WinGD X72DF Maintenance Manual
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WinGD X72DF Maintenance Manual

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Winterthur Gas & Diesel Ltd.
Winterthur Gas & Diesel AG
Winterthur Gas & Diesel S.A.
Schützenstrasse 3
P.O. Box 414, 8401
Winterthur, Switzerland
Maintenance Manual
X72DF
Tel. +41 (0)52 264 8844
Fax +41 (0)52 264 8866
www.wingd.com
Issue 002 2020-10

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Summary of Contents for WinGD X72DF

  • Page 1 Maintenance Manual X72DF Issue 002 2020-10 Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. +41 (0)52 264 8844 Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax +41 (0)52 264 8866 Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com...
  • Page 2 Information in this publication is subject to change without notice. NO LIABILITY, WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS INTENDED FOR INFORMATION PURPOSES ONLY. www.wingd.com...

  • Page 3: Table Of Contents

    X72DF Maintenance Manual Table of contents Introduction Maintenance Manual - change record........
  • Page 4 X72DF Maintenance Manual 6.3.2 Main bearing shell - examine.........
  • Page 5 X72DF Maintenance Manual 7.5.3 Cylinder cover - grind the sealing face for pilot injection valve... . . 7.5.4 Cylinder cover - grind the sealing face for prechamber....
  • Page 6 X72DF Maintenance Manual Torsional vibration damper 8.2.1 Torsional vibration damper - examine........
  • Page 7 X72DF Maintenance Manual Group 5 - Supply unit, pumps and control valves 10.1 Servo oil pump 10.1.1 Servo oil pump - do a check for wear and damage..... . .
  • Page 8 X72DF Maintenance Manual 11.2 Auxiliary blower 11.2.1 Auxiliary blower - remove..........
  • Page 9 X72DF Maintenance Manual 13.3.4 HP fuel pipe (fuel rail to injection valve) - install......13.3.5 HP fuel pipe (fuel pump to fuel rail) - prepare before removal.
  • Page 10 X72DF Maintenance Manual Page left intentionally blank - 10 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 11 X72DF Maintenance Manual List of tables Introduction Change record ..................... Data module codes (procedural data) ............Data module codes (descriptive data) ............Data module codes (illustrated parts data) ..........List of abbreviations and acronyms ............. General data for maintenance Lifting capacities (for information only) ............
  • Page 12 X72DF Maintenance Manual 13-1 Distance X for HP servo oil pipe ..............13-2 Distance X for hydraulic pipe exhaust valve ..........13-3 Distances X and Y for HP fuel pipe ............. 13-4 Distance X for HP fuel pipe ................. 13-5 Distance X for pilot fuel pipe ................
  • Page 13 X72DF Maintenance Manual List of illustrations Introduction Side view (generic) ..................End view (generic, seen from the driving end) ..........Standard and LEFT engine (generic, seen from the driving end) ....Engine numbering (generic) ................ General data for maintenance RUD-eye bolts .....................
  • Page 14 X72DF Maintenance Manual 6-16 Visual examination ..................6-17 Axial clearance .................... 6-18 Axial clearance - micrometer ............... 6-19 Cover - remove .................... 6-20 Thrust pad - removal ................... 6-21 Thrust pad - install ..................6-22 Thrust pads - configuration ................
  • Page 15 X72DF Maintenance Manual 7-34 Cylinder cover, exhaust valve cage and water guide jacket (example) ..7-35 Cylinder cover and exhaust valve cage (example) ........7-36 Fuel injection valve position - grind ............. 7-37 Grind the sealing face for pilot injection valve ..........
  • Page 16 X72DF Maintenance Manual 7-82 Pilot injection valve ..................Group 3 - Crankshaft, connecting rod and piston Dial gauge position ..................Crank positions for clockwise direction ............Definitions of positions ................Definition of deflection ................. Platforms ..................... Platforms ..................... Axial vibration damper - housing and pipes ..........
  • Page 17 X72DF Maintenance Manual 8-46 Piston - attach ..................... 8-47 Toggle lever - remove .................. 8-48 Crosshead bearing - temperature sensor ............ 8-49 Tools - prepare .................... 8-50 Bracket - attach ................... 8-51 Tools - attach ....................8-52 Connecting rod - move ................
  • Page 18 X72DF Maintenance Manual 10-2 Supply unit for pilot fuel - tool ..............10-3 Pilot fuel supply unit ..................10-4 Pilot fuel supply unit - install ................ 10-5 Pilot fuel supply unit - clearances ..............10-6 Pilot fuel supply unit - completion ..............
  • Page 19 X72DF Maintenance Manual 11-9 Auxiliary blower - remove ................11-10 Auxiliary blower - move ................11-11 Electric motor (free end) - install ..............11-12 Auxiliary blower (driving end) move ............11-13 Electric motor (driving end) - install ............. 11-14 Scavenge air cooler (example) - prepare ............
  • Page 20 X72DF Maintenance Manual 13-3 Servo oil pipes - install ................13-4 Hydraulic pipe (exhaust valve) - remove ............. 13-5 Hydraulic pipe (exhaust valve) - grind sealing face ........13-6 Hydraulic pipe (exhaust valve) - install ............13-7 HP Fuel pipe - preparation ................
  • Page 21 X72DF Maintenance Manual 1 Introduction Maintenance Manual - change record........

  • Page 22: Maintenance Manual - Change Record

    AA00-0000-00AAA-003B-A X72DF Maintenance Manual Maintenance Manual - change record Maintenance Manual - change record Tab 1-1 Change record Data module code, issue Status Chapter number - technical name Reason for change Revised issue 002, 2020-10 Different data modules Different changes and improvements.
  • Page 23 AA00-0000-00AAA-003B-A X72DF Maintenance Manual Maintenance Manual - change record Page left intentionally blank - 23 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 24: Preface

    The data, instructions, graphics and illustrations etc in this manual are related to drawings from WinGD. These data relate to the date of issue of the manual (the year of the issue is shown on the title page and on the footer). All instructions, graphics and illustrations etc can change because of continuous new development and modifications.
  • Page 25 AA00-0000-00AAA-018A-A X72DF Maintenance Manual Preface Page left intentionally blank - 25 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 26: Technical Documentation Set

    AA00-0000-00AAA-018B-A X72DF Maintenance Manual Technical documentation set Technical documentation set Because of the continuous development of the engine, the technical documentation for the engine changes and is regularly updated. The change record shows all changes. Important data and changes are given directly to the customer in the service bulletins.

  • Page 27: Technical Documentation Set

    External supplier documentation The documentation from external suppliers gives data about the parts of the engine that are not supplied by WinGD, such as turbocharger, automatic filter or damper. Most of this documentation also contains data about spare parts. 1.3.5...

  • Page 28: Data Module Codes (Procedural Data)

    00 = applicable to all engines inde- acters [0-9] pendent of the number of cylinders; ## = applicable only to engines with that specific number of cylinders. #### WinGD design group number 4 numeric char- arbitrary 5556 acters [0-9] Used for sequential numbering for the...

  • Page 29: Data Module Codes (Procedural Data)

    AA00-0000-00AAA-018E-A X72DF Maintenance Manual Data module codes (procedural data) Code Description Length/type Property Example Shipdex item location code. A = infor- 1 alphabetic Shipdex specif- mation related to items installed on the character [A-D] product; B = information related to items installed on a major assembly re- moved from the product;...

  • Page 30: Data Module Codes (Descriptive Data)

    00 = applicable to all engines inde- acters [0-9] pendent of the number of cylinders; ## = applicable only to engines with that specific number of cylinders. #### WinGD design group number 4 numeric char- arbitrary 5551 acters [0-9] Used for sequential numbering of data...
  • Page 31 AA00-0000-00AAA-018D-A X72DF Maintenance Manual Data module codes (descriptive data) Page left intentionally blank - 31 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 32: Data Module Codes (Illustrated Parts Data)

    00 = applicable to all engines inde- acters [0-9] pendent of the number of cylinders; ## = applicable only to engines with that specific number of cylinders. #### WinGD design group number 4 numeric char- arbitrary 5562 acters [0-9] Used for sequential numbering of data...
  • Page 33 AA00-0000-00AAA-018F-A X72DF Maintenance Manual Data module codes (illustrated parts data) Page left intentionally blank - 33 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 34: About This Book

    X72DF Maintenance Manual About this book About this book In the sections that follow you find the definitions of WinGD for this book. 1.7.1 Definitions for general text For general text in this book the definitions that follow are applicable: •...
  • Page 35 AA00-0000-00AAA-018C-A X72DF Maintenance Manual About this book 1.7.2 Warnings Warnings in procedures give data about a hazard. Warnings have the basic structure that follows: • Signal word The signal words that follow are applicable: ○ WARNING ○ CAUTION • Hazard The hazard data gives the dangerous situation.

  • Page 36: About The Engine

    Maintenance Manual About the engine About the engine In the sections that follow you find the definitions of WinGD for the engine. 1.8.1 Groups of components Each component of the engine has a four-digit material number. WinGD has divided these components related to the first digit of the number into 9 groups: •...

  • Page 37: Side View (Generic)

    AA00-0000-00AAA-018L-A X72DF Maintenance Manual About the engine 1.8.2 Engine sides and ends - names The sides and ends of the engine have the names and abbreviations that follow (refer to Figure Figure 1-2): • DE - Driving End (end that has a flange to attach the propeller shaft) •...

  • Page 38: End View (Generic, Seen From The Driving End)

    AA00-0000-00AAA-018L-A X72DF Maintenance Manual About the engine Fig 1-2 End view (generic, seen from the driving end) Legend Exhaust side Fuel side Turbocharger Supply unit Auxiliary blower Rail unit Flywheel - 38 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 39 AA00-0000-00AAA-018L-A X72DF Maintenance Manual About the engine 1.8.3 Standard and LEFT engine An engine is one of two types (refer to Figure 1-3): • A standard engine has the exhaust side (ES) on the right side of the engine (seen from the driving end).

  • Page 40: Engine Numbering (Generic)

    AA00-0000-00AAA-018L-A X72DF Maintenance Manual About the engine 1.8.4 Numbering of items WinGD uses the definitions for the numbering of items as follows (refer to Figure 1-4): • In axial direction the numbering starts from the flywheel. • In radial direction the numbering starts from the center of the flywheel.
  • Page 41 AA00-0000-00AAA-018L-A X72DF Maintenance Manual About the engine Page left intentionally blank - 41 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 42: List Of Abbreviations

    AA00-0000-00AAA-005A-A X72DF Maintenance Manual List of abbreviations List of abbreviations Tab 1-5 List of abbreviations and acronyms Short form Full form, meaning Angle Calculation Module crank Angle Determination Algorithm ahead alarm Alarm and Monitoring System as required astern ASTM American Society for Testing and Materials...
  • Page 43 AA00-0000-00AAA-005A-A X72DF Maintenance Manual List of abbreviations Short form Full form, meaning Emission Control Area Engine Control Room Engine Control System eg or e.g. for example (exempli gratia) Exhaust Gas Recirculation ELBA ELectrical BAlancer Exhaust Side Engine Safety System FAME...
  • Page 44 AA00-0000-00AAA-005A-A X72DF Maintenance Manual List of abbreviations Short form Full form, meaning Injection Control Unit ie or i.e. that is (id est) iELBA integrated ELectrical BAlancer iGPR integrated Gas Pressure Regulation International Maritime Organization Ind. Indenture Input Output Module International Standard Organization...
  • Page 45 Top Dead Center UNIC UNIfied Controls Universal Serial Bus exhaust Valve Control Unit Variable Exhaust valve Closing Variable Exhaust valve Opening Variable Injection Timing WECS-9520 WinGD Engine Control System 9520 - 45 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 46 AA00-0000-00AAA-005A-A X72DF Maintenance Manual List of abbreviations Short form Full form, meaning Waste Heat Recovery WiCE WinGD Integrated Control Electronics WinGD Winterthur Gas & Diesel Ltd. Work Load Limit - 46 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 47: Safety

    X72DF Maintenance Manual 2 Safety Safety precautions and safety rules.........

  • Page 48: Safety Precautions And Safety Rules

    AA00-0000-00AAA-012A-A X72DF Maintenance Manual Safety precautions and safety rules Safety precautions and safety rules 2.1.1 General safety precautions Use the data given below as a guide to the personnel. • Lighting Make sure that there is good permanent lighting in the engine room. Have a sufficient number of hand lamps available at different locations in the engine room.
  • Page 49 AA00-0000-00AAA-012A-A X72DF Maintenance Manual Safety precautions and safety rules 2.1.2 General safety rules If you do work at or near the engine, obey the rules that follow to prevent risks of harm or damage to personal, to equipment, or to environment.
  • Page 50 AA00-0000-00AAA-012A-A X72DF Maintenance Manual Safety precautions and safety rules • Rules for electric welding Do electric welding near the engine only if the engine is stopped. Set to OFF the electronic system and wait a minimum of one minute. Disconnect electronic modules or sensors in a radius of two meters from the welding place.
  • Page 51 AA00-0000-00AAA-012A-A X72DF Maintenance Manual Safety precautions and safety rules Page left intentionally blank - 51 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 52: Safety Precautions And Safety Rules For Natural Gas

    AA00-0000-00AAA-012H-A X72DF Maintenance Manual Safety precautions and safety rules for natural gas Safety precautions and safety rules for natural gas 2.2.1 General High concentrations of natural gas can cause dizziness and there is a risk of suffocation. Make sure that all related spaces have good airflow.
  • Page 53 AA00-0000-00AAA-012H-A X72DF Maintenance Manual Safety precautions and safety rules for natural gas 2.2.3 Precautions for work in gas hazardous zones If you do work in a gas hazardous zone, obey the rules that follow to prevent risks of harm or damage to personal, to equipment, or to environment: •...
  • Page 54 AA00-0000-00AAA-012H-A X72DF Maintenance Manual Safety precautions and safety rules for natural gas Page left intentionally blank - 54 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 55: General Data For Maintenance

    X72DF Maintenance Manual 3 General data for maintenance Lifting tools............. .

  • Page 56: Lifting Tools

    AA00-0000-00AAA-066A-A X72DF Maintenance Manual Lifting tools Lifting tools The permissible capacities of the engine crane, lifting tools, ropes, chains, lifting eye bolts, etc. must always correspond with the weights of the parts to be lifted. NOTE: The admissible lifting (max. loading) capacity in kg corresponds to the WLL = Working Load Limit.

  • Page 57: Lifting Capacities (For Information Only)

    AA00-0000-00AAA-066A-A X72DF Maintenance Manual Lifting tools Tab 3-1 Lifting capacities (for information only) Thread size Lifting capacity [kg] single-strand double-strand (45 degree) 1200 1800 1290 3200 2300 4600 3300 6300 4500 8600 6100 11500 8300 Full load is only permissible in the direction of the ring, thus the eye bolts or eye nuts must be put to the right position, if necessary by using distance rings.
  • Page 58 AA00-0000-00AAA-066A-A X72DF Maintenance Manual Lifting tools 3.1.4.1 Use of RUD-eye bolts • The RUD-eye bolts must be completely screwed down, lying fully on the seating surfaces. • The RUD-eye bolts are hand-screwed with their own star-profile wrenches (do not use any extension).

  • Page 59: Rud-Swivel Lugs

    AA00-0000-00AAA-066A-A X72DF Maintenance Manual Lifting tools Fig 3-2 RUD-swivel lugs Force Direction Force Force Direction Direction 00285 3.1.5 Shackles Only those shackles may be used which are in accordance with American Standard RR−C −271A or which fulfil or exceed these values, including the safety factor.

  • Page 60: Jointing Compounds

    AA00-0000-00AAA-701A-A X72DF Maintenance Manual Jointing compounds Jointing compounds Tab 3-2 Jointing compound Jointing compound Hardener Adhesive primer Manufacturer Elastosil RT 622 A RT 622 B G 790 Wacker-Chemie GmbH Geschäftsbereich Silicone Hanns-Seidel-Platz 4 D-81737 München Silcoset 105 RTV Silcoset Curing Silcoset Primer Ambersil House Ltd.
  • Page 61 AA00-0000-00AAA-701A-A X72DF Maintenance Manual Jointing compounds Page left intentionally blank - 61 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 62: Clearances - General

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances - general Clearances - general The chapter that follows gives the values for each group of components. The values given in the columns “Nominal dimension” in the tables that follow are related to design and manufacturing values, or to the settings on a new engine.
  • Page 63 AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances - general Page left intentionally blank - 63 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 64: Clearances

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances Clearances 3.4.1 Crankshaft and thrust bearing Fig 3-3 Crankshaft and Thrust Bearing Tab 3-3 Crankshaft and thrust bearing - clearances Location Item Measured Nominal Maximum code direction dimension dimension (be- (usual, new) cause of wear)

  • Page 65: Crankshaft And Main Bearings

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.2 Crankshaft and main bearings Fig 3-4 Crankshaft and main bearings 001 / 002 MAIN BEARING No. 2, MAIN BEARING No. 3 ETC. No. 1 - 65 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 66 AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances Tab 3-4 Crankshaft and main bearings Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear) [mm] Main bearing No. 1 1132 Bearing clearance Vertical +0.4 to +0.7...

  • Page 67: Crosshead Guide

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.3 Crosshead guide Fig 3-5 Crosshead Guide Tab 3-5 Crosshead guide Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear) [mm] 3326 Crosshead guide 0.2 to 1.1...

  • Page 68: Cylinder Liner

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.4 Cylinder liner Fig 3-6 Cylinder liner Tab 3-6 Cylinder liner Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear) [mm] 2130 Water guide jacket on cylinder cov- Clearance - top part 0.40 to 0.80...

  • Page 69: Piston Rod Gland

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.5 Piston rod gland Fig 3-7 Piston rod gland Tab 3-7 Piston rod gland Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear)

  • Page 70: Exhaust Valve - Spindle And Guide Bush

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.6 Exhaust valve Fig 3-8 Exhaust valve Tab 3-8 Exhaust valve - spindle and guide bush Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear)

  • Page 71: Connecting Rod - Top And Bottom End Bearings

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.7 Connecting rod - top and bottom end bearings Fig 3-9 Connecting rod - top and bottom end bearings Tab 3-9 Connecting rod - top and bottom end bearings Location Item Measured di- Nominal di-...

  • Page 72: Piston And Piston Rings

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.8 Piston and piston rings Fig 3-10 Clearances - piston rings Tab 3-10 Piston and piston rings Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be-...
  • Page 73 AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear) [mm] Rubbing ring Outer diameter 719.3 -0.1 3415 Piston rod Outer diameter 278 Minimum -0.056...

  • Page 74: Supply Unit - Drive Wheels

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.9 Supply unit - drive wheels Fig 3-11 Supply unit - drive wheels - 74 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 75 AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances Tab 3-11 Supply unit - drive wheels Location Item Measured di- Nominal di- Nominal di- code rection mension (usu- mension (usu- al, new) [mm] al, new) [mm] 4104 Intermediate wheel Bearing clearance Vertical *0.121 to 0.210 0.300 1.50...

  • Page 76: Fuel And Servo Pump Units

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.10 Fuel and servo pump units Fig 3-12 Clearances - fuel and servo pump units - 76 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 77 AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances Tab 3-12 Fuel and servo pump units Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear) [mm] 5552 Fuel pump unit Bearing clearance Radial 0.153 to 0.237...

  • Page 78: Fuel Pump

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.11 Fuel pump Fig 3-13 Fuel pump - 78 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 79: Fuel Pump

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances Tab 3-13 Fuel pump Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear) [mm] 5556 Fuel pump Plunger (diameters 40 mm, 42 mm...

  • Page 80: Integrated Electric Balancer

    AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances 3.4.12 Integrated electric balancer Fig 3-14 Clearances - ELBA - 80 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 81 AA00-0000-00AAA-034C-A X72DF Maintenance Manual Clearances Tab 3-14 Integrated electric balancer Location Item Measured di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm] mension (be- cause of wear) [mm] 7758 Bearing Bearing clearance Radial 0.16 to 0.28 0.32...

  • Page 82: Torque Values - Standard Screws

    X72DF Maintenance Manual Torque values - standard screws Torque values - standard screws WinGD highly recommends to use the torque values given in Table 3-16 - Torque values - standard screws for aII standard metric screws of grade 8.8. Lubricate the threads and base of the head of the screws with oil SAE 30.
  • Page 83 AA00-0000-00AAA-034A-A X72DF Maintenance Manual Torque values - standard screws Tab 3-16 Torque values - standard screws Standard thread - Grade 8.8 Fine thread - Grade 8.8 Torque value [Nm] M3 x 0.35 M4 x 0.5 M5 x 0.5 M6 x 0.75 M8 x 1 M10 x 1.25...
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  • Page 85: General Mainteance Procedures

    X72DF Maintenance Manual 4 General mainteance procedures Do maintenance work - general procedure........

  • Page 86: Do Maintenance Work - General Procedure

    AA00-0000-00AAA-012F-A X72DF Maintenance Manual Do maintenance work - general procedure Do maintenance work - general procedure Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 87 AA00-0000-00AAA-012F-A X72DF Maintenance Manual Do maintenance work - general procedure PROCEDURE Make sure that the pressure in all pipes is released. Make sure that you know the procedure for the access to engine spaces, refer to the Operation Manual. Make sure that no personnel and components are in the danger areas (crankcase, piston underside, propeller shaft, etc.).

  • Page 88: Tighten A Round Nut With A Pre-Tensioner

    AA00-0000-00AAA-711A-A X72DF Maintenance Manual Tighten a round nut with a pre-tensioner Tighten a round nut with a pre-tensioner Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 89 AA00-0000-00AAA-711A-A X72DF Maintenance Manual Tighten a round nut with a pre-tensioner PROCEDURE Make sure that the threads of the elastic stud (008, Figure 4-1), of the round nut (004) and of the pre-tensioner are smooth and clean. NOTE: If you have to install the complete set of elastic studs, obey the sequence given in the related figures (refer to section 16.1 Tightening...
  • Page 90 AA00-0000-00AAA-711A-A X72DF Maintenance Manual Tighten a round nut with a pre-tensioner NOTE: Make sure that the piston (002) does not move above the limit of the red groove (011). NOTE: If you have to install the complete set of elastic studs, do the procedure in two steps as noted.
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  • Page 92: Loosen A Round Nut With A Pre-Tensioner

    AA00-0000-00AAA-510A-A X72DF Maintenance Manual Loosen a round nut with a pre-tensioner Loosen a round nut with a pre-tensioner Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 93 AA00-0000-00AAA-510A-A X72DF Maintenance Manual Loosen a round nut with a pre-tensioner PROCEDURE Make sure that the threads of the elastic stud (008, Figure 4-2) and of the pre-tensioner are smooth and clean. Put the applicable pre-tensioner on the elastic stud (008).
  • Page 94 AA00-0000-00AAA-510A-A X72DF Maintenance Manual Loosen a round nut with a pre-tensioner NOTE: Make sure that the piston (002) does not move above the limit of the red groove (011). Keep the applied pressure constant. Loosen the round nut (004). Get the applicable round bar (012) from the round bar kit.
  • Page 95 AA00-0000-00AAA-510A-A X72DF Maintenance Manual Loosen a round nut with a pre-tensioner Page left intentionally blank - 95 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 96: Do A Check Of The Pre-Tension

    AA00-0000-00AAA-360A-A X72DF Maintenance Manual Do a check of the pre-tension Do a check of the pre-tension Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 97 AA00-0000-00AAA-360A-A X72DF Maintenance Manual Do a check of the pre-tension PROCEDURE Make sure that the threads of the elastic stud (008, Figure 4-3) and of the pre-tensioner are smooth and clean. Put the applicable pre-tensioner on the elastic stud (008).
  • Page 98 AA00-0000-00AAA-360A-A X72DF Maintenance Manual Do a check of the pre-tension NOTE: Make sure that the piston (002) does not move above the limit of the red groove (011). Keep the applied pressure constant. Make sure that there is no clearance between the round nut (004) and the plate (007).

  • Page 99: Maintenance Schedule

    X72DF Maintenance Manual 5 Maintenance schedule Maintenance schedule...........

  • Page 100: Maintenance Schedule

    Maintenance schedule The maintenance intervals are given in each procedure related to the recommendations of WinGD. The shown operating hours (or working hours) are always the total running hours of the engine. Data found during operation will show if it is possible to increase or decrease these maintenance intervals.

  • Page 101: Group 1 - Engine Frame And Bearings

    X72DF Maintenance Manual 6 Group 1 - Engine frame and bearings Bedplate 6.1.1 Bedplate - do a check of the foundation bolts......

  • Page 102: Bedplate

    AA00-1115-00AAA-360A-A X72DF Maintenance Manual Bedplate - do a check of the foundation bolts Bedplate 6.1.1 Bedplate - do a check of the foundation bolts Periodicity Description One Time - after first working hours 1 500 Working hours 12 000 Duration for performing preliminary requirements 1.0 man-hours...

  • Page 103: Foundation Bolts

    AA00-1115-00AAA-360A-A X72DF Maintenance Manual Bedplate - do a check of the foundation bolts PROCEDURE Do a check of the pre-tension of the foundation bolts, refer to section 4.4 Do a check of pre-tension. NOTE: In the area of the thrust bearing, the bedplate (003,...

  • Page 104: Main Bearing

    AA00-1132-00AAA-520A-A X72DF Maintenance Manual Main bearing - remove the cover Main bearing 6.2.1 Main bearing - remove the cover Periodicity Description Working hours 90 000 Personnel Description Specialization Engine crew Basic Support equipment Description Part No. Spur-geared chain block, 94017-028...

  • Page 105: Main Bearing Cover (Example)

    AA00-1132-00AAA-520A-A X72DF Maintenance Manual Main bearing - remove the cover PROCEDURE For bearing No #1 prepare the bearing cover as follows: Remove the cover (001, Figure 6-2) and the holder. Remove the related oil pipe. Fig 6-2 Main bearing cover (example) For bearing No #2 to N prepare the bearing cover as follows: Get access to the bearing cover.

  • Page 106: Thrust Device

    AA00-1132-00AAA-520A-A X72DF Maintenance Manual Main bearing - remove the cover Connect the HP oil pump 94931 to the thrust device (004). Operate the HP oil pump until oil that has no air flows out at the vent screw (007). Stop the HP oil pump to prevent injury.

  • Page 107: Bearing Cover

    AA00-1132-00AAA-520A-A X72DF Maintenance Manual Main bearing - remove the cover Fig 6-4 Bearing cover WCH03014 00612 Attach the shackle 94019K (004, Figure 6-5) to the lug 94116C (003). Attach the engine room crane to the shackle 94109K (004). Operate the engine room crane to put a light tension on the chain.

