WinGD X82-B Maintenance Manual
  1. Manuals
  2. Brands
  3. WinGD Manuals
  4. Engine
  5. X82-B
  6. Maintenance manual

WinGD X82-B Maintenance Manual

Hide thumbs Also See for X82-B:
1
2
Table Of Contents
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
Table of Contents

Advertisement

Quick Links

Download this manual
Winterthur Gas & Diesel Ltd.
Winterthur Gas & Diesel AG
Winterthur Gas & Diesel S.A.
Schützenstrasse 3
P.O. Box 414, 8401
Winterthur, Switzerland
Maintenance Manual
X82-B
Tel. +41 (0)52 264 8844
Fax +41 (0)52 264 8866
www.wingd.com
Issue 001 2020-10

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the X82-B and is the answer not in the manual?

Questions and answers

Related Manuals for WinGD X82-B

Summary of Contents for WinGD X82-B

  • Page 1 Maintenance Manual X82-B Issue 001 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

    X82-B Maintenance Manual Table of contents Introduction Maintenance Manual - change record........
  • Page 4 X82-B Maintenance Manual 6.3.1 Main bearing - bearing shell - No. 2 to # - prepare before removal..118 6.3.2 Main bearing - bearing shell - No. 2 to # - remove..... . .
  • Page 5 X82-B Maintenance Manual 7.4.2 Cylinder cover - grind the sealing face for injection valve....252 7.4.3 Cylinder cover - install..........
  • Page 6 X82-B Maintenance Manual 8.5.3 Connecting rod - install..........
  • Page 7 X82-B Maintenance Manual 10.1.3 Servo oil pump - install..........
  • Page 8 X82-B Maintenance Manual 11.2.2 Auxiliary blower - install..........
  • Page 9 X82-B Maintenance Manual 15.3 Recommended tools........... . .
  • Page 10 X82-B Maintenance Manual Page left intentionally blank - 10 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 11 X82-B 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 X82-B Maintenance Manual 13-1 Distance X for HP servo oil pipe ..............13-2 Distance X for hydraulic pipe exhaust valve ..........- 12 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 13 X82-B 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 X82-B Maintenance Manual 6-17 Bearing cover - move .................. 6-18 Thrust device ....................6-19 Bearing cover - install .................. 6-20 Bearing cover - move .................. 6-21 Bearing cover - oil pipe ................6-22 Oil pipe and round nuts ................6-23 Thrust device ....................
  • Page 15 Injection valve - removal ................7-30 Preparation of injection valve for test ............7-31 Adjust the opening pressure of the injection valve (X82 or X82-B) ..... 7-32 Injection valve (example) - disassemble ............. 7-33 Nozzle tip (example) - replace ..............
  • Page 16 X82-B Maintenance Manual Axial vibration damper - housing and pipes ..........Axial vibration damper ................. Axial vibration damper - move ..............8-10 Axial vibration damper - install ..............8-11 Axial vibration damper - bolts ..............8-12 Axial vibration damper - housing and pipes ..........
  • Page 17 X82-B Maintenance Manual 8-55 Crosshead - remove ..................8-56 Guide shoes - remove ................. 8-57 Clearance checks ..................8-58 Dimensions check ..................8-59 Guide shoe - move ..................8-60 Crosshead - move ..................8-61 Guide shoes - install ..................8-62 Connecting rod - move ................
  • Page 18 X82-B Maintenance Manual 10-4 Toothed rack removal .................. 10-5 Pump cylinder removal ................10-6 Non-return valve removal ................10-7 Pump cylinder installation ................10-8 Pump cover installation ................10-9 Toothed rack assembly ................10-10 Pump plunger and bottom housing assembly ..........
  • Page 19 X82-B Maintenance Manual 11-7 Electric motor (driving end) - remove ............11-8 Electric motor (free end) - move ..............11-9 Auxiliary blower - remove ................11-10 Auxiliary blower - move ................11-11 Electric motor (free end) - install ..............11-12 Auxiliary blower (driving end) move ............
  • Page 20 X82-B Maintenance Manual Group 9 - Monitoring instruments 14-1 Proximity sensor (flywheel) - remove ............14-2 Proximity sensor (flywheel) - install ............. 14-3 Proximity sensor - remove ................14-4 Proximity sensor - install ................Tools 15-1 Standard Tools .................... 15-2 Recommended Tools ...................
  • Page 21 X82-B Maintenance Manual 1 Introduction Maintenance Manual - change record........

  • Page 22: Maintenance Manual - Change Record

    AA00-0000-00AAA-003B-A X82-B 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 New issue 001, 2020-10 All data modules Initial issue of the fully new structured Maintenance Manual. The existing Maintenance Manual published on 2018-12 is no more applicable.
  • Page 23 AA00-0000-00AAA-003B-A X82-B Maintenance Manual Maintenance Manual - change record Page left intentionally blank - 23 - Issue 001 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 X82-B Maintenance Manual Preface Page left intentionally blank - 25 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 26: Technical Documentation Set

    AA00-0000-00AAA-018B-A X82-B 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 X82-B 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 X82-B Maintenance Manual Data module codes (descriptive data) Page left intentionally blank - 31 - Issue 001 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 X82-B Maintenance Manual Data module codes (illustrated parts data) Page left intentionally blank - 33 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 34: About This Book

    X82-B 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 X82-B 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 X82-B 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 X82-B 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 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 39 AA00-0000-00AAA-018L-A X82-B 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 X82-B 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 X82-B Maintenance Manual About the engine Page left intentionally blank - 41 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 42: List Of Abbreviations

    AA00-0000-00AAA-005A-A X82-B 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 X82-B 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 X82-B 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 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 46 AA00-0000-00AAA-005A-A X82-B 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 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 47: Safety

    X82-B Maintenance Manual 2 Safety Safety precautions and safety rules.........

  • Page 48: Safety Precautions And Safety Rules

    AA00-0000-00AAA-012A-A X82-B 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 X82-B 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 X82-B 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: General Data For Maintenance

    X82-B Maintenance Manual 3 General data for maintenance Lifting tools............. .

  • Page 52: Lifting Tools

    AA00-0000-00AAA-066A-A X82-B 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 53: Lifting Capacities (For Information Only)

    AA00-0000-00AAA-066A-A X82-B 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 54 AA00-0000-00AAA-066A-A X82-B 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 55: Rud-Swivel Lugs

    AA00-0000-00AAA-066A-A X82-B 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 56: Jointing Compounds

    AA00-0000-00AAA-701A-A X82-B 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 57 AA00-0000-00AAA-701A-A X82-B Maintenance Manual Jointing compounds Page left intentionally blank - 57 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 58: Clearances - General

    AA00-0000-00AAA-034C-A X82-B 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 59 AA00-0000-00AAA-034C-A X82-B Maintenance Manual Clearances - general Page left intentionally blank - 59 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 60: Clearances

    AA00-0000-00AAA-034C-A X82-B 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 di- Nominal di- Maximum code rection mension (usu- clearance di- al, new) [mm]...

  • Page 61: Crankshaft And Main Bearings

    AA00-0000-00AAA-034C-A X82-B Maintenance Manual Clearances 3.4.2 Crankshaft and main bearings Fig 3-4 Crankshaft and Main Bearing - 61 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 62 AA00-0000-00AAA-034C-A X82-B 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] Narrow main bearings of crank- 1132 shaft half at free end...

  • Page 63: Crosshead Guide

    AA00-0000-00AAA-034C-A X82-B 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 0.20 to 1.3...

  • Page 64: Cylinder Liner

    AA00-0000-00AAA-034C-A X82-B 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 0.60 to 1.00...

  • Page 65: Piston Rod Gland

    AA00-0000-00AAA-034C-A X82-B 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 66: Exhaust Valve - Spindle And Guide Bush

    AA00-0000-00AAA-034C-A X82-B 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 67: Connecting Rod - Top And Bottom End Bearings

    AA00-0000-00AAA-034C-A X82-B 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 68: Piston And Piston Rings

    AA00-0000-00AAA-034C-A X82-B Maintenance Manual Clearances 3.4.8 Piston and piston rings Fig 3-10 Piston and 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 69 AA00-0000-00AAA-034C-A X82-B 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] 3415 Piston rod Outer diameter 324 -0.062 Minimum 322.9 -0.119 3425 Piston rings...

  • Page 70: Supply Unit - Drive Wheels

    AA00-0000-00AAA-034C-A X82-B Maintenance Manual Clearances 3.4.9 Supply unit - drive wheels Fig 3-11 Supply unit - drive wheels - 70 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 71 AA00-0000-00AAA-034C-A X82-B 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 Axial clearance Total 0.60 to 1.10...

  • Page 72: Fuel And Servo Pump Units

    AA00-0000-00AAA-034C-A X82-B Maintenance Manual Clearances 3.4.10 Fuel and servo pump units Fig 3-12 Fuel and servo pump units - 72 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 73 AA00-0000-00AAA-034C-A X82-B 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] 5581 Fuel pump unit Axial clearance Total 0.30 to 0.65...

  • Page 74: Fuel Pump

    AA00-0000-00AAA-034C-A X82-B Maintenance Manual Clearances 3.4.11 Fuel pump Fig 3-13 Fuel pump - 74 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 75: Fuel Pump

    AA00-0000-00AAA-034C-A X82-B 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, 44 mm...

  • Page 76: Torque Values - Standard Screws

    X82-B Maintenance Manual Torque values - standard screws Torque values - standard screws WinGD highly recommends to use the torque values given in Table 3-15 - 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 77 AA00-0000-00AAA-034A-A X82-B Maintenance Manual Torque values - standard screws Tab 3-15 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...
  • Page 78 AA00-0000-00AAA-034A-A X82-B Maintenance Manual Torque values - standard screws Page left intentionally blank - 78 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 79: General Maintenance Procedures

    X82-B Maintenance Manual 4 General maintenance procedures Do maintenance work - general procedure........

  • Page 80: Do Maintenance Work - General Procedure

    AA00-0000-00AAA-012F-A X82-B 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 81 AA00-0000-00AAA-012F-A X82-B 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 82: Tighten A Round Nut With A Pre-Tensioner

    AA00-0000-00AAA-711A-A X82-B 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 83 AA00-0000-00AAA-711A-A X82-B 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 84 AA00-0000-00AAA-711A-A X82-B 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.
  • Page 85 AA00-0000-00AAA-711A-A X82-B Maintenance Manual Tighten a round nut with a pre-tensioner Page left intentionally blank - 85 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 86: Loosen A Round Nut With A Pre-Tensioner

    AA00-0000-00AAA-510A-A X82-B 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 87 AA00-0000-00AAA-510A-A X82-B 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 88 AA00-0000-00AAA-510A-A X82-B 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 89 AA00-0000-00AAA-510A-A X82-B Maintenance Manual Loosen a round nut with a pre-tensioner Page left intentionally blank - 89 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 90: Do A Check Of The Pre-Tension

    AA00-0000-00AAA-360A-A X82-B 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 91 AA00-0000-00AAA-360A-A X82-B 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 92 AA00-0000-00AAA-360A-A X82-B 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 93: Maintenance Schedule

    X82-B Maintenance Manual 5 Maintenance schedule Maintenance schedule........... . .

  • Page 94: 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 95: Group 1 - Engine Frame And Bearings

    X82-B Maintenance Manual 6 Group 1 - Engine frame and bearings Foundation bolts 6.1.1 Bedplate - do a check of the foundation bolts......

  • Page 96: Foundation Bolts

    AA00-1115-00AAA-360A-A X82-B Maintenance Manual Bedplate - do a check of the foundation bolts Foundation bolts 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 97 AA00-1115-00AAA-360A-A X82-B 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 98: Main Bearing - Bearing Shell Number

    AA00-1132-00AAA-523A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - prepare before removal Main bearing - bearing shell number 1 6.2.1 Main bearing - bearing shell - No. 1 - prepare before removal Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours...
  • Page 99 AA00-1132-00AAA-523A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - prepare before removal PROCEDURE Read the data in 3.1 Lifting tools General Guidelines for Lifting Tools. Operate the turning gear to turn the crank to the exhaust side approximately 90° after TDC.

  • Page 100: Main Bearing - Bearing Shell - No. 1 - Remove

    AA00-1132-00AAA-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - remove 6.2.2 Main bearing - bearing shell - No. 1 - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours...
  • Page 101 AA00-1132-00AAA-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - remove PROCEDURE Hydraulic rams - install Put the chain block 94017-2.5-5.4 (003, ) on the main bearing girder as shown. Put the two hydraulic rams (001) on the bracket (003) as shown.

