WinGD X82-B Maintenance Manual
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WinGD X82-B Maintenance Manual

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Maintenance Manual
"Marine"
Vessel:
Type:
Engine No.:
Document ID:
Winterthur Gas & Diesel Ltd.
Schützenstrasse 1−3
CH-8400 Winterthur
Switzerland
24hrs Support:
Wärtsilä Services Switzerland Ltd.
Zürcherstrasse 12
CH 8400 Winterthur
Switzerland
+41 52 262 80 10
technicalsupport.chts@wartsila.com

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  • Page 1 Maintenance Manual “Marine” Vessel: Type: Engine No.: Document ID: Winterthur Gas & Diesel Ltd. 24hrs Support: Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd. CH-8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland +41 52 262 80 10 technicalsupport.chts@wartsila.com...
  • Page 2 E 2017 Winterthur Gas & Diesel Ltd. – All rights reserved No part of this publication may be reproduced or copied in any form or by any means (electron- ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder.
  • Page 3 Maintenance Manual “Marine” Vessel: Type: Engine No.: Document ID: Winterthur Gas & Diesel Ltd. 24hrs Support: Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd. CH-8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland +41 52 262 80 10 technicalsupport.chts@wartsila.com...
  • Page 4 E 2017 Winterthur Gas & Diesel Ltd. – All rights reserved No part of this publication may be reproduced or copied in any form or by any means (electron- ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder.

  • Page 5: 0330-1/A1

    SCR Valve Removal New document and Installation 9403-5/A1 2018 WinGD Input Tools Pge 41: New lifting tool 94815 added. Date of publication 2018-04 0330-1/A1 Dec-18 WinGD Input Clearance Table Pge 3: Gp1132 bearing shell clearance changed Date of publication 2018-12 05/12/2018...
  • 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 Crank Angle Sensor Unit, Tools...
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  • Page 8: Table Of Contents

    Group0 Maintenance General Information Group 0 For Particular Attention ..........0000−1/A1 Preface .
  • Page 9 Intentionally blank...

  • Page 10: General

    0000−1/A1 Maintenance For Your Attention General This manual is for the operator and is for use only for the related type of diesel engine (the engine described in this manual). The data in this manual is confidential. Make sure that you read carefully the Operation Manual before you operate the engine.
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  • Page 12 0001−1/A1 Maintenance Preface The instructions contained in this Maintenance Manual are intended to help to ensure that the maintenance which must be carried out at specific intervals is correctly carried out. It is a condition that the personnel who do such important work have the necessary training and experience.
  • Page 13 Intentionally blank...
  • Page 14 0002−1/A1 Maintenance Table of Contents Table of Contents General Information Group 0 For Particular Attention ..........0000−1/A1 Preface .
  • Page 15 0002−1/A1 Maintenance Table of Contents Bedplate and Tie Rod Group 1 Bedplate and Thrust Bearing: Checking the Foundation Bolts ....1112−1/A1 Main Bearing − Loosening and Tensioning of Elastic Studs .
  • Page 16 0002−1/A1 Maintenance Table of Contents Crankshaft, Connecting Rod and Piston Group 3 Crankshaft: Measuring Crank Deflection ........3103−1/A1 Vibration Damper −...
  • Page 17 0002−1/A1 Maintenance Table of Contents Supply Unit, Injection and Exhaust Valve Control Group 5 Fuel Pump − Dismantling and Assembling ......... . 5556−1/A1 −...
  • Page 18 0002−1/A1 Maintenance Table of Contents Piping Group 8 Exhaust Waste Gate (Low-Load Tuning) ........8135−1/A1 Selective Catalytic Reduction System .
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  • Page 20 0008−1/A1 Maintenance General Engine Numbering and Designations Turbocharger 2 Turbocharger 1 Cylinder Numbering FREE DRIVING Thrust Bearing Pads Main Bearing Numbering Rail Unit FUEL EXHAUST SIDE SIDE Servo Pump Unit Fuel Pump Unit Fuel Pump Unit Clockwise Rotation Fig. 1 WCH01188 2017 1/ 2...
  • Page 21 0008−1/A1 Maintenance flex Parts: Fuel Pump B1 Fuel Pump B2 Fuel Pump B3 Actuator B1 Servo Oil Pump 3 Servo Oil Pump 2 Actuator B2 Servo Oil Pump 1 Actuator B3 Fuel Pump A1 Fuel Pump A2 Fuel Pump A3 Actuator A1 Actuator A2 EXHAUST SIDE...

  • Page 22: General Safety Precautions

    0011−1/A1 Maintenance General Guidelines for Maintenance Safety Measures and Warnings General ............General safety precautions .
  • Page 23 0011−1/A1 Maintenance Safety Measures and Warnings Precautions before the Start of Maintenance CAUTION Damage Hazard: Do not use water or cleaning fluid to clean the electronic components and control boxes on the engine and the rail unit. Damage can occur if water or cleaning CAUTION Damage Hazard: When electrical welding is done near or on the engine, electromagnetic fields or peak voltage can occur.
  • Page 24 0011−1/A1 Maintenance Safety Measures and Warnings Special safety measures WARNING Injury Hazard: After engine operation in gas mode, gas fuel can stay in the gas inlet pipes. There is a risk of explosion. You must replace the gas fuel with inert gas (e.g. nitrogen). For the procedure, refer to the documentation of the gas valve unit manufacturer.
  • Page 25 0011−1/A1 Maintenance Safety Measures and Warnings Recommendations Read the data in 3301−1 Work Platform. Do the work carefully. Make sure that all parts and equipment are clean. Use only the applicable tools and equipment for the maintenance tasks. For data about the tools and equipment, refer to 9403−5 Tool List.
  • Page 26 0012−1/A1 Maintenance General Guidelines for Lifting Tools Wire Rope Slings, Span-sets, Eye Bolts, etc. General ............Lifting Equipment .
  • Page 27 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. Lifting capacity (for information purposes only): Table 1: Values Lifting capacity [kg] Eye bolts and eye nuts, single-strand double-strand (45°) thread size 1200 1800 1290 3200 2300 4600 3300 6300 4500 8600 6100 11 500...
  • Page 28 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. 2.41. RUD Eye Bolts RUD eye bolts must be fully attached to the seating surfaces. Use the applicable star-profile wrenches to tighten RUD eye bolts with your hand (do not use an extension). After the RUD eye bolt is tightened, remove the star-profile wrench (Fig.
  • Page 29 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. 2.42. RUD Swivel Lugs RUD swivel lugs must be fully attached to the seating surfaces. Use an open-ended wrench to tighten the RUD swivel lugs with your hand. Align the RUD swivel lug with the direction of force before a load is applied (Fig.
  • Page 30 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. Data to Attach Ropes and Slings You must know the data that follow: A sling with one strand has the total of load weight For a sling with two strands, each strand has one half of the load weight For a sling with four strands of equal load, each strand has one quarter of the load weight.
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  • Page 32: General

    0330−1/A1 Maintenance Clearance Table General ............Crankshaft and Thrust Bearing .

  • Page 33: Crankshaft And Thrust Bearing

    0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing 016.893/08 Fig. 1 016.851/08 018.678/09 Fig. 2 Fig. 3 2017 2/ 25 Winterthur Gas & Diesel Ltd.
  • Page 34 0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 1132 Main bearing Bearing shell width Lateral clearance per side 1203 Thrust bearing 1224 − 0.5 Thrust bearing pad thickness −...

  • Page 35: Crankshaft And Main Bearing

    0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing 016.778/08 Fig. 4 Fig. 5 MAIN BEARING MAIN BEARINGS No. 1 No. 2 to ... Fig. 6 016.893/08 2017 4/ 25 Winterthur Gas & Diesel Ltd.
  • Page 36 0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 1132 Main bearing No. 1 Crankshaft outer ∅ 1020 − 0.10 Main bearing inner ∅ 1020 Bearing clearance vertical 0.4−0.7...

  • Page 37: Crosshead Guide

    0330−1/A1 Maintenance Clearance Table Crosshead Guide EXHAUST SIDE Fig. 7 016.783/08 2017 6/ 25 Winterthur Gas & Diesel Ltd.
  • Page 38 0330−1/A1 Maintenance Clearance Table Crosshead Guide Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 3326 Crosshead guide + 0.25 Guide bar (column) transverse 1390 − 0.20 Guide shoe transverse 1390 − 0.30 Guide way clearance 0.2−1.3 Guide rail...

  • Page 39: Cylinder Liner

    0330−1/A1 Maintenance Clearance Table Cylinder Liner Fig. 8 017.003/08 Fig. 10 016.501/07 Fig. 9 2017 8/ 25 Winterthur Gas & Diesel Ltd.
  • Page 40 0330−1/A1 Maintenance Clearance Table Cylinder Liner Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 2130 Water guide jacket on cylinder cover + 0.50 Water guide jacket upper part Ø 1137 + 0.30 Clearance total 0.60−1.00...

  • Page 41: Piston Rod Gland

    0330−1/A1 Maintenance Clearance Table Piston Rod Gland 016.997/08 99.7406 Fig. 11 2017 10/ 25 Winterthur Gas & Diesel Ltd.
  • Page 42 0330−1/A1 Maintenance Clearance Table Piston Rod Gland Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 2303 Piston rod gland Ring width radial min. 25 Ring width radial min. 22.20 Ring width radial min.

  • Page 43: Exhaust Valve

    0330−1/A1 Maintenance Clearance Table Exhaust Valve VALVE SPINDLE GUIDE BUSH 016.995/08 Fig. 13 016.994/08 Fig. 12 2017 12/ 25 Winterthur Gas & Diesel Ltd.
  • Page 44 0330−1/A1 Maintenance Clearance Table Exhaust Valve Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 2751 Valve spindle − 0.19 Spindle outer ∅ 79.40 − 0.23 2751 Guide bush + 0.03 Bore inner ∅ 80.45 + 0.03 Bore...

  • Page 45: Top And Bottom End Bearings To Connecting Rod

    0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod 016.783/08 Fig. 15 Fig. 14 016.993/08 016.993/08 Fig. 16 2017 14/ 25 Winterthur Gas & Diesel Ltd.
  • Page 46 0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 3303 Top end bearing 3326 Crosshead pin outer ∅ − 0.09 Bearing inner ∅...

  • Page 47: Piston Cooling And Crosshead Lubricating Link

    0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubricating Link EXHAUST SIDE 016.996/08 003.314/00 Fig. 17 2017 16/ 25 Winterthur Gas & Diesel Ltd.
  • Page 48 0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubricating Link Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 3603 Piston cooling and crosshead lubricating link outer ∅ Bearing clearance radial 0.03−0.09 0.20 Bearing width Lateral clearance...

  • Page 49: Piston And Piston Rings

    0330−1/A1 Maintenance Clearance Table Piston and Piston Rings Fig. 18 2017 18/ 25 Winterthur Gas & Diesel Ltd.
  • Page 50 0330−1/A1 Maintenance Clearance Table Piston and Piston Rings Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 3406 Piston head − 0 Head (tapered part) outer ∅ 813.2 − 0.2 − 0 Head outer ∅...

  • Page 51: Driving Wheels For Supply Unit

    0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit INTERMEDIATE WHEEL FOR FUEL PUMP UNIT 016.823/08 Fig. 19 INTERMEDIATE WHEEL FOR SERVO PUMP UNIT 2a 3a 3a 2a Fig. 21 Fig. 20 016.661/08 016.662?08 2017 20/ 25 Winterthur Gas & Diesel Ltd.
  • Page 52 0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 4122 Intermediate wheel fuel pump Shaft outer ∅ Bearing clearance vertical *0.096−0.170 0.27 Axial clearance total 0.6−1.1 4121...

  • Page 53: Fuel And Servo Pump Units

    0330−1/A1 Maintenance Clearance Table Fuel and Servo Pump Units FUEL PUMP UNIT 016.862/08 Fig. 22 SERVO PUMP UNIT Fig. 23 WCH01164 2017 22/ 25 Winterthur Gas & Diesel Ltd.
  • Page 54 0330−1/A1 Maintenance Clearance Table Fuel and Servo Pump Units Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 5581 Fuel pump unit Pinion outer ∅ − 0.025 + 0.212 Bearing (fitted) inner ∅ + 0.153 Bearing clearance radial...

  • Page 55: Fuel Pump

    0330−1/A1 Maintenance Clearance Table Fuel Pump PLUNGER & CYLINDER Fig. 25 014.104/06 WCH00832 Fig. 24 2017 24/ 25 Winterthur Gas & Diesel Ltd.
  • Page 56 0330−1/A1 Maintenance Clearance Table Fuel Pump Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 5556 Fuel pump Plunger (40, 44 and 46 mm) Clearance (plunger / cylinder) A−B radial 0.035−0.038 0.045 Clearance (plunger / cylinder) B−C radial 0.025−0.028 0.035...
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  • Page 58 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections Note: Do not use the values given in brackets eg [900 Nm] as the tightening value. These values are for data only, to be used comparison. When using different hydraulic jacks, the applicable pressure in bar must be calculated in relation to the jack piston surface.
  • Page 59 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2017 2/ 6 Winterthur Gas & Diesel Ltd.
  • Page 60 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2017 3/ 6 Winterthur Gas & Diesel Ltd.
  • Page 61 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2017 4/ 6 Winterthur Gas & Diesel Ltd.
  • Page 62 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2017 5/ 6 Winterthur Gas & Diesel Ltd.
  • Page 63 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2017 6/ 6 Winterthur Gas & Diesel Ltd.
  • Page 64 0352−2/A1 Maintenance Tightening Values of Standard Screwed Connections 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. The threads and base of the head must be lubricated with oil SAE 30. For the screws in high temperature areas (exhaust pipes, expansion pieces etc), a heat resistant lubricant, e.g.
  • Page 65 0352−2/A1 Maintenance Tightening Values of Standard Screwed Connections Elastic studs ⇒ Read the data in the manual of the jointing compound manufacturer. ⇒ 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 66 0360−1/A1 Maintenance Masses (Weights) Components each in kg Group Component Execution Main bearing cover (special) 900 (568) 1115 1134 Main bearing shell (special) 232 (159) 1224 Thrust bearing pad 1717 Casing (top part) free end Casing (top part) (9−cyl has two parts) driving end 65.1 to 169 1720...
  • Page 67 0360−1/A1 Maintenance Components each in kg Group Component Execution 3303 Connecting rod All parts 6561−6569 Elastic stud with nut for bottom end bearing Elastic stud with nut for top end bearing 3306 Connecting rod shank 5491−5498 3306 Bearing cover for bottom end All parts bearing with elastic studs 3310...
  • Page 68 0360−1/A1 Maintenance Components each in kg Group Component Execution 5591 Servo pump unit Dynex Bosch 5556 Fuel pump All parts 5564 Injection control unit All parts 5580 Fuel pump unit assembly With 4 fuel pumps 5581 Fuel pump unit With 4 fuel umps 5591 Servo pump unit with pumps, gear With 2 SOP...
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  • Page 70 0380−1/A1 Maintenance Maintenance Schedule Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) Lubricating oil − Laboratory analysis 3000 Main fuel and − Do a check of the filter elements −specially for 3000 white metal particles (clean or replace filter as lubricating oil filters necessary).
  • Page 71 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 1715−1 Engine stays − Hydraulic type: Do a check of the oil pressure monthly at the gauge 1903−1 Tie rod − Do a check of the pre−tension, if necessary 30000 apply tension again.
  • Page 72 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 2722−1 Injection valve − Do an external heck for tightness before engine start (main fuel after a longer engine injector) stop − Do a function check (nozzle tip inspection, 6000 opening pressure).
  • Page 73 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 3103−1 Crankshaft − Always measure the crank deflection after the 6000 ship has run aground, and after each docking. 3130−1 Torsional − Get a silicon oil sample from viscous vibration first time after vibration damper (the damper manufacturer will make a...
  • Page 74 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 3403−1 Piston − Remove and clean 36000 − Do a check for tightness on the installed piston after installation and with running oil pump. Do a visual check through scavenge ports 3403−3 −...
  • Page 75 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 4325−1 Starting air − Estimated service life: Starting air shut−off Service life of engine shut-off valve valve Control air filter − Drain the filter weekly −...
  • Page 76 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals & Service Life (operation hours) − Estimated service life: Fuel pressure control Service life of engine valve 5562−2 Fuel − Do a function check on the test bench 24000 to 36000 overpressure safety valve / Relief Valve...
  • Page 77 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals & Service Life (operation hours) 6420−1 Air filter − Clean the filter at an np increase of 50% as necessary compared to the shop test value at the same engine load (see Operation Manual 6510−1) 6545−1 Auxiliary blower...
  • Page 78 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 8135−1 Exhaust waste − General Inspection. During a longer operation In accordance with period at low engine load, manually open the gate (LLT) instructions of valve butterfly valve (refer to Operation Manual manufacturer 8135−1)
  • Page 79 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 9223−1 Crank angle − Replace the proximity sensor as necessary sensor (CAS) unit on gear wheel 9308−1 Cylinder cover − − Do a check of the blow−off pressure as necessary Relief valve 9314−1...
  • Page 80 0803−1/A1 Maintenance Engine Cross Section and Longitudinal Section Cross Section 2728−1 8460−1 8733−1 2722−1 6545−1 5562−1 5612−1 6420−1 4325−1 8447−1 6606−1 3326−1 6708−1 3326−2 3301−1 3206−1 4103−1 4103−2 1112−1 018.263/09 2017 1/ 2 Winterthur Gas & Diesel Ltd.
  • Page 81 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 3326−1 5556−1 3326−2 5591−1 3303−1 5581−1 3303−4 3140−1 4103−1 9223−1 1132−1 1132−2 3103−1 1203−1 1224−1 3130−1 3130−2 018.264/09 2017 2/ 2...