  • Page 108: Bearing Cover - Move

    AA00-1132-00AAA-520A-A X72DF Maintenance Manual Main bearing - remove the cover Fig 6-5 Bearing cover - move 00614 For bearing no. 02 to nn do this procedure in a similar way. CLOSE UP • None - 108 - Issue 002 2020-10...
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  • Page 110: Main Bearing - Install The Cover

    AA00-1132-00AAA-720A-A X72DF Maintenance Manual Main bearing - install the cover 6.2.2 Main bearing - install the cover Periodicity Description Working hours 90 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 111: Thrust Device

    AA00-1132-00AAA-720A-A X72DF Maintenance Manual Main bearing - install the cover PROCEDURE Clean all surfaces that touch on the bearing cover and bearing girder. Make sure that the oil bore in the bearing cover is clear. Attach the lug (001, Figure 6-6) to the bearing cover (002).

  • Page 112: Bearing Cover - Install

    AA00-1132-00AAA-720A-A X72DF Maintenance Manual Main bearing - install the cover Fig 6-7 Bearing cover - install 00616 Attach the shackle 94019K (004, Figure 6-8) to the lug 94116C (003). Attach engine room crane to the shackle 94109K (004). Operate the engine room crane to move the bearing cover to an applicable position on the platform.

  • Page 113: Bearing - Remove

    AA00-1132-00AAA-720A-A X72DF Maintenance Manual Main bearing - install the cover Fig 6-8 Bearing cover - move 00614 Clean the pipes (003, Figure 6-9). Install the pipes (003), their gaskets and new tab washers (006). Tighten the screws (005). Lock the screws (005) with the new tab washers (006).

  • Page 114: Bearing Cover - Oil Pipe

    AA00-1132-00AAA-720A-A X72DF Maintenance Manual Main bearing - install the cover Fig 6-9 Bearing cover - oil pipe 00617 CLOSE UP • None - 114 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 116: Main Bearing Shell - Remove

    AA00-1134-00AAA-520A-A X72DF Maintenance Manual Main bearing shell - remove Main bearing shell 6.3.1 Main bearing shell - remove Periodicity Description Working hours 90 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 117 AA00-1134-00AAA-520A-A X72DF Maintenance Manual Main bearing shell - remove PRELIMINARY OPERATIONS • The bearing cover must be removed, refer to section 6.2.1 Main bearing - remove the cover - 117 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 118 AA00-1134-00AAA-520A-A X72DF Maintenance Manual Main bearing shell - remove PROCEDURE Prepare the bearing shell before removal. Operate the turning gear to turn the crank to the exhaust side approximately 90° after TDC. Lock the turning gear to prevent movement. Install the hydraulic rams.

  • Page 119: Crankshaft And Flywheel - Lift

    AA00-1134-00AAA-520A-A X72DF Maintenance Manual Main bearing shell - remove Fig 6-10 Crankshaft and flywheel - lift 50 mm 50 mm 0.3 mm - 119 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 120: Bearing Shell - Remove

    AA00-1134-00AAA-520A-A X72DF Maintenance Manual Main bearing shell - remove Remove the bearing shell. Attach the shackle (004, Figure 6-11) to the position shown. Attach the chain block (003) to the shackle (004). Remove the Allen screws (007) from the top of the bearing shell (002).

  • Page 121: Bearing Shell - Lift

    AA00-1134-00AAA-520A-A X72DF Maintenance Manual Main bearing shell - remove Lift the bearing shell. Attach the lifting tool (002, Figure 6-12) to the bearing shell (003). Turn the bearing shell (003) sufficiently to attach the chain block (001). Attach the chain block (001) to the lifting tool (002).

  • Page 122: Main Bearing Shell - Examine

    AA00-1134-00AAA-310A-A X72DF Maintenance Manual Main bearing shell - examine 6.3.2 Main bearing shell - examine Periodicity Description Working hours 90 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.25 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 123 AA00-1134-00AAA-310A-A X72DF Maintenance Manual Main bearing shell - examine PROCEDURE Use a soft cloth to clean the bearing shell. Examine the bearing shell for damage, for example for breakouts or for cracks. CAUTION Damage Hazard: Do not use a scraper in the running area of the bearing shell. Damage to the bearing shell will occur.

  • Page 124: Main Bearing Shell - Install

    AA00-1134-00AAA-720A-A X72DF Maintenance Manual Main bearing shell - install 6.3.3 Main bearing shell - install Periodicity Description Working hours 90 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 125 AA00-1134-00AAA-720A-A X72DF Maintenance Manual Main bearing shell - install PRELIMINARY OPERATIONS • None - 125 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 126 AA00-1134-00AAA-720A-A X72DF Maintenance Manual Main bearing shell - install PROCEDURE Prepare the bearing shell for installation. Make sure that the items that follow are clean and in good condition: • Crankshaft pin • Girder bore for the bearing shell •...
  • Page 127 AA00-1134-00AAA-720A-A X72DF Maintenance Manual Main bearing shell - install Fig 6-13 Bearing shell - lift 00608 - 127 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 128 AA00-1134-00AAA-720A-A X72DF Maintenance Manual Main bearing shell - install Install the bearing shell. Remove carefully the engine room crane from the lifting tool (002). Operate carefully the chain block (001) to lower the bearing shell (003) on to the crankshaft.

  • Page 129: Bearing Shell - Install

    AA00-1134-00AAA-720A-A X72DF Maintenance Manual Main bearing shell - install Fig 6-14 Bearing shell - install WCH03015 WCH03486 00607 - 129 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 130 AA00-1134-00AAA-720A-A X72DF Maintenance Manual Main bearing shell - install Lower the crankshaft. On the HP oil pump, release the pressure to fully lower the crankshaft. Remove the hydraulic rams (001, Figure 6-15) and the HP oil pump. Remove the bracket (003) and the steel plate (002).
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  • Page 132: Thrust Bearing

    AA00-1203-00AAA-310A-A X72DF Maintenance Manual Thrust bearing - examine the housing Thrust bearing 6.4.1 Thrust bearing - examine the housing Periodicity Description Working hours 7000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 133: Visual Examination

    AA00-1203-00AAA-310A-A X72DF Maintenance Manual Thrust bearing - examine the housing PROCEDURE Remove the cover (003, Figure 6-16). Do a check of the thrust bearing housing. If necessary, remove particles from the area (001). Make sure th the channel (002) is clear.

  • Page 134: Thrust Bearing - Do A Check Of The Axial Clearance With A Dial Gauge

    AA00-1203-00AAA-360A-A X72DF Maintenance Manual Thrust bearing - do a check of the axial clearance with a dial gauge 6.4.2 Thrust bearing - do a check of the axial clearance with a dial gauge Periodicity Description Working hours 7000 Duration for performing preliminary requirements 0.0 man-hours...

  • Page 135: Axial Clearance

    AA00-1203-00AAA-360A-A X72DF Maintenance Manual Thrust bearing - do a check of the axial clearance with a dial gauge PROCEDURE Start the engine in the direction AHEAD to move the crankshaft (002, Figure 6-17) fully forward. The crankshaft must touch the thrust pads.

  • Page 136: Thrust Bearing - Do A Check Of The Axial Clearance With A Inside Micrometer

    AA00-1203-00AAA-360B-A X72DF Maintenance Manual Thrust bearing - do a check of the axial clearance with a inside micrometer 6.4.3 Thrust bearing - do a check of the axial clearance with a inside micrometer Periodicity Description Working hours 7000 Duration for performing preliminary requirements 0.0 man-hours...

  • Page 137: Axial Clearance - Micrometer

    AA00-1203-00AAA-360B-A X72DF Maintenance Manual Thrust bearing - do a check of the axial clearance with a inside micrometer PROCEDURE Start the engine in the direction AHEAD to move the crankshaft fully forward. The crankshaft (003, Figure 6-18) must touch the thrust pads (002).
  • Page 138 AA00-1203-00AAA-360B-A X72DF Maintenance Manual Thrust bearing - do a check of the axial clearance with a inside micrometer CLOSE UP • None - 138 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 140: Thrust Bearing - Remove The Pads

    AA00-1203-00AAA-520A-A X72DF Maintenance Manual Thrust bearing - remove the pads 6.4.4 Thrust bearing - remove the pads Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 141: Cover - Remove

    AA00-1203-00AAA-520A-A X72DF Maintenance Manual Thrust bearing - remove the pads PROCEDURE Read the data in 3.1 Lifting tools. Remove the cover (001, Figure 6-19). Fig 6-19 Cover - remove 00020 Record the positions of the thrust bearing pads. Remove the three bolts (001, Figure 6-20) from each of the four arbor supports (002).
  • Page 142 AA00-1203-00AAA-520A-A X72DF Maintenance Manual Thrust bearing - remove the pads WARNING 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 crankshaft in the applicable direction.

  • Page 143: Thrust Pad - Removal

    AA00-1203-00AAA-520A-A X72DF Maintenance Manual Thrust bearing - remove the pads Fig 6-20 Thrust pad - removal NOTE: If some of the thrust pads are removed, the remaining thrust pads will keep the crankshaft in position. If all thrust pads from the same side are removed, for example all the astern pads, the crankshaft can move.
  • Page 144 AA00-1203-00AAA-520A-A X72DF Maintenance Manual Thrust bearing - remove the pads 23.1 Get a piece of hardwood that has the same dimensions as a thrust pad. 23.2 Put the hardwood in the position of the removed thrust pads. CLOSE UP •...
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  • Page 146: Thrust Bearing - Install The Pads

    AA00-1203-00AAA-720A-A X72DF Maintenance Manual Thrust bearing - install the pads 6.4.5 Thrust bearing - install the pads Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 147 AA00-1203-00AAA-720A-A X72DF Maintenance Manual Thrust bearing - install the pads PROCEDURE Make sure that the thrust pads are clean. Apply clean engine oil to the thrust pads. NOTE: You must install thrust pads that you removed before in the same positions.

  • Page 148: Thrust Pad - Install

    AA00-1203-00AAA-720A-A X72DF Maintenance Manual Thrust bearing - install the pads Fig 6-21 Thrust pad - install Install the temperature sensors removed before. Do a check of the clearances between the arbor supports and the thrust pads, refer to section 6.4.2 Thrust bearing - do a check of the axial clearance with a dial gauge...

  • Page 149: Thrust Pads - Configuration

    AA00-1203-00AAA-720A-A X72DF Maintenance Manual Thrust bearing - install the pads section 6.4.3 Thrust bearing - do a check of the axial clearance with a inside micrometer. NOTE: When you replace new thrust pads (or thrust pads that have new metal), you must make sure that the dimensions are the same as the adjacent pad(s).

  • Page 150: Cover - Install

    AA00-1203-00AAA-720A-A X72DF Maintenance Manual Thrust bearing - install the pads Fig 6-23 Cover - install 00020 CLOSE UP • None - 150 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 152: Engine Stays

    AA00-1715-00AAA-360A-A X72DF Maintenance Manual Engine stays (friction shims) - do a check of the pre-tension Engine stays 6.5.1 Engine stays (friction shims) - do a check of the pre-tension Periodicity Description Working hours 7000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 8.0 man-hours...
  • Page 153 AA00-1715-00AAA-360A-A X72DF Maintenance Manual Engine stays (friction shims) - do a check of the pre-tension PROCEDURE For the applicable value for pre-tension refer to section 16.1 Tightening instructions. Do a check of the pre-tension of the engine stays, refer to section 4.4 Do a check of the...

  • Page 154: Engine Stays (Hydraulic) - Do A Check Of The Oil Pressure

    AA00-1715-00AAA-360B-A X72DF Maintenance Manual Engine stays (hydraulic) - do a check of the oil pressure 6.5.2 Engine stays (hydraulic) - do a check of the oil pressure Periodicity Description Months Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 8.0 man-hours...

  • Page 155: Engine Stays - Pressure Check

    AA00-1715-00AAA-360B-A X72DF Maintenance Manual Engine stays (hydraulic) - do a check of the oil pressure PROCEDURE Do a check of the distance (X) to make sure that the engine is not tilted. The distance (X) must be zero before you do a check of the pressure gauges (007, Figure 6-24).

  • Page 156: Tie Rod

    AA00-1903-00AAA-360A-A X72DF Maintenance Manual Tie rod - do a check of the pre-tension Tie rod 6.6.1 Tie rod - do a check of the pre-tension Periodicity Description Working hours 27 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 157: Pre-Tension Checks

    AA00-1903-00AAA-360A-A X72DF Maintenance Manual Tie rod - do a check of the pre-tension PROCEDURE Remove the protection cover (001, Figure 6-25) from all tie rods (002). Clean the faces of the intermediate rings (004). Do a check of the pre-tension of the first pair of tie rods a-a, refer to section 4.4 Do a...

  • Page 158: Tie Rod - Remove

    AA00-1903-00AAA-520A-A X72DF Maintenance Manual Tie rod - remove 6.6.2 Tie rod - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 159: Tie Rod - Removal

    AA00-1903-00AAA-520A-A X72DF Maintenance Manual Tie rod - remove PROCEDURE Remove the protection cover (001, Figure 6-26) from the tie rods (004). Clean the surface of the intermediate ring (003). Attach the two pre-tensioning jacks to the applicable tie rod (004).

  • Page 160: Tie Rod - Install

    AA00-1903-00AAA-720A-A X72DF Maintenance Manual Tie rod - install 6.6.3 Tie rod - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 161 AA00-1903-00AAA-720A-A X72DF Maintenance Manual Tie rod - install PROCEDURE Remove the applicable holder (008 or 010, Figure 6-27). Make sure that the nut (007) is correctly attached. Apply Molykote paste G to the bottom thread of the tie rod (003).

  • Page 162: Tie Rod - Apply Tension

    AA00-1903-00AAA-720A-A X72DF Maintenance Manual Tie rod - install Apply a tension of 100 bar to the tie rod (002), refer to section 4.2 Tighten a round nut with a pre-tensioner. Record the length of the tie rod (002) at L.

  • Page 163: Group 2 - Cylinder

    X72DF Maintenance Manual 7 Group 2 - Cylinder Cylinder liner 7.1.1 Cylinder liner - do a check of the bore........
  • Page 164 X72DF Maintenance Manual 7.7.5 Starting air valve - assemble......... .
  • Page 165 X72DF Maintenance Manual Page left intentionally blank - 165 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 166: Cylinder Liner

    AA00-2124-00AAA-360A-A X72DF Maintenance Manual Cylinder liner - do a check of the bore Cylinder liner 7.1.1 Cylinder liner - do a check of the bore Periodicity Description Unscheduled After each piston removal and installation Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 167 AA00-2124-00AAA-360A-A X72DF Maintenance Manual Cylinder liner - do a check of the bore CAUTION Injury Hazard: Hot parts can cause injury to personnel. Be careful when you do work in areas where there are hot parts. PRELIMINARY OPERATIONS • The cylinder cover must be removed, refer to section 7.5.1 Cylinder cover - remove...
  • Page 168 AA00-2124-00AAA-360A-A X72DF Maintenance Manual Cylinder liner - do a check of the bore PROCEDURE Operate the turning gear to move the piston to BDC. Lock the lever of the cooling water valve in the closed position. Put the ladder (007, Figure 7-1) in position in the cylinder liner (004).

  • Page 169: Cylinder Liner - Dimension Check

    AA00-2124-00AAA-360A-A X72DF Maintenance Manual Cylinder liner - do a check of the bore Fig 7-1 Cylinder liner - dimension check Clean the area (001) above the running surface (002). Remove the bottom part of the measuring gauge (005). - 169 - Issue 002 2020-10 Winterthur Gas &...
  • Page 170 AA00-2124-00AAA-360A-A X72DF Maintenance Manual Cylinder liner - do a check of the bore Put the measuring gauge (005) in position on the top face of the cylinder liner (004) in line with the longitudinal axis of the engine. Make sure that the top hole (00A) is above the ridge (003) in the non-running surface of the cylinder liner (004).
  • Page 171 AA00-2124-00AAA-360A-A X72DF Maintenance Manual Cylinder liner - do a check of the bore Page left intentionally blank - 171 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 172: Cylinder Liner - Remove

    AA00-2124-00AAA-520A-A X72DF Maintenance Manual Cylinder liner - remove 7.1.2 Cylinder liner - remove Periodicity Description Unscheduled As necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 173 AA00-2124-00AAA-520A-A X72DF Maintenance Manual Cylinder liner - remove PROCEDURE Remove the water guide jacket. If necessary, attach the lifting tools (002, Figure 7-2) to the lifting tool (001) as follows: 1.1.1 Make sure that the shackle (011) is attached to the middle hole in the lifting tool (001).

  • Page 174: Water Guide Jacket

    AA00-2124-00AAA-520A-A X72DF Maintenance Manual Cylinder liner - remove Fig 7-2 Water guide jacket Remove the pipes to the lubricating quills as follows Remove the applicable pipe holders. Disconnect the related pipes. - 174 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 175 AA00-2124-00AAA-520A-A X72DF Maintenance Manual Cylinder liner - remove Seal the pipes with applicable seals to prevent contamination. Attach the two plates (004, Figure 7-3) to the lifting tool (002) as follows: Remove the two lifting tools from the lifting tool (002).

  • Page 176: Cylinder Liner (Example) - Move

    AA00-2124-00AAA-520A-A X72DF Maintenance Manual Cylinder liner - remove Fig 7-4 Cylinder liner (example) - move CLOSE UP • None - 176 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 177 AA00-2124-00AAA-520A-A X72DF Maintenance Manual Cylinder liner - remove Page left intentionally blank - 177 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 178: Cylinder Liner - Preserve

    AA00-2124-00AAA-810A-A X72DF Maintenance Manual Cylinder liner - preserve 7.1.3 Cylinder liner - preserve Periodicity Description Unscheduled As necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 179: Cylinder Liner - Storage

    AA00-2124-00AAA-810A-A X72DF Maintenance Manual Cylinder liner - preserve PROCEDURE Attach the chain (002, Figure 7-5) to the lifting tool (003) and the engine room crane (001) as shown. Fig 7-5 Cylinder liner - storage Put the wooden underlay (005, 007) and the wooden chocks (006) in position as shown Figure 7-6.
  • Page 180 AA00-2124-00AAA-810A-A X72DF Maintenance Manual Cylinder liner - preserve Fig 7-6 Cylinder liner - storage 2 CLOSE UP • None - 180 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 181 AA00-2124-00AAA-810A-A X72DF Maintenance Manual Cylinder liner - preserve Page left intentionally blank - 181 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 182: Cylinder Liner - Grind

    AA00-2124-00AAA-655A-A X72DF Maintenance Manual Cylinder liner - grind 7.1.4 Cylinder liner - grind Periodicity Description Unscheduled As necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 183 AA00-2124-00AAA-655A-A X72DF Maintenance Manual Cylinder liner - grind PROCEDURE CAUTION Make sure that you do not cause damage to the running surface of the cylinder liner when you operate the grinding device. Put applicable protection below the cylinder liner to keep particles out of the area.

  • Page 184: Cylinder Liner - Grind The Lubricating Groove

    AA00-2124-00AAA-655B-A X72DF Maintenance Manual Cylinder liner - grind the lubricating groove 7.1.5 Cylinder liner - grind the lubricating groove Periodicity Description Unscheduled as necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 185: Lubricating Grooves - Grind

    AA00-2124-00AAA-655B-A X72DF Maintenance Manual Cylinder liner - grind the lubricating groove PROCEDURE If necessary, operate the turning gear to move the piston to BDC. If the depth of the lubricating grooves (001, Figure 7-8) has decreased to less than 1.5 mm, do as follows:...

  • Page 186: Cylinder Liner - Grind The Scavenge Ports

    AA00-2124-00AAA-655C-A X72DF Maintenance Manual Cylinder liner - grind the scavenge ports 7.1.6 Cylinder liner - grind the scavenge ports Periodicity Description Unscheduled as necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 187: Scavenge Ports - Grind

    AA00-2124-00AAA-655C-A X72DF Maintenance Manual Cylinder liner - grind the scavenge ports PROCEDURE WARNING Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. CAUTION When you polish the scavenge ports, make sure that you do not cause damage to the running surface of the cylinder liner.

  • Page 188: Cylinder Liner - Install

    AA00-2124-00AAA-720A-A X72DF Maintenance Manual Cylinder liner - install 7.1.7 Cylinder liner - install Periodicity Description Unscheduled As necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 189: Insulation Bandage

    AA00-2124-00AAA-720A-A X72DF Maintenance Manual Cylinder liner - install PROCEDURE Put the insulation bandage (001, Figure 7-10) around the water channel on the cylinder liner. Make sure that there is an overlap of approximately 30 mm. Put the plate (003) over the insulation bandage (001).
  • Page 190 AA00-2124-00AAA-720A-A X72DF Maintenance Manual Cylinder liner - install Fig 7-11 Cylinder liner (example) Attach the chain (001, Figure 7-12) to the shackle on the lifting tool (002). Operate the engine room crane to lift the cylinder liner (008) into the bottom water guide jacket (007).
  • Page 191 AA00-2124-00AAA-720A-A X72DF Maintenance Manual Cylinder liner - install Fig 7-12 Water guide jacket (example) Attach the flanges (004, Figure 7-11) to the cylinder liner with the special screws (005). Attach the holder and pin (003) to the cylinder block with the bolts.
  • Page 192 AA00-2124-00AAA-720A-A X72DF Maintenance Manual Cylinder liner - install Apply a non-hardening sealing compound to the cylinder block. Operate the engine room crane to lift and move the cylinder liner into position above the cylinder block. Operate the engine room crane to lower the cylinder liner into the cylinder block. Make sure that the pin (003) engages with the hole in the holder.
  • Page 193 AA00-2124-00AAA-720A-A X72DF Maintenance Manual Cylinder liner - install Page left intentionally blank - 193 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 194: Lubricating Quill

    AA00-2138-00AAA-520A-A X72DF Maintenance Manual Lubricating quill - remove Lubricating quill 7.2.1 Lubricating quill - remove Periodicity Description Unscheduled at each piston removal Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 195 AA00-2138-00AAA-520A-A X72DF Maintenance Manual Lubricating quill - remove PROCEDURE Loosen the nuts (005, Figure 7-13) of the unions. Carefully remove the pipe (002) from the lubricating quill (003). Seal the pipe (002) with an applicable plug to prevent contamination. Remove two the bolts (004).

  • Page 196: Lubricating Quill - Do A Functional Test

    AA00-2138-00AAA-340A-A X72DF Maintenance Manual Lubricating quill - do a functional test 7.2.2 Lubricating quill - do a functional test Periodicity Description Unscheduled at each piston removal Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.25 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 197 AA00-2138-00AAA-340A-A X72DF Maintenance Manual Lubricating quill - do a functional test PROCEDURE If necessary, remove the union (007, Figure 7-14) on the lubricating quill (002). Fig 7-14 Lubricating quill Attach the distributing piece (004) to the HP oil pump (006).

  • Page 198: Lubricating Quill - Install

    AA00-2138-00AAA-720A-A X72DF Maintenance Manual Lubricating quill - install 7.2.3 Lubricating quill - install Periodicity Description Unscheduled at each piston removal Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 199: Sealing Surface

    AA00-2138-00AAA-720A-A X72DF Maintenance Manual Lubricating quill - install PROCEDURE CAUTION Damage Hazard: The surfaces of the cylinder liner and the nozzle tip make a metallic seal. The seat angles in the cylinder liner and on the nozzle tip are different. Do not use a gasket between the cylinder liner and the nozzle tip.
  • Page 200 AA00-2138-00AAA-720A-A X72DF Maintenance Manual Lubricating quill - install Fig 7-16 Lubricating quill (example) CLOSE UP • Bleed the cylinder lubrication system, refer to 12.1.2 Cylinder lubrication system - bleed - 200 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 201 AA00-2138-00AAA-720A-A X72DF Maintenance Manual Lubricating quill - install Page left intentionally blank - 201 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 202: Gas Admission Valve

    AA00-2140-00AAA-363A-A X72DF Maintenance Manual Gas admission valve - do a check of the oil leakage flow Gas admission valve 7.3.1 Gas admission valve - do a check of the oil leakage flow Periodicity Description Working hours 6000 Duration for performing preliminary requirements 0.0 man-hours...

  • Page 203: Gav - Do A Check Of The Oil Leakage Flow

    AA00-2140-00AAA-363A-A X72DF Maintenance Manual Gas admission valve - do a check of the oil leakage flow PROCEDURE Install the measuring tool (003, Figure 7-17) as follows: Carefully remove the connection for sealing oil supply on the gas admission valve (GAV) (005).

  • Page 204: Gav - Usual Values Of Oil Leakage Flow At 25°C

    AA00-2140-00AAA-363A-A X72DF Maintenance Manual Gas admission valve - do a check of the oil leakage flow Tab 7-1 GAV - usual values of oil leakage flow at 25°C Engine type Oil leakage flow in 15 minutes X40DF 0.4 to 3 ml...
  • Page 205 AA00-2140-00AAA-363A-A X72DF Maintenance Manual Gas admission valve - do a check of the oil leakage flow Page left intentionally blank - 205 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 206: Gas Admission Valve - Remove

    AA00-2140-00AAA-520A-A X72DF Maintenance Manual Gas admission valve - remove 7.3.2 Gas admission valve - remove Periodicity Description Working hours 19 500 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 207: Compensator - Remove

    AA00-2140-00AAA-520A-A X72DF Maintenance Manual Gas admission valve - remove PROCEDURE Apply Molycote G-Rapid Plus to the disassembly / assembly tool (006, Figure 7-18). Remove the screws (003) on each side of the compensator (001). Put the tool (006) in position on the compensator (001) as shown.
  • Page 208 AA00-2140-00AAA-520A-A X72DF Maintenance Manual Gas admission valve - remove Remove the lubricating oil pipe (008) and the return pipe (009) from the GAV (004). Seal the openings of the pipes (008, 009) with plugs to prevent contamination. Install the eye bolt (004) to the GAV (005) in the position shown.
  • Page 209 AA00-2140-00AAA-520A-A X72DF Maintenance Manual Gas admission valve - remove Page left intentionally blank - 209 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 210: Gas Admission Valve - Do A Check For Gas Leakage

    AA00-2140-00AAA-362A-A X72DF Maintenance Manual Gas admission valve - do a check for gas leakage 7.3.3 Gas admission valve - do a check for gas leakage Periodicity Description Working hours 19500 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 211: Gas Admission Valve - Pressure Check

    AA00-2140-00AAA-362A-A X72DF Maintenance Manual Gas admission valve - do a check for gas leakage PROCEDURE Attach a new gasket (010, Figure 7-20) to the bush (007). Install the GAV into the bush (007). Attach the pressure reducing valve (013) to the bush (007).