  • Page 102: Crankshaft And Flywheel - Lift

    AA00-1132-00AAA-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - remove Fig 6-2 Crankshaft and flywheel - lift 50 mm 50 mm 0.3 mm 009.810/02 00606 Bearing shell - remove Attach the shackle (WLL 2000 kg) (004, Figure 6-3) to the position shown.
  • Page 103 AA00-1132-00AAA-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - remove Remove the two Allen screws (007) from the top of the bearing shell (002). Attach the turning out device (009) to the bearing shell (002). Put the wire ropes (006) around the edges of the main bearing shell (002).

  • Page 104: Bearing Shell - Remove

    AA00-1132-00AAA-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - remove Fig 6-3 Bearing shell - remove WCH03015 WCH03486 00607 3.10 Attach the lifting tool (002, Figure 6-4) to the bearing shell (003). - 104 - Issue 001 2020-10...

  • Page 105: Bearing Shell - Lift

    AA00-1132-00AAA-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - remove Fig 6-4 Bearing shell - lift 00608 3.11 Turn the bearing shell (003) sufficiently to attach the chain block (001). 3.12 Attach the chain block (001) to the lifting tool (003).
  • Page 106 AA00-1132-00AAA-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - remove 3.14 Attach the engine room crane to the lifting tool (002). 3.15 Operate the engine room crane and the chain block (001) to lift and move the bearing shell (003) out of the engine.
  • Page 107 AA00-1132-00AAA-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - remove Page left intentionally blank - 107 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 108: Main Bearing Shell - No.1 - Do A Check

    AA00-1135-00AAA-311A-A X82-B Maintenance Manual Main bearing shell - No.1 - do a check 6.2.3 Main bearing shell - No.1 - do a check 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 109 AA00-1135-00AAA-311A-A X82-B Maintenance Manual Main bearing shell - No.1 - do a check PROCEDURE Use a soft cloth to clean the bearing shell. Examine the bearing shell for damage e.g. breakouts or 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 110: Main Bearing - Bearing Shell - No. 1 - Install

    AA00-1132-00AAA-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - install 6.2.4 Main bearing - bearing shell - No. 1 - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours...
  • Page 111 AA00-1132-00AAA-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - install PRELIMINARY OPERATIONS • None - 111 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 112 AA00-1132-00AAA-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - install PROCEDURE Bearing shell - install NOTE: The bearing shell has the mark DRIVING END and must be installed in the correct position. Make sure that the items that follow are clean and in good condition: •...
  • Page 113 AA00-1132-00AAA-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - install Fig 6-5 Bearing shell - lift 00608 Remove carefully the engine room crane from the lifting tool (002). 1.10 Operate carefully the chain block (001) to lower the bearing shell (003) on to the crankshaft.
  • Page 114 AA00-1132-00AAA-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - install 1.11 Remove the chain block (001) and the lifting tool (002). 1.12 Put the wire ropes (006) of the turning-out device (006, Figure 6-6) over the bearing shell (002) and under the crankshaft.

  • Page 115: Bearing Shell - Move

    AA00-1132-00AAA-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - install Fig 6-6 Bearing shell - move WCH03015 WCH03486 00607 Crankshaft - lower On the HP oil pump, release the pressure to fully lower the crankshaft. Remove the hydraulic rams (001, Figure 6-7) and the HP oil pump.

  • Page 116: Crankshaft And Flywheel - Lift

    AA00-1132-00AAA-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - install Remove the bracket (004) and steel plate. Fig 6-7 Crankshaft and flywheel - lift 50 mm 50 mm 0.3 mm 009.810/02 00606 - 116 - Issue 001 2020-10...
  • Page 117 AA00-1132-00AAA-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 1 - install CLOSE UP • Install the No.1 bearing cover, refer to 6.4.2 Main bearing cover - No.1 - install - 117 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 118: Main Bearing - Bearing Shell Number 2 To

    AA00-1132-00AAB-523A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - prepare before removal Main bearing - bearing shell number 2 to # 6.3.1 Main bearing - bearing shell - No. 2 to # - prepare before...
  • Page 119 AA00-1132-00AAB-523A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - prepare before removal PROCEDURE Read the data in 3.1 Lifting tools General Guidelines for Lifting Tools. Operate the turning gear to turn the crank to the exhaust side approximately 90° after TDC.

  • Page 120: Main Bearing - Bearing Shell - No. 2 To # - Remove

    AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove 6.3.2 Main bearing - bearing shell - No. 2 to # - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...
  • Page 121 AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove Spare Parts Description Part No. None SAFETY PRECAUTIONS CAUTION Damage Hazard: Do not remove two adjacent main bearing shells at the same time. Damage can occur to the bearing shells.
  • Page 122 AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove PROCEDURE Hydraulic rams - install Put the bracket 94141 (003, Figure 6-8) on the main bearing girder as shown. - 122 - Issue 001 2020-10...
  • Page 123 AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove Fig 6-8 Crankshaft and flywheel - lift 50 mm 50 mm 0.3 mm 009.810/02 00606 Put the two hydraulic rams 94936 (001) on the bracket (003) as shown.
  • Page 124 AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove Put the steel plate on top of the hydraulic ram (001). Connect the hydraulic jacks (001) to the HP oil pump. Put the dial gauge (006) in position on the crankshaft (007) in the vertical axis.

  • Page 125: Bearing Shell No_2_To_N

    AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove Fig 6-9 Bearing shell No_2_to_n WCH03486 00609 Attach the deviation pipes 94117B and 94117C (006 and 007, Figure 6-10) to the column as shown.
  • Page 126 AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove NOTE: If the bearing shell (002) does not move freely during the removal procedure, you must attach the lifting plate to the other side of the turning out device.
  • Page 127 AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove Fig 6-10 Bearing shell_move - 127 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 128 AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove CLOSE UP • Install the bearing shell, refer to 6.3.4 Main bearing - bearing shell - No. 2 to # - install - 128 - Issue 001 2020-10 Winterthur Gas &...
  • Page 129 AA00-1132-00AAB-520A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - remove Page left intentionally blank - 129 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 130: Main Bearing Shell - No.2 To # - Examine

    AA00-1134-00AAA-311A-A X82-B Maintenance Manual Main bearing shell - No.2 to # - examine 6.3.3 Main bearing shell - No.2 to # - examine 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 131 AA00-1134-00AAA-311A-A X82-B Maintenance Manual Main bearing shell - No.2 to # - examine PROCEDURE Use a soft cloth to clean the bearing shell. Examine the bearing shell for damage e.g. breakouts or 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 132: Main Bearing - Bearing Shell - No. 2 To # - Install

    AA00-1132-00AAB-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - install 6.3.4 Main bearing - bearing shell - No. 2 to # - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 2.0 man-hours...
  • Page 133 AA00-1132-00AAB-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - install SAFETY PRECAUTIONS WARNING Injury and Damage Hazard: Do not turn the crankshaft when the platforms, tools and/or supports, are installed. This will cause injury to personnel and damage to equipment.
  • Page 134 AA00-1132-00AAB-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - install PROCEDURE Bearing shell - install NOTE: The bearing shell has the mark DRIVING END and must be installed in the correct position. Make sure that the items that follow are clean and in good condition: •...

  • Page 135: Bearing Shell_Move

    AA00-1132-00AAB-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - install Fig 6-11 Bearing shell - move Make sure that the crankshaft and the running surface of the bearing shell (002) are clean and fully lubricated with clean engine oil.
  • Page 136 AA00-1132-00AAB-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - install Attach the engine room crane to the lifting tool (001). Operate the engine room crane to move the bearing shell (002) to an applicable position.
  • Page 137 AA00-1132-00AAB-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - install Fig 6-12 Bearing shell No_2_to_n WCH03486 00609 Crankshaft - lower On the HP oil pump, release the pressure to fully lower the crankshaft. Remove the hydraulic rams (001, Figure 6-13) and the HP oil pump.
  • Page 138 AA00-1132-00AAB-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - install Fig 6-13 Crankshaft and flywheel 50 mm 50 mm 0.3 mm 009.810/02 00606 - 138 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 139 AA00-1132-00AAB-720A-A X82-B Maintenance Manual Main bearing - bearing shell - No. 2 to # - install CLOSE UP • Install the bearing cover, refer to 6.5.2 Main bearing cover - No. 2 to #- install - 139 - Issue 001 2020-10...

  • Page 140: Main Bearing Cover - No. 1

    AA00-1132-01AAA-520A-A X82-B Maintenance Manual Main bearing cover - No.1 - remove Main bearing cover - No. 1 6.4.1 Main bearing cover - No.1 - remove Periodicity Description Unscheduled Personnel Description Specialization Engine crew Basic Support equipment Description Part No. Spur-geared chain block,...
  • Page 141 AA00-1132-01AAA-520A-A X82-B Maintenance Manual Main bearing cover - No.1 - remove PROCEDURE Remove the cover (001, Figure 6-14) and the holder (002). Remove the oil pipe (003). Do a check of the bearing clearance, refer to 3.3 Clearances - general.

  • Page 142: Cover And Oil Pipe

    AA00-1132-01AAA-520A-A X82-B Maintenance Manual Main bearing cover - No.1 - remove Fig 6-14 Cover and oil pipe WCH03014 WCH03021 00611 Attach the lug (001, Figure 6-15) to the bearing cover (002). Make sure that the thrust device (004) is clean.

  • Page 143: Thrust Device

    AA00-1132-01AAA-520A-A X82-B Maintenance Manual Main bearing cover - No.1 - remove WARNING Injury Hazard: The thrust device has a WLL of only 70 kg. Do not use the thrust device to lift the bearing cover. Injury to personnel can occur.

  • Page 144: Bearing Cover

    AA00-1132-01AAA-520A-A X82-B Maintenance Manual Main bearing cover - No.1 - remove Fig 6-16 Bearing cover WCH03014 00612 Attach the shackle 94019K (004, Figure 6-17) to the lug 94116C (003). Attach engine room crane to the shackle 94109K (004). Operate the engine room crane to put a light tension on the chain.

  • Page 145: Bearing Cover - Move

    AA00-1132-01AAA-520A-A X82-B Maintenance Manual Main bearing cover - No.1 - remove Fig 6-17 Bearing cover - move 00614 CLOSE UP • Remove the No. 1 bearing shell, refer to 6.2.2 Main bearing - bearing shell - No. 1 - remove...

  • Page 146: Main Bearing Cover - No.1 - Install

    AA00-1132-01AAA-720A-A X82-B Maintenance Manual Main bearing cover - No.1 - install 6.4.2 Main bearing cover - No.1 - 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 147: Thrust Device

    AA00-1132-01AAA-720A-A X82-B Maintenance Manual Main bearing cover - No.1 - install 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 6-18) to the bearing cover (002).

  • Page 148: Bearing Cover - Install

    AA00-1132-01AAA-720A-A X82-B Maintenance Manual Main bearing cover - No.1 - install Fig 6-19 Bearing cover - install 00616 Attach the shackle 94019K (004, Figure 6-20) 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 149 AA00-1132-01AAA-720A-A X82-B Maintenance Manual Main bearing cover - No.1 - install Fig 6-20 Bearing cover - move 00614 Clean the pipes (003, Figure 6-21). 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 150: Bearing Cover - Oil Pipe

    AA00-1132-01AAA-720A-A X82-B Maintenance Manual Main bearing cover - No.1 - install Fig 6-21 Bearing cover - oil pipe 00617 CLOSE UP • None - 150 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 151 AA00-1132-01AAA-720A-A X82-B Maintenance Manual Main bearing cover - No.1 - install Page left intentionally blank - 151 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 152: Main Bearing Cover - No. 2 To # - Remove

    AA00-1132-01AAB-520A-A X82-B Maintenance Manual Main bearing cover - No. 2 to # - remove Main bearing cover - No. 2 to # 6.5.1 Main bearing cover - No. 2 to # - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours...
  • Page 153 AA00-1132-01AAB-520A-A X82-B Maintenance Manual Main bearing cover - No. 2 to # - remove SAFETY PRECAUTIONS WARNING Injury and Damage Hazard: Do not turn the crankshaft when the platforms, tools and/or supports, are installed. This will cause injury to personnel and damage to equipment.

