin 17 are installed (see Fig.

  • Page 151: Piston Rod Gland − Installation

    2303−1/A1 Maintenance Replace, Assembling, Wear Measurement Piston rod gland − installation To install the piston rod gland 1, do the steps that follow: Apply lubricating oil to the opening in the cylinder jacket (3) and to the area of the O-rings (4) on the housing (2, Fig.

  • Page 152: Procedure Two

    2303−1/A1 Maintenance Replace, Assembling, Wear Measurement Procedure Two Piston rod gland − removal WARNING Injury hazard. You must prevent unwanted move- ment of the crankshaft when you do the mainte- nance. Disconnect the knee lever (1) from crosshead (2) and use a chain block to lift it.
  • Page 153 2303−1/A1 Maintenance Replace, Assembling, Wear Measurement Install the lifting tool 94235 below the piston rod gland (5). Make sure there is contact between piston rod gland and lifting tool. Slightly tighten the four bolts (8). Tighten the four bolts (6) with 30 Nm. Remove eight bolts (7) together with locking plates.

  • Page 154: Piston Rod Gland − Disassemble

    2303−1/A1 Maintenance Replace, Assembling, Wear Measurement CAUTION Equipment hazard. Do not get on the platform 94234. The maximum permitted weight is 140 kg. 19) Install the assembly platform 94234 through the support plate (5, Fig.15) on the studs of the piston rod foot (6). 20) Use the chain blocks to lower the piston rod gland (135 kg)on to the assembly platform 94234.

  • Page 155: Piston Rod Gland − Installation

    2303−1/A1 Maintenance Replace, Assembling, Wear Measurement Piston rod gland − installation MARK Lift the piston rod gland (1, Fig.16) with two chain blocks (see chapter 3.1) to the mark you made. Remove the assembly platform 94234. 94234 94235 Lift the lifting tool 94235 together with Fig.
  • Page 156 2303−1/A1 Maintenance Replace, Assembling, Wear Measurement Apply oil to the eight bolts (7, Fig.18) and install them together with new locking plates. Tighten the bolts with 150 Nm. Make sure the spring dowel pin in the piston rod gland (1) goes in to the bore of the support plate (5).

  • Page 157: Cylinder Cover

    2708−1/A1 Maintenance Cylinder Cover Removal and Installation of Cylinder Cover and Water Guide Jacket Tools: 1 Lifting tool 94215 1 Connection block 94934 6 Pre-tensioning jacks 94215A 1 Pressure gauge 94934A 1 Suspension device 94265 3 HP hose 94935 1 Hydraulic unit 94942 5 Flexible hose 94935A...
  • Page 158 2708−1/A1 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve Removal Use the engine room crane to put the tool (94215, Fig. 2) in position above the cylinder cover. Lower the lifting tool (94215) to get the six pre-tensioning jacks (94215A) on to the elastic bolts.
  • Page 159 2708−1/A1 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve 12) Lift, then lower the cylinder cover and exhaust valve assembly (4) on to wooden supports (Fig. 13) Apply tension to the elastic studs (3) of the exhaust valve assembly, refer to 9403−4.
  • Page 160 2708−1/A1 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve Installation Clean the O-ring grooves. Clean the sealing surfaces of the cylinder cover. Put oil on the new O-rings (8 and 10, Fig. Install the new O-rings (8, 10). I - I Put a new soft iron joint ring (9) in position in the cylinder liner.
  • Page 161 2708−1/A1 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve 21) Attach the tools (94215 and 94215A, Fig. 8) to the engine room crane. 22) Attach the six round nuts to the elastic bolts (1) on the cylinder liner (2). 23) Lower the tool (94215) and the six pre-tensioning jacks (94215A) on to the six elastic studs on the cylinder...
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  • Page 163 2708−1/A2 Maintenance Cylinder Cover Removal and Installation of Cylinder Cover and Water Guide Jacket (with Recommended Tool) Tools: 1 Lifting tool 94215 1 Connection block 94934 6 Pre-tensioning jacks 94215A 1 Pressure gauge 94934A 1 Suspension device 94265 3 HP hose 94935 1 Hydraulic unit 94942...
  • Page 164 2708−1/A2 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve Removal CAUTION Injury Hazard: The weight of the cylinder cover with the top water guide jacket and the exhaust valve is 94215 approximately 3700 kg. Use the correct equipment for removal.
  • Page 165 2708−1/A2 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve 11) Operate the engine room crane to lift and move the exhaust valve assembly (2, Fig. 5) and the cylinder cover (4) above the retaining bracket (94270H). Note: When you do step 12), make sure I - I that the cones (3) engage in the...
  • Page 166 2708−1/A2 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve 21) Operate the engine room crane to 94265 lower the cylinder cover (1, Fig. 8) to a small distance above the wooden blocks. 22) Remove and discard the O-rings (2, 3). 23) Fully lower the cylinder cover (1) on to the wooden blocks.
  • Page 167 2708−1/A2 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve 12) Operate the engine room crane to lift 94265 the cylinder cover (1, Fig. 10) and top water guide jacket (2). I - I Note: When you do step 13), make sure that the cones (5) engage in the holes in the cylinder cover (1).
  • Page 168 2708−1/A2 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve 20) Carefully lower the exhaust valve assembly (2, Fig. 12) on to the cylinder cover (3). Make sure that the spring dowel pin on the cylinder cover engages with the related hole in the exhaust valve assembly (2).
  • Page 169 2708−1/A2 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve 30) Attach the tools (94215 and 94215A, Fig. 14) to the engine room crane. 31) Attach the six round nuts to the elastic bolts (1) on the cylinder liner (2). 32) Lower the tool (94215) and the six pre-tensioning jacks (94215A) on to the six elastic studs on the cylinder...
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  • Page 171: Injection Valve − Sealing Face Machining

    2708−3/A1 Maintenance Cylinder Cover Injection Valve − Sealing Face Machining Tools: 1 Cutting device 94270 1 Profile cutter 94270A 1 Ring spanner AF24 94000-24 General The sealing face in the cylinder cover is a metallic seal. Thus, this sealing face must be clean and have no damage.
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  • Page 173: 2722−1/A1

    2722−1/A1 Maintenance Injection Valve Removal and Installation Tools: 2 Hexagon head bolt 94270C 2 Stud bolts 94270D Removal ............Installation .

  • Page 174: Caution

    2722−1/A1 Maintenance Installation CAUTION Injury Hazard: When you do work with white spirit, always put on gloves and safety goggles that have a closed side frame. White spirit can cause damage to your skin and eyes. If applicable, remove the new injection 94270D valve from the package.
  • Page 175 2722−1/A1 Maintenance 10) If the spring cage (3, Fig. 3) was disassembled, make sure that the cup springs (1) are installed as shown (four sets of six cup springs). Note: A correct assembled spring cage has a protrusion of the uncompressed spring guide (4) of Y = 1.8 mm 11) Put the spring cages (3) in position on...
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  • Page 177: (Injection Valve With Fast)

    2722−2/A1 Maintenance Injection Valve Disassemble, Checks, Assemble (Injection Valve with FAST) Tools: 1 Torque spanner 94011−03 1 Valve holder 94273 1 Slugging wrench 94269A−65 1 HP hose 94275 1 Hydraulic cylinder 94269B 1 Leakage oil hose 94275B 1 Torque wrench extension 94269C−41 1 Nozzle removal tool 94278A...
  • Page 178 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Preparation 94272 WARNING 94275 Fire Hazard. Do not use 94275B welding or grinding equipment near the work area. WARNING Health Hazard. Calibration fluid is harmful to your health. Read and obey the data in the instruction manual of the test bench manufacturer.
  • Page 179 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Read the data in the manufacturer’s instructions to set the pressure of the test bench to 600 bar. Push the INJECT BUTTON. Do a check to make sure that injection valve operates correctly.

  • Page 180: Injection Valve

    2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Disassemble 94011A Injection Valve Make sure that the test bench has no pressure. 94269C−41 Remove the receiver (2, Fig. 1) from the valve holder (94273). Make sure that the HP hose (94275) is disconnected from the connecting piece (94272B).

  • Page 181: Removal

    2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Pilot Valve − Removal 94289A Remove the pilot valve (3, Fig. 3) from 94289C the injection valve (2) as follows: Note: When you do the step blow, it is not necessary to torque the coupling nut (1).
  • Page 182 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Installation Attach the nozzle body (1, Fig. 5) and 94278B coupling nut (2) with the injection valve (4) on the test bench. Make sure that the dowel pin (5) is installed.
  • Page 183 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Assemble 94289A Pilot Valve − Install Install the pilot valve (1, Fig. 7) in the injection valve (2) as follows: Note: When you do the step below, it is 94289B not necessary to torque the coupling nut (3).
  • Page 184 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Injection Valve − Assemble WARNING Injury and Damage Hazard: Do not use copper paste in this procedure. Copper paste can be a conductor of electricity. Injury to personnel and damage to equipment can occur.
  • Page 185 2728−1/A1 Maintenance Starting Air Valve Removal, Disassemble, Grinding, Assemble, Installation General ............Preparation .

  • Page 186: Starting Valve: Removal, Disassemble, Grinding, Assemble, Installation

    2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Removal Disconnect the electrical connection from the 3/2-way solenoid valve (15, Fig. Remove the four screws (16). Note: When you do the step below, make sure that you do not damage the pipe (3).

  • Page 187: 2728−1/A1

    2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Grinding If the seating faces of the housing (10, Fig. 2) and the valve spindle (6) have minimum damage, do as follows: Manually grind the seat faces of the housing (10) and the valve spindle (6). Make sure that you keep the radius to the values given.
  • Page 188 2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Assemble Clean all the parts of the starting air valve (1, Fig. Put a small quantity of oil on all the parts and the O-rings (2, 8 and 12). Put two new O-rings (2) on the pipe (3). Put the new O-rings (8, 12) in the housing (2).

  • Page 189: Exhaust Valve

    2751−1/A1 Maintenance Exhaust Valve Exhaust Valve − Removal and Installation Tools: 2 Sling 94202K 1 Lifting hook 94209 Preparation Drain the cylinder cooling water from the related cylinder (refer to the Operation Manual 8017−1). Close the air inlet to the air spring at the control air supply. Remove the hydraulic pipe from the related exhaust valve, refer to 8460−1, paragraph and paragraph 2.
  • Page 190 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation Put the slings (94202K, Fig. 2) in position on the expansion piece as shown. 94209 Connect the slings to the hook on the lifting tool (94209). Use the crane to put a light tension on the lifting tool and the slings.

  • Page 191: 2751−1/A1

    2751−1/A1 Maintenance Exhaust Valve − Removal and Installation Installation Clean all the sealing surfaces of the exhaust valve and the cylinder cover. Examine the sealing surfaces of the exhaust valve and cylinder cover for damage. Remove the 2.0 mm metal gasket (1, Fig.
  • Page 192 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation 14) Clean the sealing surfaces of the expansion piece (2, Fig. 7) and the related faces on the valve cage and exhaust pipe (1). 15) Apply a thin layer of heat-resistant lubricant to the sealing faces and the screws (5, 6).
  • Page 193 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation Completion Connect the plug (2, Fig. 8) of the sensor cable from the terminal box (1). Open the air inlet to the air spring at the control air supply. Install the related hydraulic pipe to the exhaust valve, refer to 8460−1, paragraph and paragraph 5.
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  • Page 195: Disassemble And Assemble

    General The International Association of Classification Societies (IACS) recommends that there are two exhaust valves on board. Only qualified personnel, or a WinGD authorized repair workshop can repair defective exhaust valves. For the inspection and overhaul intervals, refer to 0380−1, Exhaust valve.
  • Page 196 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Turned through 90 degrees Fig. 1 WCH02355 2017−10 2/ 7 Winterthur Gas & Diesel Ltd.

  • Page 197: 2751−2/A1

    2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Exhaust Valve − Disassemble Valve Drive − Disassemble Attach the lifting tool (94209) to the crane and the eye bolt (19, Fig. Remove the six nuts (21). Operate the crane to remove the top housing (3).

  • Page 198: Guide Bush − Removal

    2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Guide Bush − Removal Remove the four screws (12, Fig. Remove the spacer (10). Remove and discard the rod seal (11). Put the jack screws (94263) into the flange of the guide bush (9). WCH02355 Turn the jack screws (94263) to lift the guide bush from the valve spindle (7).

  • Page 199: Valve Spindle − Installation

    2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Valve Spindle − Installation Measure the dimensions of the valve spindle (7, Fig. Compare the values with those given in 0330−1, Exhaust Valve. Do a check of the piston seal ring (17) for damage. If you find damage, replace the piston seal ring.

  • Page 200: Damper Setting

    2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble 10) Attach the lifting tool (94209) to the housing (2, Fig. 5) and the crane. 11) Lift, then lower the bottom housing (2) on to the valve cage (1). 12) Install the six screws (42). 13) Attach the lifting tool to the eye bolt (19, Fig.

  • Page 201: Valve Stroke Sensor − Installation

    2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Valve Stroke Sensor − Installation Clean the parts that follow: The valve stroke sensor (28, Fig. The transmitter housing (27). The bore and collar in the housing (3). Put oil on the O-ring (41) and the valve stroke sensor (28).
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  • Page 203 2751−3/A1 Maintenance Exhaust Valve Valve Seat − Removal, Grind and Installation Tools: 1 Feeler gauge 94122 1 Tool, valve seat remove / install 94261 1 Gauge 94279 1 Tool, grinding 94291 General ............Preparation .
  • Page 204 2751−3/A1 Maintenance Valve Seat − Replace / Grind Valve Seat − Removal If a valve seat is removed e.g. to replace an unserviceable O-ring, you must: Grind the valve seat before installation (paragraph 4), or: Mark the position of the valve seat in the valve cage before you start the removal procedure.