  • Page 212: Valve Seat - Lap

    AA00-2140-00AAA-362A-A X72DF Maintenance Manual Gas admission valve - do a check for gas leakage 12.6 Turn the rod (001) back to release the tension in the spring (006). 12.7 Remove the dismantling and assembling tool and the bracket from the bush (007).
  • Page 213 AA00-2140-00AAA-362A-A X72DF Maintenance Manual Gas admission valve - do a check for gas leakage 14.7 Turn the rod (001) back to release the tension in the spring (006). Make sure that the valve cotter (003) is installed correctly in the spring carrier (012).

  • Page 214: Gas Admission Valve - Disassemble

    AA00-2140-00AAA-530A-A X72DF Maintenance Manual Gas admission valve - disassemble 7.3.4 Gas admission valve - disassemble Periodicity Description Working hours 19 500 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 215 AA00-2140-00AAA-530A-A X72DF Maintenance Manual Gas admission valve - disassemble PROCEDURE Apply Molykote G-Rapid Plus to the rod (001, Figure 7-22) of the disassembly / assembly tool (002). Attach the plate (015) to the bush (011). Put the plate (015) together with the bush (011) into a vice.

  • Page 216: Valve Spindle - Remove

    AA00-2140-00AAA-530A-A X72DF Maintenance Manual Gas admission valve - disassemble Fig 7-22 Valve spindle - remove CLOSE UP • None - 216 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 217 AA00-2140-00AAA-530A-A X72DF Maintenance Manual Gas admission valve - disassemble Page left intentionally blank - 217 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 218: Gas Admission Valve - Assemble

    AA00-2140-00AAA-710A-A X72DF Maintenance Manual Gas admission valve - assemble 7.3.5 Gas admission valve - assemble Periodicity Description Working hours 19500 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 219: Gav - Assemble

    AA00-2140-00AAA-710A-A X72DF Maintenance Manual Gas admission valve - assemble PROCEDURE Do step 1 to step 9 in 7.3.3 Gas admission valve - do a check for gas leakage. Remove the GAV from the vice. Remove the pusher (003, Figure 7-23).

  • Page 220: Gas Admission Valve - Install

    AA00-2140-00AAA-720A-A X72DF Maintenance Manual Gas admission valve - install 7.3.6 Gas admission valve - install Periodicity Description Working hours 19500 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 221 AA00-2140-00AAA-720A-A X72DF Maintenance Manual Gas admission valve - install PROCEDURE Attach the eye bolt (004, Figure 7-24) to the housing of the (GAV) (005). Lift and move the GAV (005) to the applicable position. Make sure that all surfaces that will touch are clean.

  • Page 222: Electrical Connection

    AA00-2140-00AAA-720A-A X72DF Maintenance Manual Gas admission valve - install Fig 7-25 Electrical connection Make sure that the compensator (001, Figure 7-26), the O-rings (008), the coupling flanges and the surface of connecting block and are clean and in good condition.

  • Page 223: Compensator - Install

    AA00-2140-00AAA-720A-A X72DF Maintenance Manual Gas admission valve - install Fig 7-26 Compensator - install Do a leakage check of the pipe (001, Figure 7-24). Do a pressure test of the opening pressure. CLOSE UP • None - 223 - Issue 002 2020-10...

  • Page 224: Piston Rod Gland

    AA00-2303-00AAA-520A-A X72DF Maintenance Manual Piston rod gland - remove Piston rod gland 7.4.1 Piston rod gland - remove Periodicity Description Unscheduled at each piston removal Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 225: Piston Rod Gland - Remove And Install

    AA00-2303-00AAA-520A-A X72DF Maintenance Manual Piston rod gland - remove PROCEDURE Remove the piston rod gland together with the piston, refer to the related procedure. Remove and discard the two O-rings (002, Figure 7-27). Remove the four screws and nuts (003, 006).

  • Page 226: Piston Rod Gland - Disassemble

    AA00-2303-00AAA-520A-A X72DF Maintenance Manual Piston rod gland - remove Fig 7-28 Piston rod gland - disassemble CLOSE UP • None - 226 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 227 AA00-2303-00AAA-520A-A X72DF Maintenance Manual Piston rod gland - remove Page left intentionally blank - 227 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 228: Piston Rod Gland - Do A Check Of The Wear

    AA00-2303-00AAA-360A-A X72DF Maintenance Manual Piston rod gland - do a check of the wear 7.4.2 Piston rod gland - do a check of the wear Periodicity Description Unscheduled at each piston removal Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 229 AA00-2303-00AAA-360A-A X72DF Maintenance Manual Piston rod gland - do a check of the wear PROCEDURE Compare the wear of the parts that follow with the maximum permitted dimensions given in section 3.3 Clearances - general. • Scraper rings (001, 007,...

  • Page 230: Piston Rod Gland - Install

    AA00-2303-00AAA-720A-A X72DF Maintenance Manual Piston rod gland - install 7.4.3 Piston rod gland - install Periodicity Description Unscheduled at each piston removal Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 231 AA00-2303-00AAA-720A-A X72DF Maintenance Manual Piston rod gland - install PRELIMINARY OPERATIONS • None - 231 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 232: Piston Rod Gland - Assemble

    AA00-2303-00AAA-720A-A X72DF Maintenance Manual Piston rod gland - install PROCEDURE Attach the two parts of the clamp ring 94231A (011, Figure 7-30) to the piston rod. Put the three parts of the ring support (010) and the scraper ring 3-part (008) on the clamp ring (011).
  • Page 233 AA00-2303-00AAA-720A-A X72DF Maintenance Manual Piston rod gland - install Put the scraper ring 4-part (001) on the top of the scraper ring (003). Make sure that there is an equal distance between the four parts. Use the assembly tool to attach the tension spring (002).

  • Page 234: Cylinder Cover

    AA00-2708-00AAA-520A-A X72DF Maintenance Manual Cylinder cover - remove Cylinder cover 7.5.1 Cylinder cover - remove Periodicity Description Unscheduled at each piston removal Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 4.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 235 AA00-2708-00AAA-520A-A X72DF Maintenance Manual Cylinder cover - remove PRELIMINARY OPERATIONS • The engine must be stopped and made safe for maintenance, refer to section 4.1 Do maintenance work - general procedure - 235 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 236: Cylinder Cover - Pipes And Expansion Piece (Example)

    AA00-2708-00AAA-520A-A X72DF Maintenance Manual Cylinder cover - remove PROCEDURE Remove the applicable hydraulic pipe (005, Figure 7-32), refer to the related procedure. Remove the applicable HP fuel pipes (004), refer to the related procedure. Remove the applicable injection valves (003), refer to the related procedure.

  • Page 237: Lifting Tool - Pre-Tensioner (Example)

    AA00-2708-00AAA-520A-A X72DF Maintenance Manual Cylinder cover - remove Fig 7-33 Lifting tool - pre-tensioner (example) Attach the engine room crane to the eye bolt (001, Figure 7-34) on the exhaust valve (002). Operate the engine room crane to lift the cylinder cover (003) together with the exhaust valve (002) and top water guide jacket (007).

  • Page 238: Cylinder Cover, Exhaust Valve Cage And Water Guide Jacket (Example)

    AA00-2708-00AAA-520A-A X72DF Maintenance Manual Cylinder cover - remove Fig 7-34 Cylinder cover, exhaust valve cage and water guide jacket (example) Attach the engine room crane to the lifting tool (002, Figure 7-35). Operate the engine room crane to lift the lifting tool (002).

  • Page 239: Cylinder Cover And Exhaust Valve Cage (Example)

    AA00-2708-00AAA-520A-A X72DF Maintenance Manual Cylinder cover - remove Fig 7-35 Cylinder cover and exhaust valve cage (example) CLOSE UP • None - 239 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 240: Cylinder Cover - Grind The Sealing Face For Injection Valve

    AA00-2708-00AAA-655A-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for injection valve 7.5.2 Cylinder cover - grind the sealing face for injection valve Periodicity Description Unscheduled as necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 241 AA00-2708-00AAA-655A-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for injection valve PROCEDURE Make sure that the stop sleeve (008, Figure 7-36) is attached to the spindle (009) of the grinding device (002). Use the applicable grade of emery cloth related to the quantity of metal you want to remove.

  • Page 242: Fuel Injection Valve Position - Grind

    AA00-2708-00AAA-655A-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for injection valve Fig 7-36 Fuel injection valve position - grind CLOSE UP • None - 242 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 243 AA00-2708-00AAA-655A-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for injection valve Page left intentionally blank - 243 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 244: Cylinder Cover - Grind The Sealing Face For Pilot Injection Valve

    AA00-2708-00AAA-655B-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for pilot injection valve 7.5.3 Cylinder cover - grind the sealing face for pilot injection valve Periodicity Description Unscheduled as necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 245 AA00-2708-00AAA-655B-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for pilot injection valve PROCEDURE Make sure that the stop sleeve (009, Figure 7-37) is attached to the spindle (010) of the grinding device (002). Make sure that the two O-rings (003) are serviceable.

  • Page 246: Grind The Sealing Face For Pilot Injection Valve

    AA00-2708-00AAA-655B-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for pilot injection valve Fig 7-37 Grind the sealing face for pilot injection valve CLOSE UP • None - 246 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 247 AA00-2708-00AAA-655B-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for pilot injection valve Page left intentionally blank - 247 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 248: Cylinder Cover - Grind The Sealing Face For Prechamber

    AA00-2708-00AAA-655C-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for prechamber 7.5.4 Cylinder cover - grind the sealing face for prechamber Periodicity Description Unscheduled as necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 249: Grind The Sealing Face For Prechamber

    AA00-2708-00AAA-655C-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for prechamber PROCEDURE Make sure that the stop sleeve (009, Figure 7-38) is attached to the spindle (010) of the grinding device (001). Use the applicable grade of emery cloth related to the quantity of metal you want to remove.
  • Page 250 AA00-2708-00AAA-655C-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for prechamber CLOSE UP • None - 250 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 251 AA00-2708-00AAA-655C-A X72DF Maintenance Manual Cylinder cover - grind the sealing face for prechamber Page left intentionally blank - 251 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 252: Cylinder Cover - Install

    AA00-2708-00AAA-720A-A X72DF Maintenance Manual Cylinder cover - install 7.5.5 Cylinder cover - install Periodicity Description Unscheduled at each piston removal Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 253 AA00-2708-00AAA-720A-A X72DF Maintenance Manual Cylinder cover - install PROCEDURE Clean the items that follow: • O-ring grooves (005, Figure 7-39) • Sealing surfaces of the cylinder cover (004). Put oil on the O-rings. Clean the threads of the two elastic studs (003).

  • Page 254: Assemble Before Installation (Example)

    AA00-2708-00AAA-720A-A X72DF Maintenance Manual Cylinder cover - install Fig 7-39 Assemble before installation (example) Lower the cylinder cover together with the exhaust valve and top water guide jacket on to the bottom water guide jacket. Remove the engine room crane from the eye bolt from the exhaust valve.
  • Page 255 AA00-2708-00AAA-720A-A X72DF Maintenance Manual Cylinder cover - install Put the round nuts (004, Figure 7-40) on the elastic studs (005). Attach the engine room crane to the lifting tool (006). Operate the engine room crane to move the lifting tool (006) and the pre-tensioners above the cylinder cover (002).
  • Page 256 AA00-2708-00AAA-720A-A X72DF Maintenance Manual Cylinder cover - install CLOSE UP • None - 256 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 257 AA00-2708-00AAA-720A-A X72DF Maintenance Manual Cylinder cover - install Page left intentionally blank - 257 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 258: Direct Controlled Injection Valve

    AA00-2722-00AAA-520A-A X72DF Maintenance Manual Direct controlled injection valve - remove Direct controlled injection valve 7.6.1 Direct controlled injection valve - remove Periodicity Description Working hours 24 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 259 AA00-2722-00AAA-520A-A X72DF Maintenance Manual Direct controlled injection valve - remove PROCEDURE Disconnect the cable (001, Figure 7-41) from the terminal box to the injection valve. Make sure that the oil supply to the injection valve is stopped. Remove the screws and their spring cages (002).

  • Page 260: Direct Controlled Injection Valve - Do A Functional Test

    AA00-2722-00AAA-340A-A X72DF Maintenance Manual Direct controlled injection valve - do a functional test 7.6.2 Direct controlled injection valve - do a functional test Periodicity Description Working hours 5000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 261: Test Bench (Example)

    AA00-2722-00AAA-340A-A X72DF Maintenance Manual Direct controlled injection valve - do a functional test PROCEDURE Prepare the test bench (001, Figure 7-42) as follows: Read and obey the data in the manufacturer’s instruction manual of the test bench. Make sure that the work area is clean.
  • Page 262 If a spray comes out from the injection nozzle, the related pressure is thus the LPOP. NOTE: The LPOP should be between 350 and 500 bar. If there is a malfunction that you cannot repair, speak to or send a message to WinGD. CLOSE UP • None...
  • Page 263 AA00-2722-00AAA-340A-A X72DF Maintenance Manual Direct controlled injection valve - do a functional test Page left intentionally blank - 263 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 264: Direct Controlled Injection Valve - Disassemble

    AA00-2722-00AAA-530A-A X72DF Maintenance Manual Direct controlled injection valve - disassemble 7.6.3 Direct controlled injection valve - disassemble Periodicity Description Working hours 10 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 265: Nozzle Tip - Remove

    AA00-2722-00AAA-530A-A X72DF Maintenance Manual Direct controlled injection valve - disassemble PROCEDURE Release the pressure of the test bench. Remove the safety container from the valve holder (003, Figure 7-43). Disconnect the HP hose from the connecting piece. Disconnect the cable from the test bench.
  • Page 266 AA00-2722-00AAA-530A-A X72DF Maintenance Manual Direct controlled injection valve - disassemble Carefully use the slugging wrench (004, Figure 7-43) and the hydraulic cylinder (001) to loosen the coupling nut. Remove the coupling nut. Remove the complete nozzle body. NOTE: If it is necessary to replace the needle or the nozzle body, you must replace the two items.
  • Page 267 AA00-2722-00AAA-530A-A X72DF Maintenance Manual Direct controlled injection valve - disassemble Page left intentionally blank - 267 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 268: Direct Controlled Injection Valve - Assemble

    AA00-2722-00AAA-710A-A X72DF Maintenance Manual Direct controlled injection valve - assemble 7.6.4 Direct controlled injection valve - assemble Periodicity Description Working hours 10 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 269 AA00-2722-00AAA-710A-A X72DF Maintenance Manual Direct controlled injection valve - assemble PROCEDURE If you have removed the pilot valve, install the pilot valve as follows: Make sure that the pin of the pilot valve is correctly in the pilot valve (plan side is flush with the surface).

  • Page 270: Direct Controlled Injection Valve - Install

    AA00-2722-00AAA-720A-A X72DF Maintenance Manual Direct controlled injection valve - install 7.6.5 Direct controlled injection valve - install Periodicity Description Working hours 24 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 271 AA00-2722-00AAA-720A-A X72DF Maintenance Manual Direct controlled injection valve - install PROCEDURE If you use a new injection valve (004, Figure 7-46), prepare it as follows: Remove the new injection valve from its package. Install the correct nozzle tip. Use white spirit (for example Shellsol TD, Shellsol T or Solvent FP68) to clean and remove grease from the injection valve.

  • Page 272: Starting Air Valve

    AA00-2728-00AAB-520A-A X72DF Maintenance Manual Starting air valve - remove the solenoid valve Starting air valve 7.7.1 Starting air valve - remove the solenoid valve Periodicity Description Working hours 12 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 273 AA00-2728-00AAB-520A-A X72DF Maintenance Manual Starting air valve - remove the solenoid valve PROCEDURE Make sure that the pressure in the starting air system is released. Disconnect the electrical connection from the 3/2-way solenoid valve (002, Figure 7-47). Remove the screws from the 3/2-way solenoid valve (002).

  • Page 274: Starting Air Valve - Remove

    AA00-2728-00AAA-520A-A X72DF Maintenance Manual Starting air valve - remove 7.7.2 Starting air valve - remove Periodicity Description Working hours 12 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 275: Starting Air Valve - Preparation

    AA00-2728-00AAA-520A-A X72DF Maintenance Manual Starting air valve - remove PROCEDURE Make sure that the pressure in the starting air system is released. Remove the air pipe (002, Figure 7-48) from the starting air valve (001). Fig 7-48 Starting air valve - preparation...
  • Page 276 AA00-2728-00AAA-520A-A X72DF Maintenance Manual Starting air valve - remove Fig 7-49 Starting air valve - remove CLOSE UP • None - 276 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 277 AA00-2728-00AAA-520A-A X72DF Maintenance Manual Starting air valve - remove Page left intentionally blank - 277 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 278: Starting Air Valve - Disassemble

    AA00-2728-00AAA-530A-A X72DF Maintenance Manual Starting air valve - disassemble 7.7.3 Starting air valve - disassemble Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 279 AA00-2728-00AAA-530A-A X72DF Maintenance Manual Starting air valve - disassemble PROCEDURE Put the starting air valve in a vice. Make sure that the vice jaws do not cause damage the starting air valve. Remove the screws (001, Figure 7-50). Remove the cover (013) together with the 3/2-way solenoid valve (002).

  • Page 280: Starting Air Valve - Grind

    AA00-2728-00AAA-655A-A X72DF Maintenance Manual Starting air valve - grind 7.7.4 Starting air valve - grind Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 281 AA00-2728-00AAA-655A-A X72DF Maintenance Manual Starting air valve - grind PROCEDURE If the seating faces of the housing (001, Figure 7-51) and of the valve spindle (002) only have minimum damage, do as follows: Use an applicable tool to manually grind the seating faces of the housing (001) and of the valve spindle (002).

  • Page 282: Starting Air Valve - Assemble

    AA00-2728-00AAA-710A-A X72DF Maintenance Manual Starting air valve - assemble 7.7.5 Starting air valve - assemble Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 283 AA00-2728-00AAA-710A-A X72DF Maintenance Manual Starting air valve - assemble PROCEDURE Clean all the parts of the starting air valve. Apply a thin layer of oil to all the parts of the starting air valve. NOTE: Do not apply lubricant to the spindle thread (012,...

  • Page 284: Starting Air Valve - Install

    AA00-2728-00AAA-720A-A X72DF Maintenance Manual Starting air valve - install 7.7.6 Starting air valve - install Periodicity Description Working hours 12 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 285 AA00-2728-00AAA-720A-A X72DF Maintenance Manual Starting air valve - install PROCEDURE Put a new gasket (006, Figure 7-53) in the bore of the cylinder cover (004). Apply a thin layer of oil to the bore of the cylinder cover (004). Carefully attach the starting air valve (001) to the cylinder cover (004) with the bolts (003).

  • Page 286: Starting Air Valve - Install The Solenoid Valve

    AA00-2728-00AAB-720A-A X72DF Maintenance Manual Starting air valve - install the solenoid valve 7.7.7 Starting air valve - install the solenoid valve Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 287 AA00-2728-00AAB-720A-A X72DF Maintenance Manual Starting air valve - install the solenoid valve PROCEDURE Put the 3/2-way solenoid valve (002, Figure 7-54) in place on the starting air valve (001). Tighten the screws of the 3/2-way solenoid valve (002). Connect the electrical connection to the 3/2-way solenoid valve (002).

  • Page 288: Relief Valve Combustion Chamber

    AA00-2740-00AAA-520A-A X72DF Maintenance Manual Relief valve combustion chamber - remove Relief valve combustion chamber 7.8.1 Relief valve combustion chamber - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 289 AA00-2740-00AAA-520A-A X72DF Maintenance Manual Relief valve combustion chamber - remove PROCEDURE Open the relief valve with the spindle (001, Figure 7-55). Disconnect the electrical cable from the connector. Remove the two screws (002). Remove the relief valve from the cylinder cover (003).

  • Page 290: Relief Valve Combustion Chamber - Install

    AA00-2740-00AAA-720A-A X72DF Maintenance Manual Relief valve combustion chamber - install 7.8.2 Relief valve combustion chamber - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 291 AA00-2740-00AAA-720A-A X72DF Maintenance Manual Relief valve combustion chamber - install PROCEDURE If the sensor (004, Figure 7-56) has been removed, install the sensor (004). Move the sensor (004) with the cable through the relief valve. Put the holder (005) to the sensor (004) and torque the sensor (004) to 15 Nm.

  • Page 292: Exhaust Valve

    AA00-2751-00AAA-520A-A X72DF Maintenance Manual Exhaust valve - remove Exhaust valve 7.9.1 Exhaust valve - remove Periodicity Description One Time - after first working hours 18 000 Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 293: Exhaust Valve - Preparation

    AA00-2751-00AAA-520A-A X72DF Maintenance Manual Exhaust valve - remove PROCEDURE Prepare the exhaust valve for removal. Remove the hydraulic pipe (001, Figure 7-57) from the exhaust valve, refer to 13.2.1 Hydraulic pipe exhaust valve - remove. Remove all other pipes from the exhaust valve.

  • Page 294: Exhaust Valve - Removal

    AA00-2751-00AAA-520A-A X72DF Maintenance Manual Exhaust valve - remove Remove and discard the O-rings (010, 011) from the valve cage and valve seat. Fig 7-58 Exhaust valve - removal 00718 - 294 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 295 AA00-2751-00AAA-520A-A X72DF Maintenance Manual Exhaust valve - remove CLOSE UP • None - 295 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 296: Exhaust Valve - Disassemble

    AA00-2751-00AAA-530A-A X72DF Maintenance Manual Exhaust valve - disassemble 7.9.2 Exhaust valve - disassemble Periodicity Description One Time - after first working hours 18 000 Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 297 AA00-2751-00AAA-530A-A X72DF Maintenance Manual Exhaust valve - disassemble PROCEDURE Disassemble the valve drive. Attach the engine room crane to the eye bolt (001, Figure 7-59). Remove the nuts (003). Remove the top housing (002). Remove the screws (008). Remove the transmitter housing (007).
  • Page 298 AA00-2751-00AAA-530A-A X72DF Maintenance Manual Exhaust valve - disassemble Fig 7-59 Exhaust valve - disassemble Remove the guide bush. Remove the Allen screws (001, Figure 7-60). Remove the distance ring (003). Remove and discard the rod joint ring (004). Put the two jack screws (008) into the two threads of the guide bush flange (003).

  • Page 299: Guide Bush - Removal

    AA00-2751-00AAA-530A-A X72DF Maintenance Manual Exhaust valve - disassemble Fig 7-60 Guide bush - removal CLOSE UP • None - 299 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 300: Exhaust Valve - Remove The Seat (With New Tool)

    AA00-2751-01AAA-520C-A X72DF Maintenance Manual Exhaust valve - remove the seat (with new tool) 7.9.3 Exhaust valve - remove the seat (with new tool) Periodicity Description One Time - after first working hours 18 000 Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours...

  • Page 301: Valve Seat - Remove

    AA00-2751-01AAA-520C-A X72DF Maintenance Manual Exhaust valve - remove the seat (with new tool) PROCEDURE Put the assembly tool (002, Figure 7-61) on an applicable surface. Attach two eye bolts (006) on the valve cage (005). Attach two slings (007) to the eye bolts (006) and to the engine room crane.
  • Page 302 AA00-2751-01AAA-520C-A X72DF Maintenance Manual Exhaust valve - remove the seat (with new tool) CLOSE UP • None - 302 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 303 AA00-2751-01AAA-520C-A X72DF Maintenance Manual Exhaust valve - remove the seat (with new tool) Page left intentionally blank - 303 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 304: Exhaust Valve - Do A Check Of The Seat

    AA00-2751-01AAA-360A-A X72DF Maintenance Manual Exhaust valve - do a check of the seat 7.9.4 Exhaust valve - do a check of the seat Periodicity Description One Time - after first working hours 18 000 Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours...

  • Page 305: Exhaust Valve, Clearance

    AA00-2751-01AAA-360A-A X72DF Maintenance Manual Exhaust valve - do a check of the seat PROCEDURE Attach the eye bolt (001, Figure 7-62) to the valve spindle (004). Attach the rope to the eye bolt (001) and the engine room crane. Put a thin layer of engineer’s blue paste on the sealing face of the valve spindle (004).

  • Page 306: Valve Seat Clearance

    AA00-2751-01AAA-360A-A X72DF Maintenance Manual Exhaust valve - do a check of the seat Fig 7-62 Valve seat clearance Engineer’s blue paste mark 00725 CLOSE UP • None - 306 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 307 AA00-2751-01AAA-360A-A X72DF Maintenance Manual Exhaust valve - do a check of the seat Page left intentionally blank - 307 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 308: Exhaust Valve - Grind The Seat

    AA00-2751-01AAA-655A-A X72DF Maintenance Manual Exhaust valve - grind the seat 7.9.5 Exhaust valve - grind the seat Periodicity Description Unscheduled as necessary Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 309: Valve Seat - Grinding Tool

    AA00-2751-01AAA-655A-A X72DF Maintenance Manual Exhaust valve - grind the seat PROCEDURE Read the data in the manufacturer’s manual for the grinding tool (003, Figure 7-63). NOTE: Use only the grinding tool (003) to grind the valve seat (001). Put the valve seat (001) in the correct position on the grinding tool (003).

  • Page 310: Exhaust Valve - Install The Seat (With New Tool)

    AA00-2751-01AAA-720C-A X72DF Maintenance Manual Exhaust valve - install the seat (with new tool) 7.9.6 Exhaust valve - install the seat (with new tool) Periodicity Description One Time - after first working hours 18 000 Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours...
  • Page 311 AA00-2751-01AAA-720C-A X72DF Maintenance Manual Exhaust valve - install the seat (with new tool) PROCEDURE Put the assembly tool (004, Figure 7-64) on an applicable surface. If necessary you can decrease the temperature of the valve seat (003) to a maximum of -30°C for easier assembly.

  • Page 312: Valve Seat - Install

    AA00-2751-01AAA-720C-A X72DF Maintenance Manual Exhaust valve - install the seat (with new tool) Fig 7-64 Valve seat - install CLOSE UP • None - 312 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 313 AA00-2751-01AAA-720C-A X72DF Maintenance Manual Exhaust valve - install the seat (with new tool) Page left intentionally blank - 313 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 314: Exhaust Valve - Assemble

    AA00-2751-00AAA-710A-A X72DF Maintenance Manual Exhaust valve - assemble 7.9.7 Exhaust valve - assemble Periodicity Description One Time - after first working hours 18 000 Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 315: Guide Bush - Installation

    AA00-2751-00AAA-710A-A X72DF Maintenance Manual Exhaust valve - assemble PROCEDURE Install the guide bush. Clean the bore in the valve cage (002, Figure 7-65). Clean the guide bush (003). Make sure that the oil bores (004) in the guide bush (003) are clear.
  • Page 316 AA00-2751-00AAA-710A-A X72DF Maintenance Manual Exhaust valve - assemble Attach the engine room crane to the chain. Operate the engine room crane to lift the valve cage (017). 2.10 Lower the valve cage (017) over the valve spindle (015). Make sure that the valve spindle does not move.