  • Page 154: Oil Pipe And Round Nuts

    AA00-1132-01AAB-520A-A X82-B Maintenance Manual Main bearing cover - No. 2 to # - remove PROCEDURE Use the feeler gauge 94123 to record the bearing clearance, refer to 3.3 Clearances - general. Remove the oil pipe (002, Figure 6-22). Remove the round nuts (001), refer to 4.3 Loosen a round nut with a...

  • Page 155: Thrust Device

    AA00-1132-01AAB-520A-A X82-B Maintenance Manual Main bearing cover - No. 2 to # - remove Fig 6-23 Thrust device Copper paste 00613 WARNING Injury Hazard: The thrust device has a WLL of only 70 kg. Do not use the thrust device to lift the bearing cover.

  • Page 156: Roller Support

    AA00-1132-01AAB-520A-A X82-B Maintenance Manual Main bearing cover - No. 2 to # - remove Attach the manual ratchet (003) to the lug (002) on the bearing cover. Fig 6-24 Roller support CAUTION Damage Hazard: Use the roller support only as shown on its Warning plate. The maximum permitted load is 16000 N at 45°.

  • Page 157: Bearing Cover No.2 To # - Lift And Lower

    AA00-1132-01AAB-520A-A X82-B Maintenance Manual Main bearing cover - No. 2 to # - remove Fig 6-25 Bearing cover No.2 to # - lift and lower Attach the sling 94039-015 (005, Figure 6-26) to the gallery. Attach the chain block 94017-029 (003) to the sling (005).

  • Page 158: Bearing Cover No. 2 To # - Remove

    AA00-1132-01AAB-520A-A X82-B Maintenance Manual Main bearing cover - No. 2 to # - remove Fig 6-26 Bearing cover No. 2 to # - remove CLOSE UP • Remove the applicable bearing shell, 6.5.2 Main bearing cover - No. 2 to #- install...
  • Page 159 AA00-1132-01AAB-520A-A X82-B Maintenance Manual Main bearing cover - No. 2 to # - remove Page left intentionally blank - 159 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 160: Main Bearing Cover - No. 2 To #- Install

    AA00-1132-01AAB-720A-A X82-B Maintenance Manual Main bearing cover - No. 2 to #- install 6.5.2 Main bearing cover - No. 2 to #- 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 AA00-1132-01AAB-720A-A X82-B Maintenance Manual Main bearing cover - No. 2 to #- install • The work area and all tools and equipment must be clean and in good condition. - 161 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 162: Thrust Device

    AA00-1132-01AAB-720A-A X82-B Maintenance Manual Main bearing cover - No. 2 to #- install 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 6-27) to the bearing cover (002).
  • Page 163 AA00-1132-01AAB-720A-A X82-B Maintenance Manual Main bearing cover - No. 2 to #- install Operate the chain block to lift the bearing cover (002) Attach the manual ratchet (004) to the shackle on the bearing cover (002). Operate the chain block (003) and the manual ratchet (004) to move the bearing cover into the engine.

  • Page 164: Bearing Cover No.2 To # - Install

    AA00-1132-01AAB-720A-A X82-B Maintenance Manual Main bearing cover - No. 2 to #- install Operate the manual ratchet (004) to lower the bearing cover on to the bearing girder. Make sure that the two spring dowel pins (001) engage correctly. Make sure that you do not cause damage to the elastic studs (004).
  • Page 165 AA00-1132-01AAB-720A-A X82-B Maintenance Manual Main bearing cover - No. 2 to #- install Fig 6-30 Bearing cover - oil pipe 00617 Remove all tools and equipment from the work area. Measure the bearing clearance and compare the value measured in 6.5.1 Main bearing...

  • Page 166: Thrust Bearing

    AA00-1203-00AAA-310A-A X82-B Maintenance Manual Thrust bearing - examine the housing Thrust bearing 6.6.1 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 167: Visual Examination

    AA00-1203-00AAA-310A-A X82-B Maintenance Manual Thrust bearing - examine the housing PROCEDURE Remove the cover (003, Figure 6-31). 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 168: Thrust Bearing - Do A Check Of The Axial Clearance With A Dial Gauge

    AA00-1203-00AAA-360A-A X82-B Maintenance Manual Thrust bearing - do a check of the axial clearance with a dial gauge 6.6.2 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 169: Axial Clearance

    AA00-1203-00AAA-360A-A X82-B 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 6-32) fully forward. The crankshaft must touch the thrust pads.

  • Page 170: Thrust Bearing - Do A Check Of The Axial Clearance With A Inside Micrometer

    AA00-1203-00AAA-360B-A X82-B Maintenance Manual Thrust bearing - do a check of the axial clearance with a inside micrometer 6.6.3 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 171: Axial Clearance - Micrometer

    AA00-1203-00AAA-360B-A X82-B 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 6-33) must touch the thrust pads (002).
  • Page 172 AA00-1203-00AAA-360B-A X82-B Maintenance Manual Thrust bearing - do a check of the axial clearance with a inside micrometer CLOSE UP • None - 172 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 173 AA00-1203-00AAA-360B-A X82-B Maintenance Manual Thrust bearing - do a check of the axial clearance with a inside micrometer Page left intentionally blank - 173 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 174: Thrust Bearing - Remove The Pads

    AA00-1203-00AAA-520A-A X82-B Maintenance Manual Thrust bearing - remove the pads 6.6.4 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 175: Cover - Remove

    AA00-1203-00AAA-520A-A X82-B Maintenance Manual Thrust bearing - remove the pads PROCEDURE Read the data in 3.1 Lifting tools. Remove the cover (001, Figure 6-34). Fig 6-34 Cover - remove 00020 Record the positions of the thrust bearing pads. Remove the three bolts (001, Figure 6-35) from each of the four arbor supports (002).
  • Page 176 AA00-1203-00AAA-520A-A X82-B 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 177: Thrust Pad - Removal

    AA00-1203-00AAA-520A-A X82-B Maintenance Manual Thrust bearing - remove the pads Fig 6-35 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 178 AA00-1203-00AAA-520A-A X82-B 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 •...
  • Page 179 AA00-1203-00AAA-520A-A X82-B Maintenance Manual Thrust bearing - remove the pads Page left intentionally blank - 179 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 180: Thrust Bearing - Install The Pads

    AA00-1203-00AAA-720A-A X82-B Maintenance Manual Thrust bearing - install the pads 6.6.5 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 181 AA00-1203-00AAA-720A-A X82-B 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 182: Thrust Pad - Install

    AA00-1203-00AAA-720A-A X82-B Maintenance Manual Thrust bearing - install the pads Fig 6-36 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 6.6.2 Thrust bearing - do a check of the axial clearance with a dial gauge...

  • Page 183: Thrust Pads - Configuration

    AA00-1203-00AAA-720A-A X82-B Maintenance Manual Thrust bearing - install the pads section 6.6.3 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 184: Cover - Install

    AA00-1203-00AAA-720A-A X82-B Maintenance Manual Thrust bearing - install the pads Fig 6-38 Cover - install 00020 CLOSE UP • None - 184 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 185 AA00-1203-00AAA-720A-A X82-B Maintenance Manual Thrust bearing - install the pads Page left intentionally blank - 185 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 186: Engine Stays

    AA00-1715-00AAA-360A-A X82-B Maintenance Manual Engine stays (friction shims) - do a check of the pre-tension Engine stays 6.7.1 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 187 AA00-1715-00AAA-360A-A X82-B 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 188: Engine Stays (Hydraulic) - Do A Check Of The Oil Pressure

    AA00-1715-00AAA-360B-A X82-B Maintenance Manual Engine stays (hydraulic) - do a check of the oil pressure 6.7.2 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 189: Engine Stays - Pressure Check

    AA00-1715-00AAA-360B-A X82-B 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 6-39).

  • Page 190: Tie Rod

    AA00-1903-00AAA-360A-A X82-B Maintenance Manual Tie rod - do a check of the pre-tension Tie rod 6.8.1 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 191: Pre-Tension Checks

    AA00-1903-00AAA-360A-A X82-B Maintenance Manual Tie rod - do a check of the pre-tension PROCEDURE Remove the protection cover (001, Figure 6-40) 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 192: Tie Rod - Remove

    AA00-1903-00AAA-520A-A X82-B Maintenance Manual Tie rod - remove 6.8.2 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 193: Tie Rod - Removal

    AA00-1903-00AAA-520A-A X82-B Maintenance Manual Tie rod - remove PROCEDURE Remove the protection cover (001, Figure 6-41) 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 194: Tie Rod - Install

    AA00-1903-00AAA-720A-A X82-B Maintenance Manual Tie rod - install 6.8.3 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 195 AA00-1903-00AAA-720A-A X82-B Maintenance Manual Tie rod - install PROCEDURE Remove the applicable holder (008 or 010, Figure 6-42). Make sure that the nut (007) is correctly attached. Apply Molykote paste G to the bottom thread of the tie rod (003).

  • Page 196: Tie Rod - Apply Tension

    AA00-1903-00AAA-720A-A X82-B 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 197: Group 2 - Cylinder

    X82-B Maintenance Manual 7 Group 2 - Cylinder Cylinder liner 7.1.1 Cylinder liner - do a check of the bore........
  • Page 198 X82-B Maintenance Manual 7.7.6 Exhaust valve - grind the seat.........
  • Page 199 X82-B Maintenance Manual Page left intentionally blank - 199 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 200: Cylinder Liner

    AA00-2124-00AAA-360A-A X82-B 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 201 AA00-2124-00AAA-360A-A X82-B 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 7.4.1 Cylinder cover - remove...
  • Page 202 AA00-2124-00AAA-360A-A X82-B 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 203: Cylinder Liner - Dimension Check

    AA00-2124-00AAA-360A-A X82-B 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). - 203 - Issue 001 2020-10 Winterthur Gas &...
  • Page 204 AA00-2124-00AAA-360A-A X82-B 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 205 AA00-2124-00AAA-360A-A X82-B Maintenance Manual Cylinder liner - do a check of the bore Page left intentionally blank - 205 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 206: Cylinder Liner - Remove

    AA00-2124-00AAA-520A-A X82-B 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 207 AA00-2124-00AAA-520A-A X82-B 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 208: Water Guide Jacket

    AA00-2124-00AAA-520A-A X82-B 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. - 208 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 209 AA00-2124-00AAA-520A-A X82-B 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 210: Cylinder Liner (Example) - Move

    AA00-2124-00AAA-520A-A X82-B Maintenance Manual Cylinder liner - remove Fig 7-4 Cylinder liner (example) - move CLOSE UP • None - 210 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 211 AA00-2124-00AAA-520A-A X82-B Maintenance Manual Cylinder liner - remove Page left intentionally blank - 211 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 212: Cylinder Liner - Preserve

    AA00-2124-00AAA-810A-A X82-B 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 213: Cylinder Liner - Storage

    AA00-2124-00AAA-810A-A X82-B 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 214 AA00-2124-00AAA-810A-A X82-B Maintenance Manual Cylinder liner - preserve Fig 7-6 Cylinder liner - storage 2 CLOSE UP • None - 214 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 215 AA00-2124-00AAA-810A-A X82-B Maintenance Manual Cylinder liner - preserve Page left intentionally blank - 215 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 216: Cylinder Liner - Grind

    AA00-2124-00AAA-655A-A X82-B 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 217 AA00-2124-00AAA-655A-A X82-B 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 218: Cylinder Liner - Grind The Lubricating Groove

    AA00-2124-00AAA-655B-A X82-B 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 219: Lubricating Grooves - Grind

    AA00-2124-00AAA-655B-A X82-B 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 220: Cylinder Liner - Grind The Scavenge Ports

    AA00-2124-00AAA-655C-A X82-B 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 221: Scavenge Ports - Grind

    AA00-2124-00AAA-655C-A X82-B 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 222: Cylinder Liner - Install

    AA00-2124-00AAA-720A-A X82-B 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 223: Insulation Bandage

    AA00-2124-00AAA-720A-A X82-B 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 224 AA00-2124-00AAA-720A-A X82-B 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 225 AA00-2124-00AAA-720A-A X82-B 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 226 AA00-2124-00AAA-720A-A X82-B 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 227 AA00-2124-00AAA-720A-A X82-B Maintenance Manual Cylinder liner - install Page left intentionally blank - 227 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 228: Lubricating Quill

    AA00-2138-00AAA-520A-A X82-B 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 229 AA00-2138-00AAA-520A-A X82-B 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 230: Lubricating Quill - Do A Functional Test

    AA00-2138-00AAA-340A-A X82-B 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 231 AA00-2138-00AAA-340A-A X82-B 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 232: Lubricating Quill - Install

    AA00-2138-00AAA-720A-A X82-B 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 233: Sealing Surface

    AA00-2138-00AAA-720A-A X82-B 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 234 AA00-2138-00AAA-720A-A X82-B 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 - 234 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 235 AA00-2138-00AAA-720A-A X82-B Maintenance Manual Lubricating quill - install Page left intentionally blank - 235 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 236: Piston Rod Gland

    AA00-2303-00AAA-520A-A X82-B Maintenance Manual Piston rod gland - remove Piston rod gland 7.3.1 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 237: Piston Rod Gland - Remove And Install

    AA00-2303-00AAA-520A-A X82-B 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 7-17). Remove the four screws and nuts (003, 006).