  • Page 82: Bedplate And Tie Rod Group

    Group1 Maintenance Bedplate and Tie Rod Group 1 Bedplate and Thrust Bearing: Checking the Foundation Bolts ....1112−1/A1 Main Bearing − Loosen and Apply Tension to Elastic Studs .
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  • Page 84: Bedplate And Thrust Bearing Checking The Foundation Bolts

    1112−1/A1 Maintenance Bedplate and Thrust Bearing Checking the Foundation Bolts Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Vent screw 11 Nut 1 Pre-tensioning jack 94145 2 Cylinder 12 Conical socket 1 HP oil pump 94931 3 Piston 13 Joint disc 2 Hydraulic distributors 94934A 4 Nut...
  • Page 85 1112−1/A1 Maintenance Bedplate and Thrust Bearing Checking the Foundation Bolts Foundation bolts − Loosen or Apply Tension You start the procedure to apply tension to the foundation at the driving end, and from one side to the other. The procedure is completed at the free end. ⇒...
  • Page 86 1112−1/A1 Maintenance Checking the Foundation Bolts ⇒ Do not move the piston (3) of the pre−tensioning jack (94145) to more than the red limit groove (LG). ⇒ Put the feeler gauge (94122) through the slot (8). Do a check for clearance between the round nut (4) and the bush (7).
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  • Page 88: Main Bearing

    1132−1/A1 Maintenance Main Bearing Loosen and Apply Tension to Elastic Studs Tools: Key to Illustrations: 2 Double pre-tensioning jacks 94114 1 Main bearing girder 1 Feeler gauge 94122 2 Main bearing cover (special) 1 Special feeler gauge 94123 3 Main bearing cover 2 Connection pieces 94215B 4 Elastic stud...
  • Page 89 1132−1/A1 Maintenance Main Bearing: Loosen and Apply Tension to Elastic Studs 94934A 94215B 94114 94935 94942 94114 94934G 017.662/08 016.894/08 Loosen ⇒ Attach the double pre-tensioning jacks as given in paragraph 2. ⇒ Start the hydraulic unit 94942. ⇒ When oil that has no air comes out, close the vent screws 8 on the jacks.
  • Page 90 1132−1/A1 Maintenance Main Bearing: Loosen and Apply Tension to Elastic Studs Elastic Studs − Apply Tension After the installation of the main bearing cover as given in 1132−2, apply tension to the elastic studs 4: ⇒ Attach the double pre-tensioning jacks as given in paragraph 2. ⇒...
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  • Page 92: 1132−2/A1

    1132−2/A1 Maintenance Main Bearing Removal and Installation Tools: Key to Illustrations: 2 Manual ratchets 94016A 1 Crankshaft 1 Assembling and dismantling device 94110 2 Bearing girder 1 Lifting tool (bearing shell) 94116 3 Main bearing cover (special) 1 Lifting tool (bearing shell special) 94116A 4 Main bearing cover 1 Lug with 4 screws M16x35...
  • Page 93 1132−2/A1 Maintenance Main Bearing: Removal and Installation 017.096/08 I - I 5, 6 3, 4 5a, 6a 017.622/08 2017 2/ 17 Winterthur Gas & Diesel Ltd.
  • Page 94 1132−2/A1 Maintenance Main Bearing: Removal and Installation Device 94110 − Install Attention! Do not use the tool 94110 to lift the bearing cover. You use the device 94110 to expand the top part of main bearing cover 4 to remove it from the bearing girder 2.
  • Page 95 1132−2/A1 Maintenance Main Bearing: Removal and Installation Main Bearing Cover (special) − Removal ⇒ Attach the wire rope / shackle 94120K to the manual ratchet H1 and the lug 94116B. ⇒ Operate the manual ratchet H1 to lift the bearing cover. ⇒...
  • Page 96 1132−2/A1 Maintenance Main Bearing: Removal and Installation 018.173/09 018.173/09 018.173/09 2017 5/ 17 Winterthur Gas & Diesel Ltd.
  • Page 97 1132−2/A1 Maintenance Main Bearing: Removal and Installation Main Bearing Cover No. 2 to No. # − Removal ⇒ Install the device 94110, refer to paragraph 2. ⇒ Install the roller support 94117 to the column with the pin. ⇒ Attach the double spring clip. ⇒...
  • Page 98 1132−2/A1 Maintenance Main Bearing: Removal and Installation 94120K 94117 94121A 94142 017.625/08 94332 94120K 94120K 94117A 017.626/08 2017 7/ 17 Winterthur Gas & Diesel Ltd.
  • Page 99 1132−2/A1 Maintenance Main Bearing: Removal and Installation Bottom Bearing Shell − Removal Attention! Do not remove two adjacent main bearing shells at the same time. Damage to equipment can occur. The removal procedure for the bottom bearing shells 6a (Fig. A) is the same for all main bearings with the exception of main bearing No.
  • Page 100 1132−2/A1 Maintenance Main Bearing: Removal and Installation 50 mm 50 mm 0.3 mm 5a, 6a 009.810/02 ⇒ Make sure that the horizontal clearances on each side of crankshaft between the crankshaft and the bearing shell y1, y2 are the same. ⇒...
  • Page 101 1132−2/A1 Maintenance Main Bearing: Removal and Installation 94120K 94936 94141 PROTECTION 017.628/08 CONNECTION SEE 9403−2 94120K 94119 94118 94118 ⇒ Remove the device 94118. ⇒ Attach the lifting tool 94116A to the bearing shell 5a. ⇒ Attach the manual ratchet H6 and wire rope 94120K to the lifting tool 94116A. ⇒...
  • Page 102 1132−2/A1 Maintenance Main Bearing: Removal and Installation ⇒ Move the manual ratchet H7 to the bottom platform. ⇒ Attach the manual ratchet to the lifting tool 94116A. ⇒ Operate the manual ratchet H7 to hold the weight of the bearing shell 5a. ⇒...
  • Page 103 1132−2/A1 Maintenance Main Bearing: Removal and Installation Bottom Bearing Shell No. 2 to No. # ⇒ Operate the turning gear to move the crank to approximately 90_ after TDC. ⇒ Install the platform 94142. ⇒ Lift the crankshaft, refer to paragraphs 5.1 and 5.2. ⇒...
  • Page 104 1132−2/A1 Maintenance Main Bearing: Removal and Installation 94121B 94119 94121B 94118A 94936 94141 017.631/08 CONNECTION SEE 9403−2 94117 94116 017.632/08 ⇒ Remove the device 94118A. ⇒ Operate the manual ratchet H6 to move the bearing shell until the tool 94116 is in the vertical position.
  • Page 105 1132−2/A1 Maintenance Main Bearing: Removal and Installation ⇒ Attach the lifting ring 94332 to the cylinder jacket with its screws (Fig. H4 to Fig. H7) ⇒ Torque the screws to 600 Nm. ⇒ Attach the manual ratchet H7 to the lifting ring 94332. ⇒...
  • Page 106 1132−2/A1 Maintenance Main Bearing: Removal and Installation Main Bearing Shells − Examine Attention! Do not use a scraper in the running area of the bearing shell. Damage to the bearing shell will occur. ⇒ Use a soft cloth to clean the bearing shell. ⇒...
  • Page 107 1132−2/A1 Maintenance Main Bearing: Removal and Installation Bearing Cover − Installation ⇒ Make sure that the work area and all tools and equipment are clean and in good condition. ⇒ Remove all plugs from the oil bore (OB). ⇒ Use the applicable equipment to get the bearing cover in the correct position above the crankshaft as follows: Use the device 94110 to install the bearing cover No.
  • Page 108 1132−2/A1 Maintenance Main Bearing: Removal and Installation 17, 16 017.635/08 2017 17/ 17 Winterthur Gas & Diesel Ltd.
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  • Page 110: Thrust Bearing

    1203−1/A1 Maintenance Thrust Bearing Checking the Axial Clearance Tools: Key to Illustrations: 1 Inside micrometer 94101 1 Crankshaft flange 6a Thrust bearing pads 1 Feeler gauge 94238 2 Oil baffle, top part for AHEAD 3 Oil baffle, bottom part 7 Cover 4 Thrust flange 8 Dial gauge 5 Crankshaft...
  • Page 111 1203−1/A1 Maintenance Thrust Bearing: Checking the Axial Clearance Procedure 2 ⇒ Start the engine in the direction AHEAD to move the crankshaft fully forward. The crankshaft must touch the thrust pads. ⇒ Stop the engine. ⇒ Make sure that the crankshaft does not move. ⇒...

  • Page 112: 1224−1/A1

    1224−1/A1 Maintenance Thrust Bearing Thrust Bearing Pads − Removal and Installation Tools: Key to Illustrations: 1 Turning-out device 94155 1 Casing 7 Support (with 1-part gear wheel) 2 Oil baffle (upper part) 8 Temperature sensor 1 Turning-out device 94155A 3 Screw 9 Cover (with 2-part gear wheel) 4, 4a Arbor support...
  • Page 113 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation ⇒ Attach the RUD-eye bolt EB to the thrust bearing pads 5 or 5a. ⇒ Attach the manual ratchets H1, H2 to the supports on the platform 7 and the eye bolt EB. ⇒...
  • Page 114 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation Installation ⇒ Make sure that the thrust pads are clean. ⇒ Apply clean engine oil to the thrust pads. Remark: You must install thrust pads that you removed before in the same positions.
  • Page 115 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation CONFIGURATION OF THRUST BEARING PADS WITH FIXED PITCH PROPELLER CLOCKWISE ROTATING ENGINE ASTERN AHEAD SUPPORT SURFACE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END PADS ON ENGINE SIDE DRIVING END ENGINE SIDE PROPELLER THRUST...
  • Page 116 1715−1/A2 Maintenance Hydraulic Engine Stays General Two hydraulic engine stays (1, Fig. A) are installed on the exhaust side and two on the fuel side of the engine. Oil around a nitrogen filled bladder in the accumulator body dampens the vibrations.
  • Page 117 1715−1/A2 Maintenance Oil Pressure Checks WCH03839 ENGINE SIDE WCH03839 Fig. A Key 1 Hydraulic engine stays 5 Rod 2 Accumulator body (with inner bladder) 6 Plug ⅜ inch NPT 3 Pressure gauge 7 Ball valve 4 Damping control valve 8 Hydraulic cylinder 2017 2/ 2 Winterthur Gas &...

  • Page 118: 1903−1/A1

    1903−1/A1 Maintenance Tie Rod Pre-tension Checks and Apply Tension Tools: Key to Illustrations: 1 Rod 94005C 1 Cylinder jacket 12 Bearing girder 1 Feeler gauge 94122 2 Intermediate ring 13 Lower backing ring 2 Pre-tensioning jacks 94180 3 Upper tie rod nut 14 Lower tie rod nut 1 Connection block 94934...
  • Page 119 1903−1/A1 Maintenance Pre-tension Checks and Apply Tension 94934A 94934G 94934 94935 94935 94005C 94942 WCH02797 PRE-TENSIONING JACK IN PRE-TENSIONING JACK IN POSITION TO TIGHTEN POSITION TO LOOSEN 2017 2/ 5 Winterthur Gas & Diesel Ltd.
  • Page 120 1903−1/A1 Maintenance Pre-tension Checks and Apply Tension Loosen and Apply Tension Loosen If the tie rods were removed and installed, do the procedure that follows: Remark: Start with the tie rods in the middle of the engine a−a, then b−b etc. ⇒...
  • Page 121 1903−1/A1 Maintenance Tie Rod Pre-tension Checks and Apply Tension Apply Tension in one procedure: Do not move the pistons 5 of the pre-tensioning jacks to more than the red limiting grooves LG (Fig. A). ⇒ Attach the pre-tensioning jacks to the hydraulic unit 94942. ⇒...
  • Page 122 1903−1/A1 Maintenance Tie Rod Pre-tension Checks and Apply Tension I - I WCH01111 FLUSH 2017 5/ 5 Winterthur Gas & Diesel Ltd.
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  • Page 124: Cylinder Liner And Cylinder Cover Group

    Group2 Maintenance Cylinder Liner and Cylinder Cover Group 2 Cylinder Liner − Bore − Measure ........... . . 2124−1/A1 −...
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  • Page 126 2124−1/A1 Maintenance Cylinder Liner Bore − Measure Tools: Key to Illustrations: 1 Inside micrometer 94101 1 Cylinder liner 1 Ladder 94224 2 Measuring holes (points A to …) 1 Gauge 94225 3 Running surface 4 Non-running surface SS Setting screw Note: Some parts of the cylinder liner can look different.

  • Page 127: 2124−1/A1

    2124−1/A1 Maintenance Cylinder Liner Bore − Measure ⇒ Use the formula below to calculate the rate: WR = (D1−D2) x 1000 Where: WR = Wear rate (mm/1000 hours) T1 = Total running hours (h) D1 = Maximum liner diameter of running surface (point B and below) (mm) D2 = Liner diameter of non−running surface (point A) (mm).

  • Page 128: 2124−2/A1

    2124−2/A1 Maintenance Cylinder Liner Removal and Installation Tools: Key to Illustrations: 1 Lifting device 94201 1 Cylinder jacket 10 Centering pin 1 Angled lever 94202A 2 Cylinder liner 11 O-ring 2 Distance plates 94202C 3 Water guide jacket 12 O-ring 8 Distance plates 94202D (bottom part)
  • Page 129 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation Cylinder Liner − Removal Lifting Tool − Install ⇒ Loosen the screws 9. ⇒ Remove (or add) the distance plates 94202D to get the applicable clearance of 2.0 mm to 5.0 mm shown. ⇒...
  • Page 130 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation Removal ⇒ Remove the screws 8. ⇒ Remove the pipe connection 7 and transition tubes 6 from the water guide jacket 3 and 5 (Fig. B). Remark: The transition tubes 6 are a push−fit in the connection tubes 7. WCH03840 WCH03840 2017...
  • Page 131 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation ⇒ Operate the engine room crane to carefully lift cylinder liner 2. ⇒ Move the cylinder liner 2 to an applicable area. ⇒ Lower the cylinder liner 2 on a wooden underlay. ⇒ Put the cylinder liner 2 into safe storage, refer to paragraph 6. 94201 FUEL SIDE 94206...
  • Page 132 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation ⇒ Apply a non-hardening sealing compound to the seating surfaces SS (Fig. E). ⇒ Operate the engine room crane to lower the cylinder liner 2. ⇒ Align the centering hole with the holder 15 and the centering pin 10 of the cylinder jacket 1.
  • Page 133 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation ⇒ Attach the connection tubes 7 to the transition tubes 6 on the water guide jackets 3 and 5 (Fig. E). ⇒ Install all the lubricating quills refer to 2138−1. ⇒ Operate the cylinder lubricating pump until oil flows from the lubricating grooves in the applicable cylinder.
  • Page 134 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation Water Guide Jacket Removal ⇒ Remove the cylinder liner, refer to paragraph 2. ⇒ Attach the three eye bolts EB to the water guide jacket 3. ⇒ Attach the manual ratchets the eye bolts EB. ⇒...
  • Page 135 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation Insulation Bandage Removal ⇒ Remove the cylinder liner, refer to paragraph 2. ⇒ Remove water guide jacket, refer to paragraph 4. ⇒ Use the assembly tool 94345E to remove the tension springs 21. ⇒...
  • Page 136 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation Safe Storage ⇒ Install the lifting device 94201, refer to paragraph 2.1. 94201 94202A 018.168/09 ⇒ Attach the the lever 94202A to the lifting tool 94201 (Fig. J). ⇒ Attach the engine room crane to the lever 94202A. ⇒...
  • Page 137 2124−2/A1 Maintenance Cylinder Liner: Removal and Installation 94201 018.167/09 018.167/09 018.167/09 2017 10/ 10 Winterthur Gas & Diesel Ltd.

  • Page 138: 2124−2/A2

    2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal Tools: Key to Illustrations: 1 Rod 94005A 1 Cylinder jacket 13 O-ring 4 Suspension straps 94208 2 Cylinder liner 14 Cylinder cover 1 Lifting hook 94209 3 Water guide jacket 15 Holder 1 Lifting tool 94210 (bottom part)
  • Page 139 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal Cylinder Liner − Removal ⇒ Remove the screws 8. ⇒ Remove the pipe connection 7 and transition tubes 6 from water guide jacket 3 and 5 (view I). Remark: The transition tubes are a push−fit in the connection tubes 6. WCH03840 WCH03840 2017...
  • Page 140 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal 2-part cylinder cover stud − Disassemble Attention: Do not use tools such as a pipe wrench etc. This could cause damage to the stud shank. Attention: The sleeve 24 weighs 116 kg. Use applicable equipment to lift and move the sleeve.
  • Page 141 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal Cylinder Liner − Lift ⇒ On the lifting tool 94210, connect the crane hooks to the pins 17. ⇒ Operate carefully the engine room crane to lift cylinder liner 2. ⇒ Move the cylinder liner 2 over the the starting air pipe and rail unit as shown in Fig.
  • Page 142 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal WCH03840 WCH03840 WCH03840 ⇒ Apply a non-hardening sealing compound to the seating surfaces SS. ⇒ Turn the cylinder liner 2 to align the centering hole in the holder 15 with the centering pin 10 of the cylinder jacket 1.
  • Page 143 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal ⇒ Apply oil to the thread of the bottom part of the elastic bolt 23. ⇒ Put the sleeve 24 in position as shown in Fig. B. make sure that there is a distance of 257 mm to the cylinder jacket.
  • Page 144 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal Water Guide Jacket Removal ⇒ Remove the cylinder liner, refer to paragraph 2. ⇒ Attach the eye bolts EB to the water guide jacket 3 (Fig. H and Fig. I). ⇒ Attach the manual ratchets the eye bolts EB. ⇒...
  • Page 145 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal Insulation Bandage Removal ⇒ Remove the cylinder liner, refer to paragraph 2. ⇒ Remove water guide jacket, refer to paragraph 4. ⇒ Use the assembly tool 94345E to remove the tension springs 21. ⇒...
  • Page 146 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal Safe Storage ⇒ Make sure that the water guide jacket is removed, refer to paragraph 4.1. ⇒ Make sure that the insulation bandage is removed, refer to paragraph 5.1. ⇒ Attach the lifting tool 94210A and the ring 94210D to the double jib crane. ⇒...
  • Page 147 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation Tilted Removal 94210A 94210D 94210 WCH01181 2017 10/ 10 Winterthur Gas & Diesel Ltd.

  • Page 148: 2124−3/A1

    2124−3/A1 Maintenance Cylinder Liner Wear Ridge Remove, Repair the Finish to Lubricating Grooves and Scavenge Ports − Tools: Key to Illustrations: 1 Grinding device 94299 1 Roller support 9 Thread nozzle 2 Holder 10 Carbide milling cutter 3 Holder 11 Cylinder liner 4 Spacer roller 12 Top piston ring 5 Pipe (column)
  • Page 149 2124−3/A1 Maintenance Cylinder Liner: Wear Ridge Remove, − Repair the Finish to Lubricating Grooves and Scavenge Ports 94299 2.0 mm to 3.0 mm 1.0 mm 009.004/01 2017 2/ 4 Winterthur Gas & Diesel Ltd.
  • Page 150 2124−3/A1 Maintenance Cylinder Liner: Wear Ridge Remove, − Repair the Finish to Lubricating Grooves and Scavenge Ports Lubricating Grooves Make sure that you keep the initial shape of the lubricating grooves when you remove sharp edges. ⇒ If the depth of the lubricating grooves LG, Fig. B has decreased to less than 1.5 mm, do as follows: ⇒...
  • Page 151 2124−3/A1 Maintenance Cylinder Liner: Wear Ridge Remove, − Repair the Finish to Lubricating Grooves and Scavenge Ports 003.267/00 EDGES EDGES ROUNDED OFF ROUNDED OFF II - II WCH01183 2017 4/ 4 Winterthur Gas & Diesel Ltd.
  • Page 152 2138−1/A2 Maintenance Lubricating Quill Removal and Installation with Pulse Jet Lubrication Tool: Key to Illustrations: 1 Case, measurement set 94720C 1 Cylinder liner 14 Pin (tool) 1 HP hose 94935 2 Lubricating pump 15 Shut-off valve servo oil 1 HP oil pump 94931 3 Accumulator 16 Vent valve servo oil...
  • Page 153 2138−1/A2 Maintenance Lubricating Quill − Removal and Installation with Pulse Jet Lubrication Remark: The steps that follow are only necessary if the cylinder liner must be removed. ⇒ Remove all the pipe brackets 18 (Fig. A). ⇒ Remove the eight pipes 11. ⇒...
  • Page 154 2138−1/A2 Maintenance Lubricating Quill − Removal and Installation with Pulse Jet Lubrication WCH01183 WCH01115 2017 3/ 6 Winterthur Gas & Diesel Ltd.
  • Page 155 2138−1/A2 Maintenance Lubricating Quill − Removal and Installation with Pulse Jet Lubrication Function Check You do a function check to make sure that the non−return valve (3) operates correctly. The pressure that opens the non−return valve is 5.0 bar. For the function check, use an oil with a viscosity as given in the specifications that follow: SAE 50 at 40_C (approx.
  • Page 156 2138−1/A2 Maintenance Lubricating Quill − Removal and Installation with Pulse Jet Lubrication Cylinder Lubricating System − Bleed Attention! Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Remark: When you bleed the cylinder lubricating system, always start at the first cylinder at the free end.
  • Page 157 2138−1/A2 Maintenance TO LUBRICATING QUILLS 019.125/10 019.002/09 2 17 6/ 6 Winterthur Gas & Diesel Ltd.