  • Page 317: Valve Spindle - Installation

    - H ±0.5 [mm] NOTE: For example for a X72DF engine, if the measured distance H is 163 mm, you must install two shims. Each shim (007) has a thickness of 1.0 mm (T = 165.2 - 163.0 = 1.8).

  • Page 318: Damper Settings

    AA00-2751-00AAA-710A-A X72DF Maintenance Manual Exhaust valve - assemble Fig 7-67 Damper setting (example) Tab 7-3 Damper settings Engine type Basic distance H [mm] X35, X35-B 80.9 X40, X40-B 90.4 X40DF 140.0 X52DF X62, X62-B 143.7 X62DF X72, X72-B 165.2 X72DF X82, X82-B 175.0...

  • Page 319: Valve Stroke Sensor, Throttle And Non-Return Valve

    AA00-2751-00AAA-710A-A X72DF Maintenance Manual Exhaust valve - assemble • The valve stroke sensor (004, Figure 7-68) • The transmitter housing (002) • The bore and collar in the top housing (001). Put oil on the O-ring (007) and on the valve stroke sensor (004).
  • Page 320 AA00-2751-00AAA-710A-A X72DF Maintenance Manual Exhaust valve - assemble CLOSE UP • Install the exhaust valve, refer to section 7.9.8 Exhaust valve - install - 320 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 321 AA00-2751-00AAA-710A-A X72DF Maintenance Manual Exhaust valve - assemble Page left intentionally blank - 321 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 322: Exhaust Valve - Install

    AA00-2751-00AAA-720A-A X72DF Maintenance Manual Exhaust valve - install 7.9.8 Exhaust valve - install Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 323: Exhaust Valve - Installation

    AA00-2751-00AAA-720A-A X72DF Maintenance Manual Exhaust valve - install PROCEDURE Clean all the sealing surfaces of the exhaust valve and the cylinder cover. Examine the sealing surfaces of the exhaust valve and cylinder cover for damage. Remove the gasket (001) from the cylinder cover (004).

  • Page 324: Expansion Piece - Installation

    AA00-2751-00AAA-720A-A X72DF Maintenance Manual Exhaust valve - install Apply a thin layer of heat-resistant lubricant to the sealing faces and the screws (001, 005). Put the two slings (007) in position on the expansion piece (004). Attach the slings (007) to the engine room crane.

  • Page 325: Exhaust Valve - Complete The Installation

    AA00-2751-00AAA-720A-A X72DF Maintenance Manual Exhaust valve - install Fig 7-71 Exhaust valve - complete the installation 00719 CLOSE UP • None - 325 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 326: Pilot Injection Valve

    AA00-2790-00AAA-520A-A X72DF Maintenance Manual Pilot injection valve - remove 7.10 Pilot injection valve 7.10.1 Pilot injection valve - remove Periodicity Description Working hours 24 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 327 AA00-2790-00AAA-520A-A X72DF Maintenance Manual Pilot injection valve - remove PROCEDURE Make sure that the drain from the pilot injection valve to the sludge tank is open. Remove the applicable HP pilot fuel pipe (001, Figure 7-72), refer to section 13.4.1 HP pilot fuel pipe - remove.

  • Page 328: Pilot Injection Valve - Remove

    AA00-2790-00AAA-520A-A X72DF Maintenance Manual Pilot injection valve - remove Fig 7-73 Pilot injection valve - remove CLOSE UP • None - 328 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 329 AA00-2790-00AAA-520A-A X72DF Maintenance Manual Pilot injection valve - remove Page left intentionally blank - 329 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 330: Pilot Injection Valve - Remove The Injection Module

    AA00-2790-00AAC-520A-A X72DF Maintenance Manual Pilot injection valve - remove the injection module 7.10.2 Pilot injection valve - remove the injection module Periodicity Description Working hours 12 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 331: Pilot Fuel Valve - Remove The Injection Module

    AA00-2790-00AAC-520A-A X72DF Maintenance Manual Pilot injection valve - remove the injection module PROCEDURE Put the pilot injection valve in position in the valve holder of the test bench. NOTE: For the use of the test bench refer to the related section.

  • Page 332: Pilot Injection Valve - Install The Injection Module

    AA00-2790-00AAC-720A-A X72DF Maintenance Manual Pilot injection valve - install the injection module 7.10.3 Pilot injection valve - install the injection module Periodicity Description Working hours 12 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 333: Pilot Fuel Valve - Install The Injection Module

    AA00-2790-00AAC-720A-A X72DF Maintenance Manual Pilot injection valve - install the injection module PROCEDURE Clean the contact surfaces of the new injection module (1, Figure 7-75) and of the distributor piece. Clean the inner side of the distributor piece (3). Make sure that the contact surfaces and the two cables (2) have no damage.

  • Page 334: Pilot Fuel Valve - Install The Nozzle Nut

    AA00-2790-00AAC-720A-A X72DF Maintenance Manual Pilot injection valve - install the injection module Fig 7-76 Pilot fuel valve - install the nozzle nut CLOSE UP • None - 334 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 335 AA00-2790-00AAC-720A-A X72DF Maintenance Manual Pilot injection valve - install the injection module Page left intentionally blank - 335 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 336: Pilot Injection Valve - Do A Functional Test

    AA00-2790-00AAA-362A-A X72DF Maintenance Manual Pilot injection valve - do a functional test 7.10.4 Pilot injection valve - do a functional test Periodicity Description Working hours 12 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 337 AA00-2790-00AAA-362A-A X72DF Maintenance Manual Pilot injection valve - do a functional test PRELIMINARY OPERATIONS • The pilot fuel valve must be removed, refer to section 7.10.1 Pilot injection valve - remove • You must read the instructions of the test bench manufacturer.
  • Page 338 AA00-2790-00AAA-362A-A X72DF Maintenance Manual Pilot injection valve - do a functional test PROCEDURE Make sure that the test bench (001, Figure 7-77) is clean. Make sure that the receiver (004) is removed from the valve holder (005). Use a brass wire brush to remove combustion particles from the external areas of the nozzle.

  • Page 339: Pilot Injection Valve - Checks

    AA00-2790-00AAA-362A-A X72DF Maintenance Manual Pilot injection valve - do a functional test Fig 7-77 Pilot injection valve - checks CLOSE UP • None - 339 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 340: Pilot Injection Valve - Remove The Pre-Chamber

    AA00-2790-00AAB-520A-A X72DF Maintenance Manual Pilot injection valve - remove the pre-chamber 7.10.5 Pilot injection valve - remove the pre-chamber Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 341 AA00-2790-00AAB-520A-A X72DF Maintenance Manual Pilot injection valve - remove the pre-chamber PROCEDURE Make sure that the cooling water in the cylinder cover is drained. Remove all pipes from the holder (004, Figure 7-78). Loosen the two screws (002) on turn.

  • Page 342: Pilot Injection Valve - Install The Pre-Chamber

    AA00-2790-00AAB-720A-A X72DF Maintenance Manual Pilot injection valve - install the pre-chamber 7.10.6 Pilot injection valve - install the pre-chamber Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 343 AA00-2790-00AAB-720A-A X72DF Maintenance Manual Pilot injection valve - install the pre-chamber PROCEDURE Make sure that the pre-chamber (006, Figure 7-79) is internally and externally clean. Install the dowel pin. Apply a thin layer of oil to the new O-ring. Attach the new O-ring (006) to the pre-chamber.

  • Page 344: Pilot Injection Valve - Install

    AA00-2790-00AAA-720A-A X72DF Maintenance Manual Pilot injection valve - install 7.10.7 Pilot injection valve - install Periodicity Description Working hours 24 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 345: Seal - Install

    AA00-2790-00AAA-720A-A X72DF Maintenance Manual Pilot injection valve - install PROCEDURE Make sure that the sealing faces of the pilot injection valve have the conditions that follow: • Clean and dry • Satisfactory condition • No lubricant. Put a new seal (002, Figure 7-80) on the pilot injection valve (001).
  • Page 346 AA00-2790-00AAA-720A-A X72DF Maintenance Manual Pilot injection valve - install Turn down equally the two nuts (002) until you get a distance of 41 mm between the flange (006) and the valve holder (004). Remove the stud bolts (001). Apply Never Seez NSBT to the threads and surfaces that touch on the two Allen screws (007).
  • Page 347 AA00-2790-00AAA-720A-A X72DF Maintenance Manual Pilot injection valve - install Fig 7-82 Pilot injection valve CLOSE UP • None - 347 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 348 AA00-2790-00AAA-720A-A X72DF Maintenance Manual Pilot injection valve - install Page left intentionally blank - 348 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 349: Group 3 - Crankshaft, Connecting Rod And Piston

    X72DF Maintenance Manual 8 Group 3 - Crankshaft, connecting rod and piston Crankshaft 8.1.1 Crankshaft - do a check of the crank deflection......

  • Page 350: Crankshaft

    AA00-3103-00AAA-360A-A X72DF Maintenance Manual Crankshaft - do a check of the crank deflection Crankshaft 8.1.1 Crankshaft - do a check of the crank deflection Periodicity Description Working hours 6000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 6.0 man-hours...

  • Page 351: Dial Gauge Position

    Do this procedure in the conditions that follow: • Related to the intervals given from the owner (related to classification societies) • Related to the intervals given from WinGD • If temperature alarms of bearings occurred • If damage of bearings occurred •...

  • Page 352: Crank Positions For Clockwise Direction

    AA00-3103-00AAA-360A-A X72DF Maintenance Manual Crankshaft - do a check of the crank deflection Operate the turning gear in the same direction to move the crank to each position of the dial gauge (001, Figure 8-2). Fig 8-2 Crank positions for clockwise direction...

  • Page 353: Maximum Permitted Difference In Mm

    AA00-3103-00AAA-360A-A X72DF Maintenance Manual Crankshaft - do a check of the crank deflection Tab 8-1 Maximum permitted difference in mm Engine type Difference X35, X35-B 0.03 X40, X40-B 0.03 X40DF 0.04 X52DF X62, X62-B 0.04 X62DF X72, X72-B 0.05 X72DF X82, X82-B 0.06...

  • Page 354: Crank-Web Deflection Limits In Mm

    AA00-3103-00AAA-360A-A X72DF Maintenance Manual Crankshaft - do a check of the crank deflection Compare the calculated values with the limits in Table 8-2 - Crank-web deflection limits Tab 8-2 Crank-web deflection limits in mm Vertical Horizontal Engine type Crank No. 1 Crank No.

  • Page 355: Definition Of Deflection

    Crankshaft - do a check of the crank deflection Fig 8-4 Definition of deflection Legend Standard Japanese If a minimum of one calculated value is more than the given limits, speak to WinGD for the related procedures. CLOSE UP • None - 355 - Issue 002 2020-10 Winterthur Gas &...

  • Page 356: Crankshaft - Install The Work Platform

    AA00-3103-00AAA-720A-A X72DF Maintenance Manual Crankshaft - install the work platform 8.1.2 Crankshaft - install the work platform Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.25 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 357 AA00-3103-00AAA-720A-A X72DF Maintenance Manual Crankshaft - install the work platform PROCEDURE Attach the platform (004, Figure 8-5) to the crankshaft (002) and to the longitudinal beam (003). Attach the adjustable platform (001) to the applicable position between the columns (005).

  • Page 358: Crankshaft - Remove The Work Platform

    AA00-3103-00AAA-520A-A X72DF Maintenance Manual Crankshaft - remove the work platform 8.1.3 Crankshaft - remove the work platform Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.25 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 359 AA00-3103-00AAA-520A-A X72DF Maintenance Manual Crankshaft - remove the work platform PROCEDURE Remove the adjustable platform (001) from the columns (005). Remove the platform (004) from the crankshaft (002) and the longitudinal beam (003). Fig 8-6 Platforms CLOSE UP • None...

  • Page 360: Torsional Vibration Damper

    AA00-3130-00AAA-310A-A X72DF Maintenance Manual Torsional vibration damper - examine Torsional vibration damper 8.2.1 Torsional vibration damper - examine Periodicity Description One Time - after first working hours 16 500 Working hours refer to manufacturer Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 6.0 man-hours...
  • Page 361 AA00-3130-00AAA-310A-A X72DF Maintenance Manual Torsional vibration damper - examine PROCEDURE Examine the torsional vibration damper related to the manufacturer’s instructions. CLOSE UP • None - 361 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 362: Axial Vibration Damper

    AA00-3140-00AAA-530A-A X72DF Maintenance Manual Axial vibration damper - disassemble Axial vibration damper 8.3.1 Axial vibration damper - disassemble Periodicity Description Working hours 42 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 363: Axial Vibration Damper - Housing And Pipes

    AA00-3140-00AAA-530A-A X72DF Maintenance Manual Axial vibration damper - disassemble PROCEDURE Prepare the axial vibration damper for removal. Read the data in 3.1 Lifting tools. Remove the oil pipes (002 and 003, Figure 8-7). Disconnect the two cables (001). Remove the housing (004).
  • Page 364 AA00-3140-00AAA-530A-A X72DF Maintenance Manual Axial vibration damper - disassemble Fig 8-8 Axial vibration damper Attach the two eye bolts (006, Figure 8-9) to the top cylinder half. Attach the chain (005) to the eye bolts (006). Attach the two shackles (001) to the platform.

  • Page 365: Axial Vibration Damper - Move

    AA00-3140-00AAA-530A-A X72DF Maintenance Manual Axial vibration damper - disassemble Fig 8-9 Axial vibration damper - move CLOSE UP • None - 365 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 366: Axial Vibration Damper - Assemble

    AA00-3140-00AAA-710A-A X72DF Maintenance Manual Axial vibration damper - assemble 8.3.2 Axial vibration damper - assemble Periodicity Description Working hours 42 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 367 AA00-3140-00AAA-710A-A X72DF Maintenance Manual Axial vibration damper - assemble PROCEDURE Apply clean oil to the 2-part gaskets (002, Figure 8-10) and the 2-part gasket (001). Install the 2-part gaskets (002, 001). Make sure that the 2-part gaskets can move freely.

  • Page 368: Axial Vibration Damper - Install

    AA00-3140-00AAA-710A-A X72DF Maintenance Manual Axial vibration damper - assemble Fig 8-10 Axial vibration damper - install Apply Molykote paste G-n to the threads of the bolts (002, Figure 8-11). Put the bolts (002) in position in the top cylinder half.

  • Page 369: Axial Vibration Damper - Bolts

    AA00-3140-00AAA-710A-A X72DF Maintenance Manual Axial vibration damper - assemble Torque symmetrically the bolts (002) to the correct value, refer to section 16.1 Tightening instructions. Put the bolts (001) in position in the top cylinder half. Torque the bolts (001). Fig 8-11...
  • Page 370 AA00-3140-00AAA-710A-A X72DF Maintenance Manual Axial vibration damper - assemble Fig 8-12 Axial vibration damper - housing and pipes CLOSE UP • None - 370 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 371 AA00-3140-00AAA-710A-A X72DF Maintenance Manual Axial vibration damper - assemble Page left intentionally blank - 371 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 372: Turning Gear

    AA00-3206-00AAA-360A-A X72DF Maintenance Manual Turning gear - do a check of the screwed connections Turning gear 8.4.1 Turning gear - do a check of the screwed connections Periodicity Description One Time - after first working hours 8 000 Working hours...
  • Page 373 AA00-3206-00AAA-360A-A X72DF Maintenance Manual Turning gear - do a check of the screwed connections PROCEDURE Remove the round nuts (001, Figure 8-13) and the bolts (002) of the turning gear (003), refer to section 4.3 Loosen a round nut with a pre-tensioner.

  • Page 374: Turning Gear - Lubricate The Teeth

    AA00-3206-00AAA-240A-A X72DF Maintenance Manual Turning gear - lubricate the teeth 8.4.2 Turning gear - lubricate the teeth Periodicity Description Working hours 2000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 375: Turning Gear And Gear Wheels

    AA00-3206-00AAA-240A-A X72DF Maintenance Manual Turning gear - lubricate the teeth PROCEDURE For the maintenance of the turning gear (001, Figure 8-14), refer to the manufacturer’s instructions. Examine the items that follow: • Condition of the tooth flanks of the gear wheels •...

  • Page 376: Recommended Suppliers

    AA00-3206-00AAA-240A-A X72DF Maintenance Manual Turning gear - lubricate the teeth Fig 8-15 Pyroshield Fig 8-16 Klüberfluid If necessary, examine the teeth more frequently than the interval given above. NOTE: For the recommended suppliers, refer to Table 8-3 - Recommended suppliers...
  • Page 377 AA00-3206-00AAA-240A-A X72DF Maintenance Manual Turning gear - lubricate the teeth Page left intentionally blank - 377 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 378: Connecting Rod

    AA00-3303-00AAA-523A-A X72DF Maintenance Manual Connecting rod - prepare before removal Connecting rod 8.5.1 Connecting rod - prepare before removal Periodicity Description Working hours 70 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 379 AA00-3303-00AAA-523A-A X72DF Maintenance Manual Connecting rod - prepare before removal PROCEDURE Attach two shackles (003, Figure 8-17) to the column. Attach the two lever chain hoists (004) to the shackles (003). Attach the two lever chain hoists (004) to the shackles (005) on the tool connecting rod (009).
  • Page 380 AA00-3303-00AAA-523A-A X72DF Maintenance Manual Connecting rod - prepare before removal Fig 8-18 Stop plate Lift the crosshead. Remove the lever chain hoists (004, Figure 8-17) from the tool (009). Remove the toggle lever (001) from the crosshead. Put protection on the toggle lever (001) and the crosshead to prevent contamination and damage.
  • Page 381 AA00-3303-00AAA-523A-A X72DF Maintenance Manual Connecting rod - prepare before removal Page left intentionally blank - 381 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 382: Connecting Rod - Remove

    AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove 8.5.2 Connecting rod - remove Periodicity Description Working hours 70 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 10.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 383 AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove PRELIMINARY OPERATIONS • The connecting rod must be prepared for removal, refer to section 8.5.1 Connecting rod - prepare before removal - 383 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 384 AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove PROCEDURE Attach an applicable rope to hold the toggle lever up to prevent damage. Attach the deviation pipe (006, Figure 8-19) to the column. Operate the lever chain hoists (001, 003) to move the connecting rod (002) to the position shown in view A.

  • Page 385: Connecting Rod - Move

    AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove Fig 8-19 Connecting rod - move NOTE: During this step, operate the chain block (002, Figure 8-20) to get the connecting rod to 45°. - 385 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 386 AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove Operate the turning gear to move the crank counterclockwise to the position shown in view A. Attach the lever chain hoist (003) to the lug (007) and tighten lightly the chain. Attach the tool connecting rod (004) to the tool (005).
  • Page 387 AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove Fig 8-20 Connecting rod - remove If it necessary to move the connecting rod away from the area, do Step 23.1 Step 23.14: 23.1 Read the applicable safety precautions. - 387 - Issue 002 2020-10 Winterthur Gas &...
  • Page 388 AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove 23.2 Put on the applicable personal protective equipment. 23.3 Operate the chain block (002) to lower the connecting rod (001) to the floor. 23.4 Remove the chain. 23.5 Attach the two chain blocks (002 and 006,...

  • Page 389: Connecting Rod - Move 2

    AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove Fig 8-21 Connecting rod - move 2 - 389 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 390 AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove CLOSE UP • None - 390 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 391 AA00-3303-00AAA-520A-A X72DF Maintenance Manual Connecting rod - remove Page left intentionally blank - 391 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 392: Connecting Rod - Remove The Top End Bearing Cover

    AA00-3303-01AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the top end bearing cover 8.5.3 Connecting rod - remove the top end bearing cover Periodicity Description Working hours 70 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours...
  • Page 393 AA00-3303-01AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the top end bearing cover PRELIMINARY OPERATIONS • The engine must be stopped and made safe for maintenance, refer to section 4.1 Do maintenance work - general procedure - 393 - Issue 002 2020-10...
  • Page 394 AA00-3303-01AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the top end bearing cover PROCEDURE Prepare the top end bearing of the connecting rod for removal. Operate the turning gear to turn the crank to BDC. Remove the round nuts (001,...

  • Page 395: Equipment - Install

    AA00-3303-01AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the top end bearing cover Fig 8-23 Equipment - install 00741 Remove the four round nuts (005, Figure 8-22) from the elastic bolts (004), refer to section 4.3 Loosen a round nut with a pre-tensioner.

  • Page 396: Top Bearing Cover - Removal

    AA00-3303-01AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the top end bearing cover Fig 8-24 Top bearing cover - removal 00740 - 396 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 397 AA00-3303-01AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the top end bearing cover CLOSE UP • None - 397 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 398: Connecting Rod - Remove The Top End Bearing

    AA00-3303-02AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the top end bearing 8.5.4 Connecting rod - remove the top end bearing Periodicity Description Working hours 70 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 399: Top End Bearing - Remove

    AA00-3303-02AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the top end bearing PROCEDURE Make sure that the platform is installed. Operate carefully the lever chain hoists (002 and 007, Figure 8-25) to move the connecting rod (003) to the fuel side.

  • Page 400: Connecting Rod - Remove The Bottom End Bearing

    AA00-3303-03AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the bottom end bearing 8.5.5 Connecting rod - remove the bottom end bearing Periodicity Description Working hours 70 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 401 AA00-3303-03AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the bottom end bearing PRELIMINARY OPERATIONS • The top end bearing must be removed, refer to section 8.5.4 Connecting rod - remove the top end bearing - 401 - Issue 002 2020-10...

  • Page 402: Bottom End Bearing Cover - Move

    AA00-3303-03AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the bottom end bearing PROCEDURE Remove the bearing cover. Operate the turning gear to move the crankshaft until the applicable crank pin (003, Figure 8-26) is at TDC. Lock the turning gear.

  • Page 403: Bottom End Bearing Shell - Remove

    AA00-3303-03AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the bottom end bearing 1.15 Operate the lever chain hoists (001, 002) to move the bearing cover (004) to the fuel side. 1.16 Remove the lever chain hoist (001) from the bearing cover (004).
  • Page 404 AA00-3303-03AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the bottom end bearing 3.4.2 For 8 to 12 cylinder engines: Attach the support (005) and the support (002). Tighten the special screws (003). Operate the turning gear to lower the crosshead (001) on to the special screws (003).

  • Page 405: Bottom End Bearing

    AA00-3303-03AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the bottom end bearing Fig 8-29 Bottom end bearing 3.11 Attach the shackles (001, Figure 8-30) to the column. 3.12 Attach the shackles (005) to the shackles (001). 3.13 Attach the lever chain hoists (002) to the shackles (005).

  • Page 406: Top Bearing Shell - Remove

    AA00-3303-03AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the bottom end bearing Fig 8-30 Top bearing shell - remove 00768 - 406 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 407 AA00-3303-03AAA-520A-A X72DF Maintenance Manual Connecting rod - remove the bottom end bearing CLOSE UP • None - 407 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 408: Connecting Rod - Examine The Bearing Shells

    AA00-3303-05AAA-310A-A X72DF Maintenance Manual Connecting rod - examine the bearing shells 8.5.6 Connecting rod - examine the bearing shells Periodicity Description Working hours 70000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 409 AA00-3303-05AAA-310A-A X72DF Maintenance Manual Connecting rod - examine the bearing shells PROCEDURE Do an inspection of the related bearing shell (001, Figure 8-31). If you find damage, remove the bearing shell (001), refer to section 8.5.2 Connecting rod remove. Fig 8-31...

  • Page 410: Connecting Rod - Install The Bottom End Bearing

    AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing 8.5.7 Connecting rod - install the bottom end bearing Periodicity Description Working hours 70 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 411 AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing SAFETY PRECAUTIONS WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel. PRELIMINARY OPERATIONS • None - 411 - Issue 002 2020-10...
  • Page 412 AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing PROCEDURE Clean the seating surface of the bearing shell. Attach the bearing shell - crank pin (008, Figure 8-32) to the console frame (004) with the four screws (006).

  • Page 413: Top Bearing Shell - Move

    AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing Fig 8-32 Top bearing shell - move 00768 Operate the turning gear to move the crank (002, Figure 8-33) to the position shown. Make sure that there is no load on the points (X) between the connecting rod (003) and the crank pin (002).

  • Page 414: Bottom End Bearing

    AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing If necessary, operate the chain block (004) to move the connecting rod (003). Fig 8-33 Bottom end bearing Loosen the screws (003, Figure 8-34). Remove the four bolts (004).

  • Page 415: Iso Vg 1000/1500 Suppliers

    AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing Fig 8-34 Supports Attach the four eye bolts (003, Figure 8-35) to the bearing shell - crank pin (005). Attach the chain (001) to the four eye bolts (003).
  • Page 416 AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing Operate the lever chain hoists (006, 007) to lift the bearing cover (004) into position on the crank pin. Put the round nuts (010) on the elastic studs.

  • Page 417: Bottom End Bearing - Install

    AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing Fig 8-35 Bottom end bearing - install 00773 - 417 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 418: Iso Vg 1000/1500 Suppliers

    AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing Tab 8-4 ISO VG 1000/1500 suppliers Supplier Type Viscosity at Viscosity at Weight at 15°C [g/ml] 40°C [mm 100°C [mm Energol DC 1000 49.0 0.913 Energol DC 1000 40.0...
  • Page 419 AA00-3303-03AAA-720A-A X72DF Maintenance Manual Connecting rod - install the bottom end bearing Page left intentionally blank - 419 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 420: Connecting Rod - Install The Top End Bearing

    AA00-3303-02AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing 8.5.8 Connecting rod - install the top end bearing Periodicity Description Working hours 70000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 421 AA00-3303-02AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing PROCEDURE Clean the seating surface of the bearing shell (004, Figure 8-36). Put bearing oil on the surface of the bearing shell (004) as follows: If you start the engine immediately after completion of this procedure, use only system oil.

  • Page 422: Top End Bearing - Move

    AA00-3303-02AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing Fig 8-36 Top end bearing - move 009 010 00766 Operate the lever chain hoists (003 and 007, Figure 8-37) to move the connecting rod to the vertical position.

  • Page 423: Crosshead - Lower

    AA00-3303-02AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing Fig 8-37 Crosshead - lower Put the round nuts (002, Fig. 9) on the elastic studs (001). Use a round bar to tighten equally the round nuts (002).

  • Page 424: Bearing Lubrication

    AA00-3303-02AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing Fig 8-38 Bearing lubrication CLOSE UP • None - 424 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 425 AA00-3303-02AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing Page left intentionally blank - 425 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 426: Connecting Rod - Install The Top End Bearing Cover

    AA00-3303-01AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing cover 8.5.9 Connecting rod - install the top end bearing cover Periodicity Description Working hours 70 000 Personnel Description Specialization Engine crew Basic Support equipment Description Part No.