  • Page 238: Piston Rod Gland - Disassemble

    AA00-2303-00AAA-520A-A X82-B Maintenance Manual Piston rod gland - remove Fig 7-18 Piston rod gland - disassemble CLOSE UP • None - 238 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 239 AA00-2303-00AAA-520A-A X82-B Maintenance Manual Piston rod gland - remove Page left intentionally blank - 239 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 240: Piston Rod Gland - Do A Check Of The Wear

    AA00-2303-00AAA-360A-A X82-B Maintenance Manual Piston rod gland - do a check of the wear 7.3.2 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 241 AA00-2303-00AAA-360A-A X82-B 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 242: Piston Rod Gland - Install

    AA00-2303-00AAA-720A-A X82-B Maintenance Manual Piston rod gland - install 7.3.3 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 243 AA00-2303-00AAA-720A-A X82-B Maintenance Manual Piston rod gland - install PRELIMINARY OPERATIONS • None - 243 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 244: Piston Rod Gland - Assemble

    AA00-2303-00AAA-720A-A X82-B Maintenance Manual Piston rod gland - install PROCEDURE Attach the two parts of the clamp ring 94231A (011, Figure 7-20) 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 245 AA00-2303-00AAA-720A-A X82-B 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 246: Cylinder Cover

    AA00-2708-00AAA-520A-A X82-B Maintenance Manual Cylinder cover - remove Cylinder cover 7.4.1 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 247 AA00-2708-00AAA-520A-A X82-B 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 - 247 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 248: Cylinder Cover - Pipes And Expansion Piece (Example)

    AA00-2708-00AAA-520A-A X82-B Maintenance Manual Cylinder cover - remove PROCEDURE Remove the applicable hydraulic pipe (005, Figure 7-22), 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 249: Lifting Tool - Pre-Tensioner (Example)

    AA00-2708-00AAA-520A-A X82-B Maintenance Manual Cylinder cover - remove Fig 7-23 Lifting tool - pre-tensioner (example) Attach the engine room crane to the eye bolt (001, Figure 7-24) 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 250: Cylinder Cover, Exhaust Valve Cage And Water Guide Jacket (Example)

    AA00-2708-00AAA-520A-A X82-B Maintenance Manual Cylinder cover - remove Fig 7-24 Cylinder cover, exhaust valve cage and water guide jacket (example) Attach the engine room crane to the lifting tool (002, Figure 7-25). Operate the engine room crane to lift the lifting tool (002).

  • Page 251: Cylinder Cover And Exhaust Valve Cage (Example)

    AA00-2708-00AAA-520A-A X82-B Maintenance Manual Cylinder cover - remove Fig 7-25 Cylinder cover and exhaust valve cage (example) CLOSE UP • None - 251 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 252: Cylinder Cover - Grind The Sealing Face For Injection Valve

    AA00-2708-00AAA-655A-A X82-B Maintenance Manual Cylinder cover - grind the sealing face for injection valve 7.4.2 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 253 AA00-2708-00AAA-655A-A X82-B Maintenance Manual Cylinder cover - grind the sealing face for injection valve PROCEDURE Make sure that the stop sleeve (008, Figure 7-26) 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 254: Fuel Injection Valve Position - Grind

    AA00-2708-00AAA-655A-A X82-B Maintenance Manual Cylinder cover - grind the sealing face for injection valve Fig 7-26 Fuel injection valve position - grind CLOSE UP • None - 254 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 255 AA00-2708-00AAA-655A-A X82-B Maintenance Manual Cylinder cover - grind the sealing face for injection valve Page left intentionally blank - 255 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 256: Cylinder Cover - Install

    AA00-2708-00AAA-720A-A X82-B Maintenance Manual Cylinder cover - install 7.4.3 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 257 AA00-2708-00AAA-720A-A X82-B Maintenance Manual Cylinder cover - install PROCEDURE Clean the items that follow: • O-ring grooves (005, Figure 7-27) • Sealing surfaces of the cylinder cover (004). Put oil on the O-rings. Clean the threads of the two elastic studs (003).

  • Page 258: Assemble Before Installation (Example)

    AA00-2708-00AAA-720A-A X82-B Maintenance Manual Cylinder cover - install Fig 7-27 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 259 AA00-2708-00AAA-720A-A X82-B Maintenance Manual Cylinder cover - install Put the round nuts (004, Figure 7-28) 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 260 AA00-2708-00AAA-720A-A X82-B Maintenance Manual Cylinder cover - install CLOSE UP • None - 260 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 261 AA00-2708-00AAA-720A-A X82-B Maintenance Manual Cylinder cover - install Page left intentionally blank - 261 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 262: Conventional Injection Valve

    AA00-2722-01AAA-520A-A X82-B Maintenance Manual Conventional injection valve - remove Conventional injection valve 7.5.1 Conventional injection valve - remove 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 263: Injection Valve - Removal

    AA00-2722-01AAA-520A-A X82-B Maintenance Manual Conventional injection valve - remove PROCEDURE Remove the leakage pipe (005) from the injection valve (003). Remove the screws (002) and their spring cages. Remove the injection valve (003) from the cylinder cover (004). Clean the injection valve (003).

  • Page 264: Conventional Injection Valve - Prepare Before The Test

    AA00-2722-01AAA-330A-A X82-B Maintenance Manual Conventional injection valve - prepare before the test 7.5.2 Conventional injection valve - prepare before the test Periodicity Description Working hours 5000 Working hours 1000 after replaced parts Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.25 man-hours...

  • Page 265: Preparation Of Injection Valve For Test

    AA00-2722-01AAA-330A-A X82-B Maintenance Manual Conventional injection valve - prepare before the test PROCEDURE Read and obey the data in the manufacturer’s instruction manual of the test bench (002, Figure 7-30). NOTE: At regular intervals, use a master pressure gauge to do checks of the pressure gauges on the test bench.

  • Page 266: Conventional Injection Valve - Do A Functional Test

    AA00-2722-01AAA-340A-A X82-B Maintenance Manual Conventional injection valve - do a functional test 7.5.3 Conventional injection valve - do a functional test Periodicity Description Working hours 5000 Working hours 1000 after replaced parts Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 267 AA00-2722-01AAA-340A-A X82-B Maintenance Manual Conventional injection valve - do a functional test NOTE: It is not recommended that diesel oil is used if the injection valve is put into storage after this procedure. Diesel oil can cause corrosion of the injection valve.
  • Page 268 AA00-2722-01AAA-340A-A X82-B Maintenance Manual Conventional injection valve - do a functional test PROCEDURE Start the test bench. Read the data in the manufacturer’s instructions to set the correct pressure of the test bench. Slowly increase the pressure of the test fluid until test fluid comes out as a spray from the injection valve.
  • Page 269 AA00-2722-01AAA-340A-A X82-B Maintenance Manual Conventional injection valve - do a functional test Page left intentionally blank - 269 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 270: Conventional Injection Valve - Adjust

    AA00-2722-00AAA-271A-A X82-B Maintenance Manual Conventional injection valve - adjust 7.5.4 Conventional injection valve - adjust 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 271: Adjust The Opening Pressure Of The Injection Valve (X82 Or X82-B)

    2.8 mm and a shim ring of 3.6 mm). Step 2 Step 3 again to do a check of the opening pressure. Fig 7-31 Adjust the opening pressure of the injection valve (X82 or X82-B) CLOSE UP • None - 271 - Issue 001 2020-10 Winterthur Gas &...

  • Page 272: Conventional Injection Valve - Disassemble

    AA00-2722-01AAA-530A-A X82-B Maintenance Manual Conventional injection valve - disassemble 7.5.5 Conventional injection valve - disassemble Periodicity Description Working hours 18 000 Working hours 6000 for DF engine 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 273 AA00-2722-01AAA-530A-A X82-B Maintenance Manual Conventional injection valve - disassemble PROCEDURE Make sure that the test bench 94272 has no pressure. Remove the cover from the valve holder. Make sure that the leakage oil hose is disconnected from the injection valve (005, Figure 7-32).

  • Page 274: Injection Valve (Example) - Disassemble

    AA00-2722-01AAA-530A-A X82-B Maintenance Manual Conventional injection valve - disassemble Fig 7-32 Injection valve (example) - disassemble 00704 Turn the valve holder through 180° so that the nozzle tip (008) points up. Use the torque spanner 94011A (002) and adapter to carefully loosen the locknut (001).
  • Page 275 AA00-2722-01AAA-530A-A X82-B Maintenance Manual Conventional injection valve - disassemble Use the slugging wrench 94269A-70 (004) and the hydraulic cylinder (007) to loosen the coupling nut (010). Remove the coupling nut (010). Remove the spring tensioner (015) and the compression spring (014).

  • Page 276: Nozzle Tip (Example) - Replace

    AA00-2722-01AAA-530A-A X82-B Maintenance Manual Conventional injection valve - disassemble If it is necessary to remove the nozzle tip (001, Figure 7-33) from the nozzle body (006), do as follows: 14.1 Make sure that the needle, the compression spring and the tappet are removed.
  • Page 277 AA00-2722-01AAA-530A-A X82-B Maintenance Manual Conventional injection valve - disassemble Page left intentionally blank - 277 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 278: Conventional Injection Valve - Assemble

    AA00-2722-01AAA-710A-A X82-B Maintenance Manual Conventional injection valve - assemble 7.5.6 Conventional injection valve - assemble Periodicity Description Working hours 18 000 Working hours 6000 for DF engine 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: Nozzle Body - Installation

    AA00-2722-01AAA-710A-A X82-B Maintenance Manual Conventional injection valve - assemble PROCEDURE Make sure that the needle (008, Figure 7-34), is removed from the nozzle body (003). Attach the nozzle body (003) to the injection valve (005) with the coupling nut (004).
  • Page 280 AA00-2722-01AAA-710A-A X82-B Maintenance Manual Conventional injection valve - assemble Fig 7-35 Nozzle body - installation 00707 Make sure that the sealing faces of the nozzle body (003, Figure 7-36) and nozzle holder (004): • Are clean and dry • Are in a satisfactory condition •...

  • Page 281: Injection Valve (Example) - Assemble

    AA00-2722-01AAA-710A-A X82-B Maintenance Manual Conventional injection valve - assemble Fig 7-36 Injection valve (example) - assemble TS = TT x D1 D2 + D1 Example: TS for coupling nut (002): 200 x 530 = 175 Nm 75 + 530 250 x 530...
  • Page 282 AA00-2722-01AAA-710A-A X82-B Maintenance Manual Conventional injection valve - assemble CLOSE UP • Install the injection valve, refer to section 7.5.7 Conventional injection valve - install - 282 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 283 AA00-2722-01AAA-710A-A X82-B Maintenance Manual Conventional injection valve - assemble Page left intentionally blank - 283 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 284: Conventional Injection Valve - Install

    AA00-2722-01AAA-720A-A X82-B Maintenance Manual Conventional injection valve - install 7.5.7 Conventional injection valve - install 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 285: Injection Valve (Example) - Install

    If the spring cage (001) was disassembled, make sure that they are correctly assembly as shown. Make sure that the starting distance X = 1.7 +- 0.1 mm (for X82-B - X = 1.6 +- 0.1 mm). NOTE: The distance Y is approximately 5 mm.
  • Page 286 AA00-2722-01AAA-720A-A X82-B Maintenance Manual Conventional injection valve - install CLOSE UP • Install the HP fuel pipe, refer to section 13.3.3 HP fuel pipe (fuel rail to injection valve) - install - 286 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 287 AA00-2722-01AAA-720A-A X82-B Maintenance Manual Conventional injection valve - install Page left intentionally blank - 287 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 288: Starting Air Valve

    AA00-2728-01AAA-520A-A X82-B Maintenance Manual Starting air valve - remove Starting air valve 7.6.1 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 289: Starting Air Valve - Preparation

    AA00-2728-01AAA-520A-A X82-B 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 7-38) from the starting air valve (001). Fig 7-38 Starting air valve - preparation...