  • Page 205: 2751−3/A1

    2751−3/A1 Maintenance Valve Seat − Replace / Grind Turn equally the three jack screws (4, Fig. 2) until the valve seat (1) falls out of the valve cage (2). Lift and move the valve cage (2) away from the valve seat (1). Remove and discard the O-ring (3).
  • Page 206 2751−3/A1 Maintenance Valve Seat − Replace / Grind Valve Seat − Check You do this procedure to make sure that the sealing face of the valve spindle correctly touches the sealing face of the valve seat. Attach the eye bolt (8, Fig.
  • Page 207 2751−3/A1 Maintenance Valve Seat − Replace / Grind Valve Seat − Installation Clean the bores and the sealing faces of the valve cage (2) and the valve seat Fig. Apply oil (or lubricants e.g. Never-Seez NBST-8, Loctite anti-seize compound) to the bores and sealing faces of the 94261 valve seat (1) and the valve cage (2).
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  • Page 209: Valve Head − Grind The Seating Surface

    2751−4/A1 Maintenance Exhaust Valve Valve Head − Grind the Seating Surface Tools: 1 Feeler gauge 94122 1 Tool, valve grinding device 94291 1 Template 94292 General Use only the tool (94291, Fig. 1) to grind the valve head. You must grind valve heads that have a = between: 30°16' and 30°18' damage or corrosion on the seating surface.
  • Page 210 Fig. 2), the valve spindle can be repaired. Note: The repair procedure can only be done in a WinGD authorized repair workshop. Valve spindles cannot be repaired when the corrosion is more 9.0 mm, but can continue to operate until the corrosion has a depth of 21 mm.

  • Page 211: Crankshaft, Connecting Rod And Piston Group

    ........3425−1/A1 X72 / MM / 2016-02 Winterthur Gas & Diesel Ltd.
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  • Page 213: 3103−1/A1

    100 service hours. If the ship has touched the sea bed. In such conditions, it is recommended that you speak to WinGD Ltd. The crankshaft equipment (94305) is held between the crank webs in the center punch marks. When the crankshaft turns, the change in distance between the crank webs can be read from the dial gauge.
  • Page 214 3103−1/A1 Maintenance Measuring Crank Deflection Equipment Settings WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. The crank to be measured must be turned as shown after BDC. The dial gauge (94305) can now be put in position next to the connecting rod in the center punch marks (see Fig.
  • Page 215 For engines without torsional vibration damper, or front disc or free end PTO. For engines with torsional vibration damper or front disc or free end PTO. Speak to WinGD, if the final indications are more than the limits given in the table above.
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  • Page 217: Vibration Damper

    3130−1/A1 Maintenance Vibration Damper Silicone Fluid Sample General Viscous vibration dampers that Hasse & Wrede, Metaldyne International UK, STE Schwingungstechnik and Geislinger manufacture can be installed at the free end of the crankshaft. The service life of a vibration damper is related to the speed range in which the engine operates.
  • Page 218 3130−1/A1 Maintenance Taking a Silicone Fluid Sample Silicone Oil Samples Metaldyne and STE Metaldyne and STE Note: Two different threads are used for the sample bores of the Metaldyne International and STE vibration dampers. Note: The sample container lets you get a specified quantity of silicone oil from the damper.
  • Page 219 3130−1/A1 Maintenance Taking a Silicone Fluid Sample 13) Send the sample to: Metaldyne International UK Ltd 131 Parkinson Lane Halifax HX1 3RD United Kingdom Tel: +44 1422 357 234 Fax: +44 1422 354 432 Note: For STE Schwingungstechnik manufactured vibration dampers, send the samples to Hasse &...
  • Page 220 3130−1/A1 Maintenance Taking a Silicone Fluid Sample 13) Send the sample to: Hasse & Wrede Georg-Knorr-Strasse 4 D-12681 Berlin Germany Tel: +49 30 93 92 3135 Fax: +49 30 70 09 0835 If you cannot get a sample as given in paragraphs and 3.2, do the procedure that follows: Leave sample container (SC) in position.

  • Page 221: Inspection − Geislinger Vibration Damper

    3130−2/A1 Maintenance Vibration Damper Inspection − GEISLINGER Vibration Damper General Some engine designs can have a Geislinger manufactured vibration damper installed at the free end of the crankshaft. The service life of a vibration damper is related to the speed range in which the engine operates.
  • Page 222 3130−2/A1 Maintenance Inspection − GEISLINGER Vibration Damper Checks Engine Filters You must do regular checks of the engine filters for steel or bronze particles. If particles are found in the housing, you must speak to, or send a message to the supplier immediately.
  • Page 223 3130−2/A1 Maintenance Inspection − GEISLINGER Vibration Damper I - I FREE SUPPLY WCH02478 000.940/93 Fig. 2: Vibration Damper (section view) 1 Vibration damper 4 Oil supply pipe 2 Damper casing 5 Crankshaft 3 Vent nozzle 6 Coupling bolt 2015 3/ 3 Winterthur Gas &...
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  • Page 225: Removal

    3140−1/A1 Maintenance Axial Detuner Removal and Installation Tools: 2 Spur-geared chain block 94017-006 2 Eye bolt 94045-M36 2 Shackle 94018A 1 Lifting plate / link 94321 1 Chain 94019C Removal When the 2-part gasket (11 or 12, Fig. 1) must be removed from the axial damper, do the procedure that follows: Read the data in 0012−1...

  • Page 226: 3140−1/A1

    3140−1/A1 Maintenance Axial Detuner: Disassembly and Assembly Attach the two eye bolts (94045-M36, Fig. 2) to the axial detuner. Attach the chain (94019C) to the eye bolts (94045-M36). 10) Attach the plate (94321) to the chain (94019C). 11) Install the two shackles (94018A, Fig.
  • Page 227 3206−1/A1 Maintenance Turning Gear Teeth and Screwed Connections − Check Tools: 1 Pre-tensioning jack 94320 General ............Pinion and Flywheel Teeth .

  • Page 228: Turning Gear: Teeth And Screwed Connections − Check

    3206−1/A1 Maintenance Turning Gear: Teeth and Screwed Connections − Check Pinion and Flywheel Teeth Procedure Note: Make sure that only a thin layer of lubricant is applied to the tooth flanks of the pinion (2) and the flywheel (3). This makes sure that the lubricant stays on the tooth surfaces during engine operation.

  • Page 229: 3206−1/A1

    3206−1/A1 Maintenance Turning Gear: Teeth and Screwed Connections − Check Elastic Bolts − Apply Tension Clean the round nuts, the threads of the elastic bolts and the seating 94320 surfaces. Read the data in 9403−4. Put the pre-tensioning jack (94320, Fig.
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  • Page 231 3301−1/A1 Maintenance Crankcase Work Platform Tools: 2 Platform, each platform includes three grids 94142 2 Support 94143 General You use the platform (94142, Fig. 1) and support (94143) when you do work in the crank area and between the columns. The platforms help to prevent accidents in these areas.
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  • Page 233: Connecting Rod

    3303−2/A1 Maintenance Connecting Rod Bottom End Bearing − Removal, Inspection and Installation Tools: 2 Manual ratchet H1/H5 1600kg 94016-009 4 Eye bolt M8 94045-M8 2 Manual ratchet H2/H3, 2500kg 94016-011 1 Deviation pipe 94117B 1 Manual ratchet H4, 6300kg 94016-017 1 Pre-tensioning jack 94252 4 Shackle, 4750...
  • Page 234 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Attach the chain (94019B) to the gallery. 94019B Attach the manual ratchet (H4) to the chain (94019B). Install the deviation pipe (94117B) on to the column. Use the manual ratchets (H2, H3) to move the bearing cover (1) to the fuel side.
  • Page 235 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Top Bearing Shell − Inspection WARNING Injury Hazard: Before you operate the turning gear, 160 mm make sure that no personnel are near the flywheel, or in the engine. Unlock the turning gear. Use the turning gear to turn the crank 94322 to fuel side until the crosshead is...
  • Page 236 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Top Bearing Shell − Removal 94018C Attach the two shackles (94018C, Fig. 6) to the column. Attach the manual ratchets (H1, H5) to the shackles (94018C). Attach the console frame (94326, Fig.
  • Page 237 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Top Bearing Shell − Installation Clean the seating surface of the connecting rod (1, Fig. 9) and the bearing shell (10). 94326 Put the bearing shell (1) on the console frame (94326) Tighten the four screws (11).
  • Page 238 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bottom Bearing Shell − Installation 94327 Attach the four eye bolts (94045-M8, Fig. 11) to the bearing shell (3). Attach the chain (94327) to the four eye bolts (94045-M8). Lift the bottom bearing shell (3). Clean the seating surface of the bearing cover (3) and the bearing shell (5).
  • Page 239 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Make sure that the bearing shell is clean. Put oil on the bearing shell as follows: If you start the engine immediately after completion of this procedure, use only bearing oil. If the engine has stopped for some days, use a mixture of high-viscosity oil (steam engine...
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  • Page 241: Top End Bearing − Removal, Inspection And Installation

    3303−3/A1 Maintenance Connecting Rod Top End Bearing − Removal, Inspection and Installation Tools: 2 Manual ratchet, 2500kg, H1,H2 94016-011 1 Protection tool 94117B 1 Manual ratchet, 6300kg, H3 94016-017 1 Platform 94143 2 Manual ratchet, 500kg, H6,H7 94016-031 1 Support 94322 1 Chain block, 1000kg, H5 94017-006...
  • Page 242 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation If necessary, put oil on the two bolts (7, Fig. Install the two holders (94333) with the four bolts (7) to the piston rod foot. Torque the four bolts (7) to 200 Nm. Tighten the bolts (6).
  • Page 243 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation 94018C Crosshead − Lift Attach the shackles (94018B, Fig. 4) to 94019B each side of the column. Attach a manual ratchet (H1, H2) to the 94016-017 shackles (94018B) and the the two (H3) lifting tools (94337).
  • Page 244 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation Bearing Shell − 94019A Removal 94019B Attach the chain (94019A, Fig. 6) to the gallery. 94017-006 (H5) Attach the chain block (94017-006, H5) to the chain (94019A). Use the manual ratchets H1 and H2 to move the connecting rod to fuel side.
  • Page 245 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation Bearing Shell − Installation Clean the seating surface of the bearing shell (2, Fig. Put oil on the surface of the bearing shell as follows: If you start the engine immediately after completion of this procedure, use only bearing oil.
  • Page 246 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation 19) Put the round nuts (9, Fig. 10) on the elastic studs (8). 20) Tighten the round bars equally with the round bar (94005). 21) Measure the distance (X1, X2) between the edges of the bearing shells and the connecting rod (3).
  • Page 247 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation Bearing Lubrication To decrease the risk of dry-running on new bearing shells, it is necessary to apply a mixture of high-viscosity oil (steam engine cylinder oil, ISO VG 1000/1500) and bearing oil. Remove the oil inlet pipe (2, Fig.
  • Page 248 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation Completion WARNING Injury Hazard: Before you operate the turning gear, make sure that no 94333 personnel are near the flywheel, the propeller shaft or inside the engine. Make sure that the piston rod foot WCH02435 Fig.

  • Page 249: Removal And Installation

    3303−4/A1 Maintenance Connecting Rod Removal and Installation Tools: 4 Manual ratchet, 1600kg, H1, H2 94016-009 1 Chain asymmetrical 94019B 2 Chain block, 5000kg, H3,H4 94017-021 1 Bracket 94334 1 Shackle, 8500kg 94018C 1 Connecting element 94334A 1 Chain symmetrical 94019A 1 Shackle 3250 kg 94018A Preparation...
  • Page 250 3303−4/A1 Maintenance Removal and Installation 94018C Removal WARNING Injury Hazard: The connecting rod weighs approximately 3900 kg. To prevent injury, be careful when you move the 94337 connecting rod. WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel.
  • Page 251 3303−4/A1 Maintenance Removal and Installation 14) Use turning gear and chain block (H4, Fig. 4) to move the crank anticlockwise to the position shown. 15) Attach the manual ratchet (H1) to the lug (3) on top of the rod (2) 94017-021 (H4) 16) Apply a light tension to the chain of the...
  • Page 252 3303−4/A1 Maintenance Removal and Installation Attach the two manual ratchets (94016-009, Fig. 6) to the connecting rod and the eyelets in the gallery as shown. 9016−009 9016−009 Fig. 6 Read and obey the data given in Fig. Load Condition 1 Load Condition 2 Permitted Load on Gallery Eyelets a = maximum 35°...
  • Page 253 3303−4/A1 Maintenance Removal and Installation Fig. 8 Installation WARNING 94019A or Injury Hazard: The 94019B connecting rod weighs 3900 kg. To prevent injury, be careful when you move the connecting rod. WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel.
  • Page 254 3303−4/A1 Maintenance Removal and Installation Use the turning gear, the chain blocks (H4, H3) and manual ratchet (H1), Fig. 9) to move the connecting rod and the crankshaft clockwise into the position shown. Remove the chain block (H3) from the 94017-021 (H4) shackle (94018A).
  • Page 255 3303−4/A1 Maintenance Removal and Installation 17) Use the turning gear and the chain block (H4, Fig. 11) to move the connecting rod (1) and crankshaft (2) clockwise into the position shown. 18) Attach the chain block (H3) to the 94017-021 bottom shackle on the lifting (H4) tool (94337).
  • Page 256 3303−4/A1 Maintenance Removal and Installation 24) Use the turning gear and the manual ratchets (H1 and H2, Fig. 13) to move 94018C the connecting rod (1) and crankshaft (2) clockwise into the position shown. 25) Make sure that there is tension on the 94019B chain block (94016−017).
  • Page 257 3303−4/A1 Maintenance Removal and Installation 36) Use the turning gear to move the connecting rod (1, Fig. 14) clockwise to TDC. 37) Attach the manual ratchets (H1, H2) to the eyelets on the the bracket (94334). 38) Apply a light tension to the chains of the manual ratchets (H1, H2).
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  • Page 259: Top End Bearing Cover − Removal, Inspection And Installation