  • Page 158: 2303−1/A1

    2303−1/A1 Maintenance Piston Rod Gland Removal, Disassemble, Measure Worn Parts, Assemble, Installation Tools: Key to Illustrations: 2 Platforms 94142 1 Housing (2-part) 13 Sealing ring 2 Supports 94143 2 Screw 14 Ring support 1 Support 94344 3 Dowel pin 15 Scraper ring 4 Stays 94344A 4 Support...
  • Page 159 2303−1/A1 Maintenance Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation Procedure One Piston Rod Gland − Removal Attention: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. ⇒ Operate the turning gear to move the piston to BDC. ⇒...
  • Page 160 2303−1/A1 Maintenance Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation I - I II - II SPRING DOWEL PIN MUST BE REMOVED WCH01156 2017 3/ 9 Winterthur Gas & Diesel Ltd.
  • Page 161 2303−1/A1 Maintenance Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation Assemble (Fig. C and Fig. D) ⇒ Make sure that the hinged covers 22 of the support device 94350 are folded down. ⇒ Attach the 2−part clamp ring 94345B to the piston rod 21. ⇒...
  • Page 162 2303−1/A1 Maintenance Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation ⇒ Put the gauge 94345C (Fig. E) over the assembled rings. Make sure that all parts are in the correct position. If necessary, correct their positions. ⇒ Apply bearing oil to the piston rod and the assembled rings. ⇒...
  • Page 163 2303−1/A1 Maintenance Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation GROOVE a GROOVE b GROOVES c−g 016.855/08 Installation (Fig. E) ⇒ Apply lubricating oil to the opening in the cylinder jacket and to the area of the O−rings on the housing 1. ⇒...
  • Page 164 2303−1/A1 Maintenance Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation 94350 94345C 94345C 94345 016.877/08 2017 7/ 9 Winterthur Gas & Diesel Ltd.
  • Page 165 2303−1/A1 Maintenance Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation Procedure 2 Removal (Fig. G) Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. ⇒ Operate the turning gear to move the piston to BDC. ⇒...
  • Page 166 2303−1/A1 Maintenance Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation 94344 94344A 94344 94344A 94143 94142 WCH01172 018.654/09 2017 9/ 9 Winterthur Gas & Diesel Ltd.
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  • Page 168: Cylinder Cover

    2708−1/A1 Maintenance Cylinder Cover Cylinder Cover and Water Guide Jacket − Removal and Installation Tools: Key to Illustrations: 1 Suspension device 94265 1 Cylinder cover 11 Elastic Stud 1 Retaining bracket 94266 2 Exhaust valve cage 12 Screw M20x40 3 Cylinder liner 13 Fixing screw 4 Joint ring M20x240...
  • Page 169 2708−1/A1 Maintenance Cylinder Cover and Water Guide Jacket − Removal and Installation Cylinder Cover − Removal ⇒ Loosen nuts of elastic studs 11, refer to see 2708−2. Water Guide Jacket 3.1 Water Guide Jacket − Removal ⇒ Turn the screws 13 fully back. ⇒...
  • Page 170 2708−1/A1 Maintenance Cylinder Cover and Water Guide Jacket − Removal and Installation Cylinder Cover − Installation ⇒ Make sure that the compression space is clean. ⇒ Make sure that the eating surfaces on the cylinder cover and cylinder liner are clean and have no damage.
  • Page 171 2708−1/A1 Maintenance Cylinder Cover and Water Guide Jacket − Removal and Installation PUSH FIT 017.640/08 WCH01175 2017 4/ 4 Winterthur Gas & Diesel Ltd.

  • Page 172: 2708−2/A1

    2708−2/A1 Maintenance Cylinder Cover Cylinder Cover Elastic Studs − Apply and Release Tension Tools: Key to Illustrations: Hydraulic tensioning device 94215 1 Cylinder cover includes: 2 Elastic stud Pre-tensioning jacks 94215A 3 Nut Connection pieces with HP hoses 94215B 4 Round nut Lifting tool 94215C 4(8*) Connecting elements...
  • Page 173 2708−2/A1 Maintenance Cylinder Cover Elastic Studs − Apply and Release Tension Elastic Studs − Apply Tension Round Nuts − Remove Remark: Apply tension to the eight elastic studs 2 at the same time (Fig. B). ⇒ Operate the hydraulic unit 94942 to apply 1500 bar to the eight elastic studs 2. ⇒...
  • Page 174 2708−2/A1 Maintenance Cylinder Cover Elastic Studs − Apply and Release Tension 94215B 94215E 94215A (94215F) 94215B 94935 94934 016.717/08 94934A 94935 94942 2017 3/ 4 Winterthur Gas & Diesel Ltd.
  • Page 175 2708−2/A1 Maintenance Cylinder Cover Elastic Studs − Apply and Release Tension Configuration with 1-part lifting tool (optional) 94215E 94215H 94215A (94215F) 94215H 94215G 94215I 94215D 94935 019.373/10 94934 94934A 94935 94209A 94942 94215E (94215F) 2017 4/ 4 Winterthur Gas & Diesel Ltd.
  • Page 176 2708−3/A1 Maintenance Cylinder Cover Sealing Face − Grind Tools: 1 Grinding device 94270G 1 Stencil General 94270G The sealing face in the cylinder cover for the injection valve must be clean and have no damage. Sealing Face − Grind WCH03837 Clean the injection valve bore in the cylinder cover 1 (Fig.
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  • Page 178: Injection Valve With Fast

    2722−1/A2 Maintenance Injection Valve Disassemble, Checks, Adjust, Assemble Injection Valve with FAST Tools: Key to Illustrations: 1 Torque spanner 94011 1 Injection valve 16 Dowel pin 1 Slugging wrench 94269A−70 2 Nozzle holder 17 Fixing piece 1 Hydraulic cylinder 94269B 3 Intermediate piece 18 Snap ring 1 Socket wrench insert...
  • Page 179 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST Injection Valve − Checks Attention: Fire Hazard. Do not use welding or grinding equipment near the work area. Attention: Health Hazard. Calibration fluid is harmful to your health. Attention: Injury Hazard: Do not put your fingers near the holes in the nozzle tip.
  • Page 180 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST ⇒ Start the test bench. ⇒ At regular intervals, use a master pressure gauge to do checks of the pressure gauges on the test bench. If necessary, adjust the pressure gauges. ⇒...
  • Page 181 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST ⇒ Remove the locknut 7. ⇒ Use the wrench 94269A−70 and the hydraulic cylinder 94269B to loosen the coupling nut 6. ⇒ Remove the coupling nut 6. ⇒ Remove the nozzle body 4 together with the: Needle 5 Nozzle tip 12 Intermediate piece 3...
  • Page 182 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST Injection Valve − Assemble ⇒ Make sure that the sealing faces of the intermediate piece Fig. D and the related faces in the injection valve 1: Are clean and dry Are in a satisfactory condition Have no lubricant.
  • Page 183 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST I - I II - II WCH00879 DESIGN OF NOZZLE BODY MANUFACTRER x DRG. NO. x EXECUTION x NEEDLE LIFT 2017 6/ 11 Winterthur Gas & Diesel Ltd.
  • Page 184 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST Opening pressure − Adjust ⇒ Disassemble the injection valve, refer to paragraph 4. ⇒ Install temporarily two shim rings 9 (total thickness of 6.0 mm). ⇒ Assemble the injection valve, refer to paragraph 5. ⇒...
  • Page 185 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST Nozzle Tip − Replace Make sure that the specified nozzle tips are used in accordance with the IMO Technical File of the engine. Removal It is not recommended but possible to replace the nozzle tip with the needle installed.
  • Page 186 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST Installation 94278B ⇒ Make sure that the needle 5, is removed from the nozzle body 4, see Fig. E. ⇒ Attach the nozzle body 4 and the coupling nut 6 to the injection valve 1 on the injection test bench.
  • Page 187 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST Spring cage − Assemble ⇒ Make sure that the cup springs, 23 Fig. H are installed in the spring cage 20 as shown. ⇒ You must use the shims 25 to adjust the distance X to 1.6 ±...
  • Page 188 2722−1/A2 Maintenance Injection Valve: Disassemble, Checks, Adjust, Assemble Injection Valve with FAST Nozzle Tip − Protection Make sure that the protection cap 94271 is installed when the injection valve is removed. 94271 017.083/08 Storage ⇒ Keep the injection valve in its original packing. ⇒...
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  • Page 190: 2728−1/A1

    2728−1/A1 Maintenance Starting Valve Removal, Disassemble, Grind, Assemble and Installation Tools Key to Illustrations: 1 Wire rope sling 94333D 1 Cylinder cover 13 Control valve (solenoid valve) Lifting tool, starting 942719 2 Housing 14 Plug air valve. Includes: 3 Cover 15 Joint ring 2 Caps 942719D...
  • Page 191 2728−1/A1 Maintenance Starting Valve: Removal, Disassemble, Grind, Assemble and Installation Grind Seat faces that have light damage can be ground manually. Seat faces that more than light damage must first be machined and then ground. Remark: The valve spindle 4 has an angle of 91_, but, the valve seat angle is 90_. Assemble ⇒...
  • Page 192 2728−1/A1 Maintenance Starting Valve: Removal, Disassemble, Grind, Assemble and Installation 942719B 942719B WCH03805 WCH03805 94333D 942719D 94333D 942719B 942719D 942719C WCH03805 WCH03805 2017 3/ 5 Winterthur Gas & Diesel Ltd.
  • Page 193 2728−1/A1 Maintenance Starting Valve: Removal, Disassemble, Grind, Assemble and Installation I - I 016.856/08 Stroke 22 mm 016.856/08 2017 4/ 5 Winterthur Gas & Diesel Ltd.
  • Page 194 2728−1/A1 Maintenance Starting Valve: Removal, Disassemble, Grind, Assemble and Installation 942719A Starting Valve WCH03806 942719A Ship Structure WCH03806 Assembly tool welded to the ship structure 2017 5/ 5 Winterthur Gas & Diesel Ltd.
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  • Page 196: 2745−1/A1

    2745−1/A1 Maintenance Cylinder Cover − Relief Valve Blow-off Pressure Check Tools: Key to Illustrations: 1 OBEL test bench 94272 1 Cylinder cover 10 Receiver 1 Valve holder 94272C 2 Relief valve 11 Gasket 1 HP oil pump 94931 3 Indicator valve 12 Gasket 2 Hydraulic distributors 94934A...
  • Page 197 2745−1/A1 Maintenance Relief Valve: Blow-off Pressure Check Removal ⇒ Stop the engine. ⇒ Open the indicator valve to make sure that there is no pressure in the compression chamber. ⇒ Remove the relief valve 2 and the gasket 11. ⇒ Do a check of the gasket 11 for damage. If necessary, replace the gasket. WCH03808 WCH03808 2017...
  • Page 198 2745−1/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. ⇒ Read the data about calibration fluid in 2722−2, paragraph 1. You can use the test and calibration fluid, or a low viscosity oil as a test fluid.
  • Page 199 2745−1/A1 Maintenance Relief Valve: Blow-off Pressure Check Procedure Two ⇒ Attach the relief valve 2, (Fig. B) to the valve holder 94272C. ⇒ Connect the HP oil pump 94931 and the hose 94935 to the pressure gauge 94934A. ⇒ Connect the pressure gauge to the valve holder 94272C. ⇒...

  • Page 200: Exhaust Valve

    2751−1/A1 Maintenance Exhaust Valve Exhaust Valve − Removal and Installation, Elastic Studs − Replace Tools: Key to Illustrations: 1 Dismantling tool 94008A−M90 1 Terminal box 6 Expansion piece 1 Assembly and transport device 94810 2 Plug 7 Protection pipe 1 Wire rope sling 94209 3 Valve cage 8 Elastic stud...
  • Page 201 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation, Elastic Studs − Replace ⇒ Attach the device 94810 to the expansion piece 6 (Fig. B). ⇒ Attach the wire rope sling 94209 to the engine room crane and the device 94810. ⇒...
  • Page 202 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation, Elastic Studs − Replace Installation ⇒ Clean all the sealing surfaces of the exhaust valve and the cylinder covers. ⇒ Examine the sealing surfaces of the exhaust valve and cylinder cover for damage.
  • Page 203 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation, Elastic Studs − Replace Elastic studs When you install a new elastic stud of the cylinder cover or exhaust valve cage, obey the instructions given below. ⇒ Read the data in the manual of the jointing compound manufacturer. ⇒...
  • Page 204 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation, Elastic Studs − Replace Jointing Compound See the table below for the recommended manufacturers of jointing compounds and adhesive primers: Jointing Hardener Adhesive Manufacturer compound primer Elastosil RT 622 B G 790 Wacker-Chemie Gmbh RT 622 A Geschäftsbereich Silicone...
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  • Page 206: 2751−2/A1

    2751−2/A1 Maintenance Exhaust Valve Disassemble and Assemble Tools: Key to Illustrations: 1 Thrust pin 94259 1 Valve cage 24 Screw plug 2 Jack screws 94263 2 Bottom housing 25 Damper 2 Jack screws 94263A 3 Top housing 26 Shim 1 Depth gauge 4 Outer piston 27 Transmitter housing 1 Torque wrench...
  • Page 207 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble 016.875/08 015.753/08 2017 2/ 8 Winterthur Gas & Diesel Ltd.
  • Page 208 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Exhaust valve − Disassemble Valve Drive − Disassemble Danger: Do not weld or grind materials in the area. The sparks from welding equipment and grinding tools can cause a fire. ⇒ Put the exhaust valve on a wooden underlay WU (Fig.
  • Page 209 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Guide Bush − Remove 11 10 ⇒ Remove the four Allen screws 12 ⇒ Remove the spacer 10. ⇒ Remove and discard the rod seal ring 11. ⇒ Attach the jack screws 94263 to the flange of guide bush 9.
  • Page 210 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Exhaust Valve − Assemble Valve Spindle − Install ⇒ Measure the dimensions of the valve spindle 7. ⇒ 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 211 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble 015.753/08 2017 6/ 8 Winterthur Gas & Diesel Ltd.
  • Page 212 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Damper Setting You set the damper 25 only after you replace a valve spindle or valve seat, or after one of the seating faces is ground. ⇒ Remove the damper 25. ⇒ Make sure that the bores (4) in the damper are clear.
  • Page 213 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Valve Stroke Sensor − Install ⇒ Clean the parts that follow: The valve stroke sensor 28, Fig. G. The transmitter housing 27. The bore and collar in the top housing 3. ⇒ Put oil on the O−ring 41 and the valve stroke sensor 28.

  • Page 214: 2751−3/A1

    2751−3/A1 Maintenance Exhaust Valve Valve Seat − Replace, Grind Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Valve seat SF Seating face 1 Tool, valve seat remove / install 94261 2 Valve cage EB Eye bolt 1 Gauge 94279 3 O-ring 1 Valve grinding device 94291...
  • Page 215 2751−3/A1 Maintenance Exhaust Valve: Valve Seat − Replace, Grind Valve seat − Grind Use only the grinding tool 94291, Fig. B to grind the valve seats. ⇒ Read the data in the manufacturer’s manual for the grinding tool 94291. ⇒ Put the valve seat 1 in the correct position on the grinding tool 94291.
  • Page 216 2751−3/A1 Maintenance Exhaust Valve: 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 EB, Fig. C to the valve spindle.
  • Page 217 2751−3/A1 Maintenance Exhaust Valve: Valve Seat − Replace, Grind Valve seat − Install ⇒ Clean the bores and the sealing faces of the valve cage 2 and the valve seat 1, Fig. E. ⇒ Apply oil (or lubricants e.g. Never−Seez NBST−8, Loctite anti−seize compound) to the bores and sealing faces of the valve seat 1 and the valve cage 2.
  • Page 218 2751−4/A1 Maintenance Exhaust Valve Valve Head − Grind the Seating Surface Tools: 1 Feeler gauge 94122 1 Valve grinding device 94291 1 Gauge 94292 SEATING SURFACE General ANGLE ON VALVE Use only the tool 94291, Fig. A to grind the valve a = between: head.

  • Page 219: 2751−4/A1

    2751−4/A1 Maintenance Exhaust Valve: Valve Head − Grind the Seating Surface ⇒ If the measured values are more than the limits given on the gauge (94122), you can repair the valve spindle (see the data below). ⇒ If more than 3.0 mm is ground off: ⇒...

  • Page 220: Crankshaft, Connecting Rod And Piston Group

    Group3 Maintenance Crankshaft, Connecting Rod and Piston Group 3 Crankshaft: Crank Deflection − Measure ........3103−1/A1 Vibration Damper −...
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  • Page 222: 3103−1/A1

    100 operation 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 223 3103−1/A1 Maintenance Crank Deflection − Measure Equipment Settings Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Remark: During the procedure, the flywheel (1, Fig. A) and pinion 2 of the turning gear must turn in the directions shown.
  • Page 224 3103−1/A1 Maintenance Crank Deflection − Measure Calculate 94305 nB.D.C nT.D.C The difference between the values shown shows the crank deflection during one full turn of the crankshaft (Fig. B). Where values are measured that are more than the maximum permitted limits, the cause must be found.
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  • Page 226: Vibration Damper

    3130−1/A1 Maintenance Vibration Damper Silicone Fluid Sample Key to Illustrations: 1 Casing trough 7 Crankshaft 2 Casing cover 8 Cap nut 3 Screw plug 4 O-ring 5 Sealing ring CP Center punch mark 6 Coupling bolts SC Sample container General Viscous vibration dampers that Hasse &...

  • Page 227: 3130−1/A1

    3130−1/A1 Maintenance Silicone Fluid Sample Metaldyne Silicone Oil Samples and STE ” BSF (M16) Metaldyne and STE Remark: Two different threads are used for sample bores Metaldyne International and STE vibration dampers. Remark: The sample container lets you get a specified quantity of silicone oil from the damper.
  • Page 228 3130−1/A1 Maintenance Silicone Fluid Sample ⇒ Send the sample to: Metaldyne International UK Ltd131 Parkinson Lane Halifax HX1 3RD United Kingdom Tel: +44 1422 357 234 Fax: +44 1422 354 432 Remark: For STE Schwingungstechnik manufactured vibration dampers, send the samples to Hasse & Wrede (see paragraph 3.2). Hasse &...
  • Page 229 3130−1/A1 Maintenance Silicone Fluid Sample ⇒ 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 3.1 and 3.2, do the procedure that follows: ⇒...

  • Page 230: Inspection (Geislinger Vibration Damper)

    3130−2/A1 Maintenance Vibration Damper Inspection (GEISLINGER Vibration Damper) Key to Illustrations: 1 Crankshaft 5 Sealing ring 2 Damper casing 6 Oil supply pipe 3 Vibration damper 7 Coupling disc 4 Hexagon head bolt (crank angle sensor unit) General Some engine designs can have a Geislinger manufactured vibration damper installed at the free end of the crankshaft.
  • Page 231 3130−2/A1 Maintenance Inspection (GEISLINGER Vibration Damper) Inner Spring Tips and Groove Flanks Remark: You must only disassemble the vibration damper if you think there is damage, or the parts have become worn to more than the specified limits. You must speak to the manufacturer for instructions. Remark: Only specialists can make adjustments of the vibration damper.
  • Page 232 3130−2/A1 Maintenance Inspection (GEISLINGER Vibration Damper) 017.009/10 000.940/93 DATA FOR STEEL SPRING DAMPER 2017 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 234: 3140−1/A1

    3140−1/A1 Maintenance Axial Damper Disassemble and Assemble Tools Key to Illustrations: 1 Spur-geared chain block 94018−016 1 Casing, top part 15 Throttle 1 Wire rope sling 94209 2 Pipe 16 Gasket 2 Manual ratchet 94016−007 3 Axial damper monitoring 17 Gasket 2 RUD eye bolt 94040−M36 4 Top cylinder part...
  • Page 235 3140−1/A1 Maintenance Axial Damper: Disassemble and Assemble ⇒ Remove the bolts 9 and 6, Fig. B. ⇒ Remove the six bolts 7 from the top cylinder part 4. On engines that have a vibration damper pull out six the bolts as far as possible. I - I 016.923/08 2017...
  • Page 236 3140−1/A1 Maintenance Axial Damper: Disassemble and Assemble ⇒ Attach the two eye bolts 94040−M36 to the top cylinder part 4. ⇒ Attach the wire rope sling 94209 to the eye bolts EB. ⇒ Attach the manual ratchets 94016−007 to the platform and the wire rope sling 94209.
  • Page 237 3140−1/A1 Maintenance Axial Damper: Disassemble and Assemble ⇒ Operate carefully the manual ratchets 94016−007 to lift the top cylinder part 4 (see Fig. D). Remark: Make sure that top cylinder part moves freely to prevent damage to the 2−part gaskets 11, 13. ⇒...
  • Page 238 3140−1/A1 Maintenance Axial Damper: Disassemble and Assemble Axial Damper: Disassemble and Assemble Throttle If it becomes necessary to remove or replace a spindle, you must measure the distance X. You must adjust the spindle to the same dimension during assembly. Do not turn back the spindle more than 16 turns (which equals a distance of 16 mm).
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  • Page 240 3206−1/A1 Maintenance Turning Gear Teeth and Screwed Connections 6 to 8 Cylinder Engines Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Turning gear 9 Elastic bolt 1 Pre-tensioning jack 94320 2 Pinion 10 Round nut 1 Round nut 94320A 3 Flywheel 11 Slot 1 HP oil pump...
  • Page 241 3206−1/A1 Maintenance Turning Gear: Teeth and Screwed Connections Pinion and Flywheel Teeth Procedure 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 242 3206−1/A1 Maintenance Turning Gear: Teeth and Screwed Connections 6 to 8 Cylinder Engines Pre−tension Check ⇒ Clean the round nuts, the threads of the elastic bolts and the seating surfaces. ⇒ Put the pre−tensioning jack 94320, (Fig. B) in position on the applicable elastic bolt 9.
  • Page 243 3206−1/A1 Maintenance Turning Gear: Teeth and Screwed Connections 6 to 8 Cylinder Engines Loosening and tensioning the bolts ⇒ Put the round nut 10 in position to get the distance of approximately 25 mm. ⇒ Put the pre−tensioning jack 94320 in position on the applicable elastic bolt. ⇒...
  • Page 244 3206−1/A2 Maintenance Turning Gear Teeth and Screwed Connections Cylinder Engines Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Turning gear 9 Bolt 1 Pre-tensioning jack 94320 2 Pinion 10 Round nut 1 Round nut 94320A 3 Toothing of flywheel 11 Slot 1 HP oil pump 94931...
  • Page 245 3206−1/A2 Maintenance Turning Gear: CTeeth and Screwed Connections Cylinder Engines Pinion and Flywheel Teeth Procedure 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 246 3206−1/A2 Maintenance Turning Gear: Teeth and Screwed Connections Cylinder Engines Pre−tension Check ⇒ Clean the round nuts, the threads of the elastic bolts and the seating surfaces. ⇒ Put the pre−tensioning jack 94320, (Fig. B) in position on the applicable elastic bolt 9.
  • Page 247 3206−1/A2 Maintenance Turning Gear: Teeth and Screwed Connections Cylinder Engines Apply and Loosen the Tension ⇒ Put the round nut 10 in position to get the distance of approximately 25 mm. ⇒ Put the pre−tensioning jack 94320 in position on the applicable elastic bolt. ⇒...
  • Page 248 3301−1/A1 Maintenance Crankcase Platform Tools: Key to Illustrations: 2 Platforms, each platform includes three grids 94142 1 Longitudinal beam 2 Supports 94143 2 Crank web 3 Step 4 Strap General Attention: Injury and Damage Hazard: Do not turn the crankshaft when the platforms and/or supports are installed.
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  • Page 250: Connecting Rod

    3303−1/A1 Maintenance Connecting Rod Connecting Rod Elastic Studs − Loosen and Apply Tension Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Connecting rod 2 Pre-tensioning jacks (2-part) 94215E 2 Bottom end bearing 2 Back-up rings 94215F 3 Top end bearing 2 Pre-tensioning jacks 94315 4 Elastic stud −...