  • Page 290: Starting Air Valve - Removal

    AA00-2728-01AAA-520A-A X82-B Maintenance Manual Starting air valve - remove Fig 7-39 Starting air valve - removal 00710 CLOSE UP • None - 290 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 291 AA00-2728-01AAA-520A-A X82-B Maintenance Manual Starting air valve - remove Page left intentionally blank - 291 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 292: Starting Air Valve - Disassemble

    AA00-2728-01AAA-530A-A X82-B Maintenance Manual Starting air valve - disassemble 7.6.2 Starting air valve - disassemble 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 293 AA00-2728-01AAA-530A-A X82-B 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 two screws (010, Figure 7-40). Remove the cover (001) together with the 3/2-way solenoid valve (009).

  • Page 294: Starting Air Valve - Grind

    AA00-2728-00AAA-655A-A X82-B Maintenance Manual Starting air valve - grind 7.6.3 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 295 AA00-2728-00AAA-655A-A X82-B Maintenance Manual Starting air valve - grind PROCEDURE If the seating faces of the housing (001, Figure 7-41) 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 296: Starting Air Valve - Assemble

    AA00-2728-01AAA-710A-A X82-B Maintenance Manual Starting air valve - assemble 7.6.4 Starting air valve - assemble 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 297 AA00-2728-01AAA-710A-A X82-B Maintenance Manual Starting air valve - assemble PROCEDURE Clean all the parts of the starting air valve. NOTE: Do not apply lubricant to the synthetic locking ring of the Allen screw (008, Figure 7-42). Apply a thin layer of oil to all the parts of the starting air valve.

  • Page 298: Starting Air Valve - Install

    AA00-2728-01AAA-720A-A X82-B Maintenance Manual Starting air valve - install 7.6.5 Starting air valve - install 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 299: Starting Air Valve - Installation

    AA00-2728-01AAA-720A-A X82-B Maintenance Manual Starting air valve - install PROCEDURE Put a new gasket (003) in the bore of the cylinder cover (002) Apply a thin layer of oil to the bore of the cylinder cover (002). Carefully attach the starting air valve to the cylinder cover (002) with the four M20 bolts (004).

  • Page 300: Exhaust Valve

    AA00-2751-00AAA-520A-A X82-B Maintenance Manual Exhaust valve - remove Exhaust valve 7.7.1 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 301: Exhaust Valve - Preparation

    AA00-2751-00AAA-520A-A X82-B Maintenance Manual Exhaust valve - remove PROCEDURE Prepare the exhaust valve for removal. Remove the hydraulic pipe (001, Figure 7-44) from the exhaust valve, refer to 13.2.1 Hydraulic pipe exhaust valve - remove. Remove all other pipes from the exhaust valve.

  • Page 302: Exhaust Valve - Removal

    AA00-2751-00AAA-520A-A X82-B Maintenance Manual Exhaust valve - remove Remove and discard the O-rings (010, 011) from the valve cage and valve seat. Fig 7-45 Exhaust valve - removal 00718 - 302 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 303 AA00-2751-00AAA-520A-A X82-B Maintenance Manual Exhaust valve - remove CLOSE UP • None - 303 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 304: Exhaust Valve - Disassemble

    AA00-2751-00AAA-530A-A X82-B Maintenance Manual Exhaust valve - disassemble 7.7.2 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 305 AA00-2751-00AAA-530A-A X82-B Maintenance Manual Exhaust valve - disassemble PROCEDURE Disassemble the valve drive. Attach the engine room crane to the eye bolt (001, Figure 7-46). Remove the nuts (003). Remove the top housing (002). Remove the screws (008). Remove the transmitter housing (007).
  • Page 306 AA00-2751-00AAA-530A-A X82-B Maintenance Manual Exhaust valve - disassemble Fig 7-46 Exhaust valve - disassemble Remove the guide bush. Remove the Allen screws (001, Figure 7-47). 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 307: Guide Bush - Removal

    AA00-2751-00AAA-530A-A X82-B Maintenance Manual Exhaust valve - disassemble Fig 7-47 Guide bush - removal CLOSE UP • None - 307 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 308: Exhaust Valve - Remove The Seat (Recommended Procedure)

    AA00-2751-01AAA-520A-A X82-B Maintenance Manual Exhaust valve - remove the seat (recommended procedure) 7.7.3 Exhaust valve - remove the seat (recommended procedure) Periodicity Description One Time - after first working hours 18 000 Working hours 36 000 Duration for performing preliminary requirements 0.0 man-hours...

  • Page 309: Valve Seat - Remove

    AA00-2751-01AAA-520A-A X82-B Maintenance Manual Exhaust valve - remove the seat (recommended procedure) PROCEDURE Mark the position of the valve seat (001, Figure 7-48) in the valve cage. Turn the valve cage (002) until the valve seat (001) points up. Carefully put the valve cage (001) on to an applicable wooden support (003).

  • Page 310: Exhaust Valve - Remove The Seat (Alternative Procedure)

    AA00-2751-01AAA-520B-A X82-B Maintenance Manual Exhaust valve - remove the seat (alternative procedure) 7.7.4 Exhaust valve - remove the seat (alternative procedure) 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: Valve Seat - Alternative Procedure

    AA00-2751-01AAA-520B-A X82-B Maintenance Manual Exhaust valve - remove the seat (alternative procedure) PROCEDURE Attach the two eye bolts to the valve cage (001, Figure 7-49). Attach an applicable chain to the eye bolts and to the engine room crane. Operate the engine room crane to move the valve cage to a position immediately above the wooden support (003).

  • Page 312: Exhaust Valve - Do A Check Of The Seat

    AA00-2751-01AAA-360A-A X82-B Maintenance Manual Exhaust valve - do a check of the seat 7.7.5 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 313: Exhaust Valve, Clearance

    X52DF X62, X62-B 0.054 to 0.070 X62DF X72, X72-B 0.054 to 0.070 X72DF X82, X82-B 0.120 to 0.150 X82DF X92, X92-B 0.120 to 0.150 X92DF Remove the valve spindle (004) from the guide bush. Do a check of the engineer’s blue paste. The paste must only show on the inner part of the full circumference of the valve spindle.

  • Page 314: Valve Seat Clearance

    AA00-2751-01AAA-360A-A X82-B Maintenance Manual Exhaust valve - do a check of the seat Fig 7-50 Valve seat clearance Engineer’s blue paste mark 00725 CLOSE UP • None - 314 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 315 AA00-2751-01AAA-360A-A X82-B Maintenance Manual Exhaust valve - do a check of the seat Page left intentionally blank - 315 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 316: Exhaust Valve - Grind The Seat

    AA00-2751-01AAA-655A-A X82-B Maintenance Manual Exhaust valve - grind the seat 7.7.6 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 317: Valve Seat - Grinding Tool

    AA00-2751-01AAA-655A-A X82-B Maintenance Manual Exhaust valve - grind the seat PROCEDURE Read the data in the manufacturer’s manual for the grinding tool (003, Figure 7-51). 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 318: Exhaust Valve - Install The Seat

    AA00-2751-01AAA-720A-A X82-B Maintenance Manual Exhaust valve - install the seat 7.7.7 Exhaust valve - install 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 Duration for performing the procedure 1.0 man-hours...

  • Page 319: Valve Seat - Install

    AA00-2751-01AAA-720A-A X82-B Maintenance Manual Exhaust valve - install the seat PROCEDURE Clean the bores and the sealing faces of the valve cage (003, Figure 7-52) and of the valve seat (005). Apply oil or Never-Seez NBST-8 to the bores and to the sealing faces of the valve cage (003) and of the valve seat (005).

  • Page 320: Exhaust Valve - Assemble

    AA00-2751-00AAA-710A-A X82-B Maintenance Manual Exhaust valve - assemble 7.7.8 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 321: Guide Bush - Installation

    AA00-2751-00AAA-710A-A X82-B Maintenance Manual Exhaust valve - assemble PROCEDURE Install the guide bush. Clean the bore in the valve cage (002, Figure 7-53). Clean the guide bush (003). Make sure that the oil bores (004) in the guide bush (003) are clear.
  • Page 322 AA00-2751-00AAA-710A-A X82-B 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 323: Valve Spindle - Installation

    AA00-2751-00AAA-710A-A X82-B Maintenance Manual Exhaust valve - assemble Fig 7-54 Valve spindle - installation 3.12 Attach the engine room crane to the eye bolt (001, Figure 7-55). 3.13 Operate the engine room crane to lift and lower the top housing (003) on to the bottom housing (006).

  • Page 324: Damper Settings

    90.4 X40DF 140.0 X52DF X62, X62-B 143.7 X62DF X72, X72-B 165.2 X72DF X82, X82-B 175.0 X82DF X92, X92-B 228.7 X92DF Install the valve stroke sensor. Clean the parts that follow: - 324 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 325: Valve Stroke Sensor, Throttle And Non-Return Valve

    AA00-2751-00AAA-710A-A X82-B Maintenance Manual Exhaust valve - assemble • The valve stroke sensor (004, Figure 7-56) • 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 326 AA00-2751-00AAA-710A-A X82-B Maintenance Manual Exhaust valve - assemble CLOSE UP • Install the exhaust valve, refer to section 7.7.9 Exhaust valve - install - 326 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 327 AA00-2751-00AAA-710A-A X82-B Maintenance Manual Exhaust valve - assemble Page left intentionally blank - 327 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 328: Exhaust Valve - Install

    AA00-2751-00AAA-720A-A X82-B Maintenance Manual Exhaust valve - install 7.7.9 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 329: Exhaust Valve - Installation

    AA00-2751-00AAA-720A-A X82-B 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 330: Expansion Piece - Installation

    AA00-2751-00AAA-720A-A X82-B 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 331: Exhaust Valve - Complete The Installation

    AA00-2751-00AAA-720A-A X82-B Maintenance Manual Exhaust valve - install Fig 7-59 Exhaust valve - complete the installation 00719 CLOSE UP • None - 331 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 332 AA00-2751-00AAA-720A-A X82-B Maintenance Manual Exhaust valve - install Page left intentionally blank - 332 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 333: Group 3 - Crankshaft, Connecting Rod And Piston

    X82-B Maintenance Manual 8 Group 3 - Crankshaft, connecting rod and piston Crankshaft 8.1.1 Crankshaft - do a check of the crank deflection......
  • Page 334 X82-B Maintenance Manual 8.8.3 Piston ring groove (piston installed) - do a check with a ring piece..496 8.8.4 Piston ring groove (piston removed) - do a check with a calliper gauge..
  • Page 335 X82-B Maintenance Manual Page left intentionally blank - 335 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 336: Crankshaft

    AA00-3103-00AAA-360A-A X82-B 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 337: 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 338: Crank Positions For Clockwise Direction

    AA00-3103-00AAA-360A-A X82-B 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 339: Maximum Permitted Difference In Mm

    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 X82DF X92, X92-B 0.06 X92DF Fig 8-3 Definitions of positions TDC ES TDC FS Legend Dial gauge position 4.11 Do also the visual inspections that follow: •...

  • Page 340: Crank-Web Deflection Limits In Mm

    X62DF -0.56 -0.40 -0.40 -0.56 -0.18 X72, X72-B 0.82 0.58 0.58 0.58 0.27 X72DF -0.82 -0.58 -0.58 -0.82 -0.27 X82, X82-B 0.90 0.64 0.64 0.64 0.29 X82DF -0.90 -0.64 -0.64 -0.90 -0.29 X92, X92-B 1.08 0.76 0.76 0.76 0.35 X92DF -1.08...

  • Page 341: 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 - 341 - Issue 001 2020-10 Winterthur Gas &...