  • Page 427: Top Bearing Cover - Move

    AA00-3303-01AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing cover PROCEDURE Make sure that the bearing cover (003, Figure 8-39) has no damage. Attach the two eye bolts (002) to the bearing cover (003). Attach the shackle (001) to the chain (005).
  • Page 428 AA00-3303-01AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing cover Make sure that the holes in the bearing cover (005) engage with the four dowel pins (009). Remove the chain blocks (002, 006), chain (004), shackles (001, 003) and eye bolts.

  • Page 429: Top Bearing Cover - Install

    AA00-3303-01AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing cover Fig 8-40 Top bearing cover - install 00742 - 429 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 430 AA00-3303-01AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing cover CLOSE UP • None - 430 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 431 AA00-3303-01AAA-720A-A X72DF Maintenance Manual Connecting rod - install the top end bearing cover Page left intentionally blank - 431 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 432: Connecting Rod - Install

    AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install 8.5.10 Connecting rod - install Periodicity Description Working hours 70 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 10.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 433 AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install PROCEDURE If it necessary to move the connecting rod away from the area, do Step 1.5 Step 1.15: Read the applicable safety precautions. Put on the applicable personal protective equipment. Attach two shackles (005, Figure 8-41) to the positions shown.
  • Page 434 AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install Fig 8-41 Connecting rod - move 2 Attach the shackles (005) to the platform at the applicable installation position. Clean the bearing shell and the crank pin. Put oil on the bearing shell and the crank pin.
  • Page 435 AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install Attach the applicable chain (001 or 004) to the shackles (005). Attach the chain block (002) to the chain (001 or 004). Operate the chain block (002, Figure 8-42) to lift the connecting rod (001) to sufficient height.
  • Page 436 AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install Fig 8-42 Connecting rod - install 1 Operate the turning gear and the chain block (002, Figure 8-43) to move the connecting rod clockwise to the position shown in view A. Attach the chain block (001) to the bottom shackle on the lifting tool.
  • Page 437 AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install Remove the chain block (002), the chain (003) and the shackle (004). Operate the turning gear and the chain block (001) to move the connecting rod clockwise to the position shown in view B.
  • Page 438 AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install Fig 8-43 Connecting rod - install 2 Operate the chain block (006, Figure 8-44) to lift the crosshead a small distance. Remove the two supports (001). - 438 - Issue 002 2020-10...
  • Page 439 AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install NOTE: During this step, make sure that the elastic bolts in the connecting rod align with the holes in the crosshead. Operate the chain block (006) to lower carefully the crosshead on to the connecting rod.

  • Page 440: Crosshead - Install

    AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install Fig 8-44 Crosshead - install Remove all lever chain hoists, chain blocks, eye bolts, shackles and other equipment. Remove the protection from the crosshead pin. - 440 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 441: Toggle Lever - Attach

    AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install CAUTION Damage Hazard. Damage will occur to an incorrectly connected toggle lever. Make sure that you connect the toggle lever correctly. Connect the toggle lever (001, Figure 8-41) to the crosshead (002). Make sure that the toggle lever is in the position shown.

  • Page 442: Piston - Attach

    AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install Fig 8-46 Piston - attach Make sure that the compression shim (003) is clean and has no damage. Unlock the turning gear. WARNING Before you operate the turning gear, make sure that no personnel are near the flywheel or in the engine.
  • Page 443 AA00-3303-00AAA-720A-A X72DF Maintenance Manual Connecting rod - install Page left intentionally blank - 443 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 444: Crosshead - Remove

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Crosshead 8.6.1 Crosshead - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel...
  • Page 445 AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Supplies Description Oil SAE 30 Spare Parts Description Part No. None SAFETY PRECAUTIONS WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are on the platform or near the flywheel.

  • Page 446: Toggle Lever - Remove

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove PROCEDURE Prepare the crosshead before removal: Remove the toggle lever (001, Figure 8-47) from the crosshead pin (002). Let the toggle lever hang in the column. Fig 8-47 Toggle lever - remove NOTE: THE CRANK SHAFT IS AT BDC...

  • Page 447: Crosshead Bearing - Temperature Sensor

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Fig 8-48 Crosshead bearing - temperature sensor Use an applicable tool to remove the compression shim. Attach the engine room crane to the lifting tool (001, Figure 8-49). Operate the engine room crane to lower the lifting tool (001) on to the crosshead pin.

  • Page 448: Tools - Prepare

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Fig 8-49 Tools - prepare 006 007 00744 Remove the toggle lever (001, Figure 8-50) from the crosshead pin. Let the toggle lever hang in the column. Attach one of the two shackles (006) to the column.

  • Page 449: Bracket - Attach

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Fig 8-50 Bracket - attach 00745 Attach the shackle (012, Figure 8-51) to the column on the fuel side. Attach the chain block (011) to the shackle (012). Operate the turning gear to move the crank of the applicable cylinder to BDC.

  • Page 450: Tools - Attach

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Fig 8-51 Tools - attach 00746 Operate the chain block (001, Figure 8-52) to lift the crosshead pin to approximately 300 mm above the center of the pin holes in the column walls.

  • Page 451: Connecting Rod - Move

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Put oil on the threads and surfaces that touch on the bolts (004) of each support (003). Attach the two supports (003) to the columns with the bolts (004). Torque the bolts (004) to the correct value, refer to section 16.1 Tightening...

  • Page 452: Crosshead - Move

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove 46.2 Attach the chain (008) to the eye bolts (005). 46.3 Attach the shackle (011) to an applicable position on the column. 46.4 Attach the lever chain hoist (010) to the shackle (011) and the chain (008).

  • Page 453: Crosshead - Remove

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Remove the lever chain hoist (007) and the eye bolt (008). Attach the deviation pipe (010) to the door frame (013). Attach the deviation pipe (012) to the support (011) on the supply unit.
  • Page 454 AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove 63.5 Move the trolley (011) and crosshead pin (003) to an applicable area. 63.6 Lower the crosshead pin on an applicable surface. 63.7 Remove the chain block (008) from the lifting tool (007) on the crosshead (003).

  • Page 455: Crosshead - Remove

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Fig 8-55 Crosshead - remove 00750 Record the positions of the guide shoes (003, Figure 8-56). The shims of the guide shoes can have different dimensions (0.3 mm, 0.5 and 1 mm thickness). This will help you during the installation procedure.

  • Page 456: Guide Shoes - Remove

    AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Attach the chain blocks (001, 004) to the eye bolt on one of the guide shoes. Operate the chain blocks (001, 004) to put a light tension on the chains. Remove the chain block (002).
  • Page 457 AA00-3326-00AAA-520A-A X72DF Maintenance Manual Crosshead - remove Page left intentionally blank - 457 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 458: Crosshead - Do A Check Of The Clearances

    AA00-3326-00AAA-360A-A X72DF Maintenance Manual Crosshead - do a check of the clearances 8.6.2 Crosshead - do a check of the clearances Periodicity Description Working hours 7000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 459: Clearance Checks

    AA00-3326-00AAA-360A-A X72DF Maintenance Manual Crosshead - do a check of the clearances PROCEDURE Measure the clearance of the guide shoe and guide way as follows: Make sure that the related crank pin is in a position so that the guide shoes...

  • Page 460: Dimensions Check

    AA00-3326-00AAA-360A-A X72DF Maintenance Manual Crosshead - do a check of the clearances Attach the tool (005, Figure 8-58) to the crosshead pin (001) with the two screws (002). Tighten equally the two screws (003) to move the crosshead pin (001).
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  • Page 462: Crosshead - Install

    AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install 8.6.3 Crosshead - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
  • Page 463 AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install Spare Parts Description Part No. Guide shoe Crosshead pin SAFETY PRECAUTIONS WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are on the platform or near the flywheel.

  • Page 464: Guide Shoe - Move

    AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install PROCEDURE If necessary, attach the eye bolt to the guide shoe (003, Figure 8-59). NOTE: Make sure that you install the guide shoes in their original positions. Attach the spur-geared chain block (004) and the spur-geared chain block (001) to the eye bolt on the guide shoe (00X).
  • Page 465 AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install Turn the crosshead pin 90°. Remove the deviation pipe (005). Fig 8-60 Crosshead - move 00754 Operate the chain block (006, Figure 8-61) to lower the guide shoe (005). Align the guide shoe with the crosshead pin (004).

  • Page 466: Guide Shoes - Install

    AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install Fig 8-61 Guide shoes - install 00755 Attach the two holding plates (001, Figure 8-62) to the guide shoe (002) with the tab washers and bolts. Make sure that there is no clearance between the holding plates (001) and crosshead pin (003).
  • Page 467 AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install NOTE: During this step, make sure that the elastic bolts in the connecting rod align with the holes in the crosshead pin. Remove the two lever chain hoists (011). Use an applicable tool and sufficient personnel to remove the two lifting tools (007, 014) from the connecting rod (008).

  • Page 468: Connecting Rod - Move

    AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install Fig 8-62 Connecting rod - move NO CLEARANCE 00756 Install the platform to top of the crosshead. Attach the lever chain hoist (012, Figure 8-63) to the shackle (008) and the platform. - 468 - Issue 002 2020-10 Winterthur Gas &...

  • Page 469: Tools - Remove

    AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install Operate the lever chain hoist (004) to lift the platform a small distance from the crankshaft. Operate the turning gear to lift the platform sufficiently to remove the tools from the cylinder block.
  • Page 470 AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install Fig 8-64 Toggle lever - attach NOTE: THE CRANK SHAFT IS AT BDC 00757 Apply Loctite 243 to the thread of the temperature sensor (002, Figure 8-65). Attach the temperature sensor (002) to the crosshead (001).
  • Page 471 AA00-3326-00AAA-720A-A X72DF Maintenance Manual Crosshead - install Fig 8-65 Crosshead bearing - temperature sensor Install the round nuts to the elastic studs on the connecting rod, refer to section Tighten a round nut with a pre-tensioner. Install the top bearing cover, refer to section 6.2.2 Main bearing - install the...

  • Page 472: Piston

    AA00-3403-00AAA-360A-A X72DF Maintenance Manual Piston (installed) - do checks of the surface and clearances Piston 8.7.1 Piston (installed) - do checks of the surface and clearances Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 473: Top Surface - Dimensions Check

    AA00-3403-00AAA-360A-A X72DF Maintenance Manual Piston (installed) - do checks of the surface and clearances PROCEDURE Operate the turning gear to move the piston to BDC. Look through the scavenge ports (002) for burn scars on the piston head (001, Figure 8-66).

  • Page 474: Piston Ring - Clearance

    15.1 Replace the defective piston rings. 15.2 Repair the defective piston head. NOTE: For the repair of piston heads, speak to the nearest WinGD Service Center. Record the data that follow: • All dimensions • Date of the overhaul •...
  • Page 475 AA00-3403-00AAA-360A-A X72DF Maintenance Manual Piston (installed) - do checks of the surface and clearances Page left intentionally blank - 475 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 476: Piston - Prepare Before Removal

    AA00-3403-00AAA-523A-A X72DF Maintenance Manual Piston - prepare before removal 8.7.2 Piston - prepare before removal Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 477: Piston - Preparation

    AA00-3403-00AAA-523A-A X72DF Maintenance Manual Piston - prepare before removal PROCEDURE Attach the four plates (002, Figure 8-68) to the antipolishing ring (003) with the four screws (004). Connect the engine room crane to the lifting tool (001). Attach the tool 94209 to the antipolishing ring (003).
  • Page 478 AA00-3403-00AAA-523A-A X72DF Maintenance Manual Piston - prepare before removal Apply Molykote past G-n to the threads of the six bolts. Use the engine room crane to put the lifting tool 94341 in position of the piston crown. Attach the three brackets to the lifting tool with the six bolts. Make sure that the brackets fully engage in the holes in the piston crown.

  • Page 479: Piston - Preparation Before Removal (Example)

    AA00-3403-00AAA-523A-A X72DF Maintenance Manual Piston - prepare before removal Fig 8-69 Piston - Preparation before removal (example) 00780 - 479 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 480 AA00-3403-00AAA-523A-A X72DF Maintenance Manual Piston - prepare before removal CLOSE UP • None - 480 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 482: Piston - Remove

    AA00-3403-00AAA-520A-A X72DF Maintenance Manual Piston - remove 8.7.3 Piston - remove Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 483 AA00-3403-00AAA-520A-A X72DF Maintenance Manual Piston - remove PROCEDURE Make sure that the piston support (005, Figure 8-70) in position on the top platform. Attach the engine room crane to the lifting tool (009). Carefully operate the engine room crane to lift the piston (001) from the cylinder liner.
  • Page 484 AA00-3403-00AAA-520A-A X72DF Maintenance Manual Piston - remove CLOSE UP • None - 484 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 485 AA00-3403-00AAA-520A-A X72DF Maintenance Manual Piston - remove Page left intentionally blank - 485 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 486: Piston - Disassemble

    AA00-3403-00AAA-530A-A X72DF Maintenance Manual Piston - disassemble 8.7.4 Piston - disassemble Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 487: Piston - Preparation Before Disassembly

    AA00-3403-00AAA-530A-A X72DF Maintenance Manual Piston - disassemble PROCEDURE Prepare the piston for disassembly. Attach the hydraulic unit (001, Figure 8-71), the pressure gauge (002), the distributing piece (003) and the flexible hoses as shown. Remove the 11 round nuts (004) in the sequence given, refer to section Loosen a round nut with a pre-tensioner.
  • Page 488 AA00-3403-00AAA-530A-A X72DF Maintenance Manual Piston - disassemble Fig 8-72 Piston - disassemble (example) 00781 - 488 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 489 AA00-3403-00AAA-530A-A X72DF Maintenance Manual Piston - disassemble CLOSE UP • None - 489 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 490: Piston (Removed) - Do Checks Of The Surface And Clearances

    AA00-3403-00AAA-360B-A X72DF Maintenance Manual Piston (removed) - do checks of the surface and clearances 8.7.5 Piston (removed) - do checks of the surface and clearances Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 491: Piston Groove Clearance - Calliper Gauge

    AA00-3403-00AAA-360B-A X72DF Maintenance Manual Piston (removed) - do checks of the surface and clearances PROCEDURE Put the template (001, Figure 8-73) in position on the top piston ring (002). Turn the template (001) around the axis of the piston head.
  • Page 492 Replace the piston rings. 14.2 Repair the piston head. NOTE: For the repair of piston heads, speak to the nearest WinGD Service Center. Measure the diameter of the piston skirt. Compare the measured value with the minimum permitted value, refer to section Clearances - general.
  • Page 493 AA00-3403-00AAA-360B-A X72DF Maintenance Manual Piston (removed) - do checks of the surface and clearances Page left intentionally blank - 493 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 494: Piston - Assemble

    AA00-3403-00AAA-710A-A X72DF Maintenance Manual Piston - assemble 8.7.6 Piston - assemble Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...

  • Page 495: Torque Values

    AA00-3403-00AAA-710A-A X72DF Maintenance Manual Piston - assemble PROCEDURE If the pipes (002, Figure 8-75) were removed, install the pipes as follows: Apply Loctite to the bottom thread of the pipe (002). NOTE: Do not install pipes that have damage. Use an applicable tool to install the pipe (002) to the spray plate (003).
  • Page 496 AA00-3403-00AAA-710A-A X72DF Maintenance Manual Piston - assemble Fig 8-75 Piston - assemble (example) Attach the hydraulic unit, the pressure gauge, the distributing piece and the flexible hoses. Install the round nuts to the elastic studs in the sequence given, refer to section Tighten a round nut with a pre-tensioner.
  • Page 497 AA00-3403-00AAA-710A-A X72DF Maintenance Manual Piston - assemble Page left intentionally blank - 497 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 498: Piston - Install

    AA00-3403-00AAA-720A-A X72DF Maintenance Manual Piston - install 8.7.7 Piston - install Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 499: Piston - Move (Example)

    AA00-3403-00AAA-720A-A X72DF Maintenance Manual Piston - install PROCEDURE Clean all parts of the piston, piston rings, gland box bore, cylinder liner, cylinder liner bore and the installation tool (002, Figure 8-76). Apply oil to the piston, piston rings, gland box bore, cylinder liner and cylinder liner bore.
  • Page 500 AA00-3403-00AAA-720A-A X72DF Maintenance Manual Piston - install Operate the engine room crane to remove fully the piston from the piston support 003, Figure 8-77). Carefully lower the piston (001) into the cylinder liner (002). Operate the turning gear to turn the crank to BDC.

  • Page 501: Piston Rod Gland - Attach (Example)

    AA00-3403-00AAA-720A-A X72DF Maintenance Manual Piston - install Fig 8-78 Piston rod gland - attach (example) 00699 Remove the distance holders (003, Figure 8-79). Attach the round nuts (001) to the elastic bolts, refer to section 4.2 Tighten a round nut with a pre-tensioner.
  • Page 502 AA00-3403-00AAA-720A-A X72DF Maintenance Manual Piston - install Fig 8-79 Piston - attach (example) 00786 CLOSE UP • None - 502 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 503 AA00-3403-00AAA-720A-A X72DF Maintenance Manual Piston - install Page left intentionally blank - 503 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 504: Piston Ring

    AA00-3425-00AAA-520A-A X72DF Maintenance Manual Piston ring - remove Piston ring 8.8.1 Piston ring - remove Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 505: Piston Ring - Remove (Example)

    AA00-3425-00AAA-520A-A X72DF Maintenance Manual Piston ring - remove PROCEDURE If the same piston rings (001, Figure 8-80) will be installed again, record their positions. Fig 8-80 Piston ring - remove (example) 00791 CAUTION Damage Hazard: Do not open the piston rings too far. This causes damage to the piston rings.

  • Page 506: Piston Ring - Install

    AA00-3425-00AAA-720B-A X72DF Maintenance Manual Piston ring - install 8.8.2 Piston ring - install Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 507: Piston Rings - Install (Example)

    AA00-3425-00AAA-720B-A X72DF Maintenance Manual Piston ring - install PROCEDURE CAUTION Damage Hazard: Do not open the piston rings too far. This causes damage to the piston rings. Make sure that the mark TOP on the piston rings (001, 003, Figure 8-81) points up.
  • Page 508 AA00-3425-00AAA-720B-A X72DF Maintenance Manual Piston ring - install Page left intentionally blank - 508 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 509: Group 4 - Supply Unit Drive And Control Components

    X72DF Maintenance Manual 9 Group 4 - Supply unit drive and control components Driving wheel 9.1.1 Gear wheel crankshaft - examine the teeth......

  • Page 510: Driving Wheel

    AA00-4106-00AAA-310A-A X72DF Maintenance Manual Gear wheel crankshaft - examine the teeth Driving wheel 9.1.1 Gear wheel crankshaft - examine the teeth Periodicity Description Working hours 7000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 511 AA00-4106-00AAA-310A-A X72DF Maintenance Manual Gear wheel crankshaft - examine the teeth PROCEDURE Operate the turning gear to turn the crankshaft while you do an inspection of all teeth. NOTE: 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 512: Gear Wheel Crankshaft - Do A Check Of The Teeth Backlash

    AA00-4106-00AAA-360A-A X72DF Maintenance Manual Gear wheel crankshaft - do a check of the teeth backlash 9.1.2 Gear wheel crankshaft - do a check of the teeth backlash Periodicity Description Working hours 7000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 513 AA00-4106-00AAA-360A-A X72DF Maintenance Manual Gear wheel crankshaft - do a check of the teeth backlash PROCEDURE Measure the gear tooth backlash with one of the procedures that follows: NOTE: For data about the gear tooth backlash values, refer to 3.3 Clearances - general.

  • Page 514: Driving Wheel - Gear Tooth Backlash

    AA00-4106-00AAA-360A-A X72DF Maintenance Manual Gear wheel crankshaft - do a check of the teeth backlash Fig 9-1 Driving wheel - gear tooth backlash 15 mm Equal Distances 15 mm 00795 - 514 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 515 AA00-4106-00AAA-360A-A X72DF Maintenance Manual Gear wheel crankshaft - do a check of the teeth backlash CLOSE UP • None - 515 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 516: Shut-Off Valve For Starting Air

    AA00-4325-00AAA-530A-A X72DF Maintenance Manual Shut-off valve for starting air - disassemble Shut-off valve for starting air 9.2.1 Shut-off valve for starting air - disassemble Periodicity Description Working hours 33 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 517: Shut-Off Valve For Starting Air - Prepare For Disassembly

    AA00-4325-00AAA-530A-A X72DF Maintenance Manual Shut-off valve for starting air - disassemble PROCEDURE Prepare the shut-off valve for starting air for disassembly. Disconnect the electrical connections from the pressure transmitter (009, Figure 9-2) and the solenoid valves (007, 008). Disconnect the pipes (004, 001) from the shut-off valve for starting air.
  • Page 518 AA00-4325-00AAA-530A-A X72DF Maintenance Manual Shut-off valve for starting air - disassemble Remove the valve body (016) together with the spring (015). Remove the two bolts (001) from the control valve (017). Remove the control valve (019). Remove the screw plug (003) together with the spring (002), valve (019) and piston (018) from the control valve (017).
  • Page 519 AA00-4325-00AAA-530A-A X72DF Maintenance Manual Shut-off valve for starting air - disassemble Fig 9-3 Shut-off valve for starting air - disassemble 017 018 019 00800 - 519 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 520 AA00-4325-00AAA-530A-A X72DF Maintenance Manual Shut-off valve for starting air - disassemble CLOSE UP • None - 520 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 521 AA00-4325-00AAA-530A-A X72DF Maintenance Manual Shut-off valve for starting air - disassemble Page left intentionally blank - 521 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 522: Shut-Off Valve For Starting Air - Assemble

    AA00-4325-00AAA-710A-A X72DF Maintenance Manual Shut-off valve for starting air - assemble 9.2.2 Shut-off valve for starting air - assemble Periodicity Description Working hours 33 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 523 AA00-4325-00AAA-710A-A X72DF Maintenance Manual Shut-off valve for starting air - assemble PROCEDURE Make sure that all bores are clear. Apply a thin layer of Molykote paste to the spring (029, Figure 9-4) and to the sliding surface of the valve guide (027) and the valve body (030).
  • Page 524 AA00-4325-00AAA-710A-A X72DF Maintenance Manual Shut-off valve for starting air - assemble Fig 9-4 Shut-off valve for starting air - assemble 1.0 ± 0.2 mm 022 021 00802 - 524 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 525 AA00-4325-00AAA-710A-A X72DF Maintenance Manual Shut-off valve for starting air - assemble CLOSE UP • None - 525 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 526: Shut-Off Valve For Starting Air - Do A Test Of The Operation

    AA00-4325-00AAA-320A-A X72DF Maintenance Manual Shut-off valve for starting air - do a test of the operation 9.2.3 Shut-off valve for starting air - do a test of the operation Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours...
  • Page 527 AA00-4325-00AAA-320A-A X72DF Maintenance Manual Shut-off valve for starting air - do a test of the operation PROCEDURE To set the shut-off valve for starting air (shut-off valve) to the initial test position, do Step Step 1.3: Make sure that the stop valves 930-V03 and 930-V04 are closed.

  • Page 528: Shut-Off Valve For Starting Air - Operation Test

    AA00-4325-00AAA-320A-A X72DF Maintenance Manual Shut-off valve for starting air - do a test of the operation Fig 9-5 Shut-off valve for starting air - operation test 00799 CLOSE UP • None - 528 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 529: Group 5 - Supply Unit, Pumps And Control Valves

    X72DF Maintenance Manual 10 Group 5 - Supply unit, pumps and control valves 10.1 Servo oil pump 10.1.1 Servo oil pump - do a check for wear and damage..... . .

  • Page 530: Servo Oil Pump

    AA00-5551-00AAA-320A-A X72DF Maintenance Manual Servo oil pump - do a check for wear and damage 10.1 Servo oil pump 10.1.1 Servo oil pump - do a check for wear and damage Periodicity Description Working hours 3000 Duration for performing preliminary requirements 0.0 man-hours...
  • Page 531 AA00-5551-00AAA-320A-A X72DF Maintenance Manual Servo oil pump - do a check for wear and damage PROCEDURE Remove the screws from the cover of the supply unit. Remove the cover from the supply unit. Do a check of the pinions and of the camshaft gear wheel for wear and damage.

  • Page 532: Servo Oil Pump - Remove

    AA00-5551-00AAA-520A-A X72DF Maintenance Manual Servo oil pump - remove 10.1.2 Servo oil pump - remove Periodicity Description Working hours 36000 (HAWE) Working hours 66000 (Bosch) Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 533 AA00-5551-00AAA-520A-A X72DF Maintenance Manual Servo oil pump - remove • The applicable HP servo oil pipes must be removed, refer to section 13.1.1 HP servo oil pipe - remove - 533 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 534 AA00-5551-00AAA-520A-A X72DF Maintenance Manual Servo oil pump - remove PROCEDURE Prepare the servo oil pumps for removal. Remove the applicable HP fuel pipes from the related fuel pumps. Disconnect the electrical connections. Remove all pipes from the servo oil pumps.
  • Page 535 AA00-5551-00AAA-520A-A X72DF Maintenance Manual Servo oil pump - remove Page left intentionally blank - 535 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 536: Servo Oil Pump - Install

    AA00-5551-00AAA-720A-A X72DF Maintenance Manual Servo oil pump - install 10.1.3 Servo oil pump - install Periodicity Description Working hours 36000 (HAWE) Working hours 66000 (Bosch) Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 537 AA00-5551-00AAA-720A-A X72DF Maintenance Manual Servo oil pump - install • The applicable HP servo oil pipes must be removed, refer to section 13.1.1 HP servo oil pipe - remove - 537 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 538 AA00-5551-00AAA-720A-A X72DF Maintenance Manual Servo oil pump - install PROCEDURE Install the first servo oil pump. Put a new O-ring in the pump support. Apply a small quantity of oil to the O-ring. Put the sling around the servo oil pump two times.
  • Page 539 AA00-5551-00AAA-720A-A X72DF Maintenance Manual Servo oil pump - install Page left intentionally blank - 539 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 540: Supply Unit For Pilot Fuel

    AA00-5555-00AAA-520A-A X72DF Maintenance Manual Supply unit for pilot fuel - remove the pump 10.2 Supply unit for pilot fuel 10.2.1 Supply unit for pilot fuel - remove the pump Periodicity Description Working hours 24 000 Duration for performing preliminary requirements 0.0 man-hours...
  • Page 541 AA00-5555-00AAA-520A-A X72DF Maintenance Manual Supply unit for pilot fuel - remove the pump PROCEDURE If necessary, remove the cover (005, Figure 10-1). Make sure that the pilot fuel pump (002) has stopped. Disconnect the electrical connection from the electric motor (006).