  • Page 251: 3303−1/A1

    3303−1/A1 Maintenance Connecting Rod Elastic Studs − Loosen and Apply Tension Loosen and Apply Tension Bottom end bearing The 2−part pre−tensioning jack can be disassembled to put the tools 94215F and 94215E on the elastic studs. Do not tighten the M6x90 Allen screws. ⇒...

  • Page 252: 3303−2/A1

    3303−2/A1 Maintenance Connecting Rod Bottom End Bearing − Removal, Inspection and Installation Tools: Key to Illustrations: 1 Deviation pipe 94117A 1 Connecting rod stud 10 Top bearing shell 1 Platform 94142 2 Nut 2 Stays 94323 3 Crank pin 12 Allen screw 1 Removal and installation tool 94326 4 Bearing cover...
  • Page 253 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bearing Cover Removal ⇒ Remove the round nuts 2, refer to 9304−4. ⇒ Carefully lower the bearing cover 4. ⇒ Examine the bearing shell 7. Remark: If the bearing shell is in good condition, lower the bearing cover on to the bottom of the crankcase.
  • Page 254 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation ⇒ Remove the manual ratchet H2 (see Fig. C). ⇒ Install the deviation pipe 94117A as shown. ⇒ Operate the turning gear to move the crank 3 approximately 70_ to the exhaust side.
  • Page 255 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bearing Shell − Remove ⇒ Remove the two screws 8. ⇒ Attach the four eye bolts EB2 to the bearing shell 7 as shown. ⇒ Attach the wire rope sling 94209 to the four eye bolts EB2. ⇒...
  • Page 256 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation 94323 016.791/08 017.680/08 017.680/08 ⇒ Operate the turning gear to move the crankshaft to the fuel side until the guide shoe touches the stays 94323 . ⇒ Put the chain of the manual ratchet around the connecting rod 5 as shown. ⇒...
  • Page 257 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation 94323 017.680/08 Top Bearing Shell − Removal ⇒ Make sure that the bottom bearing cover 4 is removed from the crankcase. ⇒ Make sure that the deviation pipe 94117A is installed. ⇒...
  • Page 258 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation H3, H5 Round bar 94326 94117A 94326 012.265/04 94142 Screw Shackle 017.679/08 ⇒ Attach the tool 94326 to the top bearing shell 10 with the four screws Fig. G. ⇒ Attach the manual ratchet H2, to the shackle on the tool 94326. ⇒...
  • Page 259 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation 94209 017.679/08 017.679/08 Bearing Shells − Installation Top Bearing Shell ⇒ Clean the seating surface of the connecting rod 5, the crank pin 3 and the bearing shell 10. ⇒ Put the bearing shell 10 on the tool 94326. ⇒...
  • Page 260 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation ⇒ Operate the manual ratchets H3, H5 to move the tool 94326 and bearing shell 10 into position (see Fig. G). Remark: Make sure that the distance between each end of the bearing shell and the connecting rod rod is the same.
  • Page 261 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bearing Cover − Installation ⇒ Attach the chain block H4 to the eye bolt EB1 on the bearing cover 4 (see Fig. I). ⇒ Operate the chain block H4 to lift the bearing cover 4. ⇒...
  • Page 262 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation ⇒ Put the round nuts 2 on the elastic studs 1, Fig. J. ⇒ Put the round nuts 2 on the elastic studs. ⇒ Tighten the round nuts 2 equally with a round bar. 016.679/08 Supplier Type...
  • Page 263 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation ⇒ Measure the distances (X1, X2) between the edges of the bearing shells and the bearing cover. ⇒ For new bearing shells, the dimensions X1 plus X2 must be between 1.45 mm and 1.61 mm.

  • Page 264: 3303−3/A1

    3303−3/A1 Maintenance Connecting Rod Top End Bearing − Removal, Inspection, Installation Tools: Key to Illustrations: 1 Platform 94142 1 Crankshaft 12 Connecting rod stud 2 Stays 94323 2 Connecting rod 13 Instruction plate 1 Lifting plate 94324 3 Piston rod 14 Head screw 1 Wire rope sling 94209...
  • Page 265 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection, Installation ⇒ Attach the two RDU-eye bolts EB into the guide shoe 6 (Fig. B). ⇒ Attach the stop plate 94335 to bearing cover 5 and guide shoe 6. ⇒ Attach the lifting rings 94332 to cylinder jacket 8 with the screws 7. ⇒...
  • Page 266 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection, Installation ⇒ Attach the RUD-eye bolts EB2 to each side of the the connecting rod (Fig. C). ⇒ Attach the manual ratchets H1, H2 to the RUD-eye bolts EB2. ⇒ Operate the manual ratchets H1, H2 to put a light tension on their chains. ⇒...
  • Page 267 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection, Installation Piston Removed ⇒ Remove the four nuts 4, refer to 3303−1. ⇒ Attach the stop plate 94335 to the bearing cover 5 and guide shoe 6. ⇒ Attach the lifting plate 94324 to the crosshead pin 3 with the nuts of the from the piston rod foot.
  • Page 268 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection, Installation Bearing Shell − Removal ⇒ Remove the toggle lever 15 Fig. E from the connecting rod. ⇒ Hold the toggle lever up with a rope as shown in Fig. F. ⇒ Remove the platform 94142. ⇒...
  • Page 269 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection, Installation Bearing Shell − Install ⇒ Clean the seating surface of the bearing shell 11, Fig. F. ⇒ Make sure that there is no damage to the bearing shell 11. ⇒ Put oil on the bearing shell as follows: ⇒...
  • Page 270 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection, Installation ⇒ Put the round nuts 4 on the elastic studs (see Fig. G). ⇒ Tighten equally the rounds nuts 4 with a round bar. ⇒ Measure the distance (X1, X2) between the edges of the bearing shells and the connecting rod 2.
  • Page 271 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. ⇒...

  • Page 272: 3303−4/A1

    3303−4/A1 Maintenance Connecting Rod Removal and Installation Tools: Key to Illustrations: 1 Deviation pipe 94117A 1 Toggle lever 12 Screw 2 Stays 94323 2 Connecting rod 13 Spur−geared chain block 2 Lifting rings 94332 3 Crosshead pin 14 Screw 1 Holder: includes: 94331 4 Piston rod 15 Screw...
  • Page 273 3303−4/A1 Maintenance Removal and Installation Holder 94331 − Install Attention: Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. ⇒ Install the deviation pipe 94117A. ⇒ Operate the turning gear to move the crankshaft approximately 70_ to the exhaust side.
  • Page 274 3303−4/A1 Maintenance Removal and Installation 94331B 017.679/08 ⇒ Operate the manual ratchets H1, H2 to lift the plate 94331A into position. ⇒ Attach the lug 5 to the nut 6. ⇒ Torque the lug 5 to 800 Nm. ⇒ Operate the manual ratchets H1, H2 to lift the plate 94331A, (Fig. D). ⇒...
  • Page 275 3303−4/A1 Maintenance Removal and Installation ⇒ Operate the turning gear to move the applicable crank BDC. ⇒ Attach the three RUD-eye bolts EB1, EB2 and EB3 to the connecting rod (see Fig. E). ⇒ Attach the manual ratchets H1, H2 to the two eye bolts EB1, EB2. ⇒...
  • Page 276 3303−4/A1 Maintenance Connecting Rod: Removal and Installation Removal Crosshead Lift − Piston Removed Remark: The piston is removed, see 3403−1. ⇒ Attach the rings 94332 to the cylinder jacket with the eight bolts 18. ⇒ Torque the eight bolts 18 to 200 Nm. ⇒...
  • Page 277 3303−4/A1 Maintenance Connecting Rod: Removal and Installation ⇒ Attach the two stays 94323 to the holes in the guide ways, refer to the instructions on the instruction plate 16 (Fig. G): Attach the four pins to the connecting rods. Tighten the two screws M12 14with your hand. Turn the M27 screws fully to the bottom.
  • Page 278 3303−4/A1 Maintenance Connecting Rod: Removal and Installation Crosshead Lift − Piston Installed ⇒ Do the procedure in 3403−2 to hold up the piston. ⇒ Remove the bottom bearing cover, refer to paragraph 1.1. ⇒ Make sure that the applicable crank pin is in the position BDC. ⇒...
  • Page 279 3303−4/A1 Maintenance Connecting Rod: Removal and Installation ⇒ Attach the two manual ratchets H1, H2 to the eye bolts EB2 on the connecting rod and the column. ⇒ Operate equally the manual ratchets H1, H2 to hold the connecting rod in the center position.
  • Page 280 3303−4/A1 Maintenance Connecting Rod: Removal and Installation Connecting Rod − Removal ⇒ Attach the shackle 94019L to the tool 94337. ⇒ Attach the tool 94019L to the connecting rod with the three screws 15. ⇒ Torque symmetrically the three screws 15 to 230 Nm. 94337 Instructions 94337...
  • Page 281 3303−4/A1 Maintenance Connecting Rod: Removal and Installation ⇒ Operate the manual ratchets H1, H2 to move the connecting rod approximately 25_ to the fuel side. ⇒ Remove the manual ratchet H1 from the eye bolt EB1. ⇒ Attach the chain block H3 to the eye bolt EB2. ⇒...
  • Page 282 3303−4/A1 Maintenance Connecting Rod: Removal and Installation ⇒ Operate the turning gear to move the crankshaft counterclockwise until crank pin is approximately 45_ before TDC. At the same time, operate the chain block H3 to keep tension on the connecting rod (Fig. M). ⇒...
  • Page 283 3303−4/A1 Maintenance Connecting Rod: Removal and Installation ⇒ Remove the plate 94331A (Fig. O and Fig. P). ⇒ Attach the connecting element 94331C to the threaded rod 94331B. ⇒ Remove the applicable bottom plates from the middle platform. Attention − Injury Hazard: To prevent an accident, close immediately the openings after you remove the bottom plates.
  • Page 284 3303−4/A1 Maintenance Connecting Rod: Removal and Installation 94333D 94333D WCH03809 WCH03809 94333D 2017 13/ 15 Winterthur Gas & Diesel Ltd.
  • Page 285 3303−4/A1 Maintenance Connecting Rod: Removal and Installation ⇒ Remove the chain block H5. ⇒ Operate the chain blocks H4 and the manual ratchet H1 to move the connecting rod full out of the engine (see Fig. Q and Fig. R). Connecting Rod −...
  • Page 286 3303−4/A1 Maintenance Connecting Rod: Removal and Installation Crosshead − Lower Crosshead Lower − Piston Removed ⇒ Attach the chain block H4 to the shackle on the tool 94324 (see Fig. F). ⇒ Operate the chain block H4 to lift the crosshead a small distance. ⇒...
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  • Page 288: 3303−5/A1

    3303−5/A1 Maintenance Connecting Rod Top End Bearing Cover − Removal and Installation Tools: Key to Illustrations: 1 Deviation pipe 94117A 1 Piston 1 Working platform 94142 2 Bearing cover 1 Chain (double sling) 94666 3 Elastic stud 1 Spur-geared chain block H3 94018−006 4 Crosshead pin 1 Spur-geared chain block H4...
  • Page 289 3303−5/A1 Maintenance Top End Bearing Cover − Removal and Installation ⇒ Attach the two shackles S1, S2 to the attachment points in the cylinder jacket (see Fig. B). ⇒ Attach the two shackles S3, S4 to the eye bolts on the bearing cover 2. ⇒...
  • Page 290 3303−5/A1 Maintenance Top End Bearing Cover − Removal and Installation ⇒ Install the deviation pipe 94117A (Fig. C). ⇒ Attach the chain block H3 to the attachment point as shown. ⇒ Attach the chain block H4 to the crane rail. ⇒...
  • Page 291 3303−5/A1 Maintenance Top End Bearing Cover − Removal and Installation Installation ⇒ Remove the protection from the crosshead pin 4. ⇒ Make sure that the bearing cover 2 and crosshead pin 4 have no damage. ⇒ Attach the double sling chain 94666 to the shackles S3, S4 on the bearing cover 2 (Fig.

  • Page 292: Crosshead

    3326−1/A1 Maintenance Crosshead Guide Shoes − Clearances Checks and Installation Tools: Key to Illustrations: 1 Feeler gauge 94238 1 Crosshead pin 6 Guide rail 2 Device 94324C 2 Guide shoe 7 Shim 3 Locking plate 8 Screw 4 Guide way in engine column 9 M20x45 Screw 5 Top end bearing General...
  • Page 293 3326−1/A1 Maintenance Guide Shoes − Clearances Checks and Installation Clearance Checks Radial Clearance ⇒ Measure the radial clearance between the guide shoe 2 and crosshead pin at all positions of the crosshead. Guide Shoe and Guide Way ⇒ Make sure that the related crank pin is in a position so that the guide shoes 2 touch the guide ways 4 on the fuel side (or exhaust side).
  • Page 294 3326−1/A1 Maintenance Guide Shoes − Clearances Checks and Installation Guide Shoe and Top End Bearing ⇒ Attach the two devices 94324C to the crosshead pin with the four M20x45 screws 1 as shown in Fig. C. ⇒ Measure the full lateral clearance between the top end bearing 5 and the the guide shoes 2.
  • Page 295 3326−1/A1 Maintenance Guide Shoes − Clearances Checks and Installation Guided Shoes − Install The two guide shoes are the same. The shims 7 (Fig. D) on the guide rails 6 can show different thicknesses, thus the guide shoes must be installed in the same positions.

  • Page 296: 3326−2/A1

    3326−2/A1 Maintenance Crosshead Crosshead Pin − Removal and Installation Tools: Key to Illustrations: 1 Deviation pipe 94117A 1 Piston rod foot 9 Spur-geared chain block 1 Platform 94142 2 Crosshead pin 10 Toggle lever 1 Lifting plate 94324 3 Column lug 11 Wooden block 2 Lifting rings 94332...
  • Page 297 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation I - I 94332 94324 94142 94324 017.090/08 ⇒ Attach the eye bolts EB3, EB4 to each side of the connecting rod 4. ⇒ Attach the manual ratchets H1, H2 to the eye bolts EB3, EB4.
  • Page 298 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation ⇒ Put the wooden block 11 in the position shown in Fig. C. ⇒ Operate the manual ratchets H1, H2 to move the connecting rod a small distance to the exhaust side. ⇒...
  • Page 299 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation ⇒ Operate the chain blocks H3, H4 to make sure that the guide shoes 5, 13 do not touch the crosshead pin (Fig. E). ⇒ Remove the two bolts, tab washers and locking plates from the guide shoes. ⇒...
  • Page 300 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation ⇒ Install the deviation pipe 94117A (Fig. F). ⇒ Turn the crosshead pin 90_. ⇒ Attach the chain blocks H6, H7 to the attachment points shown. ⇒ Attach the chain block H7 to the shackle on the plate 94324. ⇒...
  • Page 301 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation Guide Shoes − Removal ⇒ Record the positions of the guide shoes 5, 13. The shims of the guide shoes can have different dimensions. This will help you during the installation procedure (Fig. G). ⇒...
  • Page 302 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation ⇒ Attach the chain block H4 to the eye bolt EB2 on the guide shoe 13 (Fig. G). ⇒ Operate the chain blocks H4, H7 to move the guide shoe to the center position.
  • Page 303 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation ⇒ Turn the crosshead pin 90° . ⇒ Operate the chain block H4 to align, then lower the guide shoe 13 with the crosshead pin (Fig. H). ⇒ Attach the chain block H6 to the eye bolt EB and the plate 94324. ⇒...
  • Page 304 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation ⇒ Make sure that there is no clearance between the locking plates 12 and crosshead pin 2. ⇒ Operate the chain block H5 to lift the crosshead (Fig. C). ⇒ Attach the manual ratchet H1 to the eye bolt EB3. ⇒...
  • Page 305 3326−2/A1 Maintenance Crosshead Pin − Removal and Installation ⇒ Install the top bearing cover (refer to 3303−5). ⇒ Do a check of the crosshead clearances given in 0330−1, Group 3326 ⇒ Disengage the turning gear. ⇒ Set the lubricating pump to on. ⇒...