  • Page 342: Crankshaft - Install The Work Platform

    AA00-3103-00AAA-720A-A X82-B 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 343 AA00-3103-00AAA-720A-A X82-B 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 344: Crankshaft - Remove The Work Platform

    AA00-3103-00AAA-520A-A X82-B 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 345 AA00-3103-00AAA-520A-A X82-B 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 346: Torsional Vibration Damper

    AA00-3130-00AAA-310A-A X82-B 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 347 AA00-3130-00AAA-310A-A X82-B Maintenance Manual Torsional vibration damper - examine PROCEDURE Examine the torsional vibration damper related to the manufacturer’s instructions. CLOSE UP • None - 347 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 348: Axial Vibration Damper

    AA00-3140-00AAA-530A-A X82-B 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 349: Axial Vibration Damper - Housing And Pipes

    AA00-3140-00AAA-530A-A X82-B 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 350 AA00-3140-00AAA-530A-A X82-B 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 351: Axial Vibration Damper - Move

    AA00-3140-00AAA-530A-A X82-B Maintenance Manual Axial vibration damper - disassemble Fig 8-9 Axial vibration damper - move CLOSE UP • None - 351 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 352: Axial Vibration Damper - Assemble

    AA00-3140-00AAA-710A-A X82-B 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 353 AA00-3140-00AAA-710A-A X82-B 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 354: Axial Vibration Damper - Install

    AA00-3140-00AAA-710A-A X82-B 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 355: Axial Vibration Damper - Bolts

    AA00-3140-00AAA-710A-A X82-B 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 356 AA00-3140-00AAA-710A-A X82-B Maintenance Manual Axial vibration damper - assemble Fig 8-12 Axial vibration damper - housing and pipes CLOSE UP • None - 356 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 357 AA00-3140-00AAA-710A-A X82-B Maintenance Manual Axial vibration damper - assemble Page left intentionally blank - 357 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 358: Turning Gear

    AA00-3206-00AAA-360A-A X82-B 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 359 AA00-3206-00AAA-360A-A X82-B 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 360: Turning Gear - Lubricate The Teeth

    AA00-3206-00AAA-240A-A X82-B 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 361: Turning Gear And Gear Wheels

    AA00-3206-00AAA-240A-A X82-B 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 362: Recommended Suppliers

    AA00-3206-00AAA-240A-A X82-B 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 363 AA00-3206-00AAA-240A-A X82-B Maintenance Manual Turning gear - lubricate the teeth Page left intentionally blank - 363 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 364: Connecting Rod

    AA00-3303-00AAA-523A-A X82-B 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 365 AA00-3303-00AAA-523A-A X82-B 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 366 AA00-3303-00AAA-523A-A X82-B 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 367 AA00-3303-00AAA-523A-A X82-B Maintenance Manual Connecting rod - prepare before removal Page left intentionally blank - 367 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 368: Connecting Rod - Remove

    AA00-3303-00AAA-520A-A X82-B 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 369 AA00-3303-00AAA-520A-A X82-B 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 - 369 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 370 AA00-3303-00AAA-520A-A X82-B 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 371: Connecting Rod - Move

    AA00-3303-00AAA-520A-A X82-B 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°. - 371 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 372 AA00-3303-00AAA-520A-A X82-B 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 373 AA00-3303-00AAA-520A-A X82-B 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. - 373 - Issue 001 2020-10 Winterthur Gas &...
  • Page 374 AA00-3303-00AAA-520A-A X82-B 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 375: Connecting Rod - Move 2

    AA00-3303-00AAA-520A-A X82-B Maintenance Manual Connecting rod - remove Fig 8-21 Connecting rod - move 2 - 375 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 376 AA00-3303-00AAA-520A-A X82-B Maintenance Manual Connecting rod - remove CLOSE UP • None - 376 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 377 AA00-3303-00AAA-520A-A X82-B Maintenance Manual Connecting rod - remove Page left intentionally blank - 377 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 378: Connecting Rod - Install

    AA00-3303-00AAA-720A-A X82-B Maintenance Manual Connecting rod - install 8.5.3 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 379 AA00-3303-00AAA-720A-A X82-B 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 8-22) to the positions shown.

  • Page 380: Connecting Rod - Move 2

    AA00-3303-00AAA-720A-A X82-B Maintenance Manual Connecting rod - install Fig 8-22 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 381 AA00-3303-00AAA-720A-A X82-B 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 8-23) to lift the connecting rod (001) to sufficient height.
  • Page 382 AA00-3303-00AAA-720A-A X82-B Maintenance Manual Connecting rod - install Fig 8-23 Connecting rod - install 1 Operate the turning gear and the chain block (002, Figure 8-24) 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 383 AA00-3303-00AAA-720A-A X82-B 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 384 AA00-3303-00AAA-720A-A X82-B Maintenance Manual Connecting rod - install Fig 8-24 Connecting rod - install 2 Operate the chain block (006, Figure 8-25) to lift the crosshead a small distance. Remove the two supports (001). - 384 - Issue 001 2020-10...
  • Page 385 AA00-3303-00AAA-720A-A X82-B 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 386: Crosshead - Install

    AA00-3303-00AAA-720A-A X82-B Maintenance Manual Connecting rod - install Fig 8-25 Crosshead - install Remove all lever chain hoists, chain blocks, eye bolts, shackles and other equipment. Remove the protection from the crosshead pin. - 386 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 387: Toggle Lever - Attach

    AA00-3303-00AAA-720A-A X82-B 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 8-22) to the crosshead (002). Make sure that the toggle lever is in the position shown.

  • Page 388: Piston - Attach

    AA00-3303-00AAA-720A-A X82-B Maintenance Manual Connecting rod - install Fig 8-27 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 389 AA00-3303-00AAA-720A-A X82-B Maintenance Manual Connecting rod - install Page left intentionally blank - 389 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 390: Connecting Rod - Remove The Top End Bearing

    AA00-3303-02AAA-520A-A X82-B 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 391: Top End Bearing - Remove

    AA00-3303-02AAA-520A-A X82-B 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 8-28) to move the connecting rod (003) to the fuel side.

  • Page 392: Connecting Rod - Remove The Bottom End Bearing

    AA00-3303-03AAA-520A-A X82-B 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 393 AA00-3303-03AAA-520A-A X82-B 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 - 393 - Issue 001 2020-10...

  • Page 394: Bottom End Bearing Cover - Move

    AA00-3303-03AAA-520A-A X82-B 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 8-29) is at TDC. Lock the turning gear.

  • Page 395: Bottom End Bearing Shell - Remove

    AA00-3303-03AAA-520A-A X82-B 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 396 AA00-3303-03AAA-520A-A X82-B 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 397: Bottom End Bearing

    AA00-3303-03AAA-520A-A X82-B Maintenance Manual Connecting rod - remove the bottom end bearing Fig 8-32 Bottom end bearing 3.11 Attach the shackles (001, Figure 8-33) 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 398: Top Bearing Shell - Remove

    AA00-3303-03AAA-520A-A X82-B Maintenance Manual Connecting rod - remove the bottom end bearing Fig 8-33 Top bearing shell - remove 00768 - 398 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 399 AA00-3303-03AAA-520A-A X82-B Maintenance Manual Connecting rod - remove the bottom end bearing CLOSE UP • None - 399 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 400: Connecting Rod - Examine The Bearing Shells

    AA00-3303-05AAA-310A-A X82-B 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 401 AA00-3303-05AAA-310A-A X82-B Maintenance Manual Connecting rod - examine the bearing shells PROCEDURE Do an inspection of the related bearing shell (001, Figure 8-34). If you find damage, remove the bearing shell (001), refer to section 8.5.2 Connecting rod remove. Fig 8-34...

  • Page 402: Connecting Rod - Install The Bottom End Bearing

    AA00-3303-03AAA-720A-A X82-B 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 403 AA00-3303-03AAA-720A-A X82-B 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 - 403 - Issue 001 2020-10...
  • Page 404 AA00-3303-03AAA-720A-A X82-B 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 8-35) to the console frame (004) with the four screws (006).

  • Page 405: Top Bearing Shell - Move

    AA00-3303-03AAA-720A-A X82-B Maintenance Manual Connecting rod - install the bottom end bearing Fig 8-35 Top bearing shell - move 00768 Operate the turning gear to move the crank (002, Figure 8-36) 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 406: Bottom End Bearing

    AA00-3303-03AAA-720A-A X82-B Maintenance Manual Connecting rod - install the bottom end bearing If necessary, operate the chain block (004) to move the connecting rod (003). Fig 8-36 Bottom end bearing Loosen the screws (003, Figure 8-37). Remove the four bolts (004).

  • Page 407: Iso Vg 1000/1500 Suppliers

    AA00-3303-03AAA-720A-A X82-B Maintenance Manual Connecting rod - install the bottom end bearing Fig 8-37 Supports Attach the four eye bolts (003, Figure 8-38) to the bearing shell - crank pin (005). Attach the chain (001) to the four eye bolts (003).
  • Page 408 AA00-3303-03AAA-720A-A X82-B 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 409: Bottom End Bearing - Install

    AA00-3303-03AAA-720A-A X82-B Maintenance Manual Connecting rod - install the bottom end bearing Fig 8-38 Bottom end bearing - install 00773 - 409 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 410: Iso Vg 1000/1500 Suppliers

    AA00-3303-03AAA-720A-A X82-B 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 411 AA00-3303-03AAA-720A-A X82-B Maintenance Manual Connecting rod - install the bottom end bearing Page left intentionally blank - 411 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 412: Connecting Rod - Install The Top End Bearing

    AA00-3303-02AAA-720A-A X82-B 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 413 AA00-3303-02AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing PROCEDURE Clean the seating surface of the bearing shell (004, Figure 8-39). 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 414: Top End Bearing - Move

    AA00-3303-02AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing Fig 8-39 Top end bearing - move 009 010 00766 Operate the lever chain hoists (003 and 007, Figure 8-40) to move the connecting rod to the vertical position.

  • Page 415: Crosshead - Lower

    AA00-3303-02AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing Fig 8-40 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 416: Bearing Lubrication

    AA00-3303-02AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing Fig 8-41 Bearing lubrication CLOSE UP • None - 416 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 417 AA00-3303-02AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing Page left intentionally blank - 417 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 418: Connecting Rod - Remove The Top End Bearing Cover

    AA00-3303-01AAA-520A-A X82-B Maintenance Manual Connecting rod - remove the top end bearing cover 8.5.9 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 419 AA00-3303-01AAA-520A-A X82-B 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 - 419 - Issue 001 2020-10...
  • Page 420 AA00-3303-01AAA-520A-A X82-B 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 421: Equipment - Install

    AA00-3303-01AAA-520A-A X82-B Maintenance Manual Connecting rod - remove the top end bearing cover Fig 8-43 Equipment - install 00741 Remove the four round nuts (005, Figure 8-42) from the elastic bolts (004), refer to section 4.3 Loosen a round nut with a pre-tensioner.

  • Page 422: Top Bearing Cover - Removal

    AA00-3303-01AAA-520A-A X82-B Maintenance Manual Connecting rod - remove the top end bearing cover Fig 8-44 Top bearing cover - removal 00740 - 422 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 423 AA00-3303-01AAA-520A-A X82-B Maintenance Manual Connecting rod - remove the top end bearing cover CLOSE UP • None - 423 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 424: Connecting Rod - Install The Top End Bearing Cover

    AA00-3303-01AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing cover 8.5.10 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 425: Top Bearing Cover - Move

    AA00-3303-01AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing cover PROCEDURE Make sure that the bearing cover (003, Figure 8-45) has no damage. Attach the two eye bolts (002) to the bearing cover (003). Attach the shackle (001) to the chain (005).
  • Page 426 AA00-3303-01AAA-720A-A X82-B 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 427: Top Bearing Cover - Install

    AA00-3303-01AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing cover Fig 8-46 Top bearing cover - install 00742 - 427 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 428 AA00-3303-01AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing cover CLOSE UP • None - 428 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 429 AA00-3303-01AAA-720A-A X82-B Maintenance Manual Connecting rod - install the top end bearing cover Page left intentionally blank - 429 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 430: Crosshead - Remove

    AA00-3326-00AAA-520A-A X82-B 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 431 AA00-3326-00AAA-520A-A X82-B 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 432: Toggle Lever - Remove

    AA00-3326-00AAA-520A-A X82-B 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 433: Crosshead Bearing - Temperature Sensor

    AA00-3326-00AAA-520A-A X82-B 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 434: Tools - Prepare

    AA00-3326-00AAA-520A-A X82-B 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 435: Bracket - Attach

    AA00-3326-00AAA-520A-A X82-B 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 436: Tools - Attach

    AA00-3326-00AAA-520A-A X82-B 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 437: Connecting Rod - Move

    AA00-3326-00AAA-520A-A X82-B 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 438: Crosshead - Move

    AA00-3326-00AAA-520A-A X82-B 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 439: Crosshead - Remove

    AA00-3326-00AAA-520A-A X82-B 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 440 AA00-3326-00AAA-520A-A X82-B 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 441: Crosshead - Remove

    AA00-3326-00AAA-520A-A X82-B 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 442: Guide Shoes - Remove

    AA00-3326-00AAA-520A-A X82-B 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 443 AA00-3326-00AAA-520A-A X82-B Maintenance Manual Crosshead - remove Page left intentionally blank - 443 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 444: Crosshead - Do A Check Of The Clearances

    AA00-3326-00AAA-360A-A X82-B 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 445: Clearance Checks

    AA00-3326-00AAA-360A-A X82-B 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 446: Dimensions Check

    AA00-3326-00AAA-360A-A X82-B 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).
  • Page 447 AA00-3326-00AAA-360A-A X82-B Maintenance Manual Crosshead - do a check of the clearances Page left intentionally blank - 447 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 448: Crosshead - Install

    AA00-3326-00AAA-720A-A X82-B 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 449 AA00-3326-00AAA-720A-A X82-B 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 450: Guide Shoe - Move

    AA00-3326-00AAA-720A-A X82-B 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 451 AA00-3326-00AAA-720A-A X82-B 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 452: Guide Shoes - Install

    AA00-3326-00AAA-720A-A X82-B 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 453 AA00-3326-00AAA-720A-A X82-B 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 454 AA00-3326-00AAA-720A-A X82-B 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. - 454 - Issue 001 2020-10 Winterthur Gas &...