    3303−5/A1 Maintenance Connecting Rod Top End Bearing Cover − Removal, Inspection and Installation Tools: 2 Manual ratchet, 500 kg 94016-025 1 Chain, 3150 kg 94019B 1 Manual ratchet, 6300kg 94016-017 1 Chain, 1000kg 94019C 2 Eye bolt 94045-M20 1 Protection tool 94117B 2 Shackle, 4750 kg 94018B...
  • Page 260 3303−5/A1 Maintenance Top End Bearing Cover − Removal, Inspection and Installation Removal 94019C Use the pre-tensioning jack (94315) to 94045−M20 loosen the four round nuts (3, Fig. refer to 9403−4. Remove the four round nuts (3) from the elastic bolts (2). Attach the two eye bolts (94045-M20) to the bearing cover (1).
  • Page 261 3303−5/A1 Maintenance Top End Bearing Cover − Removal, Inspection and Installation 10) Attach the chain (94019B, Fig. 4) to the gallery. 11) Attach the manual ratchet (94016-017) to the chain (94019B). 12) Operate the two manual ratchets 94019B 94016−025 (94016−025) to move the bearing cover to the fuel side.
  • Page 262 3303−5/A1 Maintenance Top End Bearing Cover − Removal, Inspection and Installation Attach the round nuts (3, Fig. 6) to the elastic bolts (2). Use the pre-tensioning jack (94315) to tighten the four round nuts (3) refer to 9403−4. WCH02662 Fig. 6 Completion Attach the piston to the crosshead, refer to 3303−3, paragraph 7.

  • Page 263: Crosshead

    3326−1/A1 Maintenance Crosshead Clearance Checks Tools: 1 Feeler gauge 94238 General During an overhaul or after the installation of the crosshead, you must do as follows: Measure and record the clearances shown in Fig. 1 Fig. Compare the clearances with those given in 0330−1 Clearance Table.
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  • Page 265: Crosshead Pin − Removal, Installation, Clearance Checks

    3326−2/A1 Maintenance Crosshead Crosshead Pin − Removal, Installation, Clearance Checks Tools: 1 Protection tool 94117B 2 Eye bolt M20 94045−M20 1 Platform 94142 2 Eye bolt M30 94045−M30 1 Lifting tool 94324 4 Eye bolt M48 94045−M48 2 Chain block 5000 kg 94017−021 1 Chain 94325...
  • Page 266 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 94017−021 94018C Crosshead Pin − Removal 94016−017 Attach the lifting tool (94324) to the crosshead (see Fig. 1 View II). Attach the two eye bolts (94045−M48) 94018B to the bottom of the cylinder jacket. 94016−11 Attach the two shackles (94018C) to the top of the column.
  • Page 267 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 10) Use the manual ratchet (94016−017) to lift the crosshead approximately Turned 160 mm above the center of the pin 94045−M48 through 94016−009 hole (3, Fig. 1 view II) and 90°...
  • Page 268 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 23) Remove the two bolts, tab washers and holding plates (7, Fig. 5) from the guide shoe (4). 24) Attach the two eye bolts (94045−M20) and the chain (94325) to the crosshead pin (2).
  • Page 269 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 43) Use the manual ratchet (94016−009, Fig. 6) to lift the guide shoe (4) or (10). 44) Remove the manual ratchet (94016−031) and the eye bolt (94045−M30). Door Frame 94117B 45) Use the clamps to attach the protection tool (94117B,...
  • Page 270 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Tighten the manual ratchet (94016−017) that is attached to the gallery. At the same time, carefully loosen the manual ratchet that is attached to the link (94321, Fig. Lower the guide shoe (4) on to an applicable wooden underlay.
  • Page 271 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Note: When you do step 5) to step 6) below, keep the tension on the two manual ratchets. Tighten the manual ratchet that is attached to the link (94321, Fig.
  • Page 272 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 23) When the crosshead pin is in the first or last cylinder position, do step 25) to step 33): 24) Attach the eye bolt (94045−M30, Fig. 13) to the hole in the column. 25) Attach the manual ratchet (94016−031) to the eye bolts (94045−M30, 94045−M48).
  • Page 273 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 40) Continue with step 39) above until the connecting rod (6, Fig. 14) aligns with the crosshead. 41) Remove the wooden block (8). 42) If necessary, lift the crosshead a small distance.
  • Page 274 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Crosshead Measure the lateral clearance ( Fig. 17) at each position of the crosshead as follows: Use an applicable hardwood wedge (or an item that is almost the same) to push the crosshead axially to one side.

  • Page 275: Piston

    3403−1/A1 Maintenance Piston Removal and Installation Tools: 1 Lifting tool 94209 1 Piston suspension device 94341 2 Distance holders 94230 1 Insertion funnel 94342 2 Pre-tensioning jacks 94340 1 Piston support device 94350 1 Cover plate 94345D Preparation ............Removal .
  • Page 276 3403−1/A1 Maintenance Piston: Removal and Installation 14) Remove the four inner bolts (2, Fig. from the support 1). Fig. 3 WCH02435 15) Use turning gear to turn crank slowly to TDC while pushing out piston rod gland (7). 16) Make sure that the two distance holders (94230) stay in line with the gland box.

  • Page 277: Removal

    3403−1/A1 Maintenance Piston: Removal and Installation Removal Make sure that the device (94350, Fig.6) is installed correctly on the top platform. Use the crane to carefully lift the piston (1) from the cylinder. Note: Make sure that the piston rod foot (6) does not touch the support of the piston rod gland (7).
  • Page 278 3403−1/A1 Maintenance Piston: Removal and Installation Installation WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. 94342 Put oil on the bore of the cylinder liner Fig. 8) and the surfaces of the insertion funnel (94342).
  • Page 279 3403−1/A1 Maintenance Piston: Removal and Installation WARNING Note: Some parts Injury Hazard: You must can look different put on safety goggles and gloves when you do work on hot components. Oil can come out as a spray and cause injury. 17) Do a function check of the cylinder lubricating system.
  • Page 280 3403−1/A1 Maintenance Piston: Removal and Installation 26) Remove the distance holders (94230, Fig.13). 27) Tighten the round nuts (2) on the piston rod foot (1). Refer to the procedure in 9403−4, paragraph 3. 94230 WCH02599 Fig. 13 28) Make sure that the cylinder liner and the antipolishing ring are clean and in a 94209 satisfactory condition.

  • Page 281: Disassemble And Assemble

    3403−3/A1 Maintenance Piston Disassemble and Assemble Tools: 3 Pre-tensioning jacks 94340 3* Jacking screws 94364A 1 Suspension device 94341 2* Jacking screws 94364B 1 Piston support device 94350 3* Jacking screws 94364C * Use available screws from piston assembly Preparation CAUTION Damage Hazard: When you disassemble or assemble a piston, make sure that you do not damage the pipes or nozzles.
  • Page 282 3403−3/A1 Maintenance Piston: Disassemble and Assemble Disassemble CAUTION Damage Hazard: When you disassemble the piston, make sure that you do not damage the pipes or nozzles on the spray plate. Put the three jacking screws (94364A, Fig. 2) fully into the two tap holes in the top of the piston rod (1).
  • Page 283 3403−3/A1 Maintenance Piston: Disassemble and Assemble Assemble Note: Do not install pipes or nozzles that have damage. Apply Loctite No. 0270 to the thread of the pipe (3, Fig. Use the applicable tool to install the pipe (3) to the spray plate (1). Use a center punch to lock the pipe (3) in position.
  • Page 284 3403−3/A1 Maintenance Piston: Disassemble and Assemble Note: When you do step 14), apply tension to the elastic bolts in the sequence given in Fig. 14) Apply tension to the nine elastic bolts (1), refer to 9403−4. 15) Tighten the round nuts on the nine elastic bolts. 16) Install the piston, refer to 3403−1 paragraph 3.

  • Page 285: Top Surface Check

    3403−4/A1 Maintenance Piston Top Surface Check Tools: 1 Feeler gage 94122 1 Template 94366 1 Template 94366A General Each time you remove a piston, you must do a check of the top surface of the piston head for damage (burn scars). The causes of burn scars are as follows: Poor combustion Worn nozzles...
  • Page 286 3403−4/A1 Maintenance Piston Procedure − Piston Installed 94366A WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. WCH03211 Use the turning gear to move the piston to BDC. Look at the piston head through the scavenge ports (1, Fig.
  • Page 287 3425−1/A1 Maintenance Piston Rings Wear of Piston Rings and Ring Grooves Tools: 1 Inside micrometer 94101 1 Permascope MP0 94356 1 Feeler gauge 94122 (with instruments to 1 Piston ring tensioning device 94338 measure chrome-ceramic layers) (for Straight Cut piston ring) 1 Calliper gauge Piston ring tensioning device 94338A...

  • Page 288: Piston Rings: Wear Of Piston Rings And Ring Grooves

    3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Piston Rings − Rate of Wear Chrome-Ceramic Layer − Piston Installed WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Read the data in the suppler documentation for the tool Permascope MP0 (94356).

  • Page 289: Rate Of Wear

    3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Rate of Wear The wear of the chrome-ceramic layer is related to the operation conditions. If a piston ring that has some wear of the chrome-ceramic layer is found (see Fig.

  • Page 290: Service Life − Calculate

    3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Service Life − Calculate Use the formula below to calculate the wear rate of a piston ring: (D1−D2) x 1000 WR = T2−T1 Where: WR = Wear rate (mm/1000 hrs) T2 = Hours (hrs) T1 = First recorded operation hours (hrs) D2 = Second recorded thickness of the chrome-ceramic layer (mm)

  • Page 291: Piston Ring Grooves

    Chrome-ceramic Layer step b). Replace the piston rings. Repair the piston head. WCH02244 Note: For the repair of piston heads, Fig. 3 speak to the nearest WinGD Service Center. 2015 5/ 9 Winterthur Gas & Diesel Ltd.

  • Page 292: Piston Rings − Removal

    3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Piston Rings − Removal CAUTION Damage Hazard: Do not open the piston rings too far. This will cause damage to the piston rings. Use the tool (94338 or 94338A, Fig.
  • Page 293 Piston and Piston Rings. For the repair of piston heads, speak to the nearest WinGD Service Center. Do not install a piston head that has clearances near the maximum value. This is because the service life will be too short.

  • Page 294: Used Piston Rings − Installation

    3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Used Piston Rings − Installation For the ring types and their locations, see Table Table 3: Standard Piston Ring Locations Ring Type Material Application Top Piston Ring 1 x GTP1CC22 (gas tight) chrome-ceramic layer For new and fully honed cylinder liners and used cylinder...

  • Page 295: New Piston Rings − Installation

    3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves New Piston Rings − Installation CAUTION Damage Hazard: Do not open the piston rings too far. This will cause damage to the piston rings. Note: Make sure that the mark TOP, on the piston ring, points up. Note: For the ring types and their locations, see Table Measure and record the thickness of the chrome-ceramic layer on each piston...
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  • Page 297: Group 4

    ....... 4325−1/A1 X72 / MM / 2015 Winterthur Gas & Diesel Ltd.
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  • Page 299: Running And Backlash Clearances And Tooth Condition

    4103−1/A1 Maintenance Drive Wheels Running and Backlash Clearances and Tooth Condition Tools: 1 Feeler gauge 94122 1 Dial gauge 1 Micrometer 1 Lead wire 1.5 mm diameter General On new engines during the running-in period, you must do a visual check of the gear wheels after approximately one and two operation hours.
  • Page 300 4103−1/A1 Maintenance Running and Backlash Clearances and Tooth Condition Gear Tooth Backlash Checks Refer to 0330−1, Driving Wheels for Supply Unit (Group 4103) for data about the gear tooth backlash values. There are three procedures to measure the backlash. Feeler Gauge (94122) Measure the clearance between the tooth flanks (10, Fig.
  • Page 301 4103−1/A1 Maintenance Running and Backlash Clearances and Tooth Condition Use the micrometer to measure the lead wire. Calculate as follows: The full tooth backlash: f = f1 + f2 The parallelity: Df = a1 − b1 or a3 − b3. The permitted difference of the tooth profile parallelity is between 0.0% and 0.2% across the width of the tooth.
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  • Page 303 To prevent damage, speak to the engine supplier or to WinGD to get the applicable instructions to disassemble the crankshaft gear wheel. The spare crankshaft gear wheel is a two-part assembly.

  • Page 304: Replacing The Gear Wheel On The Crankshaft

    4103−2/A1 Maintenance Replacing the Gear Wheel on the Crankshaft Preparation Fig. 1 WCH02403 Make sure that the temperature of the crankshaft, the gear wheel and the tool to measure the dimensions is the same. Measure and record the inner diameter (d, Fig.