  • Page 306: Piston

    3403−1/A1 Maintenance Piston Removal and Installation Tools: Key to Illustrations: 1 Wire rope sling 94209 1 Piston crown 12 Screwed connection 4 Plates 94208 2 Piston rod 13 Hinged cover 1 Cover plate 94345D 3 Crosshead pin 14 Holder 2 Distance holders 94345 4 Centring pin 15 Screw...
  • Page 307 3403−1/A1 Maintenance Piston: Removal and Installation ⇒ Attach the two distance holders 94345 to the piston rod foot 19 with the four blolts18 (Fig. A). ⇒ Mark the position of the gland in the cylinder jacket. 94209 94208 94345 WCH0315 WCH0314 ⇒...
  • Page 308 3403−1/A1 Maintenance Piston: Removal and Installation Remark: Before you use the suspension device (94341) for the first time, the axial clearance between the crane hook and suspension device must be adjusted. Remark: The axial clearance between the plates of the suspension device is related to the size of the crane hook.
  • Page 309 3403−1/A1 Maintenance Piston: Removal and Installation ⇒ Attach the engine room crane to the suspension device 94341. ⇒ Operate the engine room crane to move the suspension device 94341 to the top platform ⇒ Operate carefully the engine room crane to lift the piston from the cylinder liner.
  • Page 310 3403−1/A1 Maintenance Piston: Removal and Installation ⇒ Loosen the screws 12 of the device 94350 and push the supports 11 fully outward. ⇒ Open the two hinged plates 13. ⇒ Make sure that the holder 14 lock the hinged plates 13 in the open position. ⇒...
  • Page 311 3403−1/A1 Maintenance Piston: Removal and Installation Installation Attention! Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. ⇒ Use the engine room crane and the wire rope sling 94209 to put the insertion cone 94342 in position (see Fig.
  • Page 312 3403−1/A1 Maintenance Piston: Removal and Installation 94341 94209 94342 WCH02609 94350 WCH02600 Note: Some parts can look different. 2017 7/ 9 Winterthur Gas & Diesel Ltd.
  • Page 313 3403−1/A1 Maintenance Piston: Removal and Installation ⇒ Lower carefully the piston into the cylinder liner until the piston crown 1 is immediately above the insertion cone 94342 (Fig. H). ⇒ Make sure that the piston rings are installed correctly. Remark: During the step below, make sure that the piston rod foot 19 engages correctly with the crosshead pin.
  • Page 314 3403−1/A1 Maintenance Piston: Removal and Installation ⇒ Remove the insertion cone 94342 from the cylinder liner. ⇒ Remove the distance holders 94230 (Fig. I). ⇒ Install the round nuts to the piston rod foot 19. Refer to the procedure in 9403−4.
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  • Page 316: 3403−1/A2

    3403−1/A2 Maintenance Piston Removal and Installation Tilted Removal Tools: Key to Illustrations: 1 Wire rope sling 94209 1 Piston rod 16 Countersunk screw 2 Supports 94354-L / R 2 Piston rod foot 17 Screw M16x40 1 Clamping device 94353 3 Piston crown 18 Screw M16x220 1 Suspension device 94341...
  • Page 317 3403−1/A2 Maintenance Piston: Removal and Installation Removal ⇒ Use the engine room crane (with two hooks) and applicable equipment to install the piston support device 94350B to the top platform. ⇒ Operate the turning gear to turn the crank to BDC. ⇒...
  • Page 318 3403−1/A2 Maintenance Piston: Removal and Installation ⇒ Remove all screws from the piston rod gland / cylinder jacket (refer to 2303−1). Record the position of the gland to the cylinder jacket. ⇒ Attach the locking devices 94343 to the exhaust and fuel side of the cylinder cover.
  • Page 319 3403−1/A2 Maintenance Piston: Removal and Installation Tilted Removal ⇒ Attach the supports 94354-L and 94354-R to the cylinder cover studs 12 with the two screws 17. ⇒ Attach the engine room crane to the device 94353. Remark: During the step below, do not attach the ring half 94353A. ⇒...
  • Page 320 3403−1/A2 Maintenance Piston: Removal and Installation Tilted Removal ⇒ Connect one hook of the engine room crane to the suspension device 94341. ⇒ Operate the engine room crane to lift the piston until the piston skirt is above the seating surface of the device 94353. Attention: Make sure that the piston rod foot does not touch the support of the piston rod gland.
  • Page 321 3403−1/A2 Maintenance Piston: Removal and Installation Tilted Removal ⇒ Remove the holders 94350C from the device 94350B (Fig. F). ⇒ Connect the two hooks of the engine room crane to the device 94353. ⇒ Operate the engine room crane to carefully lift the piston rod to a distance of 100 mm from the ceiling.
  • Page 322 3403−1/A2 Maintenance Piston: Removal and Installation Tilted Removal ⇒ Operate the electric chain block and engine room crane to remove the piston as shown in Fig. G. ⇒ Move the piston the a position above the device 94350B. 016.382/07 Note: Some parts can look different. 2013 7/ 13 Winterthur Gas &...
  • Page 323 3403−1/A2 Maintenance Piston: Removal and Installation Tilted Removal ⇒ Loosen the connections 11. ⇒ On the piston support device 94350B, push fully out the supports 7. ⇒ Push up the hinged covers 8. ⇒ Lower the piston rod until the piston foot is below the piston support device 94350B.
  • Page 324 3403−1/A2 Maintenance Piston: Removal and Installation Tilted Removal ⇒ Attach the suspension device 94341 to piston crown. ⇒ Attach the engine room crane to the suspension device 94341. ⇒ Operate the engine room crane to lift the piston a small distance. ⇒...
  • Page 325 3403−1/A2 Maintenance Piston: Removal and Installation ⇒ Remove the piston rings, refer to 3425−1. ⇒ Clean the exterior of the piston. Make sure that you do cause damage to the piston. ⇒ Do a height check of the piston ring grooves, refer to 0330−1 Piston ring grooves.
  • Page 326 3403−1/A2 Maintenance Piston: Removal and Installation ⇒ Operate the turning gear to move the applicable 94341 crank to TDC. ⇒ Operate the engine room crane to lift the piston a small distance. ⇒ Loosen the connections 11. 94353 ⇒ Push out the supports 7. 94350C ⇒...
  • Page 327 3403−1/A2 Maintenance Piston: Removal and Installation ⇒ Operate the engine room crane carefully lift the piston rod to a distance of 100 mm from the ceiling (see Fig. N). ⇒ Move the piston rod to the exhaust side. At the same time, tilt the piston rod. ⇒...
  • Page 328 3403−1/A2 Maintenance Piston: Removal and Installation ⇒ Remove the protection from the crosshead pin and top end bearing. ⇒ Remove the two hooks from the device 94353. WCH01108 ⇒ Attach the tool 94343 to the piston head. ⇒ Operate the engine room crane to lift the piston 94341 a small distance.
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  • Page 330: 3403−2/A1

    3403−2/A1 Maintenance Piston Compression Shims − Replace Tools: Key to Illustrations: 1 Platform 94142 1 Cylinder jacket 6 Compression shim 2 Lifting tools 94333A 2 Piston rod 7 Elastic stud 2 Suspension chains 94333B 3 Piston rod foot 8 Dowel pin 2 RUD−Eye bolts EB1, EB2 94040−M36 4 Crosshead pin...
  • Page 331 3403−2/A1 Maintenance Piston: Compression Shims − Replace 94333B ⇒ Operate the turning gear to move the crank a maximum of 40° counterclockwise. 94333A ⇒ Attach the chains 94333B to the tools 94333A. ⇒ Operate carefully the turning gear to move 35°...
  • Page 332 3403−2/A1 Maintenance Piston: Compression Shims − Replace Compression Shim − Install ⇒ Make sure that unwanted material is removed from the top of the cylinder liner bore, refer to 2124−1. ⇒ Put the new compression shim 6 in position on the crosshead pin 4 (Fig. B). ⇒...
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  • Page 334: 3403−3/A1

    3403−3/A1 Maintenance Piston Disassemble and Assemble Tools: Key to Illustrations: Connection piece w. HP hoses 94215B 1 Piston head 10 Bolt Suspension device 94341 2 Piston skirt 11 Spring dowel pin Pre-tensioning jacks 94346 3 Spray plate and oil pipe 12 Round nut Piston supporting device 94350...
  • Page 335 3403−3/A1 Maintenance Piston: Disassemble and Assemble Disassemble ⇒ Put the two jacking screws 94363 fully into the two tap holes 12 in the top of the piston rod. Make sure that the jacking screws touch the Allen screws 8 (Fig. C). ⇒...
  • Page 336 3403−3/A1 Maintenance Piston: Disassemble and Assemble Assemble Remark: Do not install pipes or nozzles that have damage. ⇒ Apply Loctite No. 0270 to the thread of the pipe 3a (Fig. B and Fig. C). ⇒ Use the applicable tool to install the pipe 3a to the spray plate 3. ⇒...
  • Page 337 3403−3/A1 Maintenance Piston: Disassemble and Assemble 94341 AF12 018.011/09 Center punch here 94350 016.528/08 SPRAY PLATE − REMOVE 94364a PISTON SKIRT − REMOVE PISTON HEAD − REMOVE 94364 016.882/08 94363 2017 4/ 5 Winterthur Gas & Diesel Ltd.
  • Page 338 3403−3/A1 Maintenance Piston: Disassemble and Assemble I - I III - III IV - IV AF14 V - V VI - VI 016.883/08 II - II VII - VII 2017 5/ 5 Winterthur Gas & Diesel Ltd.
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  • Page 340 3403−4/A1 Maintenance Piston Top Surface Check Tools: 1 Feeler gauge 94122 1 Template 94366 1 Template 94366A 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 341: 3403−4/A1

    3403−4/A1 Maintenance Piston Top Surface Check Procedure − Piston Installed Attention! Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. ⇒ Operate the turning gear to move the piston to BDC. ⇒...

  • Page 342: 3425−1/A1

    3425−1/A1 Maintenance Piston Rings Wear of Piston Rings and Ring Grooves Tools: 1 Inside micrometer 94101 1 Feeler gauge 94122 1 Piston ring tensioning device 94338 (for Straight Cut piston ring) 1 Piston ring tensioning device 94338A (for Gas Tight piston ring) 1 Permascope MP0 94356 with instruments for...
  • Page 343 3425−1/A1 Maintenance Piston: Wear of Piston Rings and Ring Grooves Piston Rings − Rate of Wear Chrome−ceramic Layer − Piston Installed ⇒ Read the data in the suppler documentation for the tool Permascope MP0 94356. ⇒ Calibrate the Permascope MP0 94356. Use the calibration foils and the top flank of a spare top piston ring to get a correct setting.
  • Page 344 3425−1/A1 Maintenance Piston: 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. B), do an overhaul of the unit as soon as possible.
  • Page 345 3425−1/A1 Maintenance Piston: Wear of Piston Rings and Ring Grooves Use the formula below to calculate the remaining piston ring lifetime according to the latest condition setting: (D2− Dmin) x 1000 LT = Where: Remaining in−service time (hrs) D2 = second recorded thickness of chrome−ceramic layer (mm) Dmin = Minimum thickness of the chrome−ceramic layer (mm) (see paragraph 2.2).
  • Page 346 3425−1/A1 Maintenance Piston: Wear of Piston Rings and Ring Grooves PISTON MOVED (C2) DOWN (C1) 94122 POSSIBLE WEAR WCH02244 SHAPE ON GROOVE WEAR STEP ON CHROMIUM LAYER (C3) WCH02244 Piston Rings − Removal Attention! Damage Hazard: Do not open the piston rings too far. This will cause damage to the piston rings.
  • Page 347 3425−1/A1 Maintenance Piston:Wear of Piston Rings and Ring Grooves Piston Ring Clearance − Piston Removed 3.3.1 Procedure with Calliper Gauge or Inside Micrometer Set ⇒ Use the calliper gauge 94357 (Fig. E) or inside micrometer set 94101 to measure the groove height at point A and point B. Measure the groove height at a minimum of four locations around the circumference of the piston head.
  • Page 348 3425−1/A1 Maintenance Piston: Wear of Piston Rings and Ring Grooves Piston Rings − Install Used Piston Rings ⇒ For the ring types and their locations, see the table below: Ring Type Material Application Top piston ring 1 x GT P1 CC 24 Chrome-ceramic layer For new and fully honed cylinder liners (GT = Gas Tight)
  • Page 349 3425−1/A1 Maintenance Piston:Wear of Piston Rings and Ring Grooves New Piston Rings Attention: Damage Hazard: Do not open the piston rings too far. This will cause damage to the piston rings. Remark: Make sure that the mark TOP, on the piston ring, points up. Remark: For the ring types and their locations, see the table in paragraph 5.

  • Page 350: Driving Wheels And Shut-Off Valve For Starting Air

    Group4 Maintenance Driving Wheels and Starting Air Shut-off Valve Group 4 Driving Wheels − Running and Backlash Clearances and Tooth Condition ....4103−1/A1 −...
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  • Page 352 4103−1/A1 Maintenance Driving Wheels Running and Backlash Clearances and Tooth Condition Tools: 1 Feeler gauge 94122 1 Micrometer 1 Dial gauge 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 353 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 .
  • Page 354 4103−1/A1 Maintenance Driving Wheels Running and Backlash Clearances and Tooth Condition ⇒ Use the micrometer to measure the lead wire. ⇒ Calculate as follows: The full tooth backlash: Df = 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 356: 4103−2/A1

    4103−2/A1 Maintenance Driving Wheels Crankshaft Gear Wheel − Replace Tools: Key to Illustrations: 1 Ring slugging wrench 94002−60 1 Gear wheel 6 Flange screw 1 Feeler gauge 94122 2 Crankshaft flange 7 Distance sleeve 1 Retaining wrench 94412E 3 Waisted stud 8 Self-locking nut 4 Castle nut 9 Dowel pin...
  • Page 357 4103−2/A1 Maintenance Crankshaft Gear Wheel − Replace Preparation 001.173/97 ⇒ 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. A) of the two−part gear wheel 1.
  • Page 358 4103−2/A1 Maintenance Crankshaft Gear Wheel − Replace Remark: When you the two steps below, do not use Molykote or oil. ⇒ Remove all grease from the applicable area on the crankshaft flange 2, Fig. B). Make sure that the area is clean and in satisfactory condition. ⇒...
  • Page 359 4103−2/A1 Maintenance Crankshaft Gear Wheel − Replace ⇒ Turn the turn the crankshaft to move the gear wheel half 1 (Fig. E) to the bottom position. ⇒ Put the other half of the crankshaft gear wheel 1 001.167/97 Fig. F (with the other two assembled elastic studs) in position on the crankshaft flange.
  • Page 360 4103−2/A1 Maintenance Crankshaft Gear Wheel − Replace ⇒ Measure the length of the elastic studs 3. Remark: The elastic studs have the correct tension when they are extended to 1.3±0.06 mm more than the length measured in paragraph 3. ⇒ Make sure that there is no clearance between the two halves of the crankshaft gear wheel.
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  • Page 362: 4325−1/A1

    4325−1/A1 Maintenance Starting Air Shut-off Valve Clean − Function Check Key to Illustrations: Valve seat 13 Screw plug 25* To instrument panel and Cover 14 Spring pressure transmitter PT4301C Spring 15 Screw plug 26* Equalizing bore Valve 16 Liner bush 27* To vent valve 2.21 Valve seat 17 Screw...
  • Page 363 4325−1/A1 Maintenance Clean − Function Check Assemble ⇒ Before you assemble all items, replace springs that have corrosion. ⇒ Replace a damaged or worn piston seal ring 10. ⇒ Make sure that the bores 26 are clear. ⇒ Remove the grease from the threads in the valve 4 and the spindle guide 19. ⇒...
  • Page 364 4325−1/A1 Maintenance CLOSED AUTOMAT OPENED 018.896/09 3/ 5 Winterthur Gas & Diesel Ltd.
  • Page 365 4325−1/A1 Maintenance Clean − Function Check Function Check Attention: Injury hazard. During this check, do not select START. Injury to personnel can occur. Attention: Injury hazard. Do not go near areas where high−pressure air can flow out. Injury to personnel can occur. Remark: You must only do this check on a fully assembled engine that is ready to start.
  • Page 366 4325−1/A1 Maintenance Clean − Function Check Automatic Mode ⇒ Make sure the shut−off valve is in the position AUTOMAT. Remark: When you the step below, air will flow through the pipe. This activates the control valve 9, which shows that the valve body and valve operate.
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  • Page 368: Supply Unit, Injection And Exhaust Valve Control

    Group5 Maintenance Supply Unit, Injection and Exhaust Valve Control Group 5 Fuel Pump − Disassemble and Assemble ......... . . 5556−1/A1 −...
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  • Page 370: 5556−1/A1

    5556−1/A1 Maintenance Fuel Pump Disassemble and Assemble Tool: Key to Illustrations: 1 2-part clamping ring 94550 1 Actuator lever 29 Intermediate flange 1 Device 94551 2 Connecting element 30 Toothed rack 1 Lifting tool 94552 3 Screw 31 Circlip 1 Spacer 94555 4 Pump cover 32 Ring...
  • Page 371 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Preparation Attention: Fire Hazard. Do not weld or grind materials in the area. Sparks can cause a fire to occur. Attention: Injury Hazard. Put on gloves and eye protection. Fuel can come out as a spray and cause injury. ⇒...
  • Page 372 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble ⇒ Remove the four screws 3 from the fuel pump (Gig. B). ⇒ Attach applicable equipment to the lifting tool 94552. ⇒ Carefully lift the fuel pump. ⇒ Attach covers to all open flanges to prevent contamination. ⇒...
  • Page 373 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble I - I 37, 38 44, 55 16 54 44a, 56 47, 38a 14, 56 WCH00832 2017 4/ 20 Winterthur Gas & Diesel Ltd.
  • Page 374 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Fuel Pump − Disassemble ⇒ Remove the screws 94592E (Fig. D), 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.
  • Page 375 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Guide Pin − Removal ⇒ Attach the device 94551 as shown. ⇒ Turn the spindle 42 in to push fully in the roller 8 and guide piston 7. 94551 ⇒ Use the handle 94009−M10 to remove the guide pin 9.
  • Page 376 5556−1/A1 Maintenance Fuel Pump:Disassemble and Assemble ⇒ Remove the pump plunger 22 from the bottom spring carrier 21. ⇒ Put the pump plunger 22 into a clean, dry storage area. ⇒ Remove the circlip 16 and push the retaining ring 17 down. ⇒...
  • Page 377 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Toothed rack − Remove ⇒ Remove the screws 28. ⇒ Remove the cover 49. ⇒ Remove the circlip 31 and ring 32. ⇒ Remove the intermediate flange 29. ⇒ Remove the toothed rack 30. I - I 28 30 019/236/10...
  • Page 378 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Non−return Valve − Removal ⇒ Attach the 2−part clamping ring 94550 (Fig. H) to the pump cover 4. ⇒ Turn the four M10x60 screws clockwise to remove the valve block 34 from the pump cover (2).
  • Page 379 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Fuel Pump − Assemble ⇒ Clean all parts of the fuel pump. 37, 38 ⇒ Examine all parts of the fuel pump for damage. Replace damaged parts with new items. ⇒ Replace all O−rings and rod seal rings. ⇒...
  • Page 380 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Guide Piston and Top Housing− Assemble ⇒ Clean all parts of the guide piston 7. ⇒ Put oil on all parts of the guide piston 7. ⇒ Put oil on the flanks of the roller 8. ⇒...
  • Page 381 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble ⇒ Turn the fuel pump to the position shown. 28 30 ⇒ Put the toothed rack 30 in position. ⇒ Put oil on the seal rings 43. ⇒ Put the seal rings 43 into the intermediate flanges 29.
  • Page 382 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Bottom Housing − Assemble ⇒ Put the O−rings 55 and 56 into the applicable grooves of the bottom spring carrier 21 and bottom housing 6. ⇒ Attach the rod seal ring 14 and seals 44, 44a into the applicable grooves.
  • Page 383 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble ⇒ Attach the device 94551 to the bottom housing. ⇒ Lift the assembly and move it into position above the upper housing. 94551 ⇒ Put new O−rings 54 on the connection pins 18. ⇒...
  • Page 384 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Top and Bottom Bottom Housings − 94551 Attach ⇒ Attach the ring 94593A to the bottom housing 6 (Fig. O). ⇒ Attach the two−part ring 94593B to the top 94593A housing 5. Align the guide rods 94593C with the bores in the ring 94593A.
  • Page 385 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble ⇒ Lower the bottom housing 6 (Fig. P) on to the top housing 5 until the spring carrier 21 is 94551 approximately 10 mm to 20 mm above the compression spring 24. ⇒ Align the wings on the pump plunger 22 with the slots in the regulating sleeve 26.
  • Page 386 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble ⇒ Turn the eye bolt in the device 94551 to move the roller down a sufficient distance for the guide pin 9 (Fig. P). 94551 ⇒ Use the handle 94009−M10 to install the guide in 9.
  • Page 387 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble 94552 Fuel Pump − Install ⇒ Remove the limiters 94592B, 94592C. ⇒ Turn the fuel pump until the pump cover 94592C points up. ⇒ Attach the lifting tool 94552 to the fuel pump. 94592B ⇒...
  • Page 388 5556−1/A1 Maintenance Fuel Pump: Disassemble and Assemble Oil Flow Check Attention: Do not operate the engine. Injury to personnel can occur. Attention: Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Remark: The oil flows through the throttle 48 to the bottom housing 6 and the guide piston 7.
  • Page 389 5556−1/A1 Maintenance Fuel Pump: Disassemble and 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. ⇒...