  • Page 455: Tools - Remove

    AA00-3326-00AAA-720A-A X82-B 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 456 AA00-3326-00AAA-720A-A X82-B 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 457 AA00-3326-00AAA-720A-A X82-B 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 [section not applicable for this engine].

  • Page 458: Piston

    AA00-3403-00AAA-360A-A X82-B 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 459: Top Surface - Dimensions Check

    AA00-3403-00AAA-360A-A X82-B 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 460: 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 461 AA00-3403-00AAA-360A-A X82-B Maintenance Manual Piston (installed) - do checks of the surface and clearances Page left intentionally blank - 461 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 462: Piston - Prepare Before Removal

    AA00-3403-00AAA-523A-A X82-B 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 463: Piston - Preparation

    AA00-3403-00AAA-523A-A X82-B 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 464 AA00-3403-00AAA-523A-A X82-B 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 465: Piston - Preparation Before Removal (Example)

    AA00-3403-00AAA-523A-A X82-B Maintenance Manual Piston - prepare before removal Fig 8-69 Piston - Preparation before removal (example) 00780 - 465 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 466 AA00-3403-00AAA-523A-A X82-B Maintenance Manual Piston - prepare before removal CLOSE UP • None - 466 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 467 AA00-3403-00AAA-523A-A X82-B Maintenance Manual Piston - prepare before removal Page left intentionally blank - 467 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 468: Piston - Remove

    AA00-3403-00AAA-520A-A X82-B 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 469 AA00-3403-00AAA-520A-A X82-B 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 470 AA00-3403-00AAA-520A-A X82-B Maintenance Manual Piston - remove CLOSE UP • None - 470 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 471 AA00-3403-00AAA-520A-A X82-B Maintenance Manual Piston - remove Page left intentionally blank - 471 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 472: Piston - Disassemble

    AA00-3403-00AAA-530A-A X82-B 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 473: Piston - Preparation Before Disassembly

    AA00-3403-00AAA-530A-A X82-B 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 474 AA00-3403-00AAA-530A-A X82-B Maintenance Manual Piston - disassemble Fig 8-72 Piston - disassemble (example) 00781 - 474 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 475 AA00-3403-00AAA-530A-A X82-B Maintenance Manual Piston - disassemble CLOSE UP • None - 475 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 476: Piston (Removed) - Do Checks Of The Surface And Clearances

    AA00-3403-00AAA-360B-A X82-B 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 477: Piston Groove Clearance - Calliper Gauge

    AA00-3403-00AAA-360B-A X82-B 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 478 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 479 AA00-3403-00AAA-360B-A X82-B Maintenance Manual Piston (removed) - do checks of the surface and clearances Page left intentionally blank - 479 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 480: Piston - Assemble

    AA00-3403-00AAA-710A-A X82-B 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 481: Torque Values

    AA00-3403-00AAA-710A-A X82-B 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 482 AA00-3403-00AAA-710A-A X82-B 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 483 AA00-3403-00AAA-710A-A X82-B Maintenance Manual Piston - assemble Page left intentionally blank - 483 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 484: Piston - Install

    AA00-3403-00AAA-720A-A X82-B 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 485: Piston - Move (Example)

    AA00-3403-00AAA-720A-A X82-B 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 486 AA00-3403-00AAA-720A-A X82-B 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 487: Piston Rod Gland - Attach (Example)

    AA00-3403-00AAA-720A-A X82-B 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 488 AA00-3403-00AAA-720A-A X82-B Maintenance Manual Piston - install Fig 8-79 Piston - attach (example) 00786 CLOSE UP • None - 488 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 489 AA00-3403-00AAA-720A-A X82-B Maintenance Manual Piston - install Page left intentionally blank - 489 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 490: Piston Ring

    AA00-3425-00AAA-520A-A X82-B 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 491: Piston Ring - Remove (Example)

    AA00-3425-00AAA-520A-A X82-B 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 492: Piston Ring - Examine

    AA00-3425-01AAA-360A-A X82-B Maintenance Manual Piston ring - examine 8.8.2 Piston ring - examine Periodicity Description Working hours 1750 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 493: Piston Rings - Measure

    AA00-3425-01AAA-360A-A X82-B Maintenance Manual Piston ring - examine PROCEDURE Chrome ceramic layer - piston installed Step 1.1 Step 1.7 to measure the chrome ceramic layer: Read the data in the suppler documentation for the Permascope MP0 (with instruments to measure chrome-ceramic layers)

  • Page 494: Examples Of Wear Rate

    AA00-3425-01AAA-360A-A X82-B Maintenance Manual Piston ring - examine Fig 8-82 Equation wear rate Where: • WR = wear rate (mm each 1000 hrs) • D1 = first recorded thickness of the chrome ceramic layer (mm) • D2 = second recorded thickness of the chrome ceramic layer (mm) •...

  • Page 495: Chrome Ceramic Layer

    AA00-3425-01AAA-360A-A X82-B Maintenance Manual Piston ring - examine If a piston ring that has some wear of the chrome-ceramic layer is found, do an overhaul of the unit as soon as possible. Refer to Figure 8-84 for data about worn areas of the chrome ceramic layer.

  • Page 496: Piston Ring Groove (Piston Installed) - Do A Check With A Ring Piece

    AA00-3425-01AAA-361A-A X82-B Maintenance Manual Piston ring groove (piston installed) - do a check with a ring piece 8.8.3 Piston ring groove (piston installed) - do a check with a ring piece Periodicity Description Working hours 54000 Duration for performing preliminary requirements 0.0 man-hours...
  • Page 497 If the clearance at point A is more than the permitted value, do Step 7.1 Step 7.2. Replace the piston rings. Repair the piston head. NOTE: For the repair of piston heads, speak to the nearest WinGD Service Center. CLOSE UP • None - 497 - Issue 001 2020-10...

  • Page 498: Piston Ring Groove (Piston Removed) - Do A Check With A Calliper Gauge

    AA00-3425-01AAA-361B-A X82-B Maintenance Manual Piston ring groove (piston removed) - do a check with a calliper gauge 8.8.4 Piston ring groove (piston removed) - do a check with a calliper gauge Periodicity Description Working hours 54000 Duration for performing preliminary requirements 0.0 man-hours...
  • Page 499 AA00-3425-01AAA-361B-A X82-B Maintenance Manual Piston ring groove (piston removed) - do a check with a calliper gauge PROCEDURE NOTE: You can use the Inside micrometer set, or the Inside micrometer set for this procedure. Measure the height at point A and point B at a minimum of four locations around the circumference of the piston head.

  • Page 500: Piston Ring Groove (Piston Removed) - Do A Check

    AA00-3425-01AAA-361C-A X82-B Maintenance Manual Piston ring groove (piston removed) - do a check 8.8.5 Piston ring groove (piston removed) - do a check Periodicity Description Working hours 54000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...

  • Page 501: Piston Groove Clearance - Ring Piece

    NOTE: If the clearance at X1 is more than the permitted value, you must repair the piston head. For the repair of piston heads, speak to the nearest WinGD Service Center. Do not install a piston head that has clearances near the maximum value because the service life will be too short.

  • Page 502: Piston Ring - Install

    AA00-3425-00AAA-720B-A X82-B Maintenance Manual Piston ring - install 8.8.6 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 503: Piston Rings - Install (Example)

    AA00-3425-00AAA-720B-A X82-B 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 8-88) points up.

  • Page 504: Piston Ring - Do The Preservation

    AA00-3425-01AAA-810A-A X82-B Maintenance Manual Piston ring - do the preservation 8.8.7 Piston ring - do the preservation Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
  • Page 505 AA00-3425-01AAA-810A-A X82-B Maintenance Manual Piston ring - do the preservation PROCEDURE Keep the piston rings in their original packages in a dry area. Make sure that the piston rings are in a horizontal position on a flat surface. To prevent damage, be careful when you prepare the piston rings for installation and during movement.
  • Page 506 AA00-3425-01AAA-810A-A X82-B Maintenance Manual Piston ring - do the preservation Page left intentionally blank - 506 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 507: Group 4 - Supply Unit Drive And Control Components

    X82-B Maintenance Manual 9 Group 4 - Supply unit drive and control components Driving wheels 9.1.1 Gear wheel crankshaft - examine the teeth......

  • Page 508: Driving Wheels

    AA00-4106-00AAA-310A-A X82-B Maintenance Manual Gear wheel crankshaft - examine the teeth Driving wheels 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 509 AA00-4106-00AAA-310A-A X82-B 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 510: Gear Wheel Crankshaft - Do A Check Of The Teeth Backlash

    AA00-4106-00AAA-360A-A X82-B 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 511 AA00-4106-00AAA-360A-A X82-B 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 512: Driving Wheel - Gear Tooth Backlash

    AA00-4106-00AAA-360A-A X82-B 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 - 512 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 513 AA00-4106-00AAA-360A-A X82-B Maintenance Manual Gear wheel crankshaft - do a check of the teeth backlash CLOSE UP • None - 513 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 514: Driving Wheel Gear Train - Monitor The Condition

    AA00-4103-01AAA-370A-A X82-B Maintenance Manual Driving wheel gear train - monitor the condition 9.1.3 Driving wheel gear train - monitor the condition 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 515 AA00-4103-01AAA-370A-A X82-B Maintenance Manual Driving wheel gear train - monitor the condition PROCEDURE After commissioning, do a check of the performance of the gear train as follows: Apply a thin layer of oil resistant engineer’s blue ink to three of the teeth on each of the gear wheels.

  • Page 516: Shut-Off Valve For Starting Air

    AA00-4325-00AAA-530A-A X82-B 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 X82-B 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 X82-B 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: Shut-Off Valve For Starting Air - Disassemble

    AA00-4325-00AAA-530A-A X82-B 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 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 520 AA00-4325-00AAA-530A-A X82-B Maintenance Manual Shut-off valve for starting air - disassemble CLOSE UP • None - 520 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 521 AA00-4325-00AAA-530A-A X82-B Maintenance Manual Shut-off valve for starting air - disassemble Page left intentionally blank - 521 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

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

    AA00-4325-00AAA-710A-A X82-B 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 X82-B 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 X82-B 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 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 525 AA00-4325-00AAA-710A-A X82-B Maintenance Manual Shut-off valve for starting air - assemble CLOSE UP • None - 525 - Issue 001 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 X82-B 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 X82-B 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 X82-B 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 001 2020-10 Winterthur Gas & Diesel Ltd.