  • Page 305: 4103−2/A1

    4103−2/A1 Maintenance Replacing the Gear Wheel on the Crankshaft Note: When you step 6) and step 7), do not use Molykote or oil. Remove all grease from the applicable area on the crankshaft flange (2, Fig. Make sure that the area is clean and in satisfactory condition. Remove grease from the bore of the crankshaft gear wheel.
  • Page 306 4103−2/A1 Maintenance Replacing the Gear Wheel on the Crankshaft Put three flange screws (6, Fig. 4) in position as shown in the wheel half (1). Tighten the screws temporarily. Turn the turn the crankshaft to move the gear wheel half (1, Fig.
  • Page 307 4103−2/A1 Maintenance Replacing the Gear Wheel on the Crankshaft 17) Measure the length of the elastic studs (3, Fig. Note: The elastic studs have the correct tension if they are extended to 1.3± 0.06 mm more than the length measured in paragraph 3, step 1). 18) Make sure that there is no clearance between the two halves of the crankshaft gear wheel.
  • Page 308 4103−2/A1 Maintenance I - I WCH02403 MOLYKOTE 94002−60 LOCTITE Fig. 9 6/ 6 Winterthur Gas & Diesel Ltd.

  • Page 309: 4325−1/A1

    4325−1/A1 Maintenance Shut-off Valve for Starting Air Cleaning and Function Check General ............Preparation .
  • Page 310 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check Disassembly Remove the eight screws (26, Fig. 2) from the cover (9). Turn the handwheel fully in. This will move the cover (9) out of spindle (13). Remove the handwheel (25), the cover (9) and the spring (11). Use an AF 60 swan neck spanner to remove the spindle nut (14).
  • Page 311 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check 17 18 WCH02229 To Ball Valve 35−8353_E0_2 ZV7014C ZV7013C PS5017C Fig. 2 2015 3/ 6 Winterthur Gas & Diesel Ltd.
  • Page 312 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check Assembly Make sure that all bores are clear. Remove grease from the surfaces of the spindle (13, Fig. 2) and the threads of the spindle nut (14). Apply a thin layer of Molykote paste to the stopper (27), the spring (17) and the valve body (18).
  • Page 313 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check 21) Attach the silencer (28) to the control valve (19, Fig. 22) Put the assembled shut-off valve in position as shown in Fig. 23) Attach the flange (7) to the valve guide (16) with the eight screws (6).
  • Page 314 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check Use the handwheel (25, Fig. 5) to move the shut-off valve to the position AUTOMAT. Make sure that the lever (34) engages the groove in the spindle. Make sure that no air flows from the bore of the screw plug (5). When no air flows, the automatic function of the shut-off valves operates correctly.

  • Page 315: Group 5

    ....5612−1/A1 Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation X72 / MM / 2019−08 Winterthur Gas & Diesel Ltd. 1/ 2 Winterthur Gas & Diesel Ltd.
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  • Page 317 5552−5/A1 Maintenance Supply Unit Lubrication of Supply Unit during Maintenance Tools: 1 Lubricating tool 94844 1 Adapter 1 Adapter General The engine has a manual lubrication system. This system prevents damage to the bearings and bushes of the supply unit (7, Fig.
  • Page 318 5552−5/A1 Maintenance Lubrication of Supply Unit during Maintenance I - I 94844 II - II WCH03860 Fig. 1 2018 2/ 2 Winterthur Gas & Diesel Ltd.

  • Page 319: 5556−1/A1

    5556−1/A1 Maintenance Fuel Pump Disassemble, Assemble Tools: 1 Circlip pliers 94007−A41 1 Guide bracket 94593 1 Handle 94009−M10 Which includes: 1 Manual ratchet 94016−031 1 Ring 94593A 1 2-part clamping ring 94550 2 Ring (2-part) 94593B 1 Spindle press 94551 2 Guide rods 94593C 1 Lifting tool...
  • Page 320 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Preparation Stop the engine. Set to off the fuel supply Set to off the main oil supply. Make sure that the fuel return valve is open, refer to the Operation Manual, Control Diagram 4003−2 and Pipe Diagram 4003−11. Close the fuel inlet valve, refer to the Operation Manual, Control Diagram 4003-2 and the Pipe Diagram 4003-11.
  • Page 321 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble CAUTION Damage Hazard: Do not operate the engine with a fuel pump removed. This will decrease the supply of oil, i.e. there could be a decrease of lubrication to the other fuel pumps. Damage to equipment can then occur.
  • Page 322 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble 94552 Fuel Pump − Disassemble Remove the screws (94592E, Fig. then remove the two limiters (94592B). Turn the fuel pump until the roller (8) points up. Attach the two limiters (94592B) to each side of the fuel pump with the screws (94592E) to hold the fuel pump in position.
  • Page 323 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Use the eye bolt (1, Fig. 5) to move the spindle (2) up. Carefully lift the lower housing (4) together with the guide piston (3), the lower spring carrier (5) and pump 94551 plunger (7). Remove the compression spring (6).
  • Page 324 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Guide Piston − Disassemble Attach the the two M10 eye bolts (1, Fig. 6) to the guide piston (5). Remove the guide piston (5) from the housing. Remove the circlip (6). Remove the pin (7). Push out the roller pin (3), then remove the roller (4), bush (8) and the two pressure discs (2).
  • Page 325 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Pump Cylinder − Removal Note: The pump cylinder (7, Fig. 8) and pump plunger are not interchangeable and must stay together as a unit. Turn the fuel pump until the pump cover (2) points up. Remove symmetrically the 12 Allen screws (1).
  • Page 326 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Fuel Pump − Assemble Clean all parts of the fuel pump. Examine all parts of the fuel pump for damage. Replace damaged parts with new items. Replace all O-rings and rod seal rings. Use a low-pressure air supply air to make sure that all the bores in the housings and the pump cylinder (3, Fig.
  • Page 327 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Carefully put the valve block (8, Fig. 12) into the pump cover (2). Make sure that the valve body (9) moves freely. Apply Never-Seez NSBT-8 to the threads and seating surfaces of the screws (1). Torque the 12 Allen screws in the sequence given in Fig 13...
  • Page 328 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Upper Housing − Assemble Turn the fuel pump into the position shown in Fig. Put the toothed rack (2) in position. Note: Make sure that the toothed rack (2) moves easily. Put oil on the rod seal ring (5). Put the rod seal ring (5) into the intermediate flange (11).
  • Page 329 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble 16) Move the toothed rack (3, Fig. 17) to the middle position. 17) Put the compression spring (1) in position in the upper housing (2). Lower Housing − Assemble 18) Put the assembled guide piston (9) in the lower housing (10).
  • Page 330 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Upper and Lower Housings 94551 − Connect Attach the ring (94593A, Fig. 19) to the bottom housing (1). 94593A Attach the two-part ring (94593B) to the top housing (2). Align the guide rods (94593C) with the bores in the ring (94593A).
  • Page 331 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Lower the bottom housing (1, Fig. on to the top housing (3) until the spring carrier (6) is approximately 94551 10 mm to 20 mm above the compression spring (5). Align the wings (5) on the pump plunger (4) with the slots in the regulating sleeve (2).
  • Page 332 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Function Check 94551 Turn the eye bolt on the spindle press (94551, Fig. 22) to move the roller (1) down 59 mm. Note: The distance of 59 mm is equal to a hub stroke of 55 mm. Turn the eye bolt on the spindle press (94551) back to the initial position.
  • Page 333 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Fuel Pump − Install WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Use the turning gear to turn the camshaft until the applicable cam is at BDC.
  • Page 334 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Fuel Pump 15) Make sure that the the connecting link (2, Fig. 25) moves freely. 16) Apply Molykote paste G to the connecting link (2). 17) Connect the connecting link (2) to the toothed rack (1) with the screw (3) and a new self-locking nut (4).
  • Page 335 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Oil Flow Check WARNING Injury Hazard: Do not operate the engine. Injury to personnel can occur. WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Note: The oil flows through the throttle Fig.
  • Page 336 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Storage Do the procedure that follows to put the fuel pump into storage: Make sure that the storage area is clean and dry. Put oil on the fuel pump to prevent contamination. Put the pump in a vertical position. Put petroleum jelly (e.g.

  • Page 337: Removal Of A Seized Pump Plunger

    5556−2/A1 Maintenance Fuel Pump Removal of a Seized Pump Plunger Tools: 1 Piston reset tool 94595D 2 Screws 94595E 1 Hydraulic ram 94595 1 HP oil pump 94931 1 Short push rod 94595B 1 Pressure gauge 94932 1 Long push rod 94595C 1 HP hose 94935...
  • Page 338 5556−2/A1 Maintenance Fuel Pump: Removal of a Seized Pump Plunger Hydraulic Ram − Preparation 94595 Open the vent screw (5, Fig. Use the push rod (4) to push the piston (2) to the top of the cylinder of 94595D hydraulic ram (94595). If you cannot move the piston (2) with WCH02281 your hand, do step a) and step c):...
  • Page 339 5556−2/A1 Maintenance Fuel Pump: Removal of a Seized Pump Plunger Removal with Tool 94595B Note: Some internal parts of the fuel 94595 pump can look different. 94595B Connect the hydraulic ram (94595, Fig. 4) to the HP oil pump (94931). Close the relief valve (5).
  • Page 340 5556−2/A1 Maintenance Fuel Pump: Removal of a Seized Pump Plunger Removal with Tool 94595C Note: Some internal parts of the fuel 94595 pump can look different. 94595C Remove the short push rod (94595B) from the hydraulic ram (94595). Put the long push rod (94595C) into the hydraulic ram (94595).
  • Page 341 ............General To prevent failure of the pressure control valve (PCV), WinGD Ltd recommends that you only do the procedures that follow: Do a check and adjust the PCV.

  • Page 342: Fuel Pressure Control Valve: Removal, Check, Installation

    5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Check, Installation Removal Make sure that the fuel rail (4, Fig. 1) has no pressure. Disconnect the electrical connection from the solenoid valve (2). Loosen the angle union (7). Remove the fuel return pipe 5 from the PCV 1. Remove the four screws (8).

  • Page 343: Preparation

    5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Check, Installation PCV Check Preparation Put protection (5, Fig. 2) around the PCV test block (94556). Put the test block (94556) in a bench vice. Make sure that the sealing surfaces of the PCV and the test block (94556) are clean and have no damage.

  • Page 344: Adjustment Procedure

    5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Check, Installation Adjustment Procedure CAUTION Damage Hazard. Do not connect the solenoid valve. Damage to the PCV can occur. Operate the HP oil pump (94931, Fig. Adjust the SAV (7) to get a value of 100 bar. Do a check for leaks.
  • Page 345 5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Check, Installation Installation Do a check of the lip seal (9, Fig. 1). Replace the lip seal if necessary. Make sure that the sealing surfaces of the PCV and the valve block are clean and have no damage.
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  • Page 347: 5562−1/A2

    1) from the fuel rail (2) to do this procedure. Note: For the full PCV overhaul instructions, speak to or send a message to WinGD. Stop the engine Make sure that the PCV (1) is open. Note: If HFO is used, the drain port will be hot when the PCV is open.
  • Page 348 5562−1/A2 Maintenance Fuel Pressure Control Valve: Manual Release Valve − Clean Carefully remove the rubber cap (Fig. Rubber Solenoid Record the installed position of the Plastic plastic collar. Collar Remove the nut, plastic collar and solenoid. Solenoid Tube Remove the solenoid tube. Hole Use your finger to push the lever.
  • Page 349 5562−1/A2 Maintenance Fuel Pressure Control Valve: Manual Release Valve − Clean 11) Carefully remove the pusher (Fig. Note: It is possible that the pusher will stay on the PCV body. 12) Remove the plunger and spring from the PCV. Block Clean and Apply NeverSeez Remove the grease from all components (pusher, plunger, spring...
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  • Page 351: Removal

    Refer to the Maintenance Schedule 0380−1 Relief Valve for the frequency to do the function test. Unserviceable relief valves must be sent to the manufacturer, or a WinGD authorized repair workshop for inspection and repair.

  • Page 352: 5562−2/A1

    5562−2/A1 Maintenance Removal, Check, Installation Relief Valve Test Test and Calibration Fluid − Physical Conditions You use the test bench (94272) and the test and calibration fluid (e.g. Shell Calibration Fluid S.9365) to test the relief valve. Table gives the mandatory data for the test and calibration fluid.

  • Page 353: Installation

    5562−2/A1 Maintenance Removal, Check, Installation 94934A 94935 94272A 013.484/05 94272 94931 94934A 013.486/05 Fig. 2 Installation Apply Never-Seez NSBT to the thread of valve housing (2, Fig. Install the relief valve (1) in the valve block (3). Torque the relief valve (1) to 300 Nm. AF80 Fuel Rail WCH03213...
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  • Page 355: 5562−3/A1

    It is possible to do the maintenance of the flow limiting valve (FLV) on board. Speak to, or send a message to WinGD to get a repair kit including instruction: Maintenance on the flow limiting valve must only be done by approved personnel who have the special knowledge of the flow limiting valve.
  • Page 356 5562−3/A1 Maintenance Flow Limiting Valve Preparation Cut out the injection, refer to the Operation Manual 0510−1. Let the engine temperature decrease. Let the pressure in the fuel rail decrease to zero. Make sure that the fuel injection system has no pressure. Make sure that all tools and equipment are clean and in good condition.