  • Page 390: 5556−2/A1

    5556−2/A1 Maintenance Fuel Pump Pump Plunger that is Caught − Removal Tool: Key to Illustrations: 1 HP hose 94935 1 Top housing 12 Vent screw 1 Jack 94595 2 Bottom housing 13 Allen screw 1 Short tappet 94595B 3 Pump plunger 14 Spindle 1 Long tappet 94595C...
  • Page 391 5556−2/A1 Maintenance Fuel Pump: Pump Plunger that is Caught − Removal Hydraulic Ram − Preparation ⇒ Remove the tappet 94595B from the piston 11. ⇒ Attach the piston reset tool 94595D to the jack 94595 with the two Allen screws 13. Remark: The screws 13 are from the fuel pump cover.
  • Page 392 5556−2/A1 Maintenance Fuel Pump: Pump Plunger that is Caught − Removal Removal with Tool 94595B Remark: Some internal parts of the fuel pump can look different. ⇒ Connect the hydraulic ram 94595 to the HP oil pump 94931 (Fig. C). 94595 ⇒...
  • Page 393 5556−2/A1 Maintenance Fuel Pump: Pump Plunger that is Caught − Removal Removal with Tool 94595C Remark: Some internal parts of the fuel pump can look different. ⇒ Remove the short push rod 94595B from the 94595 hydraulic ram 94595. ⇒ Put the long push rod 94595C into the 94595C hydraulic ram 94595 (Fig.

  • Page 394: 5562−1/A1

    FI Fuel inlet FO Oil outlet OI Oil inlet pipe 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. Adjust the PCV.
  • Page 395 5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal and Installation Preparation Attention: Use gloves and eye protection. Hot fuel can come out as a spray and cause injury. Attention: Fire hazard. Do not weld or grind materials in the area. Sparks can cause a fire.
  • Page 396 5562−1/A1 Maintenance 19 20 25 16 013.408/05 3/ 5 Winterthur Gas & Diesel Ltd.
  • Page 397 5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal and Installation Filter − Clean ⇒ Remove the oil inlet pipe OI and the union 14. ⇒ Remove the filter 13. ⇒ Clean the filter 13. If necessary, replace the filter. ⇒ Put oil on the filter 13. ⇒...
  • Page 398 5562−1/A1 Maintenance Storage The spare parts must be carefully protected against corrosion. ⇒ Make sure that the PCV has no dirt, oil or grease. ⇒ Apply a special liquid (eg Tectil 506, ISOTEC 337) to the applicable surfaces. ⇒ Put protection on all blind and tapped holes. ⇒...
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  • Page 400: 5562−2/A1

    5562−2/A1 Maintenance Relief Valve Checks and Setting Tools: Key to Illustrations: 1 OBEL test bench 94272 1 Relief valve 5 Receiver 1 Valve holder 94272A 2 Holes 6 Housing 1 HP oil pump 94931 3 Valve block 2 Hydraulic distributors 94934A 4 Valve (on HP oil pump) 2 HP hoses...
  • Page 401 5562−2/A1 Maintenance Relief Valve: Checks and Setting Relief Valve − Removal ⇒ Read the data in the manufacturer’s instructions for the test bench 94272. ⇒ Stop the engine. ⇒ Make sure that the fuel rail has no pressure. ⇒ Use an AF80 spanner to remove the relief valve 1. Relief Valve Test Test and Calibration Fluid −...
  • Page 402 5562−2/A1 Maintenance Relief Valve: Checks and Setting 94934A 94935 94272A 013.484/05 94272 94931 94934A 013.486/05 Installation ⇒ Apply Never-Seez NSBT-8 to the thread of the relief valve housing 6. ⇒ Attach the relief valve 1 to the valve block 3 on the pressure control valve. ⇒...
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  • Page 404: 5564−1/A1

    5564−1/A1 Maintenance Injection Control Unit Removal and Installation Tools: Key to Illustrations: 1 Pipe 94583 1 Flexible hose (outlet) 8 Rail valve 1 Lifting plate 94584 2 Flexible hose (inlet) 9 Screw 4 Conical plugs 94587 3 Fuel leakage return 10 Lip seal 2 Removal tools 94589...
  • Page 405 5564−1/A1 Maintenance Injection Control Unit: Removal and Installation ⇒ Remove the six screws 7 (Fig. B). ⇒ Remove the four screws 6. ⇒ Attach the lifting plate 94584 to the ICU 5. ⇒ Disconnect the electrical connections from the rail valves 8 and the position sensor 11.
  • Page 406 5564−1/A1 Maintenance Injection Control Unit: Removal and Installation Installation ⇒ Put the lip seal 10 in position (Fig. C). ⇒ Carefully operate the engine room crane to lower the injection control unit 6 on to the dowel pin 14 in the fuel rail 4. ⇒...
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  • Page 408: Fuel Pump Unit

    5581−1/A1 Maintenance Fuel Pump Unit Camshaft and Bearing Shells − Removal and Installation Tools: Key to Illustrations: 2 Pre-tensioning devices 94557 1 Fuel pump 14 Cover 1 Support 94566 2 Housing 15 Cover 1 Support 94566A 3 Bearing cover 16 Cover 2 Holders 94566B 4, 4a Thrust bearing cover...
  • Page 409 5581−1/A1 Maintenance Fuel Pump Unit: Camshaft and Bearing Shells − Removal and Installation Rollers − Lift ⇒ Make sure that the bearing covers at positions No. 3, No 4 and No. 5 and the housing 2, have marks to identify them as a set (Fig. B). ⇒...
  • Page 410 5581−1/A1 Maintenance Fuel Pump Unit: Camshaft and Bearing Shells − Removal and Installation Bearing Shells − Removal ⇒ Remove the bearing covers 3, 4. Do not remove the two outer bearing covers (No. 1 and 6) during this step. ⇒ Put the jacking screw 94567B in position. ⇒...
  • Page 411 5581−1/A1 Maintenance Fuel Pump Unit: Camshaft and Bearing Shells − Removal and Installation Camshaft − Removal ⇒ Put the support 94566A to bearing No. 2. ⇒ Use the AF18 open−ended ring spanner 22 to turn the shaft 22 to the mark CLAMPED. Make sure that the bottom of the support touches the camshaft 10.
  • Page 412 5581−1/A1 Maintenance Fuel Pump Unit: Camshaft and Bearing Shells − Removal and Installation ⇒ Put the screwjack 94567B in position (Fig. E). ⇒ Turn the screwjack 94567B to lift the camshaft between 0.05 mm and 0.15 mm. ⇒ Put the assembly template 94567A on the bottom elastic bolt 8.
  • Page 413 5581−1/A1 Maintenance Fuel Pump Unit: Camshaft and Bearing Shells − Removal and Installation Completion ⇒ Refer to 0330−1, Clearance Table, Fuel pump unit 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 3).

  • Page 414: 5581−2/A1

    5581−2/A1 Maintenance Fuel Pump Unit Lubrication during Maintenance Tools: Key to Illustrations: 1 Lubricating device 94844 1 Blank flange 5 Screw 2 Blank flange 6 Screw 3 Oil pipe 7 Warning plate 4 Ball valve General During maintenance, the turning gear operates to turn the engine. The lubricating device 94844 prevents damage from dry running to the bearing shells of the fuel pump unit.
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  • Page 416: Fuel Pump Actuator

    5583−1/A1 Maintenance Fuel Pump Actuator Connection to Fuel Pump 6 to 8 Cylinder Engines Key to Illustrations: 1 Fuel pump 7 Screw 2 Actuator 8 Connecting element 3 Indicator 9 Screw 4 Output shaft 10 Self-locking nut 5 Lever 11 Toothed rack 6 Clamping sleeve General Maintenance of the connection between the fuel pump and the actuator is not...
  • Page 417 5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump 6 to 8 Cylinder Engines Actuator and Fuel Pump − Align If there was an overhaul on the actuator, or the actuator was replaced do the procedure that follows: ⇒ Make sure that the actuator is electrically disconnected. ⇒...
  • Page 418 5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump 6 to 8 Cylinder Engines 48 mm WCH03821 I - I 2017 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 420 5583−1/A2 Maintenance Fuel Pump Actuator Connection to Fuel Pump to 12 Cylinder Engines Key to Illustrations: 1 Fuel pump 7 Screw 2 Actuator 8 Connecting element 3 Indicator 9 Screw 4 Output shaft 10 Self-locking nut 5 Lever 11 Toothed rack 6 Clamping sleeve General Maintenance of the connection between the fuel pump and the actuator is not...
  • Page 421 5583−1/A2 Maintenance Fuel Pump Actuator: Connection to Fuel Pump to 12 Cylinder Engines Actuator and Fuel Pump − Align If there was an overhaul on the actuator, or the actuator was replaced do the procedure that follows: ⇒ Make sure that the actuator 2 is electrically disconnected (Fig. B). ⇒...
  • Page 422 5583−1/A2 Maintenance Fuel Pump Actuator: Connection to Fuel Pump to 12 Cylinder Engines 48 mm WCH03821 I - I 2017 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 424: Servo Pump Unit

    5591−1/A1 Maintenance Servo Pump Unit Servo Oil Pump and Drive − Removal and Installation (with Dynex SOP) Key to Illustrations: 1 Servo oil pump 11 Allen screw 2 Gear wheel pair 12 Screw 3 Casing 13 Supply pipe (servo oil) 4, 4a Bearing 14 Copper rod 16 5 Pump support...
  • Page 425 5591−1/A1 Maintenance Servo Pump Unit: Servo Oil Pump and Drive − Removal and Installation (with Dynex SOP) Servo Oil Pump − Removal Attention: The servo oil pump weighs 227 kg. To prevent injury, use applicable equipment to lift and move the servo oil pump. ⇒...
  • Page 426 5591−1/A1 Maintenance Servo Pump Unit: Servo Oil Pump and Drive − Removal and Installation (with Dynex SOP) Pinion − Removal ⇒ Remove the four Allen screws 11 (Fig. B). ⇒ Use the jacking screws 15 to remove pump support 5. ⇒...
  • Page 427 5591−1/A1 Maintenance Servo Pump Unit: Servo Oil Pump and Drive − Removal and Installation (with Dynex SOP) Pinion − Installation ⇒ Put oil on the new O−rings 18, 19 (Fig. B). ⇒ Put the shaft 8 together with the pinion 7 into the casing 5 and the bearing bush 6.
  • Page 428 5591−1/A2 Maintenance Servo Pump Unit Servo Oil Pump and Drive − Removal and Installation (with Bosch SOP) Key to Illustrations: 1 Servo oil pump 12 Screw 14 2 Gear wheel pair 13 Supply pipe (servo oil) 15 3 Casing 14 Copper rod 16 4, 4a Bearing 15 Jacking screw (M16) 17 5 Pump support...
  • Page 429 5591−1/A2 Maintenance Servo Pump Unit Servo Oil Pump and Drive − Removal and Installation (with Bosch SOP) Servo Oil Pump − Removal Attention: The servo oil pump weighs 230 kg. To prevent injury, use applicable equipment to lift and move the servo oil pump. ⇒...
  • Page 430 5591−1/A2 Maintenance Servo Pump Unit Servo Oil Pump and Drive − Removal and Installation (with Bosch SOP) Pinion − Removal ⇒ Remove the four Allen screws 11 (Fig. B). ⇒ Use the jacking screws 15 to remove pump support 5. ⇒...
  • Page 431 5591−1/A2 Maintenance Servo Pump Unit Servo Oil Pump and Drive − Removal and Installation (with Bosch SOP) Pinion − Installation ⇒ Put oil on the new O−rings 18, 19 (Fig. B). ⇒ Put the shaft 8 together with the pinion 7 into the casing 5 and the bearing bush 6.

  • Page 432: 5612−1/A1

    5612−1/A1 Maintenance Exhaust Valve Control Unit Removal, Disassemble, Assemble and Installation Key to Illustrations: 1 Valve control block 13 Cover 2, 2a, 2b Pipe 14 Compression spring 3 Rail valve 15 Slide rod 4 Allen screw 16 Screw plug 5 Screw 17 Seal 6 Servo oil rail 18 Screw plug...
  • Page 433 5612−1/A1 Maintenance Exhaust Valve Control Unit: Removal, Disassemble, Assemble and Installation Removal Attention! The exhaust valve control unit (VCU) weighs approximately 88 kg. Use applicable equipment and sufficient personnel to lift and move the VCU. ⇒ Make sure that the servo oil rail 6 has no pressure.
  • Page 434 5612−1/A1 Maintenance Exhaust Valve Control Unit: Removal, Disassemble, Assemble and Installation Assemble ⇒ Remove the screw plug 20 (Fig. C). ⇒ Put oil on the the slide rod 15, the piston 11. ⇒ Put the slide rod 15 and the compression spring 14 in position in the VCU 1 (Fig.
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  • Page 436: Scavenge Air Receiver And Auxiliary Blower

    Group6 Maintenance Scavenge Air Receiver and Auxiliary Blower Group 6 Scavenge Air Receiver − Clean and do Checks ......6420−1/A1 Auxiliary Blower: Maintenance .
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  • Page 438: 6420−1/A1

    6420−1/A1 Maintenance Scavenge Air Receiver Clean and do Checks Key to Illustrations: 1 Scavenge air receiver 9 Plate 2 Auxiliary blower box 10 Spacer 3 Air flap 11 Guide 4 Door 12 Stop plate 5 Auxiliary blower 13 Axle 6 Cover 14 Pin 7 Screw 15 Drain...
  • Page 439 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Flaps Removal ⇒ Remove the three screws 8 and the tab washers 8a. ⇒ Remove the flat bars 9 and stop plates 12. ⇒ Remove the guides 11, spacer 10, axle 13 and the flap 3. Installation ⇒...
  • Page 440 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 WinGD Ltd Switzerland. ⇒ Do a check of the relief valve (Fig. C) during each engine overhaul as follows: ⇒...
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  • Page 442: Auxiliary Blower Maintenance

    6545−1/A1 Maintenance Auxiliary Blower Maintenance Tools: Key to Illustrations: 1 Spur-geared chain block (H1) 94650 1 Electric motor 7 Screw 1 Dismantling device 94651 2 Motor plate 8 Screw Includes: 3 Casing 9 I−beam 1 Trolley 94651C 4 Impeller 10 Attachment point 2 Centering studs 94652 5 Support...
  • Page 443 6545−1/A1 Maintenance Auxiliary Blower: Maintenance Note: Some parts Removal can look different. ⇒ Read the data 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 1.
  • Page 444 6545−1/A1 Maintenance Auxiliary Blower: Maintenance ⇒ Move chain block H1 and electric motor 1 along Note: Some parts can look different. the I−beam 9 to the end stop (Fig. C). ⇒ Turn the electric motor 1 90° . ⇒ Attach the chain block H2 to the attachment point 10 and the two chains 12.
  • Page 445 6545−1/A1 Maintenance Auxiliary Blower: Maintenance Auxiliary Blower: Maintenance Disassemble and Assemble ⇒ Disassemble and assemble the electric motor Note: Some parts accordance with manufacturer’s can look different. instructions. Installation ⇒ Make sure that the shims 6 are in the correct 94651C positions (Fig.

  • Page 446: 6606−1/A1

    6606−1/A1 Maintenance Scavenge Air Cooler Removal and Installation (with Integrated Lifting IL) Tools: Key to Illustrations: 3 Spur-geared chain block H1, H2, H3 94018−006 1 Butterfly valve 2 Manual ratchet H3, H4 94016−01 2 Cooling water inlet pipe 2 Chains (double sling) 94666 3 Cooling water outlet pipe 6 Swivel lugs...
  • Page 447 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) Removal Attention: The cover 7 weighs 268 kg. To prevent injury to personnel and damage to equipment, use applicable equipment to lift and move the cover. ⇒ Attach the two chain blocks H1, H2 to the rail 11. ⇒...
  • Page 448 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) ⇒ Operate the manual ratchet H4 to pull out the SAC approximately 100 mm (Fig. C). ⇒ Attach the tool 94663F to the SAC 9. ⇒ Attach the tool 94663E to the bottom center position of the SAC 9a. WCH00822 94666 94048−M30...
  • Page 449 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) ⇒ Attach the chain block H2 to the chain 94666 (Fig. D). ⇒ Operate the the chain block H2 to hold the weight of the SAC 9. ⇒ Remove the manual ratchet H4. ⇒...
  • Page 450 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) ⇒ Use the correct safety chains as follows: 2050 mm for SAC71 2572 mm for SAC73 1865 mm for SAC275. ⇒ Attach the two safety chains 94663D to the lugs 94663C (Fig E). ⇒...
  • Page 451 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) ⇒ Operate the chain blocks H1, H1 to lower fully the SAC. ⇒ Remove the chain block H2. ⇒ Attach the chain block H3 to the SAC. WCH00822 2017 6/ 11 Winterthur Gas &...
  • Page 452 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) ⇒ Operate the chain blocks H1, H3 to move the SAC fully to the end of the rail. ⇒ Attach the engine room crane 14 to the SAC. ⇒...
  • Page 453 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) Installation ⇒ Make sure that all seals are serviceable. Replace damaged items. ⇒ Clean the sealing surfaces 12 of the SAC and the receiver (Fig K). ⇒ Clean the seating surfaces 13 on each side of the SAC and the receiver. ⇒...
  • Page 454 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) ⇒ Operate the manual ratchet H4 to move the SAC into the receiver until the SAC is in the position shown in Fig. M. ⇒ Remove the chain block H1 and the chain 94666 from the swivel lugs 94048−M30.
  • Page 455 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) ⇒ Operate the manual ratchet H4 to pull in the SAC to approximately 100 mm (Fig. N). ⇒ Remove the chain block H2, the chain 94666 and swivel lug 9408−M30. ⇒...
  • Page 456 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation (with Integrated Lifting IL) Completion ⇒ Install the outlet pipe 3 to each SAC. ⇒ Install the inlet pipe 2 to each SAC. ⇒ Install the vent pipes (not shown) to the SAC. ⇒...
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  • Page 458: 6606−1/A2

    6606−1/A2 Maintenance Scavenge Air Cooler Removal and Installation for 3 turbochargers Tools: Key to Illustrations: 1 Spur-geared chain block (H1) 94018−006 1 Butterfly valve 1 Spur-geared chain block (H2) 94018-020 2 Cooling water inlet pipe 2 Manual ratchet (H3, H4) 94016-017 3 Cooling water outlet pipe 2 Spur-geared chain block (H5...
  • Page 459 6606−1/A2 Maintenance Scavenge Air Cooler: Removal and Installation for 3 turbochargers Removal Attention: The cover 7 weighs 268 kg. To prevent injury to personnel and damage to equipment, use applicable equipment to lift and move the cover. ⇒ Attach the spur-geared chain blocks H1, H2 to the rail 11. ⇒...
  • Page 460 6606−1/A2 Maintenance Scavenge Air Cooler: Removal and Installation for 3 turbochargers ⇒ Attach the supports 94663A/B. ⇒ Operate the manual ratchet H7 to pull out the SAC 9b approximately 100 mm Fig. C. ⇒ Attach the ring 94210−003 to the shackle 94019H on the chain block H2. ⇒...
  • Page 461 6606−1/A2 Maintenance Scavenge Air Cooler: Removal and Installation for 3 turbochargers ⇒ Move the SAC 9b fully out of the scavenge air receiver 10. ⇒ Attach the chain block H1 to the swivel lug at the rear of the SAC 9b. ⇒...
  • Page 462 6606−1/A2 Maintenance Scavenge Air Cooler: Removal and Installation for 3 turbochargers Installation ⇒ Make sure that all seals are serviceable. Replace damaged items. ⇒ Use the chain blocks H5, H6 to move the SAC to the bottom position shown in Fig.
  • Page 463 6606−1/A2 Maintenance Scavenge Air Cooler: Removal and Installation for 3 turbochargers ⇒ Operate the manual ratchet H7 to move the SAC 9b into the receiver 10. ⇒ Remove the supports 94663A/B. ⇒ Remove the lifting tools 94664A. ⇒ Operate the manual ratchet H7 to move the SAC 9b fully into the receiver 10. ⇒...