  • Page 542: Supply Unit For Pilot Fuel - Tool

    AA00-5555-00AAA-520A-A X72DF Maintenance Manual Supply unit for pilot fuel - remove the pump Turn back 5.0 mm the special nut (003). Make sure that the hydraulic force pushes the coupling-half against the spherical disc (004). Make sure that the coupling-half is loose.
  • Page 543 AA00-5555-00AAA-520A-A X72DF Maintenance Manual Supply unit for pilot fuel - remove the pump Page left intentionally blank - 543 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 544: Supply Unit For Pilot Fuel - Lubricate The Coupling

    AA00-5555-00AAA-913A-A X72DF Maintenance Manual Supply unit for pilot fuel - lubricate the coupling 10.2.2 Supply unit for pilot fuel - lubricate the coupling Periodicity Description Working hours 2250 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 545: Pilot Fuel Supply Unit

    AA00-5555-00AAA-913A-A X72DF Maintenance Manual Supply unit for pilot fuel - lubricate the coupling PROCEDURE Remove the cover (003, Figure 10-3). Remove the two Allen screws (004). Remove the service cover (002). Turn the flange (001) until you see the grease nipple.

  • Page 546: Supply Unit For Pilot Fuel - Install The Pump

    AA00-5555-00AAA-720A-A X72DF Maintenance Manual Supply unit for pilot fuel - install the pump 10.2.3 Supply unit for pilot fuel - install the pump Periodicity Description Working hours 24 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 547: Pilot Fuel Supply Unit - Install

    AA00-5555-00AAA-720A-A X72DF Maintenance Manual Supply unit for pilot fuel - install the pump PROCEDURE Push as far as possible the special nut (003, Figure 10-4) on the shaft of the pilot fuel valve (001). Make sure that the coupling is at 90° to the shaft of the pilot fuel valve.

  • Page 548: Pilot Fuel Supply Unit - Clearances

    AA00-5555-00AAA-720A-A X72DF Maintenance Manual Supply unit for pilot fuel - install the pump Push the flange on the motor shaft until you get a distance of X=3.0 mm. Lock the hubs with an M8 screw (008). Fill the coupling with grease.

  • Page 549: Pilot Fuel Supply Unit - Completion

    AA00-5555-00AAA-720A-A X72DF Maintenance Manual Supply unit for pilot fuel - install the pump Fig 10-6 Pilot fuel supply unit - completion CLOSE UP • None - 549 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 550: Fuel Pump

    AA00-5556-00AAA-520A-A X72DF Maintenance Manual Fuel pump - remove 10.3 Fuel pump 10.3.1 Fuel pump - remove Periodicity Description Working hours 20 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 551 AA00-5556-00AAA-520A-A X72DF Maintenance Manual Fuel pump - remove PROCEDURE Prepare the fuel pump before removal. Make sure that the fuel return valve is open. Close the fuel inlet valve. Make sure that the pressure in the supply unit decreases to zero.
  • Page 552 AA00-5556-00AAA-520A-A X72DF Maintenance Manual Fuel pump - remove Use the two jacking screws to lift the fuel pump until the pin disengages. Attach the cover to the pump cover (005). Use the applicable lifting equipment to lift and move the fuel pump.
  • Page 553 AA00-5556-00AAA-520A-A X72DF Maintenance Manual Fuel pump - remove Page left intentionally blank - 553 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 554: Fuel Pump - Disassemble

    AA00-5556-00AAA-530A-A X72DF Maintenance Manual Fuel pump - disassemble 10.3.2 Fuel pump - disassemble Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 555: Guide Pin Removal

    AA00-5556-00AAA-530A-A X72DF Maintenance Manual Fuel pump - disassemble PROCEDURE To remove the guide pin, do the steps that follow: Attach the fuel pump to the work bench. Make sure that the top of the fuel pump points down. Attach the spindle press (001, Figure 10-8) as shown.

  • Page 556: Guide Piston And Roller Removal

    AA00-5556-00AAA-530A-A X72DF Maintenance Manual Fuel pump - disassemble Fig 10-9 Guide piston and roller removal 00423 Remove the guide piston (004) from the housing. Remove the roller (008) together with the two pressure discs (008) and the bush (007). Remove and discard the O-ring (006).

  • Page 557: Toothed Rack Removal

    AA00-5556-00AAA-530A-A X72DF Maintenance Manual Fuel pump - disassemble Fig 10-10 Toothed rack removal To remove the toothed rack, do the steps that follow: Disassemble the bottom spring carrier (001, Figure 10-10) together with the pump plunger (003). Put the pump plunger (003) in a dry, clean area to prevent damage.

  • Page 558: Pump Cylinder Removal

    AA00-5556-00AAA-530A-A X72DF Maintenance Manual Fuel pump - disassemble Fig 10-11 Pump cylinder removal 00425 To remove the pump cylinder, do the steps that follow: Turn the pump cover (002, Figure 10-11) to point up. Use applicable equipment to hold the pump cover (002) to the work bench.

  • Page 559: Non-Return Valve Removal

    AA00-5556-00AAA-530A-A X72DF Maintenance Manual Fuel pump - disassemble Fig 10-12 Non-return valve removal 00426 To remove the non-return valve, do the steps that follow: Put the two applicable screwdrivers in the nut of the valve block (001, Figure 10-12). NOTE:...

  • Page 560: Fuel Pump - Assemble

    AA00-5556-00AAA-710A-A X72DF Maintenance Manual Fuel pump - assemble 10.3.3 Fuel pump - assemble Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 561: Pump Cylinder Installation

    AA00-5556-00AAA-710A-A X72DF Maintenance Manual Fuel pump - assemble PROCEDURE Clean all parts of the fuel pump. Do a check the condition of all parts. If necessary, replace damaged parts. Replace all O-rings and rod seal rings. Use a low-pressure air supply to make sure that bores in the housings and in the pump...

  • Page 562: Pump Cover Installation

    AA00-5556-00AAA-710A-A X72DF Maintenance Manual Fuel pump - assemble Fig 10-14 Pump cover installation 00428 To assemble the pump cover, do the steps that follow: Make sure that all the joint faces are clean and in a satisfactory condition. Lubricate the O-rings (005, Figure 10-14).

  • Page 563: Toothed Rack Assembly

    AA00-5556-00AAA-710A-A X72DF Maintenance Manual Fuel pump - assemble Fig 10-15 Toothed rack assembly 008 009 00430 To assemble the toothed rack, do the steps that follow: Turn the fuel pump until the pump cover (004, Figure 10-15) points down. Attach the top housing (002) to the work bench.

  • Page 564: Pump Plunger And Bottom Housing Assembly

    AA00-5556-00AAA-710A-A X72DF Maintenance Manual Fuel pump - assemble Fig 10-16 Pump plunger and bottom housing assembly 00430 To assemble the pump plunger and bottom housing, do the steps that follow: Install the top spring carrier (005, Figure 10-16) and the compression spring (002).

  • Page 565: Plunger Position Check

    AA00-5556-00AAA-710A-A X72DF Maintenance Manual Fuel pump - assemble Fig 10-17 Plunger position check I - I 00431 To do a check the plunger position, do the steps that follow: 10.1 Move the toothed rack (002, Figure 10-17) to the position shown.
  • Page 566 AA00-5556-00AAA-710A-A X72DF Maintenance Manual Fuel pump - assemble 10.3 Remove the screw plug (not shown) from the check bore (004). 10.4 Install fully the gauge (001) into the check bore (004). 10.5 Remove the spacer (003). 10.6 Make sure the toothed rack (002) cannot move. If the toothed rack cannot move, the pump plunger is correctly installed.
  • Page 567 AA00-5556-00AAA-710A-A X72DF Maintenance Manual Fuel pump - assemble Page left intentionally blank - 567 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 568: Fuel Pump - Install

    AA00-5556-00AAA-720A-A X72DF Maintenance Manual Fuel pump - install 10.3.4 Fuel pump - install Periodicity Description Working hours 20 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 569: Fuel Pump Installation

    AA00-5556-00AAA-720A-A X72DF Maintenance Manual Fuel pump - install PROCEDURE Clean the seating surfaces of the supply unit housing and the fuel pump. Make sure that these seating surfaces are in a satisfactory condition. Lubricate the guide parts. Fig 10-18 Fuel pump installation...
  • Page 570 AA00-5556-00AAA-720A-A X72DF Maintenance Manual Fuel pump - install Operate the turning gear to move the cam. Make sure that there are no leaks or an unusual temperature increase. CLOSE UP • None - 570 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 572: Fuel Pump - Do A Test Of The Operation

    AA00-5556-00AAA-320A-A X72DF Maintenance Manual Fuel pump - do a test of the operation 10.3.5 Fuel pump - do a test of the operation Periodicity Description Working hours 6000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 573: Fuel Pump - Oil Flow

    AA00-5556-00AAA-320A-A X72DF Maintenance Manual Fuel pump - do a test of the operation PROCEDURE Operate the turning gear to move the roller of the related fuel pump to its highest position (TDC). NOTE: The oil flows through the throttle (001,...
  • Page 574 AA00-5556-00AAA-320A-A X72DF Maintenance Manual Fuel pump - do a test of the operation CLOSE UP • None - 574 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 576: Fuel Pump Actuator

    AA00-5583-00AAA-273A-A X72DF Maintenance Manual Fuel pump actuator - calibrate 10.4 Fuel pump actuator 10.4.1 Fuel pump actuator - calibrate Periodicity Description Working hours 24 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 577: Calibration Illustration

    AA00-5583-00AAA-273A-A X72DF Maintenance Manual Fuel pump actuator - calibrate PROCEDURE Turn the power supply of E85 “off”. Remove the top cover from the actuator terminal box. Make sure that no particles or liquids enter the box. Put a bridging wire between terminals 6 and 35. See number 1 in Figure 10-20 Put a bridging wire between terminals 5 and 43.
  • Page 578 AA00-5583-00AAA-273A-A X72DF Maintenance Manual Fuel pump actuator - calibrate CLOSE UP • None - 578 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 579 AA00-5583-00AAA-273A-A X72DF Maintenance Manual Fuel pump actuator - calibrate Page left intentionally blank - 579 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 580: Fuel Pump Actuator - Adjust

    AA00-5583-00AAA-360A-A X72DF Maintenance Manual Fuel pump actuator - adjust 10.4.2 Fuel pump actuator - adjust Periodicity Description Working hours 24 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 581: Actuator - Adjust

    AA00-5583-00AAA-360A-A X72DF Maintenance Manual Fuel pump actuator - adjust PROCEDURE Make sure that the power supply to the fuel pump actuator is set to OFF in E85. Disconnect the connecting element (001, Figure 10-21) from the lever (002). Put the lever (002) in position on the shaft (003).

  • Page 582: Actuator - Adjust -2

    AA00-5583-00AAA-360A-A X72DF Maintenance Manual Fuel pump actuator - adjust Fig 10-22 Actuator - adjust -2 CLOSE UP • None - 582 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 583 AA00-5583-00AAA-360A-A X72DF Maintenance Manual Fuel pump actuator - adjust Page left intentionally blank - 583 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 584: Fuel Pressure Control Valve

    AA00-5562-00AAA-520A-A X72DF Maintenance Manual Fuel rail - remove the pressure control valve 10.5 Fuel pressure control valve 10.5.1 Fuel rail - remove the pressure control valve Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 585: Pressure Control Valve - Remove

    AA00-5562-00AAA-520A-A X72DF Maintenance Manual Fuel rail - remove the pressure control valve PROCEDURE Loosen the angle union (006, Figure 10-23). Remove the fuel return pipe (005) from the pressure control valve (PCV) (001). Disconnect the electrical connection from the solenoid valve (009).

  • Page 586: Fuel Rail - Do A Check Of The Pressure Control Valve

    AA00-5562-00AAA-360A-A X72DF Maintenance Manual Fuel rail - do a check of the pressure control valve 10.5.2 Fuel rail - do a check of the pressure control valve Periodicity Description Working hours 6000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 587: Pcv - Do A Check

    AA00-5562-00AAA-360A-A X72DF Maintenance Manual Fuel rail - do a check of the pressure control valve PROCEDURE Prepare the equipment as follows: Make sure that the work area is clean. Put protection (010, Figure 10-24) around the PCV test block (009).
  • Page 588 AA00-5562-00AAA-360A-A X72DF Maintenance Manual Fuel rail - do a check of the pressure control valve Do a check for leaks. NOTE: If oil flows into the groove (011), the PCV has a leak, or the O-ring in the test block (009) has damage.
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  • Page 590: Fuel Rail - Install The Pressure Control Valve

    AA00-5562-00AAA-720A-A X72DF Maintenance Manual Fuel rail - install the pressure control valve 10.5.3 Fuel rail - install the pressure control valve Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 591: Pressure Control Valve - Install

    AA00-5562-00AAA-720A-A X72DF Maintenance Manual Fuel rail - install the pressure control valve PROCEDURE Remove the protection from the valve block (003, Figure 10-25). Do a check of the lip seal (002). If necessary replace the lip seal. Make sure that the sealing surfaces of the PCV (001) and of the valve block (003) are clean and have no damage.

  • Page 592: Fuel Overpressure Safety Valve

    AA00-5562-01AAA-520A-A X72DF Maintenance Manual Fuel rail - remove the overpressure safety valve 10.6 Fuel overpressure safety valve 10.6.1 Fuel rail - remove the overpressure safety valve Periodicity Description Working hours 30 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 593 AA00-5562-01AAA-520A-A X72DF Maintenance Manual Fuel rail - remove the overpressure safety valve PROCEDURE Use the socket wrench to remove the relief valve (001, Figure 10-26) from the connecting piece (004) on the fuel rail (005). NOTE: The two bores (002) identify the relief valve (001) as a new item.

  • Page 594: Fuel Rail - Do A Check Of The Overpressure Safety Valve

    AA00-5562-01AAA-360A-A X72DF Maintenance Manual Fuel rail - do a check of the overpressure safety valve 10.6.2 Fuel rail - do a check of the overpressure safety valve Periodicity Description Working hours 30 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 595 Remove the overpressure safety valve (003) from the valve holder (002). Record the results in the Inspection Report. NOTE: Unserviceable overpressure safety valves must be sent to the manufacturer, or a WinGD authorized repair workshop for inspection and repair. - 595 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 596: Fuel Overpressure Safety Valve - Pressure Check

    AA00-5562-01AAA-360A-A X72DF Maintenance Manual Fuel rail - do a check of the overpressure safety valve Fig 10-27 Fuel overpressure safety valve - pressure check 00827 CLOSE UP • None - 596 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 598: Fuel Rail - Install The Overpressure Safety Valve

    AA00-5562-01AAA-720A-A X72DF Maintenance Manual Fuel rail - install the overpressure safety valve 10.6.3 Fuel rail - install the overpressure safety valve Periodicity Description Working hours 30 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 599: Fuel Overpressure Safety Valve - Installation

    AA00-5562-01AAA-720A-A X72DF Maintenance Manual Fuel rail - install the overpressure safety valve PROCEDURE Apply Never-Seez NSBT-8 to the thread of valve housing (002, Figure 10-28). Put the relief valve (001) in the connecting piece (004) of the fuel rail (003).

  • Page 600: Flow Limiting Valve

    AA00-5565-00AAA-281A-A X72DF Maintenance Manual Flow limiting valve - do an inspection 10.7 Flow limiting valve 10.7.1 Flow limiting valve - do an inspection Periodicity Description Working hours 12000 (if MGO is used) Working hours 6000 (if other fuel is used) Duration for performing preliminary requirements 0.0 man-hours...

  • Page 601: Flow Limiting Valve - Inspection

    AA00-5565-00AAA-281A-A X72DF Maintenance Manual Flow limiting valve - do an inspection PROCEDURE Make sure that the pressure in the fuel rail is zero. Remove the fuel leakage pipe. Remove the Allen screws (003) and the cover (004) from the flange (005).
  • Page 602 AA00-5565-00AAA-281A-A X72DF Maintenance Manual Flow limiting valve - do an inspection CLOSE UP • None - 602 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 604: Flow Limiting Valve - Remove

    AA00-5565-00AAA-520A-A X72DF Maintenance Manual Flow limiting valve - remove 10.7.2 Flow limiting valve - remove Periodicity Description Working hours 48 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 605 AA00-5565-00AAA-520A-A X72DF Maintenance Manual Flow limiting valve - remove PROCEDURE Make sure that the pressure in the fuel rail is zero. Prepare the flow limiting valve (FLV) for removal. Clean the work area adjacent to the FLV. Remove the HP fuel pipes.
  • Page 606 AA00-5565-00AAA-520A-A X72DF Maintenance Manual Flow limiting valve - remove If it is necessary to disassemble the flange (005, Figure 10-31) and the piston rod (008), do as follows: Remove the Allen screws (003) and the cover (004) from the flange (005).
  • Page 607 AA00-5565-00AAA-520A-A X72DF Maintenance Manual Flow limiting valve - remove Page left intentionally blank - 607 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 608: Flow Limiting Valve - Install

    AA00-5565-00AAA-720A-A X72DF Maintenance Manual Flow limiting valve - install 10.7.3 Flow limiting valve - install Periodicity Description Working hours 48 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 609: Flow Limiting Valve - Install The Flange

    AA00-5565-00AAA-720A-A X72DF Maintenance Manual Flow limiting valve - install PROCEDURE If it is necessary to assemble the flange (005, Figure 10-32) and the piston rod (008), do as follows: NOTE: If possible do this step with the FLV in vertical position.
  • Page 610 AA00-5565-00AAA-720A-A X72DF Maintenance Manual Flow limiting valve - install Turn over the valve block (001, Figure 10-33). Clean the sealing surface in the valve block (001). Put the new lip seal (003) into the valve block (001). Turn over the valve block (001).

  • Page 611: Flow Limiting Valve And Fuel Rail

    AA00-5565-00AAA-720A-A X72DF Maintenance Manual Flow limiting valve - install Install the leakage pipes (002 and 003, Figure 10-34) to the flow limiting valve (004). Fig 10-34 Flow limiting valve and fuel rail Note: Some parts can look different. WCH03227 00505 Install the HP fuel pipes (001), refer to section 13.3.4 HP fuel pipe (fuel rail to injection...

  • Page 612: Exhaust Valve Control Unit

    AA00-5612-00AAA-520A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - remove 10.8 Exhaust valve control unit 10.8.1 Exhaust valve control unit (VCU) - remove Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 613: Exhaust Valve Control Unit - Remove

    AA00-5612-00AAA-520A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - remove PROCEDURE If the valve control unit (VCU) to be removed is adjacent to the driving end of the servo oil rail, remove the HP hose (003, Figure 10-35) from the VCU (006).

  • Page 614: Exhaust Valve Control Unit (Vcu) - Disassemble

    AA00-5612-00AAA-530A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - disassemble 10.8.2 Exhaust valve control unit (VCU) - disassemble Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 615: Exhaust Valve Control Unit - Disassemble/Assemble

    AA00-5612-00AAA-530A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - disassemble PROCEDURE Remove the pan head screw (007, Figure 10-36). Fig 10-36 Exhaust valve control unit - disassemble/assemble FLUSH 00401 Remove the plug (008). Remove and discard the O-ring (006) and the back-up ring (005).

  • Page 616: Exhaust Valve Control Unit (Vcu) - Assemble

    AA00-5612-00AAA-710A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - assemble 10.8.3 Exhaust valve control unit (VCU) - assemble Periodicity Description Working hours 18 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 617 AA00-5612-00AAA-710A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - assemble PROCEDURE Put a new oil filter (001, Figure 10-37) in the valve block (010). If necessary, put a new seal (004) on the filter holder (002). Apply oil to the thread of the filter holder (002).

  • Page 618: Exhaust Valve Control Unit (Vcu) - Install

    AA00-5612-00AAA-720A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - install 10.8.4 Exhaust valve control unit (VCU) - install Periodicity Description Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 619: Exhaust Valve Control Unit - Install

    AA00-5612-00AAA-720A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - install PROCEDURE If the exhaust valve control unit (VCU) is a new item, carefully remove it from its package. Use oil to clean the VCU (005, Figure 10-38). Remove the blanks from the ports in the VCU (005).

  • Page 620: Distance X For Vcu

    AA00-5612-00AAA-720A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - install Make sure that the distance X (Figure 10-39) between the washer (001) and the holder (002) is in the correct range, refer to Table 10-1 - Distance X for VCU.
  • Page 621 AA00-5612-00AAA-720A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - install CLOSE UP • None - 621 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 622 AA00-5612-00AAA-720A-A X72DF Maintenance Manual Exhaust valve control unit (VCU) - install Page left intentionally blank - 622 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 623: 11 Group 6 - Scavenge Air Components

    X72DF Maintenance Manual 11 Group 6 - Scavenge air components 11.1 Scavenge air receiver 11.1.1 Scavenge air receiver - examine........

  • Page 624: Scavenge Air Receiver

    AA00-6420-00AAA-310A-A X72DF Maintenance Manual Scavenge air receiver - examine 11.1 Scavenge air receiver 11.1.1 Scavenge air receiver - examine Periodicity Description Working hours 5000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 625 AA00-6420-00AAA-310A-A X72DF Maintenance Manual Scavenge air receiver - examine PROCEDURE Open the covers (002 and 003, Figure 11-1). Lock the covers (002, 003) in position with the pins (001, (004). Clean the scavenge air receiver. - 625 - Issue 002 2020-10...

  • Page 626: Scavenge Air Receiver - Visual Examination

    AA00-6420-00AAA-310A-A X72DF Maintenance Manual Scavenge air receiver - examine Fig 11-1 Scavenge air receiver - visual examination 00859 If necessary clean the filters (007) and the drain pipes (005, 006). Make sure that the flaps (010) have no dirt or damage, and have free movement. If necessary, clean the flaps.

  • Page 627: Level Switches And Filters

    AA00-6420-00AAA-310A-A X72DF Maintenance Manual Scavenge air receiver - examine NOTE: If necessary, replace the flaps, refer to the related procedures. Remove the pins (001 and 004, Figure 11-1) from the locked position. Close the covers (002, 003). Put the pins (001, 004) in their stowage positions.

  • Page 628: Scavenge Air Receiver - Do A Check Of The Relief Valve

    AA00-6420-00AAA-360A-A X72DF Maintenance Manual Scavenge air receiver - do a check of the relief valve 11.1.2 Scavenge air receiver - do a check of the relief valve Periodicity Description Unscheduled During each engine overhaul Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 629 AA00-6420-00AAA-360A-A X72DF Maintenance Manual Scavenge air receiver - do a check of the relief valve PROCEDURE Do a visual check for damage and corrosion. If necessary, replace the relief valve (001, Figure 11-3). Make sure that there is a clearance (Y) between the flange (004) and the seal plate (003), thus the O-ring (005) is serviceable.

  • Page 630: Scavenge Air Receiver - Remove The Flaps

    AA00-6420-00AAA-520A-A X72DF Maintenance Manual Scavenge air receiver - remove the flaps 11.1.3 Scavenge air receiver - remove the flaps Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 631: Flaps - Remove

    AA00-6420-00AAA-520A-A X72DF Maintenance Manual Scavenge air receiver - remove the flaps PROCEDURE Remove the screws (010, Figure 11-4) and the tab washers (011). Remove the two flat bars (002, 003) and the stop plate (009). Remove the screw (008) and the tab washer (007).

  • Page 632: Scavenge Air Receiver - Install The Flaps

    AA00-6420-00AAA-720A-A X72DF Maintenance Manual Scavenge air receiver - install the flaps 11.1.4 Scavenge air receiver - install the flaps Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 633: Flaps - Install

    AA00-6420-00AAA-720A-A X72DF Maintenance Manual Scavenge air receiver - install the flaps PROCEDURE Put the guide (006), distance ring (005), shaft (004), and the flap (001) in position (Figure 11-5). Put the flat bar (003), stop plate (009), flat bar (002) new tab washers (011), and screws (010) in position.

  • Page 634: Auxiliary Blower

    AA00-6545-00AAA-520A-A X72DF Maintenance Manual Auxiliary blower - remove 11.2 Auxiliary blower 11.2.1 Auxiliary blower - remove Periodicity Description Working hours 30 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 635: Electric Motor (Driving End) - Move

    AA00-6545-00AAA-520A-A X72DF Maintenance Manual Auxiliary blower - remove PROCEDURE Driving end Step 1.1 Step 1.26 for the electric motor at the driving end: Disconnect the electrical connection from the electric motor. Attach the shackle (WLL 8500 kg) (009, Figure 11-6) to the strut (008).

  • Page 636: Electric Motor (Driving End) - Remove

    AA00-6545-00AAA-520A-A X72DF Maintenance Manual Auxiliary blower - remove 1.16 Attach the (003) to the trolley (002). 1.17 Attach the spur-geared chain-block (004) to the shackle (003) and the slings. 1.18 Operate the chain block (007) to hold the weight of the electric motor (005).

  • Page 637: Electric Motor (Free End) - Move

    AA00-6545-00AAA-520A-A X72DF Maintenance Manual Auxiliary blower - remove Operate the chain blocks (004, 009) to hold the weight of the electric motor. Remove the four nuts, bolts and eight washers (006) from the support. Remove the screws from the flange (006).
  • Page 638 AA00-6545-00AAA-520A-A X72DF Maintenance Manual Auxiliary blower - remove 2.25 Operate the engine room crane to move the electric motor (004) to an applicable surface. Fig 11-9 Auxiliary blower - remove CLOSE UP • None - 638 - Issue 002 2020-10...
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  • Page 640: Auxiliary Blower - Install

    AA00-6545-00AAA-720A-A X72DF Maintenance Manual Auxiliary blower - install 11.2.2 Auxiliary blower - install Periodicity Description Working hours 30 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 641 AA00-6545-00AAA-720A-A X72DF Maintenance Manual Auxiliary blower - install PROCEDURE Electric motor - free end Step 1.1 Step 1.28 to install the applicable electric motor at the free end: Attach the two slings (003, Figure 11-10) to the electric motor (004) and the shackle on the lifting tool (002).

  • Page 642: Auxiliary Blower - Move

    AA00-6545-00AAA-720A-A X72DF Maintenance Manual Auxiliary blower - install Fig 11-10 Auxiliary blower - move 1.20 Make sure that the shackle (003, Figure 11-11) is attached to the strut (002). 1.21 Attach the spur-geared chain block (004) to the shackle (003) and the lifting tool (009).

  • Page 643: Electric Motor (Free End) - Install

    AA00-6545-00AAA-720A-A X72DF Maintenance Manual Auxiliary blower - install Fig 11-11 Electric motor (free end) - install 00867 Electric motor - driving end Step 2.1 Step 2.22 for the electric motor (006, Figure 11-12) at the driving end: Attach the two slings (005) to the electric motor (006).