  • Page 357: Removal

    Inspect the running surfaces (RS) of piston rod (4) and flange (3), piston (2) and valve block (1). Contact WinGD for replacement parts and instruction or send it to a WinGD Service Station for an overhaul. Clean all parts and running surfaces (RS).
  • Page 358 5562−3/A1 Maintenance Injection Control Unit: Removal and Installation Apply lubricating oil to all running surfaces (RS). 10) Push piston rod (4, Fig. 5) together with piston (2) into flange (3). Check for smooth running (full stroke and turning). 11) Slide the piston (2) together with flange into the valve block (1).
  • Page 359 5562−3/A1 Maintenance Injection Control Unit: Removal and Installation Completion Install the leakage pipes (4), (5) to the flow limiting valve (1, Fig. 7). Install the HP fuel pipes, refer to 8733.1. Cut in the injection, refer to the Operation Manual, 0510−1. Operate the engine for a minimum of one hour with marine diesel oil.
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  • Page 361: Camshaft And Bearing Shells − Removal And Installation

    5581−1/A1 Maintenance Supply Unit Camshaft and Bearing Shells − Removal and Installation Tools: Pre-tensioning jack 94557 1 Screwjack 94567B Support 94566 1 Connection block 94934 1 or 2 Holders 94566B 1 Pressure gages 94934A Holder 94566C 3 HP hoses 94935 Assembly template 94567 1 Hydraulic unit...
  • Page 362 5581−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Make sure that the bearing covers at positions No. 3, No 4 and No. 5 Fig. 2 the housing (1), have marks to identify them as a set. Note: The bearing at position No. 2 has the two thrust bearing ring halves (3). Install the holders (94566B and 94566C) to lift up the rollers and guide pistons of the fuel pumps.

  • Page 363: Removal

    5581−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Bearing Shells − Removal Loosen the Allen screws (3, Fig. 3) and remove the filling piece (1) from bearing cover No.3. Use the pre-tensioning jacks (94557) to loosen the round nuts (5) of bearing covers No.1, No.3, No.4 and No.5, refer to 9403−4.
  • Page 364 5581−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Camshaft − Removal Put the two supports (94566, Fig. 4) in the positions No.1 and No.5. On the two supports, tighten the nuts (4). Make sure the camshaft stays in position before you remove the last bearing cover.
  • Page 365 5581−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Put the screwjack (94567B, Fig. 5) in position. Turn the screwjack (94567B) to lift the camshaft between 0.05 mm and 0.15 mm. Put the assembly template (94567A) on the lower elastic bolt (7). 10) Put the round nut (8) on the elastic bolt (7).
  • Page 366 5581−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Completion Refer to 0330−1, Clearance Table, Group 5552 for the axial clearances. If the axial clearances are not in the specified range, loosen the round nuts on one of the bearing covers (see the procedure in paragraph step 2)).

  • Page 367: Fuel Pump Actuator

    5583−1/A1 Maintenance Fuel Pump Actuator Connection to Fuel Pump General Maintenance of the connection between the fuel pump and the actuator is not necessary. Do a check of the connecting element (1, Fig. 1) as follows: Make sure that the connecting element is lubricated with Molykote paste G. Make sure that the connecting element can move freely.
  • Page 368 5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump Actuator and Fuel Pump − Align If there was an overhaul on the actuator, or the actuator was replaced do step 1) to step 9): Make sure that the actuator is electrically disconnected. Make sure that the connecting element (1, 2) is disconnected from the lever (2).
  • Page 369 5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump 48 mm WCH02410 WCH02411 Fig. 2 2015 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 371: Servo Pump Unit

    5591−1/A1 Maintenance Servo Pump Unit Servo Oil Pump − Removal and Installation Tools: 2 Sling 94202K General ............Checks .

  • Page 372: Servo Oil Pump − Removal And Installation (With Hawe Sop)

    5591−1/A1 Maintenance Servo Oil Pump − Removal and Installation Pinions and Camshaft Gear Wheel Remove the 20 screws (2, Fig. Remove the cover (1) from the supply unit casing (3). WCH02395 Fig. 2 Do a check of the pinions (1 and 2 Fig.
  • Page 373 5591−1/A1 Maintenance Servo Oil Pump − Removal and Installation Servo Oil Pump − Removal Preparation Stop the engine (see the Operation Manual 4002-2). Set to off the main bearing oil pump. Remove the HP servo oil pipes (12, Fig. 4), refer to 8447-1. For engines with 4-6 cylinders (three fuel pumps) do step a).
  • Page 374 5591−1/A1 Maintenance Servo Oil Pump − Removal and Installation Removal CAUTION Injury Hazard: The weight of the servo oil pump is 114 kg. Make sure that you use the correct equipment to lift and move the servo oil pump. This will prevent injury to personnel. Put the sling (94202K, Fig.
  • Page 375 5591−1/A1 Maintenance Servo Oil Pump − Removal and Installation Bearing Bushes CAUTION Injury Hazard: The weight of the pinion and shaft is approximately 45 kg. Use the correct equipment to lift and move the pinion and shaft. This will prevent injury to personnel.
  • Page 376 5591−1/A1 Maintenance Servo Oil Pump − Removal and Installation 18) Put oil on the two bearing bushes (1, 3 Fig. 8) and the shaft (2) of the pinion. 19) Use the engine room crane and the two slings (94202K, Fig. 9) to lift the pinion (1) and shaft (5) into position above the casing (2).
  • Page 377 5591−1/A1 Maintenance Servo Oil Pump − Removal and Installation Servo Oil Pump − Installation CAUTION Injury Hazard: The weight of the servo oil pump is 114 kg. Make sure that you use the correct equipment to lift and move the servo oil pump.
  • Page 378 5591−1/A1 Maintenance Servo Oil Pump − Removal and Installation Completion Attach the oil inlet pipes (5 and 11, Fig. 12) to the servo oil pumps (4, 6). WCH02395 Fig. 12 Attach the drain pipes (8, 10) to the servo oil pumps (4, 6). Attach the oil pipe (9) to the servo oil pump (6).

  • Page 379: Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation

    5612−1/A1 Maintenance Servo Oil Rail Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation General ............Preparation .

  • Page 380: Disassemble

    5612−1/A1 Maintenance Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation Removal Make sure that the servo oil rail (1, Fig. 1) has no pressure. If the valve control unit (VCU) to be removed is adjacent to the driving end of the servo oil rail, do step a): Remove the HP hose (3) from the VCU (6).

  • Page 381: 5612−1/A1

    5612−1/A1 Maintenance Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation Installation If the VCU is a new item, carefully remove it from its package. WARNING Injury Hazard: You must put on gloves and eye protection when you use white spirit. White spirit can damage the skin and eyes.

  • Page 382: Relief Valve

    5612−1/A1 Maintenance Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation Relief Valve Maintenance of the relief valve (4, Fig. 5) is not necessary. The relief valve has a factory-set opening pressure of 350 bar. At each major engine overhaul, do a check of the relief valve. Note: A relief valve that has damage or has a leak, must be replaced with a new item.

  • Page 383: Group 6

    ........6735-1/A1 X72 / MM / 2015 Winterthur Gas & Diesel Ltd.
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  • Page 385: Scavenge Air Receiver − Checks And Cleaning

    6420−1/A1 Maintenance Scavenge Air Receiver Clean and do Checks Scavenge Air Receiver − Checks and Cleaning ..... . Flaps ............Removal .
  • Page 386 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Scavenge Air Receiver − Checks and Cleaning Read the data in 0380−1 Scavenge Air Receiver for the applicable Inspection and Overhaul Intervals to clean the scavenge air receiver. You must also clean and do a check of the scavenge air receiver after each piston overhaul.
  • Page 387 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Flaps Removal Remove the three screws (7, Fig. 3) and the tab washers (4). Remove the two flat bars (9, 10) and the stop plate (6). Remove the screw (3) and the tab washer (4). Remove the guide (2), distance ring (8), flap (5) and axle (1).
  • Page 388 Parts can eject at high speed and cause injury. If there is damage or a malfunction, speak to the manufacturer of the relief valve or to WinGD. Do a check of the relief valve during each engine overhaul as follows: Do a visual check for damage and corrosion.

  • Page 389: General

    6545−1/A1 Maintenance Auxiliary Blower Maintenance Tools: 2 Lever chain hoist 94016-009 1 Chain (asymmetric) 94019A 2 Spur gear chain block 94017-006 1 Trolley 94021 4 Shackle 94018C 2 Sling 94650 General ............Procedure One .

  • Page 390: Procedure One

    6545−1/A1 Maintenance Auxiliary Blower: Maintenance Procedure One Preparation Note: Read and obey the data given in 0012-1 General Guidelines for Lifting Tools. Stop the engine. Set to off the power supply. Disconnect the electrical connection from the electric motor (5, Fig.

  • Page 391: 6545-1/A1

    6545−1/A1 Maintenance Auxiliary Blower: Maintenance CAUTION Damage Hazard: Do not put the electric motor on the floor without an applicable support or damage to the impeller can 94018C occur. 94017-006(1) Use the lever chain hoists (94016-009) to carefully move the electric motor (3, Fig.

  • Page 392: Installation

    6545−1/A1 Maintenance Auxiliary Blower: Maintenance Installation Attach the two slings (94650, Fig.5) to the electric motor (3) and impeller (2). Attach the chain block (94017-006(2)) to the trolley (94021). 94021 Attach the chain block (94017-006(2)) to the slings (94650). 94017-006(2) Lift the electric motor (3) and impeller(2).

  • Page 393: Procedure Two

    6545−1/A1 Maintenance Auxiliary Blower: Maintenance 11) Install the screws (4, Fig. 7) to the support (3). 12) Install the screws (2) to the casing (1). 13) Connect the electrical connections to the electric motor (5). 14) Remove all tools and equipment from the area.

  • Page 394: Installation

    6545−1/A1 Maintenance Auxiliary Blower: Maintenance CAUTION Damage Hazard: Do not put the electric motor on 94018C the floor without an applicable support or 94019A damage to the impeller can occur. 94017-006 Put protection on the pipe (4) where the chain block (94017-006) and the lever 94016-009 chain hoist (94016−009) can touch.
  • Page 395 6545−1/A1 Maintenance Auxiliary Blower: Maintenance Use the Carefully operate the chain block (94017−026) and the lever chain hoists (94016−009) to move the electric motor Fig. 10) and impeller (2) under the pipe (4). Continue to operate the chain block 94018C (94017−026) and the lever chain hoists (94016−009).
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  • Page 397: 6606-1/A1

    6606−1/A1 Maintenance Scavenge Air Cooler Removal and Installation Tools: 1 Manual ratchet H3 (WLL 1600kg) 94016-009 2 Safety lugs 94663C 2 Spur-gear chain block 94017-021 2 Safety chains 94663D H1, H2 (WLL 5000kg) 1 Dismantling tool 94663F 2 Trolleys (WLL 5000kg) 94021 1 Support 94663I...
  • Page 398 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation I - I I - I Fig. 2 WCH02408 WCH02408 Removal Removal Procedure − Front SAC Note: If the front SAC (3, Fig. 3) only is to be removed, do only paragraph 2.1. If the rear SAC (2) only, or the two SAC are to be removed, you must first remove the front SAC (3).
  • Page 399 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Remove the four holders (18, Fig. 4) from each end of the SAC (5). Remove the flanges (16), O-rings (19) and the inserts (15). Discard the O−rings. Attach the two safety lugs (94663C) to the SAC (5). Attach the supports (94663A, 94663B) to the positions shown with the screws (20).
  • Page 400 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 14) Attach the spur-gear chain block (H1, Fig. 5) to the double-chain sling (94666). 15) Apply a light tension to the spur-gear chain block (H1). WARNING Injury Hazard: The SAC weighs 3400 kg. When you do the step below, make sure that you do not move the SAC too far.
  • Page 401 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 23) Carefully operate the spur-geared chain block (H1, Fig. 7) to lower the front of the SAC (5). At the same time, carefully move the spur-geared chain block (H2). 24) Continue with step 23) above until the SAC (5) is in a vertical position. WCH02409 WCH02409 Fig.
  • Page 402 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Removal Procedure − Rear SAC Remove the front SAC, refer to paragraph 2.1. Remove the screws (17, Fig. 8), then remove the four holders(18) from the rear SAC (12). Remove the flanges (16), O-rings (19) and the inserts (15). Discard the O-rings. Put the bracket (94664) in position between the two scavenge air receivers.
  • Page 403 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Attach the manual ratchet (94016−009, Fig. 9) to the dismantling pipe (94664A). 10) Attach the manual ratchet (94016−009) to the dismantling pipe (94664A) and to the center swivel lug on the SAC 12. 94048−M30 94016−009 94666C...
  • Page 404 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 13) Attach the two safety chains (94663D, Fig. 10) to the supports (94663A, 94663B) and the safety lugs (94663C). Make sure that the length of the safety chains is sufficient for the full range of travel. 14) Attach the double-chain slings (94666) to the swivel lugs (94666) on the front and rear of the SAC (12).
  • Page 405 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 23) Carefully move the spur-geared chain blocks (H1 and H2, Fig. 12) together with the SAC (12) along the rail (13) until H1 touches the end stop (21). WCH02409 Fig. 12 24) Carefully operate the spur-gear chain block (H1, Fig.
  • Page 406 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Installation Installation Procedure − Rear SAC Make sure that all the surfaces of the SAC (12) and the related surfaces in the scavenge air receiver are clean and have no damage. Apply a layer of silicon compound to each side of the SAC (12) and the related surfaces in the housing in the scavenge air receiver.
  • Page 407 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 11) Continue with step 10) above until the SAC (12, Fig. 16) is in a horizontal position. Make sure that the rear of the SAC is on the supports (94663A/B). 12) Attach the manual ratchet to the support (94663I). 13) Attach the manual ratchet to the center rear swivel lug on the SAC (12).
  • Page 408 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 18) Continue to operate the manual ratchet until the the SAC (12, Fig. 18) is fully in position. 19) Remove the wire rope from the manual ratchet and the rear double-chain sling (94666).
  • Page 409 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Installation Procedure − Front SAC Make sure that all the surfaces of the SAC (5, Fig. 19) and the related surfaces in the scavenge air receiver are clean and have no damage. Apply a layer of silicon compound to each side of the SAC (5) and the related surfaces in the housing in the scavenge air receiver.
  • Page 410 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Use the spur-gear chain block (H1, Fig. 20) to lift the front of the SAC (5). At the same time, move the spur-gear chain block (H2) rearward. 10) Continue with step 9) above until the SAC (5) is in a horizontal position. Make sure that the rear of the SAC is on the supports (94663B).
  • Page 411 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 17) Continue to operate the manual ratchet (94016−029, Fig. 22) until the the SAC (5) is fully in. 94016−009 WCH02409 94663I 94663A 94663B Fig. 22 18) Remove the two double-chain slings (94666) from the SAC (5). 19) Remove the six swivel lugs (94048−M30) from the SAC (5).
  • Page 412 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Completion Install the drain pipes (4 and 10, Fig. 23). Install the vent pipes (7, 8). I - I FRONT REAR WCH02408 WCH02408 I - I WCH02408 Fig. 23 2015 16/ 17 Winterthur Gas &...
  • Page 413 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Install the outlet pipes (6 and 9, Fig. 23). Install the inlet pipes (3 and 11). Open the butterfly valves (1 and 12, Fig. 1) of each SAC (5, 12). Release the air in each SAC (5, 12). Start the cooling water pump.
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  • Page 415: 6708-1/A1