  • Page 464: 6708−1/A1

    6708−1/A1 Maintenance Water Separator Removal and Installation Tools: Key to Illustrations: 1 Wire rope with shackle 94666A 1 Receiver 11 Frame 1 Dismantling and assembling tool 94667 2 Scavenge air cooler 12 Rail 1 Dismantling and assembling tool 94667A 3 Water separator 13 Platform 1 Lifting tool 94667B...
  • Page 465 6708−1/A1 Maintenance Water Separator: Removal and Installation ⇒ Remove the screws 8 and the intermediate rings 7 (Fig. B). I - I II - II FLOW 018.911/09 III - III IV - IV 2017 2/ 9 Winterthur Gas & Diesel Ltd.
  • Page 466 6708−1/A1 Maintenance Water Separator: Removal and Installation Removal ⇒ Attach the chain blocks H1, H2 to the rail 12. ⇒ Attach the tools 94667, 94667C to the water separator. ⇒ Attach the manual ratchet H3 and wire rope 94666A between the two tools 94667, 94667C.
  • Page 467 6708−1/A1 Maintenance Water Separator: Removal and Installation ⇒ Continue to remove the water separator until there is tension on the wire rope 94667D. At the same time, operate the chain block H2 to keep the water separator at the same height. ⇒...
  • Page 468 6708−1/A1 Maintenance Water Separator: Removal and Installation ⇒ Remove the manual ratchet H3, tool 94667C and chain block H2. ⇒ Operate the chain block H1 to lower the water separator. H1 94667B 94667C 94667 018.926/09 2017 5/ 9 Winterthur Gas & Diesel Ltd.
  • Page 469 6708−1/A1 Maintenance Water Separator: Removal and Installation Installation ⇒ Make sure that the parts that follow (see Fig. B), are clean and have no damage: Guide bars 6 Seating surfaces on the water separator The areas of the rubber cords 19 and 20. ⇒...
  • Page 470 6708−1/A1 Maintenance Water Separator: Removal and Installation ⇒ Attach the manual ratchet H3 and the wire rope 94666A to the support 94667G (Fig. I). ⇒ Attach a new rubber cord 19 to the rod 11 (see Fig. B). ⇒ Bond the ends of the rubber cord 19 together with an adhesive compound. ⇒...
  • Page 471 6708−1/A1 Maintenance Water Separator: Removal and Installation ⇒ Remove the chain block H1 and the tool 94667B. ⇒ Operate the manual ratchet H3 to pull the water separator almost fully into the receiver. ⇒ Remove the wire rope 94666A. Attach manual ratchet H3 to the tool 94667A. ⇒...
  • Page 472 6708−1/A1 Maintenance Water Separator: Removal and Installation ⇒ Attach a new rubber cord 19 to the rod 11 (see Fig. B). ⇒ Bond the ends of the rubber cord 19 together with an adhesive compound. ⇒ Put oil on the threads of the screws 8. ⇒...
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  • Page 474 6735−1/A1 Maintenance Scavenge Air Waste Gate Disassemble and Assemble Key to Illustrations: 1 Housing 7 Lock nut 2 Cover 8 Screw 3 Piston 9 Guide ring 4 Pressure reducing valve 10 Piston seal ring 5 Adjusting screw 11 Compression spring (stroke limitation) 12 Solenoid valve 6 Seal (1 mm thickness)
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  • Page 476: Cylinder Lubrication Group

    Group7 Maintenance Cylinder Lubrication Group 7 Lubrication Pump CLU4−C: Gas Pre-charge Pressure − Check ....7218−1/A2 X82−B / MM / 2017 Winterthur Gas & Diesel Ltd. 1/ 3 Winterthur Gas &...
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  • Page 478: 7218−1/A2

    7218−1/A2 Maintenance Lubricating Pump CLU4−C Gas Pre-charge Pressure − Check Tool: Key to Illustrations: 1 Case (for CLU4−C) 94720C 1 Hydraulic accumulator 8 Lubricating pump (CLU4−C) Includes: 2 Protection cap 9 4/2-way solenoid valve Full measurement set 3 Pressure reducing valve 10 Shut-off valve servo oil To check and fill the 4, 4a Hose (1m, 4 m)
  • Page 479 7218−1/A2 Maintenance Lubricating Pump CLU4−C: Gas Pre-charge Pressure − Check ⇒ Remove the cap 2 from the accumulator 1 TO LUBRICATING (Fig. B). QUILLS ⇒ On the control unit 5, close the three valves A, B and C. ⇒ Use the short hose 4 to connect the accumulator 1 to the control unit 5.
  • Page 480 7218−1/A2 Maintenance Lubricating Pump CLU4−C: Gas Pre-charge Pressure − Check ⇒ Open the stop valve 4.30−5 on servo oil rail 4.11 (see Fig. A). ⇒ Close screw plug 13 on the last lubricating pump 8. ⇒ Operate the servo oil system. ⇒...
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  • Page 482: Group 8

    Group8 Maintenance Piping Group 8 Exhaust Waste Gate (Low-load Tuning) ........8135−1/A1 Selective Catalytic Reduction System .
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  • Page 484: Exhaust Waste Gate (Low-Load Tuning)

    8135−1/A1 Maintenance Exhaust Waste Gate (Low-Load Tuning) Key to Illustrations: 1 Butterfly valve 7 Control air pipe 2 Control actuator (one or two) 8 Turbocharger 3 Throttle 9 Exhaust manifold 4 Solenoid valve ZV7076C 10 Exhaust by-pass line 5 Control air supply 11 Shaft 6 Air spring air pipe General...
  • Page 485 8135−1/A1 Maintenance Exhaust Waste Gate (Low-Load Tuning) WCH03824 2017 2/ 2 Winterthur Gas & Diesel Ltd.

  • Page 486: Selective Catalytic Reduction System

    8135−2/A1 Maintenance Selective Catalytic Reduction System General The high pressure Selective Catalytic Reduction System (SCR) is an optional system to decrease the level of nitrogen oxides in the exhaust gas. This makes sure that the emissions of nitrogen oxides obey the Tier III regulations of the International Maritime Organisation (IMO).
  • Page 487 8135−2/A1 Maintenance WCH03875 Fig. 2: SCR Bypass System 1 Exhaust manifold 3 Expansion piece 2 Butterfly valve 4 Actuator 2018 2/ 2 Winterthur Gas & Diesel Ltd.

  • Page 488: Scr Valve − Removal And Installation

    8155−1/A1 Maintenance SCR Valve − Removal and Installation Tools: 1 Lifting tool 94815 1 Sling 94049F Preparation Note: The preparation, removal and installation procedures that follow are for the SCR valve (5). The procedures for the other SCR valves (2, 3) are almost the same.
  • Page 489 8155−1/A1 Maintenance SCR Valve − Removal and Installation Disconnect the electrical connection from the feedback positioner (12, Fig. Remove the four bolts (11) from the holder (10). Remove the actuator (9) together with holder (10) from the SCR valve (3). Put the sling (94049F) around the expansion piece (6).
  • Page 490 8155−1/A1 Maintenance SCR Valve − Removal and Installation CAUTION Injury Hazard: The lifting tool (94815) together with the plate weighs approximately 50 kg. The SCR valve weighs approximately 390 kg. Use only applicable equipment to lift and move the lifting tool and the SCR valve. 12) Record the position of the SCR valve (2).
  • Page 491 8155−1/A1 Maintenance SCR Valve − Removal and Installation Operate the engine room crane to lower the SCR valve into position (Fig. Remove the lifting tool (94815). Put a new gasket (not shown) in position. Attach the SCR valve (3) to the flange with the four M30x110 bolts and washers (2) and the nuts (5).
  • Page 492 8155−1/A1 Maintenance SCR Valve − Removal and Installation III-III WCH03875 Fig. 4 2018 5/ 5 Winterthur Gas & Diesel Ltd.
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  • Page 494: Hp Servo Oil Pipe

    8447−1/A1 Maintenance HP Servo Oil Pipe Removal, Grind, Installation (Dynex SOP) Tools: Key to Illustrations: 1 Tool box with 94835 1 Servo oil rail 10 Leakage oil pipe grinding machine 2 HP servo oil pipe 11 Valve housing 1 Grinding tool 94871 3 HP servo oil pipe 12 Connecting block...
  • Page 495 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind, Installation (Dynex SOP) ⇒ Loosen the Allen screws 4, 4a, 4b on the related V - V flanges 5, 5b. ⇒ Disengage the flanges 5, 5a to get air into the HP servo oil pipes 2, 3. Remark: After approximately one minute, the oil drains through the leakage oil pipes 10.
  • Page 496 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind, Installation (Dynex SOP) Sealing Faces − Grind ⇒ Put the template 94871A on the back of the 94871A emery cloth. ⇒ Use the applicable grade of the emery cloth related to the quantity of metal you want to remove.
  • Page 497 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind, Installation (Dynex SOP) Adjustment 6.0 mm ⇒ Make sure that the claw 9 is correctly attached to the HP servo oil pipe (Fig. D). ⇒ Put oil on the new O−rings 13, 14. 2, 3 ⇒...
  • Page 498 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind, Installation (Dynex SOP) ⇒ Carefully put the HP servo oil pipe 3 in position III - III in the connecting block 12 and the intermediate piece 7 (Fig. F). ⇒ Torque symmetrically the four screws 4 to the connecting block 14 to 70 Nm.
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  • Page 500: 8460−1/A1

    8460−1/A1 Maintenance Hydraulic Pipe for Exhaust Valve Drive Removal, Grind, Installation Tools: Key to Illustrations: 1 Tool box 94835 1 Hydraulic pipe with grinding machine 2 Top housing 1 Grinding tool 94871 3 Exhaust valve control unit 1 Stencil 94871A 4 Rail valve 1 Feeler gauge 5 Screw (M12x120)
  • Page 501 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind, Installation Removal Attention: Injury Hazard: The weight of the hydraulic pipe is approximately 56 kg. Use approved equipment or sufficient personnel to lift and move the hydraulic pipe. ⇒ Loosen the Allen screws 5 and 6. ⇒...
  • Page 502 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind, Installation Sealing Faces − Grind ⇒ Put the template 94871A on the back of the 94871A emery cloth. ⇒ Use the applicable grade of the emery cloth related to the quantity of metal you want to remove.
  • Page 503 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind, Installation Adjustment ⇒ Make sure that the claws 8 are correctly attached to the hydraulic pipe 1. ⇒ Make sure that there is a distance of 6.0 mm between the end of the hydraulic pipe 1 and the claw 8.
  • Page 504 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind, Installation Installation Attention: Injury Hazard: The weight of the hydraulic pipe is approximately 56 kg. Use approved equipment or sufficient personnel to lift and move the hydraulic pipe. Attention. Damage Hazard: Make sure that you do not damage the sealing faces (SF) or the hydraulic pipes.
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  • Page 506 8733−1/A1 Maintenance HP Fuel Pipe Removal, Grind, Installation Tools: Key to Illustrations: 1 Grinding tool 94871 1 Cylinder cover 7 Flange 1 Stencil 94871A 2 Injection valve 8 Pipe bracket 3 HP fuel pipe 9 Fuel leakage pipe 3.49 4 Injection control unit 10 O-ring 5 Claw 11 O-ring...

  • Page 507: Hp Fuel Pipe

    8733−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation Sealing Faces − Grind ⇒ Put the template 94871A on the back of the 94871A emery cloth. ⇒ Use the applicable grade of the emery cloth related to the quantity of metal you want to remove.
  • Page 508 8733−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation Installation Attention: Damage Hazard: Make sure that you do not cause damage to the sealing faces SF or the HP injection pipes. ⇒ Put oil on the new O−rings 10, 11. ⇒ Attach the new O−rings 10, 11 to the HP injection pipe 3.
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  • Page 510 8752−1/A1 Maintenance HP Fuel Pipe Removal, Grind, Installation to 8 Cylinder Engines Tools: Key to Illustrations: 1 Grinding tool 94870 1 HP fuel pipe 14 Spring includes: 2 HP fuel pipe 15 Non-return valve 1 Screw-on sleeve 94870E 3 HP fuel pipe 16 Claw 1 Grinding tool 94870F...
  • Page 511 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation to 8 Cylinder Engines Removal HP fuel pipe 1 − Removal Attention. Injury Hazard: The HP fuel pipe weighs approximately 28 kg. Use sufficient personnel or applicable equipment to lift and move the HP fuel pipe.
  • Page 512 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation to 8 Cylinder Engines I - I 89 mm 40.5 mm 41 mm 54 mm WCH02620 2017 3/ 7 Winterthur Gas & Diesel Ltd.
  • Page 513 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation to 8 Cylinder Engines HP fuel pipe 2, 3 and 4 − Removal Attention. Injury Hazard: The HP fuel pipes weigh approximately 28 kg. Use sufficient personnel or applicable equipment to lift and move the HP fuel pipe.
  • Page 514 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation to 8 Cylinder Engines Sealing Faces − Grind 94870H To remove deep notches of more than 0.1 mm, use emery cloth of medium to coarse grain (30 to 80 CAMI). For a smooth finish, use emery cloth with fine or ultra-fine grains (100 to 600 CAMI).
  • Page 515 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation to 8 Cylinder Engines Installation Attention. Injury Hazard: The HP fuel pipes weigh approximately 28 kg. Use sufficient personnel or applicable equipment to lift and move the HP fuel pipe. ⇒ Replace all O−rings. ⇒...
  • Page 516 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation to 8 Cylinder Engines ⇒ Align the marks MA on the HP fuel pipe 2 with the flange 8. ⇒ Torque the Allen screws as given in the procedure above. ⇒ Tighten the screws 18, 18a. ⇒...
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  • Page 518 8752−1/A2 Maintenance HP Fuel Pipe Removal, Grind, Installation Cylinder Engines Tools: Key to Illustrations: 1 Regrinding device 94870 1−7 HP fuel pipe 18 Claw 8 Fuel rail 19 Support consisting of: 1 Screw-on sleeve 94870E 9 Fuel pump cover 20, 20a Screw 1 Grinding tool 94870F 10, 10a Screw...
  • Page 519 8752−1/A2 Maintenance HP Fuel Pipe: Removal, Grind, Installation Cylinder Engines III - III Preparation ⇒ Stop the engine, refer to the operation manual 0510−1. ⇒ Put an oil tray below the applicable HP fuel pump. ⇒ Set to off the fuel supply pump. ⇒...
  • Page 520 8752−1/A2 Maintenance HP Fuel Pipe: Removal, Grind, Installation Cylinder Engines Removal HP fuel pipe 1 − Removal Attention. Damage Hazard: The HP fuel pipe weighs approximately 28 kg. Use sufficient personnel or applicable equipment to lift and move the HP fuel pipe.
  • Page 521 8752−1/A2 Maintenance HP Fuel Pipe: Removal, Grind, Installation Cylinder Engines HP fuel pipes 2 to 7 − Removal ⇒ Remove the Allen screws 10, 10a of the applicable HP fuel pipe. ⇒ Push back the flanges 11, 11a. ⇒ For HP fuel pipes 2, 3, 4 and 6 only ⇒...
  • Page 522 8752−1/A2 Maintenance HP Fuel Pipe: Removal, Grind, Installation Cylinder Engines Sealing Faces − Grind 94870H To remove deep notches of more than 0.1 mm, use emery cloth of medium to coarse grain (30 to 80 CAMI). For a smooth finish, use emery cloth with fine or ultra-fine grains (100 to 600 CAMI).
  • Page 523 8752−1/A2 Maintenance HP Fuel Pipe: Removal, Grind, Installation Cylinder Engines Installation Attention. Injury Hazard: The HP fuel pipe weighs approximately 28 kg. Use sufficient personnel or applicable equipment to lift and move the HP fuel pipe. ⇒ Replace all O−rings. ⇒...
  • Page 524 8752−1/A2 Maintenance HP Fuel Pipe: Removal, Grind, Installation Cylinder Engines ⇒ Install the intermediate piece 13 ⇒ Make sure that there is a distance of 54 mm as shown. ⇒ On then intermediate piece, 13 tighten the screw 20a. ⇒ Do the procedure above for the remaining HP fuel pumps 2 to 7. 2017 7/ 7 Winterthur Gas &...
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  • Page 526: Crank Angle Sensor Unit, Tools

    Group9 Maintenance Crank Angle Sensor Unit, Tools Group 9 Crank Angle Sensor Unit: Disassemble, Assemble and Adjust ....9223−1/A1 Tools: Data ............9403−1/A1 Hydraulic Jacks and Pumps: Configuration and Application .
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  • Page 528: 9223−1/A1

    9223−1/A1 Maintenance Crank Angle Sensor Unit: Proximity Sensor − Replace General The crank angle sensor (CAS) unit (Fig. A) 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 529 9223−1/A1 Maintenance Crank Angle Sensor Unit: Proximity Sensor − Replace Procedures Proximity Sensors (ST5131−34C) Replace Attention: Injury Hazard. Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. ⇒ Stop the engine. ⇒...
  • Page 530 9223−1/A1 Maintenance Crank Angle Sensor Unit: Proximity Sensor − Replace Proximity Sensors (ZS5123−24C) Replace Attention: 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. C) on the flywheel wheel opposite the unserviceable proximity sensor.
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  • Page 532 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 534: 9403−2/A1

    9403−2/A1 Maintenance Hydraulic Jacks and Pumps Configuration and Application 11 13 WCH03830 WCH03830 A = Apply tension / release tension of tie rods, elastic studs to exhaust valve cages, top and bottom end bearings to connecting rod, piston rod, elastic studs to piston crown and elastic studs on supply unit B = Apply tension / release tension of elastic studs to cylinder cover =Apply tension / release tension of elastic studs to cylinder cover (alternative...
  • Page 535 9403−2/A1 Maintenance Hydraulic Jacks and Pumps: Configuration and Application 11 13 WCH03830 D = Tensioning / loosening of foundation bolts E = Fitting and removing roller lifting device 94430A F= Tensioning / loosening of elastic studs to main bearing G= Assembling and dismantling of main bearing cover H = Removal and fitting of main bearing shells I = Checking and setting of fuel overpressure safety valve J = Checking of non-return valve in lubricating quill for pulse lubrication...
  • Page 536 9403−2/A1 Maintenance Hydraulic Jacks and Pumps: Configuration and Application Tool 1 Assembling and dismantling device ..... . 94110 2 Double pre-tensioning jack ......94114 3 Pre-tensioning jack .
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  • Page 538: Hydraulic Pre-Tensioning Jacks

    9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks Overview, 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.

  • Page 539: 9403−3/A1

    9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Dimensions of Back-up Rings and O-rings Fig. Tool Position and application of Part Back-up ring O-ring (concave uncut) pre−tensioning jack Dimension [mm] o∅ x i∅ x t i∅ x s 94114 Main bearing piston...
  • Page 540 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Pre-tensioning jacks − Data Tool 94114 Double pre-tensioning jack for elastic bolts to main bearing 1, 1a Double cylinder 7, 7a Adapter 2, 2a Piston 8 Connection piece 3 Round nut 9, 9a Back-up ring 4 Distance sleeve 10, 10a, 10b O-ring...
  • Page 541 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94145 Pre-tensioning jack for foundation bolts and engine stays 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7 Adapter 8 Connection piece 94145−KJ Kit for pre-tensioning jacks with O-rings and back-up rings (9, 9a, 10, 10a)
  • Page 542 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94180 Pre-tensioning jack for tie rods 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7 Adapter 8 Connection piece 94180−KJ Kit for pre-tensioning jacks with O-rings and back-up rings (9, 9a, 10, 10a) 94180...
  • Page 543 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94215A Pre-tensioning jack for elastic bolts to the cylinder cover 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7 Adapter 8 Connection piece 94215A−KJ Kit for pre-tensioning jacks with O-rings and back-up...
  • Page 544 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94215E Pre-tensioning jack for cylinder cover, connecting rod and bottom end bearing 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 15 Allen bolt 4 Distance sleeve 6 Vent screw 7 Adapter...
  • Page 545 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94252 Pre-tensioning jack for exhaust valve cage 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7 Adapter 8 Connection piece 94252−KJ Kit for pre-tensioning jacks with O-rings and back-up rings (9, 9a, 10, 10a)
  • Page 546 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94315 Pre-tensioning jack for connecting rod, top end bearing 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7 Adapter 8 Connection piece 94315−KJ Kit for pre-tensioning jacks with O-rings and back-up rings (9, 9a, 10, 10a)
  • Page 547 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94320 Pre-tensioning jack for turning gear attachment 1, 1a Cylinder 9, 9a Back-up ring 2, 2a Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7 Adapter 8 Connection piece 94320−KJ Kit for pre-tensioning jacks with O-rings and back-up rings (9, 9a, 10, 10a)
  • Page 548 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94340 Pre-tensioning jack for piston rod foot attachment 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7a Adapter 8 Connection piece 94340−KJ Kit for pre-tensioning jacks with O-rings and back-up rings (9, 9a, 10, 10a)
  • Page 549 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94346 Pre-tensioning jack for piston crown 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7 Adapter 8 Connection piece 94346−KJ Kit for pre-tensioning jacks with O-rings and back-up rings (9, 9a, 10, 10a) 94346...
  • Page 550 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94557 Pre-tensioning jack for supply unit (fuel pump unit) 1 Cylinder 9, 9a Back-up ring 2 Piston 10, 10a O-ring 3 Round nut 6 Vent screw 7 Adapter 8 Connection piece 94557−KJ Kit for pre-tensioning jacks with O-rings and back-up rings (9, 9a, 10, 10a)
  • Page 551 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Overview, Storage, Servicing and Maintenance Tool 94110 Press for removal and installation of main bearing cover 1 Cylinder 9 Back-up ring 2 Piston 10, 10b O-ring 3 Round nut 11 Stop valve 6 Vent screw 12 Nipple 7 Adapter 13 Spring...