  • Page 644: Auxiliary Blower (Driving End) Move

    AA00-6545-00AAA-720A-A X72DF Maintenance Manual Auxiliary blower - install Fig 11-12 Auxiliary blower (driving end) move 2.17 Attach the shackle (002, Figure 11-13) to the strut (001). 2.18 Attach the spur-geared chain block (003) to the shackle (002) and the two slings (007).

  • Page 645: Electric Motor (Driving End) - Install

    AA00-6545-00AAA-720A-A X72DF Maintenance Manual Auxiliary blower - install Fig 11-13 Electric motor (driving end) - install 00865 On the control panel set to ON the auxiliary blower, refer to the Operation Manual. Make sure that the electric motor operates in the correct direction.

  • Page 646: Scavenge Air Cooler

    AA00-6606-00AAA-520A-A X72DF Maintenance Manual Scavenge air cooler - remove 11.3 Scavenge air cooler 11.3.1 Scavenge air cooler - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 647 AA00-6606-00AAA-520A-A X72DF Maintenance Manual Scavenge air cooler - remove PRELIMINARY OPERATIONS • The engine must be stopped and made safe for maintenance, refer to section 4.1 Do maintenance work - general procedure - 647 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 648: Scavenge Air Cooler (Example) - Prepare

    AA00-6606-00AAA-520A-A X72DF Maintenance Manual Scavenge air cooler - remove PROCEDURE Prepare the scavenge air cooler (SAC) for removal. NOTE: Related to the engine you first have to remove the adjacent SAC to make free the way. All pictures are examples.
  • Page 649 AA00-6606-00AAA-520A-A X72DF Maintenance Manual Scavenge air cooler - remove Prepare the expansion (front) side of the SAC for removal. If applicable, remove the two rollers (002, Figure 11-15). Remove the flange (003). Remove and discard the O-ring (005). Attach three swivel lugs (008).
  • Page 650 AA00-6606-00AAA-520A-A X72DF Maintenance Manual Scavenge air cooler - remove Prepare the fixed (rear) side of the SAC for removal. If applicable, install the two rollers (002, Figure 11-16). Remove the clamps (009), the collar (010) and the flange (008). Remove and discard the O-ring (011).
  • Page 651 AA00-6606-00AAA-520A-A X72DF Maintenance Manual Scavenge air cooler - remove Pull out the SAC from the receiver. Attach the lever chain hoist (010, Figure 11-17) to the chain (004) and to an applicable point on the engine room wall. Operate the lever chain hoist to pull the SAC a small distance.
  • Page 652 AA00-6606-00AAA-520A-A X72DF Maintenance Manual Scavenge air cooler - remove Put down the SAC to the stowage position. Operate the equipment until the SAC is clear of the supports (008, Figure 11-18). Operate the equipment until the SAC is in the correct position.
  • Page 653 AA00-6606-00AAA-520A-A X72DF Maintenance Manual Scavenge air cooler - remove Page left intentionally blank - 653 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 654: Scavenge Air Cooler - Install

    AA00-6606-00AAA-720A-A X72DF Maintenance Manual Scavenge air cooler - install 11.3.2 Scavenge air cooler - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 655 AA00-6606-00AAA-720A-A X72DF Maintenance Manual Scavenge air cooler - install PRELIMINARY OPERATIONS • The engine must be stopped and made safe for maintenance, refer to section 4.1 Do maintenance work - general procedure - 655 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 656: Scavenge Air Cooler (Example) - Prepare For Installation

    AA00-6606-00AAA-720A-A X72DF Maintenance Manual Scavenge air cooler - install PROCEDURE Prepare the SAC for installation. Make sure that all the applicable surfaces of the SAC and the related surfaces in the receiver are clean and have no damage. Apply a layer of silicon compound to each side of the SAC and the related surfaces in the receiver housing.

  • Page 657: Scavenge Air Cooler (Example) - Follow Up Front And Rear Side

    AA00-6606-00AAA-720A-A X72DF Maintenance Manual Scavenge air cooler - install Follow up the fixed (rear) side and the expansion (front) side. Put new O-rings (011, Figure 11-20) in position. Put the collars (011) in position. Attach the flanges (008) and the clamps (009).

  • Page 658: Water Separator

    AA00-6708-00AAA-520A-A X72DF Maintenance Manual Water separator - remove 11.4 Water separator 11.4.1 Water separator - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 659: Water Separator - View 1

    AA00-6708-00AAA-520A-A X72DF Maintenance Manual Water separator - remove PROCEDURE Fig 11-21 Water separator - view 1 00445 Remove the front cover (001, Figure 11-21) from the housing of the water separator. - 659 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 660: Water Separator - View 2

    AA00-6708-00AAA-520A-A X72DF Maintenance Manual Water separator - remove Fig 11-22 Water separator - view 2 00446 Install the lifting tool (001, Figure 11-22) to the front of the water separator. Install the disassembly tool (003) to the housing of the receiver.

  • Page 661: Water Separator - View 3

    AA00-6708-00AAA-520A-A X72DF Maintenance Manual Water separator - remove Fig 11-23 Water separator - view 3 00447 Operate the lever chain hoist (001, Figure 11-23) until you can see the bores in the middle of the top side of the water separator.

  • Page 662: Water Separator - View 4

    AA00-6708-00AAA-520A-A X72DF Maintenance Manual Water separator - remove Fig 11-24 Water separator - view 4 00448 Continue to move out the water separator with the lever chain hoist (001) and the spur- geared chain block (003) until the water separator is fully out of the casing.

  • Page 663: Water Separator - View 5

    AA00-6708-00AAA-520A-A X72DF Maintenance Manual Water separator - remove Fig 11-25 Water separator - view 5 00449 Put the spur-geared chain block (001, Figure 11-25) into the middle hole of the lifting tool. Move the water separator until it hangs vertical to the spur-geared chain block (001).

  • Page 664: Water Separator - Install

    AA00-6708-00AAA-720A-A X72DF Maintenance Manual Water separator - install 11.4.2 Water separator - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 665: Water Separator - View 6

    AA00-6708-00AAA-720A-A X72DF Maintenance Manual Water separator - install PROCEDURE Fig 11-26 Water separator - view 6 00500 Remove the rear cover from the housing of the water separator. Install the holder (001, Figure 11-26) to the housing. Put the lever chain hoist (002) into the holder (001).

  • Page 666: Water Separator - View 7

    AA00-6708-00AAA-720A-A X72DF Maintenance Manual Water separator - install Fig 11-27 Water separator - view 7 00501 Put the water separator (003, Figure 11-27) with the spur-geared chain block (001) in front of the opening. Make sure that the water separator (003) is in the correct position.
  • Page 667 AA00-6708-00AAA-720A-A X72DF Maintenance Manual Water separator - install Fig 11-28 Water separator - view 8 00452 Remove the lifting tool (003, Figure 11-28) from the top of the water separator (004) and attach it to the front of the water separator (004).
  • Page 668 AA00-6708-00AAA-720A-A X72DF Maintenance Manual Water separator - install Fig 11-29 Water separator - view 9 Remove the lever chain hoist (003, Figure 11-29), the lifting tool (001) and the holder (002). Remove all chain blocks and tools. Attach the covers to the water separator.

  • Page 669: Group 7 - Cylinder Lubrication And Balancer

    X72DF Maintenance Manual 12 Group 7 - Cylinder lubrication and balancer 12.1 Cylinder lubrication system 12.1.1 Cylinder lubrication system - do a functional test......

  • Page 670: Cylinder Lubrication System

    AA00-7218-00AAA-340A-A X72DF Maintenance Manual Cylinder lubrication system - do a functional test 12.1 Cylinder lubrication system 12.1.1 Cylinder lubrication system - do a functional test Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 671 AA00-7218-00AAA-340A-A X72DF Maintenance Manual Cylinder lubrication system - do a functional test PROCEDURE Make sure that the turning gear is engaged. Operate the turning gear to get the piston of the first cylinder to the TDC position. On the local control panel, get the cylinder lubrication page.

  • Page 672: Cylinder Lubrication System - Bleed

    AA00-7218-00AAA-231A-A X72DF Maintenance Manual Cylinder lubrication system - bleed 12.1.2 Cylinder lubrication system - bleed Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 673 AA00-7218-00AAA-231A-A X72DF Maintenance Manual Cylinder lubrication system - bleed PROCEDURE Bleed the cylinder lubricating pump as follows: NOTE: When you bleed the cylinder lubricating system, always start at the first cylinder at the free end. The hydrostatic pressure in the cylinder lubricating...
  • Page 674 AA00-7218-00AAA-231A-A X72DF Maintenance Manual Cylinder lubrication system - bleed Fig 12-2 Cylinder lubrication system - bleed - 674 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 675 AA00-7218-00AAA-231A-A X72DF Maintenance Manual Cylinder lubrication system - bleed CLOSE UP • None - 675 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 676: Cylinder Lubricating Pump - Remove

    AA00-7206-00AAA-520A-A X72DF Maintenance Manual Cylinder lubricating pump - remove 12.1.3 Cylinder lubricating pump - remove Periodicity Description Working hours 45 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 677 AA00-7206-00AAA-520A-A X72DF Maintenance Manual Cylinder lubricating pump - remove PROCEDURE Remove the cover (011, Figure 12-3) from the rail unit for access. NOTE: The figure is for MK-E pump. For MK-1 pump the pump and the pipes are partly different.
  • Page 678 AA00-7206-00AAA-520A-A X72DF Maintenance Manual Cylinder lubricating pump - remove Fig 12-3 Cylinder lubricating pump (MK-E, example) - remove CLOSE UP • None - 678 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 679 AA00-7206-00AAA-520A-A X72DF Maintenance Manual Cylinder lubricating pump - remove Page left intentionally blank - 679 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 680: Cylinder Lubricating Pump (Mk-1) - Examine

    AA00-7206-00AAA-310A-A X72DF Maintenance Manual Cylinder lubricating pump (MK-1) - examine 12.1.4 Cylinder lubricating pump (MK-1) - examine Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 681 AA00-7206-00AAA-310A-A X72DF Maintenance Manual Cylinder lubricating pump (MK-1) - examine PROCEDURE Examine the cylinder lubricating pump for damage or wear (for example main bore surface, control edges, injection piston) and for leaks. If damage, wear or leaks occur, repair the fault.

  • Page 682: Cylinder Lubricating Pump (Mk-E) - Do A Service

    AA00-7206-00AAA-200A-A X72DF Maintenance Manual Cylinder lubricating pump (MK-E) - do a service 12.1.5 Cylinder lubricating pump (MK-E) - do a service Periodicity Description Working hours 45 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 683 AA00-7206-00AAA-200A-A X72DF Maintenance Manual Cylinder lubricating pump (MK-E) - do a service PROCEDURE Disassemble the cylinder lubricating pump as follows: Remove the solenoid valve (011). Put the cylinder lubricating pump with the air vent screw (010) point down into a vice with soft jaws.
  • Page 684 AA00-7206-00AAA-200A-A X72DF Maintenance Manual Cylinder lubricating pump (MK-E) - do a service Examine the cylinder lubricating pump as follows: Do a check of the tightness of the non return valves (013) as follows: 2.1.1 Blow air trough the non return valves (013) with your mouth.
  • Page 685 AA00-7206-00AAA-200A-A X72DF Maintenance Manual Cylinder lubricating pump (MK-E) - do a service Page left intentionally blank - 685 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 686: Cylinder Lubricating Pump - Install

    AA00-7206-00AAA-720A-A X72DF Maintenance Manual Cylinder lubricating pump - install 12.1.6 Cylinder lubricating pump - install Periodicity Description Working hours 45 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 687 AA00-7206-00AAA-720A-A X72DF Maintenance Manual Cylinder lubricating pump - install PROCEDURE Attach the cylinder lubricating pump (009, Figure 12-5) to the rail unit with the screws (002). NOTE: The figure is for MK-E pump. For MK-1 pump the pump and the pipes are partly different.

  • Page 688: Integrated Electric Balancer (Ielba)

    AA00-7758-00AAA-523A-A X72DF Maintenance Manual Integrated electric balancer - prepare before the bearings removal 12.2 Integrated electric balancer (iELBA) 12.2.1 Integrated electric balancer - prepare before the bearings removal Periodicity Description Working hours 6000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 689 AA00-7758-00AAA-523A-A X72DF Maintenance Manual Integrated electric balancer - prepare before the bearings removal PROCEDURE Make sure that the electric motor (001, Figure 12-6) has stopped. Stop the lubricating oil supply. Close the oil inlet. At driving end, put an oil tray under applicable oil pipe (002).

  • Page 690: Integrated Electric Balancer - Remove The Bearing (Engine Side)

    AA00-7758-00AAA-520A-A X72DF Maintenance Manual Integrated electric balancer - remove the bearing (engine side) 12.2.2 Integrated electric balancer - remove the bearing (engine side) Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 691: Counterweights - Lock

    AA00-7758-00AAA-520A-A X72DF Maintenance Manual Integrated electric balancer - remove the bearing (engine side) PROCEDURE Lock the top and bottom counterweights as follows: Apply lubricating oil to the thread and bottom of the head of the clamping screw (004, Figure 12-7) and the nut (006).

  • Page 692: Bearing - Remove

    AA00-7758-00AAA-520A-A X72DF Maintenance Manual Integrated electric balancer - remove the bearing (engine side) Attach the eye bolt (008, Figure 12-8) to the applicable position in the gallery above the bearing (005). Attach the lever chain hoist to the eye bolt (008).
  • Page 693 AA00-7758-00AAA-520A-A X72DF Maintenance Manual Integrated electric balancer - remove the bearing (engine side) Fig 12-9 Bearing - remove 2 00580 2.10 Move the lifting tool (001) to a position in front of the bearing (007). 2.11 Tighten lightly the screw (004) into the pin (008).

  • Page 694: Integrated Electric Balancer - Remove The Bearing (Outer Side)

    AA00-7758-00AAA-520B-A X72DF Maintenance Manual Integrated electric balancer - remove the bearing (outer side) 12.2.3 Integrated electric balancer - remove the bearing (outer side) Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 695 AA00-7758-00AAA-520B-A X72DF Maintenance Manual Integrated electric balancer - remove the bearing (outer side) PROCEDURE Lock the top and bottom counterweights as follows: Apply lubricating oil to the thread and bottom of the head of the clamping screw (004, Figure 12-10) and the nut (006).

  • Page 696: Outer Bearing - Remove

    AA00-7758-00AAA-520B-A X72DF Maintenance Manual Integrated electric balancer - remove the bearing (outer side) On the outer side, remove the four screws (004, Figure 12-11) from the bearing cover (003). Remove the bearing cover (003). Remove the eight screws (002) from the bearing (001).
  • Page 697 AA00-7758-00AAA-520B-A X72DF Maintenance Manual Integrated electric balancer - remove the bearing (outer side) Fig 12-12 Outer bearing - remove 2 OUTER SIDE 00581 Tighten the nut (003) to push the lifting tool (002) against the pin (005). Put the two M20 x 140 mm screws into the two threaded holes (007) in the bearing (006).

  • Page 698: Integrated Electric Balancer - Do A Check Of The Bearing Clearance

    AA00-7758-00AAA-360A-A X72DF Maintenance Manual Integrated electric balancer - do a check of the bearing clearance 12.2.4 Integrated electric balancer - do a check of the bearing clearance Periodicity Description Working hours 6000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 699: Integrated Electric Balancer - Adjust

    AA00-7758-00AAA-360A-A X72DF Maintenance Manual Integrated electric balancer - do a check of the bearing clearance PROCEDURE Remove the Allen screws (006, Figure 12-13) and the locking plates (010) on the bearing cover (007) at the free end. Fig 12-13 Integrated electric balancer - adjust 00541 Remove the bearing cover (007).
  • Page 700 AA00-7758-00AAA-360A-A X72DF Maintenance Manual Integrated electric balancer - do a check of the bearing clearance Torque symmetrically the Allen screws (006, 002). Lock the Allen screws (006) with the locking plates (010). Install the applicable oil pipe (002, Figure 12-14).
  • Page 701 AA00-7758-00AAA-360A-A X72DF Maintenance Manual Integrated electric balancer - do a check of the bearing clearance Page left intentionally blank - 701 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 702: Integrated Electric Balancer - Adjust The Bearings

    Spare Parts Description Part No. None SAFETY PRECAUTIONS NOTE: It is recommended that you speak to a service partner (for example WinGD) when you do this procedure for the first time. PRELIMINARY OPERATIONS • The engine must be stopped. •...

  • Page 703: Electric Balancer - Adjust Bearings

    AA00-7758-00AAA-271A-A X72DF Maintenance Manual Integrated electric balancer - adjust the bearings PROCEDURE Loosen the bolts (005, 007, 008 and 010) from the bearings (004, 006, 009, 011). NOTE: Loosen only the bearings of the top gear wheel if the backlash of the bottom...
  • Page 704 AA00-7758-00AAA-271A-A X72DF Maintenance Manual Integrated electric balancer - adjust the bearings Fig 12-16 Electric balancer - adjust bearings 2 I - I 15 mm 00575 Turn equally the two screws (008) to lower the top gear wheel (007). Make sure that the gear wheel stays level.
  • Page 705 AA00-7758-00AAA-271A-A X72DF Maintenance Manual Integrated electric balancer - adjust the bearings Page left intentionally blank - 705 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 706: Electric Balancer Sensor Unit - Remove The Proximity Sensor

    AA00-7762-00AAA-520A-A X72DF Maintenance Manual Electric balancer sensor unit - remove the proximity sensor 12.2.6 Electric balancer sensor unit - remove the proximity sensor Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.25 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 707: Proximity Sensor - Remove

    AA00-7762-00AAA-520A-A X72DF Maintenance Manual Electric balancer sensor unit - remove the proximity sensor PROCEDURE Disconnect the electrical connection from the applicable proximity sensor (002, Figure 12-17). Loosen the lock-nut (003). Remove the proximity sensor (002) from the sensor adapter (001).

  • Page 708: Electric Balancer Sensor Unit - Install The Proximity Sensor

    AA00-7762-00AAA-720A-A X72DF Maintenance Manual Electric balancer sensor unit - install the proximity sensor 12.2.7 Electric balancer sensor unit - install the proximity sensor Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 709: Proximity Sensor - Install

    AA00-7762-00AAA-720A-A X72DF Maintenance Manual Electric balancer sensor unit - install the proximity sensor PROCEDURE Put the proximity sensor (002, Figure 12-18) into the sensor adapter (001). Turn the proximity sensor until the end of the proximity sensor is 3.5 ±0.5 mm from the mark (004).

  • Page 710: Integrated Electric Balancer - Do A Check Of The Backlash

    AA00-7758-00AAA-360B-A X72DF Maintenance Manual Integrated electric balancer - do a check of the backlash 12.2.8 Integrated electric balancer - do a check of the backlash Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours...

  • Page 711: Integrated Electric Balancer - Backlash

    AA00-7758-00AAA-360B-A X72DF Maintenance Manual Integrated electric balancer - do a check of the backlash PROCEDURE On the outer side, remove the 10 screws (011, Figure 12-19) and the cover (010). On the outer side, remove the four screws (007) and the bottom bearing cover (008).
  • Page 712 AA00-7758-00AAA-360B-A X72DF Maintenance Manual Integrated electric balancer - do a check of the backlash CLOSE UP • None - 712 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 714: Integrated Electric Balancer - Install The Bearing (Engine Side)

    AA00-7758-00AAA-720A-A X72DF Maintenance Manual Integrated electric balancer - install the bearing (engine side) 12.2.9 Integrated electric balancer - install the bearing (engine side) Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 715: Bearing - Install

    AA00-7758-00AAA-720A-A X72DF Maintenance Manual Integrated electric balancer - install the bearing (engine side) PROCEDURE Make sure that the new bearing (007, Figure 12-20) is clean, dry and in good condition. Apply Molykote D to the bearing surface. Attach the lifting tool (003) to the bearing (007).

  • Page 716: Integrated Electric Balancer - Install The Bearing (Outer Side)

    AA00-7758-00AAA-720B-A X72DF Maintenance Manual Integrated electric balancer - install the bearing (outer side) 12.2.10 Integrated electric balancer - install the bearing (outer side) Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 717: Outer Bearing - Install

    AA00-7758-00AAA-720B-A X72DF Maintenance Manual Integrated electric balancer - install the bearing (outer side) PROCEDURE Make sure that the new bearing (002, Figure 12-21) is clean, dry and in good condition. Fig 12-21 Outer bearing - install OUTER SIDE Molykote D...
  • Page 718 AA00-7758-00AAA-720B-A X72DF Maintenance Manual Integrated electric balancer - install the bearing (outer side) CLOSE UP • None - 718 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 719: 13 Group 8 - Pipes

    X72DF Maintenance Manual 13 Group 8 - Pipes 13.1 HP servo oil pipe 13.1.1 HP servo oil pipe - remove......... . .

  • Page 720: Hp Servo Oil Pipe

    AA00-8447-00AAA-520A-A X72DF Maintenance Manual HP servo oil pipe - remove 13.1 HP servo oil pipe 13.1.1 HP servo oil pipe - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 721 AA00-8447-00AAA-520A-A X72DF Maintenance Manual HP servo oil pipe - remove PROCEDURE Put an oil tray under the applicable servo oil pump (002, Figure 13-1). Remove the stirrup bolts (001, 003) from the applicable HP servo oil pipe. Loosen the screw plug (022) to drain the applicable HP servo oil pipes (007, 018, 019).

  • Page 722: Servo Oil Pipes - Remove

    AA00-8447-00AAA-520A-A X72DF Maintenance Manual HP servo oil pipe - remove Fig 13-1 Servo oil pipes - remove - 722 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 723 AA00-8447-00AAA-520A-A X72DF Maintenance Manual HP servo oil pipe - remove CLOSE UP • None - 723 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 724: Hp Servo Oil Pipe - Grind The Sealing Face

    AA00-8447-00AAA-655A-A X72DF Maintenance Manual HP servo oil pipe - grind the sealing face 13.1.2 HP servo oil pipe - grind the sealing face Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 725: Distance X For Hp Servo Oil Pipe

    AA00-8447-00AAA-655A-A X72DF Maintenance Manual HP servo oil pipe - grind the sealing face PROCEDURE Remove and discard the O-ring (003, Figure 13-2). Loosen the claw (004). Put an applicable piece of material (for example a cloth) into the opening of the HP servo oil pipe (001).

  • Page 726: Hp Servo Oil Pipe - Grind And Adjust

    AA00-8447-00AAA-655A-A X72DF Maintenance Manual HP servo oil pipe - grind the sealing face Fig 13-2 HP servo oil pipe - grind and adjust X mm 00960 CLOSE UP • None - 726 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 727 AA00-8447-00AAA-655A-A X72DF Maintenance Manual HP servo oil pipe - grind the sealing face Page left intentionally blank - 727 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 728: Hp Servo Oil Pipe - Install

    AA00-8447-00AAA-720A-A X72DF Maintenance Manual HP servo oil pipe - install 13.1.3 HP servo oil pipe - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 729 AA00-8447-00AAA-720A-A X72DF Maintenance Manual HP servo oil pipe - install PROCEDURE Remove all of the protection from the sealing faces (007, 013 and 018, Figure 13-3) of the servo oil pipes and the servo oil pump. Apply oil to the threads of all the Allen screws (005, 008, 010, 015) and the bolts (009).

  • Page 730: Servo Oil Pipes - Install

    AA00-8447-00AAA-720A-A X72DF Maintenance Manual HP servo oil pipe - install Fig 13-3 Servo oil pipes - install - 730 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 731 AA00-8447-00AAA-720A-A X72DF Maintenance Manual HP servo oil pipe - install CLOSE UP • None - 731 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 732: Hydraulic Pipe Exhaust Valve

    AA00-8460-00AAA-520A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - remove 13.2 Hydraulic pipe exhaust valve 13.2.1 Hydraulic pipe exhaust valve - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 733 AA00-8460-00AAA-520A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - remove PROCEDURE Put an oil tray under the applicable hydraulic pipe (004, Figure 13-4). Loosen the screws (008) on the flange (003) to drain the applicable hydraulic pipe (004) through the check bore (006) in the housing of the exhaust valve control unit (VCU) (002).

  • Page 734: Hydraulic Pipe (Exhaust Valve) - Remove

    AA00-8460-00AAA-520A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - remove Fig 13-4 Hydraulic pipe (exhaust valve) - remove I - I II - II 00956 - 734 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 735 AA00-8460-00AAA-520A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - remove CLOSE UP • None - 735 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 736: Hydraulic Pipe Exhaust Valve - Grind The Sealing Face

    AA00-8460-00AAA-655A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - grind the sealing face 13.2.2 Hydraulic pipe exhaust valve - grind the sealing face Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 737 AA00-8460-00AAA-655A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - grind the sealing face PROCEDURE Put the template (001, Figure 13-5) on the back of the emery cloth (002). Use the applicable grade of the emery cloth related to the quantity of metal you want to remove.

  • Page 738: Hydraulic Pipe (Exhaust Valve) - Grind Sealing Face

    AA00-8460-00AAA-655A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - grind the sealing face Fig 13-5 Hydraulic pipe (exhaust valve) - grind sealing face 00957 CLOSE UP • None - 738 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 739 AA00-8460-00AAA-655A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - grind the sealing face Page left intentionally blank - 739 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 740: Hydraulic Pipe Exhaust Valve - Install

    AA00-8460-00AAA-720A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - install 13.2.3 Hydraulic pipe exhaust valve - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 741: Distance X For Hydraulic Pipe Exhaust Valve

    AA00-8460-00AAA-720A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - install PROCEDURE Remove all the protection from the sealing faces in the top housing (001, Figure 13-6) and the exhaust valve control unit (VCU) (002). Put oil on the new O-rings (009) and O-rings (010).
  • Page 742 AA00-8460-00AAA-720A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - install Fig 13-6 Hydraulic pipe (exhaust valve) - install - 742 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 743 AA00-8460-00AAA-720A-A X72DF Maintenance Manual Hydraulic pipe exhaust valve - install CLOSE UP • None - 743 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 744: Hp Fuel Pipe

    AA00-8733-00AAA-523A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - prepare before removal 13.3 HP fuel pipe 13.3.1 HP fuel pipe (fuel rail to injection valve) - prepare before removal Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours...

  • Page 745: Hp Fuel Pipe - Preparation

    AA00-8733-00AAA-523A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - prepare before removal PROCEDURE Step 1.1 Step 1.4 to make sure that there is no pressure in the fuel rail as follows: In the plant, set to OFF the fuel booster pump.