    6708−1/A1 Maintenance Water Separator Removal and Installation Tools: 2 Manual ratchet, H1/H2 94016−009 2 Shackle, WLL 3250 kg 94018A WLL 1600 kg 3 Lifting tool 94667 2 Manual ratchet, H3/H4 94016−031 1 Holder 94667G WLL 500 kg 1 Holder 94667H Preparation .
  • Page 416 6708−1/A1 Maintenance Water Separators: Removal and Installation Removal Procedure Front Water Separator Operate the manual ratchet (H2, Fig. 94667 to pull the water separator (4) sufficiently so you can attach the tool (94667) to the water separator. Attach the tool (94667) to the top of the water separator (4).
  • Page 417 6708−1/A1 Maintenance Water Separators: Removal and Installation 17) Operate the manual ratchet (H1, Fig. to increase the tension. At the same time, operate the manual ratchet (H2) to decrease tension and keep the water 94018A separator level. 18) Attach the engine room crane to the lifting tool (94667).
  • Page 418 6708−1/A1 Maintenance Water Separators: Removal and Installation 13) Attach the manual ratchet (H2, Fig. to the tool (94667) on top of the water separator (2). 14) Disconnect the manual ratchet (H4) from the rear of the water separator (2). 94667 WCH02415 Fig.
  • Page 419 6708−1/A1 Maintenance Water Separators: Removal and Installation Installation 94018A Rear Water Separator Attach the tools (94667, Fig. 10) to the applicable positions on the water separator (2). 94667 Note: When you do step 2), make sure 94667G 94667 that the lugs (3) are at the front. Use the manual ratchets and shackles used before to get the water separator 94667...
  • Page 420 6708−1/A1 Maintenance Water Separators: Removal and Installation Remove the manual ratchets (H1, H2, H3 and H4, Fig. 12). Remove the holder (94667G). Remove the tool (94667) from the rear water separator. 94018A Remove the shackles from the points (P1, P2). 94667G WCH02415 94667...

  • Page 421: 6735-1/A1

    6735−1/A1 Maintenance Scavenge Air Waste Gate Disassemble and Assemble General You must do a function check of the waste gate each six months. To do a function check of the waste gate, refer to the Operation Manual, 6735−1. If a malfunction of the waste gate occurs, do the procedure below as soon as possible: Disassemble Note: The screw...
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  • Page 423: Group 7

    ........... . . 7762−1/A1 X72 / MM / 2016-02 Winterthur Gas & Diesel Ltd.
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  • Page 425 7218−1/A1 Maintenance Cylinder Lubrication System Cylinder Lubricating System ........Cylinder Lubricating System −...

  • Page 426: Cylinder Lubrication System

    7218−1/A1 Maintenance Cylinder Lubricating System DRIVING END 019.002/09 WCH02282 Fig. 1: Cylinder Lubrication Pump − Location 2015 2/ 6 Winterthur Gas & Diesel Ltd.

  • Page 427: Cylinder Lubricating System

    7218−1/A1 Maintenance Cylinder Lubricating System Function Check Visually examine the cylinder oil supply as follows: If necessary, bleed the cylinder lubricating system (see paragraph 3). Make sure that the applicable piston is in the TDC position. Set to on the cylinder lubricating system for the applicable cylinder (see paragraph 1.1).

  • Page 428: 7218−1/A1

    7218−1/A1 Maintenance Cylinder Lubricating System Cylinder Lubricating System − Bleed Bleed the flex lube pump and oil pipes each time you do the maintenance on the cylinder lubricating system. Flex Lube Pump To bleed the flex lube pump (2, Fig. 1), do the steps that follow: Note: When you bleed the cylinder lubricating system, always start at the first cylinder at the free end (nearest to the lubricating oil inlet).

  • Page 429: Duplex Filter

    7218−1/A1 Maintenance Cylinder Lubricating System Duplex Filter For data about the duplex filter (3, Fig. 2), see the Operation Manual, 7218-1, paragraph 2. Clogged Filter Element − Replace Close the ball valve (8). Open the cover (2) of the rail unit (1). Move the lever (6) to select the clean filter element (7).
  • Page 430 7218−1/A1 Maintenance Cylinder Lubricating System FREE END WCH02359 WCH02364 WCH02360 Fig. 2: Duplex Filter 2015 6/ 6 Winterthur Gas & Diesel Ltd.
  • Page 431 7758−1/A1 Maintenance Integrated Electric Balancer Integrated Electric Balancer, Bearing Replacement and Adjustment Tools: 1 Adjusting tool 94701 1 Lifting tool 94704 1 Transportation tool 94702 2 Alignment tools 94705 1 Turning device 94703 Magnetic drill Reamer for taper General ............Preparation .

  • Page 432: General

    Two ELBA installed − one at the driving end and one at the free end. It is only necessary to replace the bearings and replace the bearings always as a pair. If replacing the bearing the first time, it’s recommended to call WinGD for expert advice.

  • Page 433: 7758−1/A1

    7758−1/A1 Maintenance Integrated Electric Balancer DRIVING END Preparation Stop the engine, refer to Operation Manual, 0310−1. Make sure that the electric motor (5, Fig. 1) has stopped. Stop the lubricating oil supply and close the oil inlet. At driving end, put an oil tray under applicable oil pipe (1, Fig.2).

  • Page 434: Bearings − Replace

    7758−1/A1 Maintenance Integrated Electric Balancer I - I Bearings − Replace OUTER ENGINE CAUTION SIDE SIDE Injury Hazard: The weight of the bearing is 45 kg. Use the correct equipment to lift and move the bearing. This will prevent injury to personnel and damage to equipment.
  • Page 435 7758−1/A1 Maintenance Integrated Electric Balancer Attach the lifting tool 94704 to the 94704 manual ratchet and move it in front of the bearing (6, Fig. 5). Turn the screw (4) into the pin (3) and tighten slightly. 10) Turn the nut (5) against the bearing (6) in order to push the lifting tool 94704 against the pin (3).
  • Page 436 7758−1/A1 Maintenance Integrated Electric Balancer 94704 4.1.2 Installation Make sure that the new bearing is clean, dry and in good condition. Apply Molycote D to the bearing surface. Do not install the two taper pins (8, Fig. Attach the lifting 94704 tool to the new bearing (6, Fig.

  • Page 437: Bearing − Outer Side

    7758−1/A1 Maintenance Integrated Electric Balancer I - I Bearing − Outer Side OUTER ENGINE SIDE 4.2.1 Removal SIDE Remove the four screws (3, Fig. 7) on the bearing cover (4) at the outer side. Remove the bearing cover (4). Remove the eight screws (2) from the bearing (5).
  • Page 438 7758−1/A1 Maintenance Integrated Electric Balancer 94704 4.2.2 Installation Make sure that the new bearing (6, Fig. 8) is clean, dry and in good condition. Apply Molycote D to the bearing surface. Do not install the two taper pins (8, Fig. Attach the lifting 94704 tool to the new STEP 2 bearing (6, Fig.

  • Page 439: Check

    Replace bearing if clearance is more than the allowed maximum clearance. For the first time, it’s recommended to Fig. 10 call WinGD for expert advice. Measure Backlash Remove the eight screws (4, Fig. 11) and the cover (5). Make sure the clamping screws (4, Fig.
  • Page 440 7758−1/A1 Maintenance Integrated Electric Balancer CAUTION Injury Hazard: Entanglement of hands can occur. Keep the hands LEAD WIRE away from gears. Use pliers. Get a second person and use 1 mm lead wire to measure the backlash and the parallelism with lead wire between the pinion of the electric motor (1, Fig.

  • Page 441: Adjust Bearings

    Maintenance Integrated Electric Balancer Adjust bearings It is recommended to consult a preferred service partner (e.g. WinGD) if you perform this adjustment the first time. Principle: Loosen all bearings. Remove pins. Lift the upper bearing. Lift lower bearings until the backlash between the pinion and the lower gear wheel is within tolerances.
  • Page 442 7758−1/A1 Maintenance Integrated Electric Balancer Install the four alignment tools 94705 with screws (8). One for each bearing back and front. Apply oil to the screw (8) and tighten it with 280 Nm. Lift the upper bearings rear and front (4 94705 and 4a) with screw (9) to unload the lower gear wheel (2).

  • Page 443: Final Steps

    7758−1/A1 Maintenance Integrated Electric Balancer Final steps: Install eight bolts M20x70 (6, Fig. 17) on each bearing at outer side and tighten them with standard torque. Install eight bolts M20x70(6a) on each bearing at engine side with locking plates (5). Tighten bolts with standard torque and lock them.
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  • Page 445: 7762−1/A1

    7762−1/A1 Maintenance Electric Balancer Sensor Unit Replacement of Proximity Sensor General For position and speed of the balance weights (1) one proximity sensor is installed on each end of the engine: ZS5401C on Driving End ZS5405C on Free End Both are connected to the terminal box (2). Another two proximity sensors (ZS5141C und ZS5142C) for engine speed and crank position are installed at the flywheel (3) near...
  • Page 446 7762−1/A1 Maintenance Crank Angle Sensor Unit: Replacement of Proximity Sensor Replacement Replacement of proximity I - I sensors for balance weights 10) Disconnect the plug with cable from the proximity sensor (ZS540xC). 11) Loosen the nut (4). 12) Remove the sensor (ZS540xC) 13) Screw the new sensor into the sensor adapter (5) to the end stop.
  • Page 447 ......8752−1/A1 X72 / MM / 2016−11 Winterthur Gas & Diesel Ltd. 1/ 1...
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  • Page 449: Exhaust Waste Gate (Low-Load Tuning)

    8135−1/A1 Maintenance Exhaust Waste Gate (Low-load Tuning) General The Low-load Tuning (LLT) uses a specially designed turbocharger system and specified engine parameters. These parameters are related to fuel injection and exhaust valve control and get the best decreased part-load BSFC in LLT. For more data about the exhaust waste gate and LLT, see the Operation Manual 8135−1.
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  • Page 451: Scr Valve − Removal And Installation

    8155−1/A1 Maintenance SCR Valve − Removal and Installation Tools: 1 Lifting tool 94815 Preliminary Operations Stop the engine (refer to the Operation Manual 0310−1). Stop the SCR system (refer to the Operation Manual 9270−1). Stop the control air supply (refer to the Operation Manual 4605−1). Close the ball valve 50−8135_E0_3 (refer to Operation Manual 4003−10).
  • Page 452 8155−1/A1 Maintenance SCR Valve − Removal and Installation II - II For view III, see Fig. 3 WCH03765 Fig. 2: SCR Valve − Removal Note: The procedure that follows shows the removal of one of the SCR valves (1, Fig. 1). The procedures for the other SCR valves (1) are the same.
  • Page 453 8155−1/A1 Maintenance SCR Valve − Removal and Installation Remove the eight screws M12x25 (11) from the hub (8). Carefully remove the cardan rod (3) from the hub (8) Make sure that the cardan rod (3) cannot move. CAUTION The hub (8) is attached to the SCR valve (1) only with the screw (7).
  • Page 454 8155−1/A1 Maintenance SCR Valve − Removal and Installation CAUTION Injury Hazard: The SCR valve (1) is attached to the flange (19) with the four screws (20). Do not remove the four screws (20) before you have installed the tool 94815. Injury to personnel or damage to components will occur.
  • Page 455 8155−1/A1 Maintenance SCR Valve − Removal and Installation 20, 25 26, 27 WCH03765 Fig. 5: SCR Valve − Removal 26) Remove the four screws M36x80 (20, Fig. 5) and washer (25) from the flange (19). 27) Operate carefully the engine room crane to remove the SCR valve (1). 28) Remove the gasket (17).
  • Page 456 8155−1/A1 Maintenance SCR Valve − Removal and Installation Installation Note: The procedure that follows shows the installation of one of the SCR valves (1, Fig. 1). The procedures for the other SCR valves (1) are the same. 94815 WCH03759 Fig. 6: SCR Valve − Tool 94815 Installation Note: Install the lug (21, Fig.
  • Page 457 8155−1/A1 Maintenance SCR Valve − Removal and Installation 20, 25 26, 27 WCH03765 Fig. 7: SCR Valve − Installation Carefully operate the engine room crane to put the SCR valve (1) in the position shown. Attach the two screws M36x80 (20) and washers (25) to the bottom of the flange (19).
  • Page 458 8155−1/A1 Maintenance SCR Valve − Removal and Installation 18) Install the gasket (24) from the top of the flange (18). 19) Attach two hexagon nuts (12) and screws M36x320 (13) to the top of the flanges (18, 19). 20) Slightly tighten the two hexagon nuts (12) and screws M36x320 (13) on the top of the flanges (18, 19).
  • Page 459 8155−1/A1 Maintenance SCR Valve − Removal and Installation 27) Attach the hub (8) to the SCR valve (1). Note: Make sure that the bore in the hub (8) is behind the feather key on the shaft of the SCR valve (1). This will make sure that the screw will hold the hub in position.
  • Page 460 8155−1/A1 Maintenance SCR Valve − Removal and Installation Close Up Make sure that the SCR valve (1) can move freely (refer to the documentation of the valve supplier). Note: For the applicable lubricants and the maintenance guidelines of the cardan rod, refer to the documentation of the cardan rod supplier. Apply applicable lubricant to the cardan rod.
  • Page 461 8447−1/A1 Maintenance HP Servo Oil Pipe Removal, Grind the Sealing Faces and Installation (with Hawe SOP) Tools: 1 Grinding tool 94841 Emery cloth (as necessary) 1 Template 94841A 1 Hand drill Preparation ............Removal .