  • Page 552: General Application Instructions

    9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks General Application Instructions Tools: Key to Illustrations: 1 Cylinder Version 1 − Hydraulic pre-tensioning jacks for: Foundation bolt and engine stay 94145 2 Piston Exhaust valve cage 94252 3 Round nut Connecting rod, top end bearing 94315 4 Nut Piston foot fastening...
  • Page 553 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Application Instructions Round Nut − Loosen Version 1 − Preparation ⇒ Make sure that the vent screw 6 is open (see Fig. A). ⇒ Put the hydraulic jack on to the elastic stud 5. ⇒...
  • Page 554 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Application Instructions Elastic Bolt/Stud − Apply Tension ⇒ Turn the round nut 4 fully down (Fig. A and Fig. B). 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. C and Fig.
  • Page 555 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Application Instructions Table 1 − Hydraulic Jacks − Values and Comparison Group Jack Tightening Comparison [_(, mm] Reset of jack / value [bar] round nut [turns] 1112−1 94145 step 1000) − ¼ 1500 1132−1 94114 step 600) to 2...

  • Page 556: Tool List

    9403−5/A1 Maintenance Tool List Standard Tools 94000 Combination wrenches 94000−36 2 Pieces ..AF36 94000−41 2 Pieces ..AF41 94000−46 2 Pieces ..AF46 94000−50 2 Pieces ..AF50 2 Pieces .
  • Page 557 9403−5/A1 Maintenance Standard Tools 94005 Rods for pre-tensioning jacks 94005H 1 Piece ..Ø 4 mm 94005A 1 Piece ..Ø 6 mm 94005B 1 Piece ..Ø 9.5 mm Ø...
  • Page 558 9403−5/A1 Maintenance Standard Tools 94009 Handle 94009−M4 2 Pieces ..M4x150 94009−M5 2 Pieces ..M5x150 94009−M6 2 Pieces ..M6x150 000.372/93 94009−M8 2 Pieces ..M8x150 94009−M10 2 Pieces .
  • Page 559 9403−5/A1 Maintenance Standard Tools 94016−007 Manual ratchets (WLL 1600 kg) 2.5 m 94016−017 Manual ratchets (WLL 6300 kg) 3.5 m 94016−020 Manual ratchets (WLL 9000 kg) 3.5 m 012.233/04 94018−008 Spur-geared chain block (WLL 7500 kg, Stroke 6m) 94018−018 Spur-geared chain blocks (WLL 3000 kg, Stroke 5m and flange width W30) 94018−020...
  • Page 560 9403−5/A1 Maintenance Standard Tools 94026 1 Tool box with hex. head drivers ½” (AF5−10, 12, 14, 17) 000.368/93 94032 1 High pressure grease gun To lubriacte grease nipples on fuel pump regulating linkage 000.370/93 94040 RUD-eye bolts 94040−M8 6 Pieces .
  • Page 561 9403−5/A1 Maintenance Standard Tools 94050 Tool for pressure measurement for pneumatic elements 94050A 1 Compressed air pump 94050B 1 Pressure gauge 0 bar to 4 bar 94050C 1 Pressure gauge 0 bar to 6 bar 94050D 1 Pressure gauge 0 bar to 16 bar 94050E 2 HP hoses 94050F...
  • Page 562 9403−5/A1 Maintenance Standard Tools 94114 2 Double pre-tensioning jacks for elastic studs to main bearing, X = 360 mm Mass approximately 143 kg including: 94114A 94114A Top cylinder 94114B Bottom cylinder 94114B WCH02667 94116 Lifting tool for removal and installation of main bearing shell X = 395 mm (WLL 130 kg)
  • Page 563 9403−5/A1 Maintenance Standard Tools 94117 1 Roller supports for removal and installation of main bearing cover X = 160 mm (WLL 1200 kg) 016.732/08 94117A 1 Deviation pipe for removal and installation of: − main bearing, cover, shell − connecting rod, cover, shell −...
  • Page 564 9403−5/A1 Maintenance Standard Tools 94120K 2 Ropes (∅ 10 mm) with a shackle for removal and installation of main bearing cover and shell X = 2047mm (WLL 1050 kg) 005.932/00 94121A 1 Chain for main bearing assembly X = 1597 mm (WLL 1500 kg) 016.732/08 94121B 1 Chain...
  • Page 565 9403−5/A1 Maintenance Standard Tools 94122 1 Feeler gauge X = 100 mm Blade thickness 0.03 mm to 1.00 mm (14-part) 000.361/93 94123 1 Special feeler gauge for main bearing X = 620 mm Blade thickness 0.1 mm to 0.7 mm 000.395/93 (7-part) 94141...
  • Page 566 9403−5/A1 Maintenance Standard Tools 94145 1 Pre-tensioning jack for foundation bolts and engine stays, X = ∅ 156 mm Y = 151 mm 016.744/08 94155 1 Turning-out device with screws M30x160 for turning out thrust bearing pads (with 1-part gear wheel) X = 491 mm Y = 210 mm Z = 260 mm...
  • Page 567 9403−5/A1 Maintenance Standard Tools 94201 1 Lifting device To install and move a cylinder 94202E 94202D 94202C liner Mass approximately 274 kg (WLL 8900 kg) Includes: 94202 1 Lifting gear X = 613 mm Mass approximately 219 kg 94202A 1 Angled lever 94202A X = 417 mm Mass approximately 33 kg...
  • Page 568 9403−5/A1 Maintenance Standard Tools 94209 1 Wire rope sling with hook for removal and installation of the antipolishing ring X = 1000 mm (WLL 800 kg) 012.242/04 94209A See 94215K Tools for tilted removal of cylinder liner according to 2124−2/A2 94210 1 Lifting tool for removal and installation of a...
  • Page 569 9403−5/A1 Maintenance Standard Tools 94215 1 Hydraulic tensioning device for cylinder cover studs Mass approximately 26 kg 94215C includes: 94215C 1 Lifting tool 94215D 94215D 4 Connecting elements 019.377/10 94215K 1 Hydraulic tensioning device * (alternative design) for cylinder cover studs Mass approximately 76 kg includes: 94215G...
  • Page 570 9403−5/A1 Maintenance Standard Tools 94215A 6 Pre-tensioning jacks for cylinder cover studs, X = 262 mm Mass approximately 44 kg 016.759/08 94215E Pre-tensioning jacks for cylinder cover studs and connecting rod studs to bottom end bearing, X = 262 mm Mass approximately 44 kg Back-up rings 94215F...
  • Page 571 9403−5/A1 Maintenance Standard Tools 94219 1 Cylinder pressure measuring tool (indicator), including a wooden box 165 mm 012.243/04 94223 1 Cover Plate X = 816 mm WCH02631 94224 1 Ladder for measuring cylinder liner bore X = 350 mm Y = 3760 mm 000.420/93 94225 1 Measuring gauge...
  • Page 572 9403−5/A1 Maintenance Standard Tools 94259 2 Thrust pin for exhaust valve X = 294 mm 016.765/08 94261 1 Valve seat device X = 690 mm Mass approximately 55 kg 016.766/08 94263 2 Jack screws M16x120 To disassemble the guide bush to exhaust valve 016.769/08 94263A 2 Jack screws M12x140...
  • Page 573 9403−5/A1 Maintenance Standard Tools 94269A−70 1 Slugging wrench for loosening and tightening of coupling nut to injection valve with FAST X = 232 mm WCH01208 94269B 1 Hydraulic cylinder for loosening and tightening of coupling WCH01208 nut to injection valve with FAST X = 395 mm 94269C−55 Socket wrench insert...
  • Page 574 9403−5/A1 Maintenance Standard Tools 94272 1 OBEL test bench To set and do a test of: − injection valve − safety valve X = 1498 mm Mass approximately 192 kg including: 94272B 1 Connecting piece To adjust the injection valve X = 145 mm 94272C 1 Valve holder...
  • Page 575 9403−5/A1 Maintenance Standard Tools 94279 1 Gauge To do checks on for wear on exhaust valve seat X = 175 mm 001.633/97 94278A 1 Nozzle disassembly tool To disassemble the injection nozzle X = AF 60 mm WCH02740 94278B 1 Nozzle assembly tool To assemble the injection nozzle X = AF 55 mm WCH02740...
  • Page 576 9403−5/A1 Maintenance Standard Tools 94315 2 Pre-tensioning jacks for connecting rod studs to top end bearing, X = 194 mm 016.790/08 94320 1 Pre-tensioning jack for screwed connection of turning gear, and round nut 94320A X = 132 mm includes: 94320A 1 Round nut 94320A...
  • Page 577 9403−5/A1 Maintenance Standard Tools 94326 1 Removal and installation tool for removal and installation of bottom end bearing shell X = 356 mm Mass approximately 24 kg (WLL 100 kg) 012.265/04 94331 1 Holder for removal and installation of the connecting rod (∅...
  • Page 578 9403−5/A1 Maintenance Standard Tools 94333 1 Lifting tool to piston for removal of top end bearing cover (WLL 4000 kg) includes: 94040−M36 94333A 2 Lifting tools X = 265 mm with screws M24x70 94333B 94333B 2 Chains with hook and shackle X = 672 mm (94040−M36) 2 Eye bolts M36...
  • Page 579 9403−5/A1 Maintenance Standard Tools 94338 Piston ring tensioning device X = 550 mm Y = 299.5 mm Claw width = 12 mm 94338A Piston ring tensioning device X = 550 mm Y = 299.5 mm Claw width = 19 mm 94338 or 94338A for gas−tight piston ring...
  • Page 580 9403−5/A1 Maintenance Standard Tools 94345 2 Distance holders for removal and installation of the piston rod gland and piston, including 4 screws M24x30 X = 735 mm 016.756/08 94345A 1 Suspension plate for tilted removal and installation of the piston X = 450 mm 94345B 1 Clamping ring 2-parts WCH02632...
  • Page 581 9403−5/A1 Maintenance Standard Tools 94346 2 Pre-tensioning jacks for elastic studs to piston crown, X = ∅ 94 mm 016.821/08 94348 1 Tap M24 for cleaning carbon deposits in threaded holes of piston crown 000.398/93 94350 1 Device To hold the piston and removal of piston rod gland X = 1050 mm Y = 1321 mm...
  • Page 582 9403−5/A1 Maintenance Standard Tools Tools for tilted removal of piston with piston rod gland In accordance with 3403−1/A2 94350B Piston supporting device 94350C To hold the piston and removal of piston rod gland X = 1194 mm Y = 1347 mm Z = 1524 mm Mass approximately 533 kg 94350B...
  • Page 583 9403−5/A1 Maintenance Standard Tools 94363 2 Jacking screws To remove the piston crown from the piston skirt X = M24x50 017.028/08 94364 * Jacking screws To remove the piston skirt from the piston rod X = M16x90 * Use 2 available screws from piston assembly 017.028/08 94364A * Jacking screws...
  • Page 584 9403−5/A1 Maintenance Standard Tools 94410 Adjusting devices To align the intermediate wheel X = 207 mm 7056−03/F101217 94410a Adjusting devices To align the intermediate wheel X = 262 mm 94430 3 Roller lifting tools To cut out and cut in the fuel pump, includes: elastic bolts and round nut X = 197 mm 016.788/08...
  • Page 585 9403−5/A1 Maintenance Standard Tools 94552 1 Lifting tool with Allen screws M14x40 for removal and installation of the fuel pump X = ∅ 120 mm (WLL 600 kg) 017.758/08 94553 Lifting tool To move the supply unit of 6 to 8 cylinder engines X = 1704 mm (WLL 5500 kg)
  • Page 586 9403−5/A1 Maintenance Standard Tools 94566 1 Support for camshaft assembly, including clamping nut X = 760 mm Y1 = 180 mm Mass approximately 20 kg 016.788/08 94566A 1 Support for camshaft assembly, Includes a clamp nut X = 760 mm Y2 = 165.2 mm Mass approximately 20 kg 016.788/08...
  • Page 587 9403−5/A1 Maintenance Standard Tools 94567 1 Assembly template for removal and installation of bearing shells to fuel pump unit X = 90 mm 016.788/08 94567A 1 Assembly template for installation of bearing shells to fuel pump unit X = 177 mm 016.788/08 94567B 1 Jacking screw for camshaft assembly...
  • Page 588 9403−5/A1 Maintenance Standard Tools 94583 1 Pipe To increase pressure in the fuel rail during commissioning X = 650 mm 016.772/08 94584 1 Lifting plate for removal and installation of injection control unit, includes 4 screws M10x25 X = 119 mm (WLL 140 kg) 016.772/08 94587...
  • Page 589 9403−5/A1 Maintenance Standard Tools 94592 1 Fuel pump rack for fuel pump 94592C X = 1029 mm 94592B Mass approximately 89 kg Includes: 94592E 94592A 1 Oil trough 94592B 1 Limiter with 4 screws M12x100 and washers 94592D 94592C 2 Screws 94592A 94592D 4 Screws (M20x50)
  • Page 590 9403−5/A1 Maintenance Standard Tools 94598 Pneumatic impact wrench To loosen and tighten the fuel pump on the fuel pump unit X = 256 mm 94598 Extensions: 1 inch 94598A X = 330 mm Socket spanner insert: 1 inch 94598B AF 46 mm 94598B 94598A 014.38...
  • Page 591 9403−5/A1 Maintenance For a turbocharger malfunction Cover to exhaust manifold outlet 94653E−M66 for MET 66, X = 665 mm, 16 holes 94653E−M71 for MET 71, X = 665 mm, 16 holes 94653E−M83 for MET 83, X = 840 mm, 16 holes 94653E−A180 for ABB 180, X = 870 mm, 24 holes 94653E−A175...
  • Page 592 9403−5/A1 Maintenance Standard Tools Tools for engines with scavenge air cooler In accordance with 6606−1/A1 94663A 1 Support, left for removal and installation of scavenge air cooler X = 697 mm 94663C (WLL 870 kg) Mass approximately 34 kg 94663D 016.822/08 94663B 1 Support, right for removal and installation of scavenge air cooler...
  • Page 593 9403−5/A1 Maintenance Standard Tools 94663E 1 Removal tool for removal of scavenge air cooler, includes 2 screws M20x70 X = 290 mm (SAC71 IL and SAC73 IL) X = 270 mm (SAC275 IL) (WLL 600 N) 016.822/08 94663F 1 Removal tool for removal of scavenge air cooler, includes 2 screws M20x55 X = 180 mm ( SAC71 IL and SAC73 IL)
  • Page 594 9403−5/A1 Maintenance Standard Tools 94667 1 Removal tool for removal of water separator, includes: 4 screws M12x25 800 kg 1 shackle X = 330 mm (WLL 200 kg or 800 kg, marked on the 200 kg plate) 016.829/08 94667A 1 Removal tool for removal of water separator, includes: 4 screws M12x25...
  • Page 595 9403−5/A1 Maintenance Standard Tools 94720C 1 Case (for CLU4−C) consisting of: measurement set complete for checking / refilling of 018.472/09 hydraulic accumulator 94810 Transportation tool for removal and installation of expansion piece, includes: 4 screws M20x35 X = 556 mm Y = 354.4 mm Z = 591 mm (WLL 150 kg)
  • Page 596 9403−5/A1 Maintenance Standard Tools 94844 1 Lubricating device For the fuel pump unit X = 604 mm 015.219/07 94870 1 Grinding tool 94870F for sealing surfaces on HP fuel pipe 94870E X = 166 mm, 88 conical including: 94870G 94870E 1 Screw-on sleeve AF60 016.741/08...
  • Page 597 9403−5/A1 Maintenance Standard Tools 94924 Hook spanner for crank angle sensor X = 205 mm Hook spanner 94925 008.771/00 for crank angle sensor X = 242 mm 94930 1 SW-download package to WECS−9520 for flexView operator consisting of: 1 USB−memory stick 1 CAN cable (ca.
  • Page 598 9403−5/A1 Maintenance Standard Tools 94934G 4 Coupling elements 013.620/05 94934I 1 Connection nipple (G¼”) WCH00724 94935 4 HP hoses with closing valves and coupling sockets X = 2130 mm Maximum operation pressure: 2000 bar 005.954/00 94935C 1 Hose for set-up of pre-tensioning jacks Length = 2000 mm 013.621/05 94936...

  • Page 599: Recommended Special Tools

    9403−5/A1 Maintenance Recommended Special Tools 94016−001 Manual ratchet (WLL 800 kg) 2.5 m 94016−004 Manual ratchet (WLL 1000 kg) 2.5 m 012.233/04 94018−006 2 Spur-geared chain block platform with crane rail Lifting capacity 3000 kg 5 m stroke Flange width standard 012.232/04 94017−019 Spur-geared chain block...
  • Page 600 9403−5/A1 Maintenance Recommended Special Tools 942719 1 Lifting tool, starting air valve 94019E Includes: 94019E Shackle 942719D Cap 94271−9D 942719B Long special screw X = 203 mm 94271−9C Y = 34 mm 942719C Short special screw X = 140 mm Y = 34 mm 94271−9B 94291...
  • Page 601 9403−5/A1 Maintenance Recommended Special Tools 94336 1 Connecting flange for pre-lubrication of top and bottom end bearings X = ∅ 185 mm 016.798/08 94344 1 Support for removal of piston rod gland down X = 1400 mm Y = 1000 mm (WLL 180 kg) Includes: WCH01172...
  • Page 602 9403−5/A1 Maintenance Recommended Special Tools 94481 1 Metal box for storage of spare filter cartridges Remark: Dimensions are related to the size of parts 012.235/04 inside. 94595 1 Jack for removal of a fuel pump that cannot move Plunger (with 12-hole pump cover) X = ∅...
  • Page 603 9403−5/A1 Maintenance Recommended Special Tools 94595E 2 Screws M30 with nuts X = 400 mm 014.502/06 94650 1 Spur-geared chain block for removal and installation of electric motor on auxiliary blower (WLL 2000 kg) 000.460/93 94655 1 Cover to turbocharger outlet with suction pipe For turbocharger malfunction X = 630 mm (TPL 80−B type) X = 750 mm (TPL 85−B type)
  • Page 604 9403−5/A1 Maintenance Special Tools Obtainable on Loan 94105 1 Apparatus To make the bedplate level includes: 4 Supports 4 Weights with wire 1 Underlay X = 1830 mm 000.459/93 94174 4 Thread protectors For top threads of tie rods,during installation of a cylinder jacket X = j 140 mm incl.
  • Page 605 9403−5/A1 Maintenance Special Tools Obtainable on Loan Lifting tool to move the rail unit 94690 1 Lifting tool for 7 Cylinder rail unit module (WLL 13 500 kg) X = 4655 mm Mass approximately 1525 kg 016.795/08 94691 1 Lifting tool for 6, 8 or 9 Cylinder rail unit modules (WLL 13 500 kg) X = 6160 mm...
  • Page 606 9403−5/A1 Maintenance Special Tools Obtainable on Loan 94922 1 Alignment tool for crank angle sensor X = 172 mm 008.773/00 2017 51/ 51 Winterthur Gas & Diesel Ltd.

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