  • Page 746: Hp Fuel Pipe (Fuel Rail To Injection Valve) - Remove

    AA00-8733-00AAA-520A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - remove 13.3.2 HP fuel pipe (fuel rail to injection valve) - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 747: Hp Fuel Pipe - Removal

    AA00-8733-00AAA-520A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - remove PROCEDURE Remove the four screws (008, Figure 13-8) from the flange (007). Remove the four screws (003) from the flange (004). Carefully remove the HP fuel pipe (001) from the injection valve (009) and the and flow limiting valve (005).

  • Page 748: Hp Fuel Pipe (Fuel Rail To Injection Valve) - Grind The Sealing Face

    AA00-8733-00AAA-655A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - grind the sealing face 13.3.3 HP fuel pipe (fuel rail to injection valve) - grind the sealing face Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 749: Hp Fuel Pipe - Grind

    AA00-8733-00AAA-655A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - grind the sealing face PROCEDURE Use the applicable grade of emery paper (005, Figure 13-9) related to the quantity of metal you want to remove. Fig 13-9 HP fuel pipe - grind 3.0 mm...
  • Page 750 AA00-8733-00AAA-655A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - grind the sealing face Make sure that the circular marks around the sealing face (009) of the HP fuel pipe (004) are concentric. Change the emery cloth for a smoother grade, then do...
  • Page 751 AA00-8733-00AAA-655A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - grind the sealing face Page left intentionally blank - 751 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 752: Hp Fuel Pipe (Fuel Rail To Injection Valve) - Install

    AA00-8733-00AAA-720A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - install 13.3.4 HP fuel pipe (fuel rail to injection valve) - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 753: Distances X And Y For Hp Fuel Pipe

    AA00-8733-00AAA-720A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - install PROCEDURE Remove all the protection from the sealing faces, the injection valve and the flow limiting valve. Attach new O-rings to the flanges (002, 006). Apply Never-Seez NSBT to threads of the Allen screws (004 and 008, Figure 13-10).

  • Page 754: Hp Fuel Pipe - Install

    AA00-8733-00AAA-720A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - install Fig 13-10 HP fuel pipe - install Attach the clamp (003, Figure 13-11) to the flat bar (002) with the bolts (004), washers and nuts (005).

  • Page 755: Hp Fuel Pipe - Completion

    AA00-8733-00AAA-720A-A X72DF Maintenance Manual HP fuel pipe (fuel rail to injection valve) - install Fig 13-11 HP fuel pipe - completion I - I 00560 CLOSE UP • None - 755 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 756: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Prepare Before Removal

    AA00-8752-00AAA-523A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - prepare before removal 13.3.5 HP fuel pipe (fuel pump to fuel rail) - prepare before removal Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.25 man-hours...
  • Page 757 AA00-8752-00AAA-523A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - prepare before removal PROCEDURE Set to off the trace heating. If necessary, remove the insulation from the HP fuel pipes (003 and 005, Figure 13-12). If necessary, disconnect the trace heating pipes.

  • Page 758: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Remove

    AA00-8752-00AAA-520A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove 13.3.6 HP fuel pipe (fuel pump to fuel rail) - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 759: Hp Fuel Pipes - Remove And Install

    AA00-8752-00AAA-520A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove PROCEDURE Remove the clamps (015 and 016, Figure 13-13). Remove the four screws (002) from the flange (003). Fig 13-13 HP fuel pipes - remove and install...

  • Page 760: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Grind The Sealing Face

    AA00-8752-00AAA-655A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - grind the sealing face 13.3.7 HP fuel pipe (fuel pump to fuel rail) - grind the sealing face Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 761 AA00-8752-00AAA-655A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - grind the sealing face PROCEDURE Use the applicable grade of emery cloth (005, Figure 13-14) related to the quantity of metal you want to remove. NOTE: To remove the deep notches of more than 0.1 mm, use the emery cloth of medium to coarse grain (30 to 80 CAMI).
  • Page 762 AA00-8752-00AAA-655A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - grind the sealing face Remove the grinding tool (007) from the screw-on sleeve (002). Use a low-pressure air supply to remove unwanted material from the HP fuel pipe (004).
  • Page 763 AA00-8752-00AAA-655A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - grind the sealing face Page left intentionally blank - 763 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 764: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Install

    AA00-8752-00AAA-720A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install 13.3.8 HP fuel pipe (fuel pump to fuel rail) - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 765: Distance X For Hp Fuel Pipe

    AA00-8752-00AAA-720A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install PROCEDURE Attach the O-rings to the applicable HP fuel pipes (002 and 007, Figure 13-15). Remove all of the protection from the sealing faces. Make sure that the claws (001, 004, 006, 010) are correctly attached to the HP fuel pipes (002, 007).

  • Page 766: Hp Fuel Pipes - Adjust

    AA00-8752-00AAA-720A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install Fig 13-15 HP fuel pipes - adjust Apply Never-Seez NSBT to the threads of all the screws (002, 005, 007 and 012, Figure 13-16). - 766 - Issue 002 2020-10 Winterthur Gas &...
  • Page 767 AA00-8752-00AAA-720A-A X72DF Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install Fig 13-16 HP fuel pipes - remove and install I - I DRIVING END FUEL SIDE II - II 00565 Carefully put the HP fuel pipe (008) in position in the fuel pump cover (014) and the intermediate piece (010).

  • Page 768: Hp Pilot Fuel Pipe

    AA00-8790-00AAA-520A-A X72DF Maintenance Manual HP pilot fuel pipe - remove 13.4 HP pilot fuel pipe 13.4.1 HP pilot fuel pipe - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 769 AA00-8790-00AAA-520A-A X72DF Maintenance Manual HP pilot fuel pipe - remove PROCEDURE Make sure that the pilot fuel supply unit (002, Figure 13-17) is set to OFF. Make sure that the pressure in the pilot fuel supply unit is zero. Remove the pilot fuel pipe (005 or 008).

  • Page 770: Pilot Fuel Pipe - Remove

    AA00-8790-00AAA-520A-A X72DF Maintenance Manual HP pilot fuel pipe - remove Fig 13-17 Pilot fuel pipe - remove - 770 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 771 AA00-8790-00AAA-520A-A X72DF Maintenance Manual HP pilot fuel pipe - remove CLOSE UP • None - 771 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 772: Hp Pilot Fuel Pipe - Install

    AA00-8790-00AAA-720A-A X72DF Maintenance Manual HP pilot fuel pipe - install 13.4.2 HP pilot fuel pipe - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 773: Distance X For Pilot Fuel Pipe

    AA00-8790-00AAA-720A-A X72DF Maintenance Manual HP pilot fuel pipe - install PROCEDURE Remove all protection from all openings and sealing faces. Make sure that all sealing faces (004) have no damage. Put a new O-ring (005) and a new O-ring (006) on each end the applicable pilot fuel pipe (001).

  • Page 774: Pilot Fuel Pipe- Prepare

    AA00-8790-00AAA-720A-A X72DF Maintenance Manual HP pilot fuel pipe - install Fig 13-18 Pilot fuel pipe- prepare Install the pilot fuel pipe (004 or 007). Attach the pilot fuel pipe (004 or 007, Figure 13-19) to the distributor block (006) and the pilot injection valve.

  • Page 775: Pilot Fuel Pipe - Install

    AA00-8790-00AAA-720A-A X72DF Maintenance Manual HP pilot fuel pipe - install Fig 13-19 Pilot fuel pipe - install - 775 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 776 AA00-8790-00AAA-720A-A X72DF Maintenance Manual HP pilot fuel pipe - install CLOSE UP • None - 776 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 777: 14 Group 9 - Monitoring Instruments

    X72DF Maintenance Manual 14 Group 9 - Monitoring instruments 14.1 Crank angle sensor unit 14.1.1 Crank angle sensor unit (supply unit) - remove the proximity sensor..14.1.2 Crank angle sensor unit (supply unit) - install the proximity sensor..

  • Page 778: Crank Angle Sensor Unit

    AA00-9223-00AAA-520A-A X72DF Maintenance Manual Crank angle sensor unit (supply unit) - remove the proximity sensor 14.1 Crank angle sensor unit 14.1.1 Crank angle sensor unit (supply unit) - remove the proximity sensor Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours...
  • Page 779 AA00-9223-00AAA-520A-A X72DF Maintenance Manual Crank angle sensor unit (supply unit) - remove the proximity sensor PROCEDURE Operate the turning gear to get a tooth (004, Figure 14-1) of the intermediate wheel opposite the applicable proximity sensor (001). If necessary, put a mark on the applicable cable to identify its position.
  • Page 780 AA00-9223-00AAA-520A-A X72DF Maintenance Manual Crank angle sensor unit (supply unit) - remove the proximity sensor Fig 14-1 Proximity sensor - remove III - III ST5133C ST5136C ST5132C ST5135C ST5131C ST5134C 5131 - 36C 00969 - 780 - Issue 002 2020-10...
  • Page 781 AA00-9223-00AAA-520A-A X72DF Maintenance Manual Crank angle sensor unit (supply unit) - remove the proximity sensor CLOSE UP • None - 781 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 782: Crank Angle Sensor Unit (Supply Unit) - Install The Proximity Sensor

    AA00-9223-00AAA-720A-A X72DF Maintenance Manual Crank angle sensor unit (supply unit) - install the proximity sensor 14.1.2 Crank angle sensor unit (supply unit) - install the proximity sensor Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 783 AA00-9223-00AAA-720A-A X72DF Maintenance Manual Crank angle sensor unit (supply unit) - install the proximity sensor PROCEDURE Attach the proximiy sensor (001, Figure 14-2) to the holder (002). Turn the proximity sensor (001) fully down until the tip of the proximity sensor touches the bottom of the holder (002).
  • Page 784 AA00-9223-00AAA-720A-A X72DF Maintenance Manual Crank angle sensor unit (supply unit) - install the proximity sensor Fig 14-2 Proximity sensor - install III - III -0.2 ST5133C ST5136C ST5132C ST5135C ST5131C ST5134C 5131 - 36C 00970 - 784 - Issue 002 2020-10...
  • Page 785 AA00-9223-00AAA-720A-A X72DF Maintenance Manual Crank angle sensor unit (supply unit) - install the proximity sensor CLOSE UP • None - 785 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 786: Crank Angle Sensor Unit (Flywheel) - Remove The Proximity Sensor

    AA00-9223-00AAA-520B-A X72DF Maintenance Manual Crank angle sensor unit (flywheel) - remove the proximity sensor 14.1.3 Crank angle sensor unit (flywheel) - remove the proximity sensor Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 787 AA00-9223-00AAA-520B-A X72DF Maintenance Manual Crank angle sensor unit (flywheel) - remove the proximity sensor PROCEDURE Operate the turning gear to get the crank angle mark (003, Figure 14-3) of the flywheel (001) opposite the applicable proximity sensor (005). Put a mark on the applicable cable to identify its position.
  • Page 788 AA00-9223-00AAA-520B-A X72DF Maintenance Manual Crank angle sensor unit (flywheel) - remove the proximity sensor Fig 14-3 Proximity sensor (flywheel) - remove 5125C 5124C 00971 - 788 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 789 AA00-9223-00AAA-520B-A X72DF Maintenance Manual Crank angle sensor unit (flywheel) - remove the proximity sensor CLOSE UP • None - 789 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 790: Crank Angle Sensor Unit (Flywheel) - Install The Proximity Sensor

    AA00-9223-00AAA-720B-A X72DF Maintenance Manual Crank angle sensor unit (flywheel) - install the proximity sensor 14.1.4 Crank angle sensor unit (flywheel) - install the proximity sensor Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 791 AA00-9223-00AAA-720B-A X72DF Maintenance Manual Crank angle sensor unit (flywheel) - install the proximity sensor PROCEDURE Attach the proximity sensor (005, Figure 14-4) to the holder (004). Make sure that the proximity sensor (005) touches the crank angle mark (003). Loosen the proximity sensor three full turns (3 x 360°) to get a clearance of 4 -0.2...
  • Page 792 AA00-9223-00AAA-720B-A X72DF Maintenance Manual Crank angle sensor unit (flywheel) - install the proximity sensor Fig 14-4 Proximity sensor (flywheel) - install 5125C 5124C -0.2 00972 - 792 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 793 AA00-9223-00AAA-720B-A X72DF Maintenance Manual Crank angle sensor unit (flywheel) - install the proximity sensor CLOSE UP • None - 793 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 794: Selective Catalytic Reduction System (Scr)

    AA00-9270-02AAA-520A-B X72DF Maintenance Manual SCR - remove the valve 14.2 Selective catalytic reduction system (SCR) 14.2.1 SCR - remove the valve Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 795 AA00-9270-02AAA-520A-B X72DF Maintenance Manual SCR - remove the valve PROCEDURE Stop the SCR system (refer to the Operation Manual). NOTE: The procedure that follows shows the removal of one of the SCR valves. The procedures for the other SCR valves are the same.

  • Page 796: Scr - Install The Valve

    AA00-9270-02AAA-720A-B X72DF Maintenance Manual SCR - install the valve 14.2.2 SCR - install the valve Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 797 AA00-9270-02AAA-720A-B X72DF Maintenance Manual SCR - install the valve PROCEDURE Stop the SCR system (refer to the Operation Manual). NOTE: The procedure that follows shows the installation of one of the SCR valves. The procedures for the other SCR valves are the same.

  • Page 798: Electronic Components

    AA00-9223-00AAA-273A-A X72DF Maintenance Manual Gas detector - calibrate 14.3 Electronic components 14.3.1 Gas detector - calibrate Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 799: Location Of Gas Detectors

    AA00-9223-00AAA-273A-A X72DF Maintenance Manual Gas detector - calibrate PROCEDURE On the gas pipes, close the shut-off valves (not shown). Set to OFF the gas monitor. Disconnect the power supply to the applicable gas detector (001, Figure 14-5). Fig 14-5 Location of gas detectors...

  • Page 800: Gas Detector - Prepare

    AA00-9223-00AAA-273A-A X72DF Maintenance Manual Gas detector - calibrate Fig 14-6 Gas detector - prepare Attach the valve (002, Figure 14-7) to the gas bottle (001). Attach the FKM hose (003) to the connection on the adapter (004) and the valve (002).
  • Page 801 AA00-9223-00AAA-273A-A X72DF Maintenance Manual Gas detector - calibrate Do the calibration procedure and zero point adjustment procedure in accordance with the procedure given in Draeger PIR-7000-pi-9046393. NOTE: For the zero point adjustment and sensitivity calibration, the magnet (005) is necessary.

  • Page 802: Gas Detector - Completion

    AA00-9223-00AAA-273A-A X72DF Maintenance Manual Gas detector - calibrate Fig 14-8 Gas detector - completion - 802 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 803 AA00-9223-00AAA-273A-A X72DF Maintenance Manual Gas detector - calibrate CLOSE UP • None - 803 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 804: Ldu-20 - Remove

    AA00-9606-00AAA-520A-A X72DF Maintenance Manual LDU-20 - remove 14.3.2 LDU-20 - remove Periodicity Description Working hours 66 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 805: Ldu-20 Rear View

    AA00-9606-00AAA-520A-A X72DF Maintenance Manual LDU-20 - remove PROCEDURE To remove a defective LDU-20 in the local control panel do the steps that follow: NOTE: The LDU-20 in the local control panel is the master. Fig 14-9 LDU-20 rear view 00137...
  • Page 806 AA00-9606-00AAA-520A-A X72DF Maintenance Manual LDU-20 - remove Step 1.2 Step 1.11. CLOSE UP • None - 806 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 807 AA00-9606-00AAA-520A-A X72DF Maintenance Manual LDU-20 - remove Page left intentionally blank - 807 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 808: Ldu-20 - Install

    AA00-9606-00AAA-720A-A X72DF Maintenance Manual LDU-20 - install 14.3.3 LDU-20 - install Periodicity Description Working hours 66 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...

  • Page 809: Ldu-20 Rear View

    Approximately five minutes are necessary to do the full start procedure of the LDU-20. 1.11 Do a check to make sure that the LDU-20 operates correctly. If you get an error message, speak to or send a message to WinGD. 1.12 Step 1.1 Step 1.8 to install the spare LDU-20 to the position in the ECR.
  • Page 810 1.15 Do a check to make sure that the LDU-20 operates correctly. If you get an error message, speak to or send a message to WinGD. 1.16 If applicable, start the engine at the remote control system (RCS), refer to the Operation Manual.
  • Page 811 AA00-9606-00AAA-720A-A X72DF Maintenance Manual LDU-20 - install Page left intentionally blank - 811 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 812: Ccm-20 - Remove

    AA00-9606-00ABA-520A-A X72DF Maintenance Manual CCM-20 - remove 14.3.4 CCM-20 - remove Periodicity Description Working hours 66 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 813 Disconnect the power supply to the defective CCM-20 on the related cylinder. NOTE: WinGD recommends to make a software back-up from the LDU-20. This will make sure that the correct configuration is loaded. For more data, speak to or send a message to WinGD.

  • Page 814: Ccm-20 - Install

    AA00-9606-00ABA-720A-A X72DF Maintenance Manual CCM-20 - install 14.3.5 CCM-20 - install Periodicity Description Working hours 66 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 815 AA00-9606-00ABA-720A-A X72DF Maintenance Manual CCM-20 - install PROCEDURE Install the CCM-20. Connect the power supply to the CCM-20. After a reboot of the CCM-20, the ECS activates a software download. NOTE: You can monitor the software download on the LDU-20 at the local control panel.

  • Page 816: Mcm-11 - Remove

    AA00-9606-00ACA-520A-A X72DF Maintenance Manual MCM-11 - remove 14.3.6 MCM-11 - remove Periodicity Description Working hours 66 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 817 Disconnect the power supply to the defective MCM-11 on the related cylinder. NOTE: WinGD recommends to make a software back-up from the LDU-20. This will make sure that the correct configuration is loaded. For more data, speak to or send a message to WinGD.

  • Page 818: Mcm-11 - Install

    AA00-9606-00ACA-720A-A X72DF Maintenance Manual MCM-11 - install 14.3.7 MCM-11 - install Periodicity Description Working hours 66 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 819 AA00-9606-00ACA-720A-A X72DF Maintenance Manual MCM-11 - install PROCEDURE Install the MCM-11. Connect the power supply to the MCM-11. After a reboot of the MCM-11, the ECS activates a software download. NOTE: You can monitor the software download on the MCM-11 at the local control panel.

  • Page 820: Iom-10 - Remove

    AA00-9606-00ADA-520A-A X72DF Maintenance Manual IOM-10 - remove 14.3.8 IOM-10 - remove Periodicity Description Working hours 66 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 821 Disconnect the power supply to the defective IOM-10 on the related cylinder. NOTE: WinGD recommends to make a software back-up from the LDU-20. This will make sure that the correct configuration is loaded. For more data, speak to or send a message to WinGD.

  • Page 822: Iom-10 - Install

    AA00-9606-00ADA-720A-A X72DF Maintenance Manual IOM-10 - install 14.3.9 IOM-10 - install Periodicity Description Working hours 66 000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 823 AA00-9606-00ADA-720A-A X72DF Maintenance Manual IOM-10 - install PROCEDURE Install the IOM-10. Connect the power supply to the IOM-10. After a reboot of the IOM-10, the ECS activates a software download. NOTE: You can monitor the software download on the IOM-10 at the local control panel..
  • Page 824 AA00-9606-00ADA-720A-A X72DF Maintenance Manual IOM-10 - install Page left intentionally blank - 824 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 825: 15 Tools

    X72DF Maintenance Manual 15 Tools 15.1 General for tools............

  • Page 826: General For Tools

    Maintenance Manual General for tools 15.1 General for tools For the maintenance of the engine it is necessary to have the correct tools. WinGD has specified a number of tools in the three groups that follow: • Standard tools Standard tools are general available tools (for example wrenches or pliers) or are specially made for the engine.
  • Page 827 AA00-0000-00AAA-018O-A X72DF Maintenance Manual General for tools Page left intentionally blank - 827 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 828: Standard Tools

    AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools 15.2 Standard tools 002 - 027 029 - 036 059 - 069 042 - 056 071 - 074 081 - 084 Ø - 828 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 829 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools 077 - 080 087 - 095 097 - 099 110 111 - 829 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 830 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools 136 - 140 - 830 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 831 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools 147 - 149 - 831 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 858 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark Tool general combination wrench 001 2 94000 1 Piece Combination wrench 002 3 94000−06 1 Piece Combination wrench 003 3 94000−07 1 Piece Combination wrench 004 3 94000−08...
  • Page 859 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 048 3 94002−50 1 Piece Slugging wrench/ ring SW50 049 3 94002−55 1 Piece Slugging wrench/ ring SW55 050 3 94002−60 1 Piece Slugging wrench/ ring SW60 051 3 94002−65...
  • Page 860 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 096 1 94009 1 Piece Handle screw 097 2 94009−M5 1 Piece Handle screw M5 x 150 098 2 94009−M8 1 Piece Handle screw M8 x x100 099 2 94009−M10...
  • Page 861 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 133 3 KX 94095 1 Piece Adapter piece 3/8" to 1/2" Tool general spanners 1 Piece Accessory parts 136 3 94022B−60 1 Piece Socket wrench insert SW60 137 3 94022B−50...
  • Page 862 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 180 3 TN 94087 2 Pieces Lever chain hoist L5 LB025 181 3 TN 94088 2 Pieces Lever chain hoist L5 LB063 1 Piece Tool general chain block...
  • Page 863 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark Tool main bearing shell assembly (JIS) - 225 2 TN 94161 1 Piece Bracket FCV3, X = 1130 mm, Y = 345 mm, Z = 300 mm,...
  • Page 864 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 268 3 94214D 1 Piece Dismantling and assembling tool 269 3 94214E 1 Piece Bush 270 3 94214F 1 Piece Angle steel 271 3 94214A 1 Piece Handle X = 37.5 mm...
  • Page 865 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark Tool injector test bench 1 Piece Tool injector test bench 318 3 94272 1 Piece Injector test bench X = 1039 mm 319 3 94273 1 Piece...
  • Page 866 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 362 2 94322 1 Piece Support Y = 460 mm 363 2 94324 1 Piece Lifting tool X = 336 mm, Mass approx. 56.9 kg, (WLL 8200 kg)
  • Page 867 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 403 3 94344A 1 Piece Distance bush X = 405 mm 404 3 94344B 2 Pieces Chain Tool piston/-rod/crosshd.pretens 406 2 94340 3 Pieces Pre-tensioner X = Ø 76 mm...
  • Page 868 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 446 3 94566 2 Pieces Supporting device X = 925 mm, Y = 180 mm, Mass approx. 69.1 kg 447 3 94566B 2 Pieces Holder X = 290 mm...
  • Page 869 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 492 4 94593A 1 Piece Ring 493 5 94593B 1 Piece Ring 2- parts 494 4 94593C 2 Pieces Guide rod 495 4 94593D 2 Pieces Hexagon head bolt...
  • Page 870 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark Tool tc failure - ABB A175 For number of TC 2 534 2 94653 1 Piece Tool tc failure 535 3 94653D-A175 2 Pieces Cover For TC 1 and TC 2; X = 680 mm; Ø = 600 mm;...
  • Page 871 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark Tool tc failure ABB A275 (SCR-HP- For number of TC 1 & 2 INTERFACE) 565 2 94653 1 Piece Arrangement of covers 566 3 TN 94119 4 Pieces Cover Y = 890 mm;...
  • Page 872 AA00-0000-00AAA-941A-C X72DF Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 609 2 94844 1 Piece Supply unit oil feed system for supply unit lubrication during maintenance 610 3 TN 94125 1 Piece Bottle Y = 600 mm...
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  • Page 874: Recommended Tools

    AA00-0000-00AAA-941B-C X72DF Maintenance Manual Recommended tools 15.3 Recommended tools Ø - 874 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
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  • Page 877 AA00-0000-00AAA-941B-C X72DF Maintenance Manual Recommended tools Pos. Ind. Part No. Quantity Description Remark Tool cylinder liner grinding 001 2 94299 1 Piece Wear ridge grinding device X = 834 mm Tool gland box assembly platform (ISO) - X = ∅ 850 mm, Mass approx. 35 kg...
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  • Page 879: Tightening Instructions

    X72DF Maintenance Manual 16 Tightening instructions 16.1 Tightening instructions...........

  • Page 880: Tightening Instructions

    AA00-0000-00AAA-018N-A X72DF Maintenance Manual Tightening instructions 16.1 Tightening instructions On the pages that follow you find the document “Tightening instructions” for important connections of the engine. Use the number of the design group to find the related connection. - 880 - Issue 002 2020-10 Winterthur Gas &...
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  • Page 895: Maintenance Overview

    X72DF Maintenance Manual 17 Maintenance overview 17.1 Maintenance overview........... .
  • Page 896 AA00-0000-00AAA-280C-A X72DF Maintenance Manual Maintenance overview 17.1 Maintenance overview On the pages that follow you find the document “Maintenance Intervals / Lifetime” for the related components of the engine. - 882 - Issue 002 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 897 Intervals & Lifetime Component Work to be carried out [operating hours] System oil Laboratory analysis 3000 Check filter elements - in particular for white metal particles (clean or Main fuel and lubricating oil filters 3000 replace filter as necessary). Follow manufacturer’s instructions Calculate quality, concentration of inhibitor and pH value (follow Cooling water weekly...
  • Page 898 Intervals & Lifetime Component Work to be carried out [operating hours] Piston rod gland (Group 23xx) Estimated lifetime: Piston rod gland 36000 (refers to rings) Do a check for cracks and dirty seat sealing faces of the injection valve. at every cylinder cover Cylinder cover (Group 27xx) Make sure that the seat sealing faces have no damage.
  • Page 899 Intervals & Lifetime Component Work to be carried out [operating hours] gear manufacturer Lubrication of tooth flanks of pinion and flywheel, related to visual 2000 inspections, however latest each 2000 Op. h of main engine Check screwed connections, first time after one year 12000 Connecting rod bearings (Group Check bearing clearances (see 0330-1)
  • Page 900 Intervals & Lifetime Component Work to be carried out [operating hours] Servo oil pump drive Check pinion and driving wheels to servo oil pump drive 3000 Check filter below the plug in the compensator for particles 2000 90000 (replacement if Estimated lifetime: supply unit pinion bearing bushes required) Fuel oil pump drive...
  • Page 901 Intervals & Lifetime Component Work to be carried out [operating hours] Cleaning of filter at a ∆p increase of 50% compared to the shop test value Air filter (Group 65xx) as necessary at same engine load (see Operating Manual 6510-1) Auxiliary blower (Group 65xx) Clean impeller and casing 24000 - 36000...
  • Page 902 Only genuine spare parts used; Careful and continuous engine monitoring. “Estimated lifetime” refers to the life expectancy in hours under normal operating conditions before the component is removed for replacement or remanufacturing. WINGD service providers: Wärtsilä, CMS. Maintenance Intervals / Rev. F Lifetime...

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