  • Page 462: Hp Servo Oil Pipe: Removal, Grind The Sealing Faces And Installation (With Hawe Sop)

    8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind the Sealing Faces and Installation (with Hawe SOP) I - I Loosen the screw plug (22, Fig. 2) to drain the HP servo oil pipes (3, 12 and 13). On the flange (1), loosen the four screws (2).
  • Page 463 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind the Sealing Faces and Installation (with Hawe SOP) 15) Loosen the two screws (9, Fig. 2) on the intermediate piece (8). 16) Remove the four screws (6) from the flange (7). 17) Move the flange (7) up. 18) Remove the four screws (2) from the flange (1).
  • Page 464 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind the Sealing Faces and Installation (with Hawe SOP) 16) Make sure that the circular marks around the sealing face of the HP servo oil pipe (1, Fig. 3) are concentric. 17) Change the emery cloth for a smoother grade, then do step 1) to step 16) again until you get a smooth finish.
  • Page 465 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind the Sealing Faces and Installation (with Hawe SOP) I - I Installation Remove all of the protection from the sealing faces (SF) in the valve housing Fig. 5), the intermediate pieces (8, 16) and the servo oil pump (23).
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  • Page 467 8460−1/A1 Maintenance Hydraulic Pipe − Exhaust Valve Drive Removal, Grind the Sealing Faces and Installation Tools: 1 Grinding tool 94841 1 Stencil 94841A Preparation ............Removal .
  • Page 468 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind the Sealing Faces and Installation Preparation WARNING Injury Hazard: The servo oil system has high pressure. Replace a defective hydraulic pipe only when the engine has stopped. Stop the engine (refer to the Operation Manual 4002-2). Set to off the servo oil service pump.

  • Page 469: 8460−1/A1

    8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind the Sealing Faces and Installation Removal I - I CAUTION Damage Hazard: Make sure that you do not damage the sealing faces or the hydraulic pipes. Remove the four screws (1, Fig. from the flange (3). Carefully move the flange (3) away from the VCU (2).
  • Page 470 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind the Sealing Faces and Installation Sealing Faces − Grind To get a clean and smooth finish on the 94841A hydraulic pipe (1, Fig. 5) , do step 1) to step 20): Put the template (94841A) on the back of the emery cloth.
  • Page 471 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind the Sealing Faces and Installation Adjustment Make sure that the claw (3, Fig. 6) is correctly attached to the hydraulic pipe (4). Do a check of the O-rings (1, 2). If the O-rings are unserviceable, replace them.
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  • Page 473: 8733−1/A1

    8733−1/A1 Maintenance HP Fuel Pipe (Injection Valve) Removal, Grind the Sealing Faces and Installation Tools: 1 Grinding tool 94871 1 Hand drill 1 Stencil 94871A Preparation Stop the engine (refer to the Operation Manual 4003−1. Make sure that there is no pressure in the fuel rail as follows: Set to off the fuel booster pump (plant).
  • Page 474 8733−1/A1 Maintenance HP Fuel Pipe (Injection Valve): Removal, Grind the Sealing Faces and Installation 3. Sealing Faces − Grind To get a clean and smooth finish on the HP 94871A injection pipe do the procedure that follows: Put the template (94871A, Fig.
  • Page 475 8733−1/A1 Maintenance HP Fuel Pipe (Injection Valve): Removal, Grind the Sealing Faces and Installation Installation CAUTION Damage Hazard: Make sure that you do not damage the sealing faces or the HP injection pipes. If necessary, replace the O-rings (8, 11, 12 and 15 Fig.
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  • Page 477: 8752−1/A1

    8752−1/A1 Maintenance HP Fuel Pipe Removal, Grind the Sealing Faces and Installation 1 Grinding tool 94870 Grinding tool 94870F 1 Screw-on sleeve 94870E Locknut 94870G Template 94870H Preparation ............Removal .
  • Page 478 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation Preparation WARNING Injury Hazard: The fuel system has high pressure. Replace a defective HP fuel pipe only when the engine has stopped. You must obey the data given in the Operation Manual 0520-1. Stop the engine (see the Operation Manual 4002-2).
  • Page 479 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation Loosen the four screws (2, Fig. 3) on I - I the flange (3) a maximum of three turns. 10) Move the flange (3) away from the valve housing (4) and make sure that air goes into the HP fuel pipe (1).
  • Page 480 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation Removal II - II CAUTION Damage Hazard: Make sure that you do not damage the sealing faces or the HP fuel pipes. Remove the clamps (1, Fig. Remove the four screws (1, Fig.
  • Page 481 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation II - II Remove the four screws (3, 7) from the flange (2). Carefully move the flange (2) away from the intermediate piece (1). WCH02293 Fig. 7 10) Remove the four screws (3, 8) from III - III the flange (2).
  • Page 482 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation 16) Remove the four screws (2, Fig. III - III from the flange (3). 17) Carefully move the flange (3) away from the intermediate piece (4). CAUTION Injury Hazard: The weight of the HP fuel pipe is approximately 32 kg.
  • Page 483 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation Sealing Faces − Grind To remove deep notches of more than 0.1 mm, use emery cloth of medium to 94870H coarse grain (30 to 80 CAMI). For finish grinding, use emery cloth with fine or ultra-fine grains (100 to 600 CAMI).
  • Page 484 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation Installation CAUTION Injury Hazard: The weight of the HP fuel pipe is approximately 32 kg. Use approved equipment or sufficient personnel to lift and move the HP fuel pipe. WCH02293 Do a check for damage of the O-rings (1 and 3,...
  • Page 485 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation III - III CAUTION Damage Hazard: Do not apply lateral force to the HP fuel pipe and the flanges. Damage the sealing faces (SF) and the HP fuel pipe can occur. Loosen the screws (2, Fig.
  • Page 486 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation II - II 13) Loosen the screws (6, Fig. 14) on the support (5) of the intermediate piece (1). CAUTION Injury Hazard: The weight of the HP fuel pipe is approximately 32 kg.
  • Page 487 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation II - II 54.0 mm CAUTION Injury Hazard: The weight of the HP fuel pipe is approximately 43 kg. Use approved equipment or sufficient personnel to lift and move the HP fuel pipe. 39.5 mm 19) Carefully put the HP fuel pipe (8, Fig.
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  • Page 489 ............Pages 36 to 38 X72 / MM / 2015 Winterthur Gas & Diesel Ltd.
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  • Page 491: 9223−1/A1

    9223−1/A1 Maintenance Crank Angle Sensor Unit Proximity Sensor − Replace General The crank angle sensor (CAS) unit (Fig. 1) is installed on the supply unit drive at the driving end. The CAS has four proximity sensors (ST5131−34C). There are two crank angle systems (for redundancy) that monitor the teeth on the intermediate wheel (1).
  • Page 492 9223−1/A1 Maintenance Crank Angle Sensor Unit: Proximity Sensor − Replace Procedures Proximity Sensors (ST5131−34C) − Replace WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Stop the engine. Operate the turning gear to get a tooth (1, Fig.
  • Page 493 9223−1/A1 Maintenance Crank Angle Sensor Unit: Proximity Sensor − Replace Proximity Sensors (ZS5123C−24C) − Replace WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Stop the engine. Operate the turning gear to get the applicable crank angle mark (2, Fig.
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  • Page 495: 9308−1/A1

    9308−1/A1 Maintenance Relief Valve on Cylinder Cover Blow-off Pressure Check Tools: 1 OBEL test bench 94272 2 Pressure gauge 94934A 1 Valve holder 94272C 1 HP hose 94935 1 HP oil pump 94931 General Some cylinder covers have an indicator valve installed together with a relief valve. Other cylinder covers have only an indicator valve.
  • Page 496 9308−1/A1 Maintenance Relief Valve: Blow-off Pressure Check Relief Valve Check There are two alternative procedures to do a check of the relief valve. Procedure One Read the data in the manual for the test bench (94272). 94272C Read the data about calibration fluid in 2722−2, paragraph 1.
  • Page 497 9308−1/A1 Maintenance Relief Valve: Blow-off Pressure Check Installation Apply Never−Seez NSBT-8 to the thread of the relief valve (3, Fig. Install the relief valve (3) and gasket (2) to the adapter (5). Close the indicator valve (1). Fig. 4 WCH02400 2015−06 3/ 3 Winterthur Gas &...
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  • Page 499 9403−1/A1 Maintenance Tools Description of Tool Categories General The tools necessary for the maintenance of the engine are divided into three groups: Standard Tools Recommended Special Tools Special tools available on loan. When it becomes necessary to order more tools or replacements, the tool number and the tool description, which must include the engine type, must be shown (refer to 9403−5).
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  • Page 501: Configuration And Application

    9403−2/A1 Maintenance Hydraulic Jacks and Pumps Configuration and Application Tools: HP oil Pump, 2800 bar 94931 6 Adapter piece 94934F Adapter piece 94934F 7 Distributing piece 94934C Hydraulic unit, 2000 bar 94942 8 Coupling element 94934G HP hose 94935 9 Flexible hose 94935A Pressure gauge 94934A...
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  • Page 503: 9403−3/A1

    9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks Storage, Servicing and Maintenance General The hydraulic pre-tensioning jacks must be kept in their tool boxes when not in use. After you use the pre-tensioning jacks, close the connections with plugs and apply grease. We recommend that, for each jack, you keep a sealing kit (KJ−) in stock. Always make sure that new back-up rings and O-rings are installed in their correct positions, as shown in the data that follows.
  • Page 504 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Overview of Pre-tensioning Jacks Tool 94110 Thrust Device for Main Bearing Cover 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring...
  • Page 505 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94114 Double pre-tensioning jack for elastic bolts to main bearing 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Double cylinder 10 Backing bush 5 Back-up ring 11 Tension sleeve...
  • Page 506 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94145 Pre-tensioning jack for foundation bolts and engine stays 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring 94145−KJ Kit with back-up and O-rings...
  • Page 507 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94180 Pre-tensioning jack for tie rods 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring 94180−KJ Kit with back-up and O-rings for double pre-tensioning Jack...
  • Page 508 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94215A Pre-tensioning jack for elastic bolts to cylinder cover 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring 94215A−KJ Kit with back-up and O-rings...
  • Page 509 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94252 Pre-tensioning jack for elastic bolts to exhaust valve cage and bottom connecting rod studs 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring...
  • Page 510 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94315 Pre-tensioning jacks for elastic bolts to top connecting rod bearing 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring...
  • Page 511 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94320 Pre-tensioning jacks for elastic bolts to turning gear 1 Piston 7 Vent screw 2 Back-up ring 8 Casket Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring 94320−KJ Kit with back-up and O-rings...
  • Page 512 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94340 Pre-tensioning jack for piston and piston rod foot to crosshead 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter Piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring...
  • Page 513 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94430A Pre-tensioning jack for roller lifting tool (supply unit) 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring 94430A−KJ Kit with back-up and O-rings...
  • Page 514 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Tool 94557 Pre-tensioning jacks for elastic bolts to top end bearing (supply unit) 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring...

  • Page 515: General Instructions

    9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks General Instructions Hydraulic pre-tensioning jacks for: Version 1: Version 2: Foundation bolt and engine stay 94145 Main bearing 94114 Tie rod 94180 Cylinder cover 94215A Exhaust valve cage and 94252 bottom connecting rod studs Top end bearing 94315 Turning gear 94320...

  • Page 516: 9403−4/A1

    9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Instructions Loosen Version 1 − Preparation Make sure that the vent screw (6) is open (see Fig. Put the hydraulic jack on to the elastic stud (5). Turn the hydraulic jack until it is tight. Make sure that there is no clearance at X. Version 2 −...
  • Page 517 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Instructions Apply Tension Turn the round nut (4) fully down (Fig. 1 Fig. 2). Make sure that there is no clearance at the slot (10). Put one reference mark (Y) on the nut and one on the part below (X) (see Fig.
  • Page 518 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Instructions Table 1 − Hydraulic Jacks − Values and Comparison Application Group Jack Tightening Comparison Reset Jack / Lubricating Value [bar] [_(, mm] Round Nut Agent 2) [turns] Foundation bolts 1112−1 94145 1500 − MOLYKOTE step 1000) ¼...
  • Page 519 9403−5/A1 Maintenance Tool List Standard Tools 94000 Combination wrenches, set complete consisting of: 34 wrenches AF6 to AF60 for ordering single wrenches state AF 94000−06 Example: ..94000−06 94000−60 94000−60 94001 Open end wrenches 94001−85 1 Piece .

  • Page 520: 9403−5/A1

    9403−5/A1 Maintenance Standard Tools 94009 Handle − screw 94009−M5 1 Pieces ..M5x150 94009−M8 1 Pieces ..M8x100 000.372/93 94009−M10 1 Pieces ..M10x100 94011−02 1 Torque spanner ½” No ratchet mechanism WCH02296 (Range of adjustment 12−68 Nm) 94011−03...

  • Page 521: Standard Tools

    9403−5/A1 Maintenance Standard Tools Shackle 94018A WLL 3250 kg 94018B WLL 4750 kg 94018C WLL 8500 kg WCH02297 Chain 94019A 1089x1323 mm, WLL 5300 kg 94019B 1089x1089 mm, WLL 5300 kg 94019C 314x314 mm, WLL 1000 kg WCH02297 94021 1 Trolley WLL 5000 kg WCH02297 Socket wrench inserts...
  • Page 522 9403−5/A1 Maintenance Standard Tools 94045 Eye bolt 94045−M8 6 Pieces ..94045−M10 4 Pieces ..94045−M12 3 Pieces ..94045−M16 4 Pieces ..94045−M20 2 Pieces ..94045−M24 4 Pieces .
  • Page 523 9403−5/A1 Maintenance Standard Tools 94101 1 Inside micrometer Set (7 pieces with a measuring range 50 ... 1010 mm), with case WCH02258 94110 1 Thrust device for removal and fitting of main bearing cover X = 880 mm Mass approx. 84 kg WCH02251 94114 2 Double pre-tensioner...
  • Page 524 9403−5/A1 Maintenance Standard Tools 94117 1 Roller support for removal and fitting of main bearing cover X = 232 mm (WLL 1200 kg) WCH02247 94117B 1 Deviation pipe for removal and fitting of: − main bearing, cover, shell − connecting rod, cover, shell −...
  • Page 525 9403−5/A1 Maintenance Standard Tools 94123 1 Bearing feeler gauge for main bearing X = 620 mm Blade thickness 0.1 ... 1.1 mm 000.395/93 (11-part) 94126 1 Depth gauge with case X = 310 mm WCH02250 94141A 1 Bracket for removal and fitting of main bearing shells X = 300 mm Y = 345 mm...
  • Page 526 9403−5/A1 Maintenance Standard Tools 94142 2 Working platforms X =770 mm WCH02246 Z = 240 mm Mass approx. 10.4 kg (max. loading 200 kg/m 94143 2 Working supports consisting of 3 grids each X =1969 mm Z = 947 mm Mass approx.
  • Page 527 9403−5/A1 Maintenance Standard Tools 94180 2 Pre-tensioner for tie rods X = 286 mm Y = 451 mm Mass approx. 73 kg WCH02424 94201 1 Lifting device for fitting and transporting a cylinder Liner X = 1054 mm Mass approx. 250 kg 94201D 94201A (WLL 6500 kg)
  • Page 528 9403−5/A1 Maintenance Standard Tools 94213 1 Dismantling tool X = 104 mm WCH02256 94215 1 Lifting tool for cylinder cover pre-tensioners Mass approx. 63.6 kg 94209A Including: 94215D 94209A 1 Wire rope sling with hook 94215G 94215G 1 Lifting tool 94215D 6 Hook with shackle = 1252 mm...
  • Page 529 9403−5/A1 Maintenance Standard Tools 94224 1 Ladder for measuring cylinder liner bore X = 350 mm Y = 3550 mm 000.420/93 94225 1 Measuring gauge for measuring cylinder liner bore (accessory for it: inside micrometer tool 94101) 000.419/93 X = 3370.5 mm 94230 2 Distance holders for removal and fitting of piston rod...
  • Page 530 9403−5/A1 Maintenance Standard Tools 94231E 1 Template for fitting scraper rings X = 262 mm 016.756/08 94232 1 Covering for covering bore of piston rod gland in cylinder jacket (when piston and gland are removed) X = ∅ 516 mm Mass approx.
  • Page 531 9403−5/A1 Maintenance Standard Tools 94261 1 Valve seat fitting and dismantling device X = 616 mm Mass approx. 43 kg 016.766/08 94263 2 Jack screws M12x150 for assembling guide bush to exhaust valve, including: 2 hexagon nut M12 016.769/08 94265 1 Suspension device for cylinder cover (WLL 2900 kg)
  • Page 532 9403−5/A1 Maintenance Standard Tools 94270 1 Cutting device 94270A for overhauling injection valve (with FAST) seat in cylinder cover X = 564 mm including: 94270A 1 Profile cutter WCH02302 94270C 2 Hexagon head bolt For Injection valve X = 170 mm WCH02263 94270D 2 Stud bolt...
  • Page 533 9403−5/A1 Maintenance Standard Tools 94273 1 Valve holder to OBEL test bench WCH01208 for fastening injection valve with FAST X = 582 mm Y = 602 mm 94275 1 HP hose to OBEL test bench for testing, loosening and tightening of coupling nut to injection valve WCH01208 X = 1350 mm...
  • Page 534 9403−5/A1 Maintenance Standard Tools 94292 1 Template for checking wear of exhaust valve spindle X = 300 mm WCH02386 94305 1 Crankshaft checking equipment for measuring crank deflection (in wooden box) X = 364 mm 000.412/93 94315 2 Pre-tensioner for connecting rod studs to top end bearing X = 138 mm WCH02265...
  • Page 535 9403−5/A1 Maintenance Standard Tools 94322 2 Support For crosshead X = 344 mm WCH02266 94322A 1 Support (Engines with ELBA) For crosshead X = 800 mm WCH03102 94324 1 Lifting tool For connecting rod assembly X = 336 mm Mass approx. 56.9 kg (WLL 8200 kg) WCH02266 94325...
  • Page 536 9403−5/A1 Maintenance Standard Tools 94327 1 Chain for removal and fitting lower connecting rod bearing shell 4 slings à 654 mm Mass approx. 5 kg (WLL 1120 kg) WCH02420 94333 1 Holder To hold the piston X = 200 mm WCH02271 94334 1 Bracket...
  • Page 537 9403−5/A1 Maintenance Standard Tools 94336 1 Connecting flange for pre-lubrication of top and bottom end bearings X = ∅ 160 mm 016.798/08 9433 1 Connecting piece for pre-lubrication of top and bottom end bearings X = 105 mm Y = 107 mm 94337 2 Lifting tools with 4 screws M20x90...
  • Page 538 9403−5/A1 Maintenance Standard Tools 94340 3 Pre-tensioner for piston rod foot fastening and Piston head. including a metal box X = ∅ 76 mm WCH02273 94341 1 Piston suspension device X = 611 mm Y = 238 mm Z = 215 mm 94341B (WLL 7350 kg) 94341A...
  • Page 539 9403−5/A1 Maintenance Standard Tools 94348 1 Tap M24 for cleaning carbon deposits in threaded holes of piston crown 000.398/93 94364A Jacking screws for separating of piston head M20x220 94364B Jacking screws for separating of the spraying plate M12x70 94364C Jacking screws 017.028/08 for separating of piston skirt M20x70...
  • Page 540 9403−5/A1 Maintenance Standard Tools 94430 1 Roller lifting tools for cutting out and cutting in of fuel pump, including: elastic bolts and round nut X = 197 mm WCH02278 94430A 1 Pre-tensioner for roller lifting tool X = ∅ 108 mm WCH02278 94550 1 Clamping ring 2-parts...
  • Page 541 9403−5/A1 Maintenance Standard Tools 94552 1 Lifting tool with head screws M14x40 for removal and fitting of a fuel pump X = ∅ 120 mm (WLL 600 kg) WCH02281 94553 1 Rod Guide rod to fuel pump X = 470 mm WCH02281 94555 2 Distance piece...
  • Page 542 9403−5/A1 Maintenance 94557 2 Pre-tensioning jacks for elastic bolts to camshaft bearing X = ∅ 112 mm 016.863/08 24/ 37 Winterthur Gas & Diesel Ltd.
  • Page 543 9403−5/A1 Maintenance Standard Tools 94566 2 Support for camshaft assembly, including clamping nut X = 925 mm Y1 = 180 mm Mass approx. 23 kg WCH02278 94566B 1 Holder for camshaft assembly, including hexagon socket screw X = 172 mm WCH02278 94566C 1 Holder for camshaft assembly,...
  • Page 544 9403−5/A1 Maintenance Standard Tools 94567B 1 Jacking screw for camshaft assembly X = ∅ 75 mm WCH02278 94569 1 Blank flange to fuel pump, including screws M14x25 X = ∅ 120 mm WCH02278 94569A 1 Blank flange to intermediate piece, including screws M14x50 X = ∅...
  • Page 545 9403−5/A1 Maintenance Standard Tools 94593 1 Guide bracket for Pre-tensioning device X = ∅ 370 mm Mass approx. 23.5 kg 94593C 94593A 1 Ring 94593D 94593B 1 Ring (2-part) 94593A 94593C 2 Guide rods 94593B 94593E 94593D 4 Screws M12x130 With special nuts 94593E 2 Screws M30x110...
  • Page 546 9403−5/A1 Maintenance Standard Tools 94650 2 Round sling X = 1750 mm WCH02379 If a turbocharger becomes defective, engines with one MET 60 MB turbocharger 94653D 1 Cover To turbocharger outlet X = 520 mm 000.487/93 If a turbocharger becomes defective, engines with two MET 60 MB turbochargers 94653D Covers (only with suction pipe)
  • Page 547 9403−5/A1 Maintenance Standard Tools 94663A 1 Support left including safety chain 94663D and 94663C safety lug 94663C 94663D for removal and fitting of scavenge air cooler X = 681 mm (WLL 3800 kg) Mass approx. 33 kg WCH02285 94663B 1 Support right 94663C including safety chain 94663D and 94663D...
  • Page 548 9403−5/A1 Maintenance Standard Tools 94666 1 Chains (double sling) for removal and fitting of scavenge air cooler X = 625 mm WCH02285 94667 3 Lifting tool for removal of water separator, including: 4 Hexagon head screw M12x30 X = 300 mm (WLL = 240 kg WCH02287 94667G 1 Holder...
  • Page 549 9403−5/A1 Maintenance Standard Tools 94820 1 Cover SCR failure X = 1105 mm including: 48 Hexagon head screw M36x100 48 Hexagon nut M36 WCH03756 94831 1 Blind flange for blanking off starting air pipe during emergency operation X = ∅ 235 mm WCH02289 94841 Grinding tool...
  • Page 550 9403−5/A1 Maintenance Standard Tools 94870 1 Grinding device 94870F For HP fuel pipe X = 166 mm 94870E consisting of: 94870G 94870E 1 Screw-on sleeve AF60 WCH02751 94870F 1 Grinding tool with countersunk screw 94870H 94870G 1 Lock nut M36x2, AF46 94870H 1 Template X = 70 mm...
  • Page 551 9403−5/A1 Maintenance Standard Tools Hydraulic parts and pump 94931 HP oil pump working pressure maximum allowable 94934F 2800 bar 010.001/02 Adapter piece 94934F 94934 2 Connection block 005.956/00 94934A 2 Pressure gauges 010.242/02 94934C 1 Distributing piece WCH00911 94934G 4 Coupling elements 013.620/05 94935 5 HP hoses...
  • Page 552 9403−5/A1 Maintenance Standard Tools 94935C 1 Hose for oil drain of pre-tensioning jacks 013.621/05 94936 2 Hydraulic ram with closing valves working range 933 ... 1002 kN (95 ... 100 t) 005.952/00 94942 1 Hydraulic unit working pressure max. 2000 bar 013.622/05 2015 34/ 37...

  • Page 553: Recommended Special Tools

    9403−5/A1 Maintenance Recommended Special Tools 94234 1 Platform for piston rod gland removal inside the engine X = ∅ 850 mm Mass approx. 35 kg WCH02382 94235 1 Lifting tool for piston rod gland X = 453 mm WCH03571 94270H 1 Retaining bracket X = 1749 mm Y = 1306 mm Mass approx.
  • Page 554 9403−5/A1 Maintenance Standard Tools 94291 Valve grinding device complete 94291A for valve spindle and valve seat 94291A Grinding discs (C-M No. 11373-01-01) WCH03339 WCH03339 94299 1 Grinding device X = ∅ 834 mm WCH02384 94300 1 Tool Cupboard X = 725 mm Y = 1000 mm Z = 717 mm Mass approx.
  • Page 555 9403−5/A1 Maintenance Recommended Special Tools 94356 1 Equipment case with instruments for measuring thickness of chrome- ceramic-layer on piston rings WCH01216 94595 1 Hydraulic ram for assembling fuel pump X = ∅ 270 mm Mass approx. 79.4 kg consisting of: WCH02281 94595D 1 Piston reset device X = 255 mm...
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