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

    X82-B 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 X82-B 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 X82-B 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 X82-B 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 X82-B 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 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 534 AA00-5551-00AAA-520A-A X82-B 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 X82-B Maintenance Manual Servo oil pump - remove Page left intentionally blank - 535 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 536: Servo Oil Pump - Install

    AA00-5551-00AAA-720A-A X82-B 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 X82-B 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 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 538 AA00-5551-00AAA-720A-A X82-B 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 X82-B Maintenance Manual Servo oil pump - install Page left intentionally blank - 539 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 540: Fuel Pump

    AA00-5556-00AAA-520A-A X82-B Maintenance Manual Fuel pump - remove 10.2 Fuel pump 10.2.1 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 541 AA00-5556-00AAA-520A-A X82-B 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 542 AA00-5556-00AAA-520A-A X82-B Maintenance Manual Fuel pump - remove Attach the cover to the pump cover (005). Use the applicable lifting equipment to lift and move the fuel pump. Move the fuel pump to an applicable work bench. Put the fuel pump on its side on the wooden surface. Make sure that you do not cause damage to the toothed rack (008) or and the roller (007).
  • Page 543 AA00-5556-00AAA-520A-A X82-B Maintenance Manual Fuel pump - remove Page left intentionally blank - 543 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 544: Fuel Pump - Disassemble

    AA00-5556-00AAA-530A-A X82-B Maintenance Manual Fuel pump - disassemble 10.2.2 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 545: Guide Pin Removal

    AA00-5556-00AAA-530A-A X82-B 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 10-2) as shown.

  • Page 546: Guide Piston And Roller Removal

    AA00-5556-00AAA-530A-A X82-B Maintenance Manual Fuel pump - disassemble Fig 10-3 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 547: Toothed Rack Removal

    AA00-5556-00AAA-530A-A X82-B Maintenance Manual Fuel pump - disassemble Fig 10-4 Toothed rack removal To remove the toothed rack, do the steps that follow: Disassemble the bottom spring carrier (001, Figure 10-4) together with the pump plunger (003). Put the pump plunger (003) in a dry, clean area to prevent damage.

  • Page 548: Pump Cylinder Removal

    AA00-5556-00AAA-530A-A X82-B Maintenance Manual Fuel pump - disassemble Fig 10-5 Pump cylinder removal 00425 To remove the pump cylinder, do the steps that follow: Turn the pump cover (002, Figure 10-5) to point up. Use applicable equipment to hold the pump cover (002) to the work bench.

  • Page 549: Non-Return Valve Removal

    AA00-5556-00AAA-530A-A X82-B Maintenance Manual Fuel pump - disassemble Fig 10-6 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 10-6). NOTE:...

  • Page 550: Fuel Pump - Assemble

    AA00-5556-00AAA-710A-A X82-B Maintenance Manual Fuel pump - assemble 10.2.3 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 551: Pump Cylinder Installation

    AA00-5556-00AAA-710A-A X82-B 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 552: Pump Cover Installation

    AA00-5556-00AAA-710A-A X82-B Maintenance Manual Fuel pump - assemble Fig 10-8 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 10-8).

  • Page 553: Toothed Rack Assembly

    AA00-5556-00AAA-710A-A X82-B Maintenance Manual Fuel pump - assemble Fig 10-9 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 10-9) points down. Attach the top housing (002) to the work bench.

  • Page 554: Pump Plunger And Bottom Housing Assembly

    AA00-5556-00AAA-710A-A X82-B Maintenance Manual Fuel pump - assemble Fig 10-10 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 10-10) and the compression spring (002).

  • Page 555: Plunger Position Check

    AA00-5556-00AAA-710A-A X82-B Maintenance Manual Fuel pump - assemble Fig 10-11 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 10-11) to the position shown.
  • Page 556 AA00-5556-00AAA-710A-A X82-B 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 557 AA00-5556-00AAA-710A-A X82-B Maintenance Manual Fuel pump - assemble Page left intentionally blank - 557 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 558: Fuel Pump - Install

    AA00-5556-00AAA-720A-A X82-B Maintenance Manual Fuel pump - install 10.2.4 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 559: Fuel Pump Installation

    AA00-5556-00AAA-720A-A X82-B 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 10-12 Fuel pump installation...
  • Page 560 AA00-5556-00AAA-720A-A X82-B 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 - 560 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 561 AA00-5556-00AAA-720A-A X82-B Maintenance Manual Fuel pump - install Page left intentionally blank - 561 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 562: Fuel Pump - Do A Test Of The Operation

    AA00-5556-00AAA-320A-A X82-B Maintenance Manual Fuel pump - do a test of the operation 10.2.5 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 563: Fuel Pump - Oil Flow

    AA00-5556-00AAA-320A-A X82-B 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 564 AA00-5556-00AAA-320A-A X82-B Maintenance Manual Fuel pump - do a test of the operation CLOSE UP • None - 564 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 565 AA00-5556-00AAA-320A-A X82-B Maintenance Manual Fuel pump - do a test of the operation Page left intentionally blank - 565 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 566: Fuel Pump Actuator

    AA00-5583-00AAA-273A-A X82-B Maintenance Manual Fuel pump actuator - calibrate 10.3 Fuel pump actuator 10.3.1 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 567: Calibration Illustration

    AA00-5583-00AAA-273A-A X82-B 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 10-14 Put a bridging wire between terminals 5 and 43.
  • Page 568 AA00-5583-00AAA-273A-A X82-B Maintenance Manual Fuel pump actuator - calibrate CLOSE UP • None - 568 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 569 AA00-5583-00AAA-273A-A X82-B Maintenance Manual Fuel pump actuator - calibrate Page left intentionally blank - 569 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 570: Fuel Pump Actuator - Adjust

    AA00-5583-00AAA-360A-A X82-B Maintenance Manual Fuel pump actuator - adjust 10.3.2 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 571: Actuator - Adjust

    AA00-5583-00AAA-360A-A X82-B 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 10-15) from the lever (002). Put the lever (002) in position on the shaft (003).

  • Page 572: Actuator - Adjust -2

    AA00-5583-00AAA-360A-A X82-B Maintenance Manual Fuel pump actuator - adjust Fig 10-16 Actuator - adjust -2 CLOSE UP • None - 572 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 573 AA00-5583-00AAA-360A-A X82-B Maintenance Manual Fuel pump actuator - adjust Page left intentionally blank - 573 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 574: Fuel Pressure Control Valve

    AA00-5562-00AAA-520A-A X82-B Maintenance Manual Fuel rail - remove the pressure control valve 10.4 Fuel pressure control valve 10.4.1 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 575: Pressure Control Valve - Remove

    AA00-5562-00AAA-520A-A X82-B Maintenance Manual Fuel rail - remove the pressure control valve PROCEDURE Loosen the angle union (006, Figure 10-17). Remove the fuel return pipe (005) from the pressure control valve (PCV) (001). Disconnect the electrical connection from the solenoid valve (009).

  • Page 576: Fuel Rail - Do A Check Of The Pressure Control Valve

    AA00-5562-00AAA-360A-A X82-B Maintenance Manual Fuel rail - do a check of the pressure control valve 10.4.2 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 577: Pcv - Do A Check

    AA00-5562-00AAA-360A-A X82-B 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 10-18) around the PCV test block (009).
  • Page 578 AA00-5562-00AAA-360A-A X82-B 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.
  • Page 579 AA00-5562-00AAA-360A-A X82-B Maintenance Manual Fuel rail - do a check of the pressure control valve Page left intentionally blank - 579 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 580: Fuel Rail - Install The Pressure Control Valve

    AA00-5562-00AAA-720A-A X82-B Maintenance Manual Fuel rail - install the pressure control valve 10.4.3 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 581: Pressure Control Valve - Install

    AA00-5562-00AAA-720A-A X82-B Maintenance Manual Fuel rail - install the pressure control valve PROCEDURE Remove the protection from the valve block (003, Figure 10-19). 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 582: Fuel Overpressure Safety Valve

    AA00-5562-01AAA-520A-A X82-B Maintenance Manual Fuel rail - remove the overpressure safety valve 10.5 Fuel overpressure safety valve 10.5.1 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 583 AA00-5562-01AAA-520A-A X82-B Maintenance Manual Fuel rail - remove the overpressure safety valve PROCEDURE Use the socket wrench to remove the relief valve (001, Figure 10-20) 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 584: Fuel Rail - Do A Check Of The Overpressure Safety Valve

    AA00-5562-01AAA-360A-A X82-B Maintenance Manual Fuel rail - do a check of the overpressure safety valve 10.5.2 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 585 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. - 585 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 586: Fuel Overpressure Safety Valve - Pressure Check

    AA00-5562-01AAA-360A-A X82-B Maintenance Manual Fuel rail - do a check of the overpressure safety valve Fig 10-21 Fuel overpressure safety valve - pressure check 00827 CLOSE UP • None - 586 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 587 AA00-5562-01AAA-360A-A X82-B Maintenance Manual Fuel rail - do a check of the overpressure safety valve Page left intentionally blank - 587 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 588: Fuel Rail - Install The Overpressure Safety Valve

    AA00-5562-01AAA-720A-A X82-B Maintenance Manual Fuel rail - install the overpressure safety valve 10.5.3 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 589: Fuel Overpressure Safety Valve - Installation

    AA00-5562-01AAA-720A-A X82-B Maintenance Manual Fuel rail - install the overpressure safety valve PROCEDURE Apply Never-Seez NSBT-8 to the thread of valve housing (002, Figure 10-22). Put the relief valve (001) in the connecting piece (004) of the fuel rail (003).

  • Page 590: Injection Control Unit

    AA00-5562-03AAA-520A-A X82-B Maintenance Manual Injection control unit - remove 10.6 Injection control unit 10.6.1 Injection control unit - remove Periodicity Description Working hours 36000 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 591 AA00-5562-03AAA-520A-A X82-B Maintenance Manual Injection control unit - remove PRELIMINARY OPERATIONS • The engine must be stopped and made safe for maintenance. • The fuel rail must have no pressure. • The fuel injection system must have no pressure. •...
  • Page 592 AA00-5562-03AAA-520A-A X82-B Maintenance Manual Injection control unit - remove PROCEDURE Remove the pipes (001, 002, 003 and 004, 005, Figure 10-23) from the ICU. Apply protection to the pipes (001, 002, 003, 004 and 005). Apply protection to the openings on the injection control unit (ICU).

  • Page 593: Icu - Move

    AA00-5562-03AAA-520A-A X82-B Maintenance Manual Injection control unit - remove Make sure that the dowel pins (005) stay in the fuel rail (004). Apply protection to the bottom of the ICU (002). Fig 10-24 ICU - move CLOSE UP • If necessary, do the preservation procedure, refer to 10.6.3 Injection control unit - do the...

  • Page 594: Injection Control Unit - Install

    AA00-5562-03AAA-720A-A X82-B Maintenance Manual Injection control unit - install 10.6.2 Injection control unit - install Periodicity Description Working hours 36000 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 595 AA00-5562-03AAA-720A-A X82-B Maintenance Manual Injection control unit - install PROCEDURE Attach the eye bolt (005, Figure 10-25) to the Injection control unit (003). Attach the chain to the engine room crane and the eye bolt (005). Make sure that the lip seal (002) is in position in the bottom of the ICU (003).

  • Page 596: Icu - Connect Pipes

    AA00-5562-03AAA-720A-A X82-B Maintenance Manual Injection control unit - install Fig 10-26 ICU - connect pipes CLOSE UP • Install the HP fuel pipes, refer to 13.3.3 HP fuel pipe (fuel rail to injection valve) - install • Cut in the injection, refer to the Operation Manual.
  • Page 597 AA00-5562-03AAA-720A-A X82-B Maintenance Manual Injection control unit - install Page left intentionally blank - 597 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 598: Injection Control Unit - Do The Preservation

    AA00-5562-03AAA-810A-A X82-B Maintenance Manual Injection control unit - do the preservation 10.6.3 Injection control unit - do the preservation 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 599 AA00-5562-03AAA-810A-A X82-B Maintenance Manual Injection control unit - do the preservation PROCEDURE Use a vacuum cleaner to remove dirt from all openings. Clean the ICU. Lubricate correctly the ICU. Put the ICU in a plastic bag. Remove as much air as possible from the plastic bag.

  • Page 600: Supply Unit

    AA00-5581-01AAA-523A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - prepare before removal 10.7 Supply unit 10.7.1 Supply unit camshaft and bearing shell - prepare before removal Periodicity Description Working hours 90000 Support equipment Description Part No. roller lifting tool...
  • Page 601 AA00-5581-01AAA-523A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - prepare before removal PROCEDURE NOTE: These procedures are applicable to a supply unit that has an independent lubrication system. Remove the covers (002, Figure 10-27) from the casing (003).

  • Page 602: Rollers - Lift

    AA00-5581-01AAA-523A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - prepare before removal Fig 10-28 Rollers - lift NOTE: The oil baffle has four parts. Remove the four bolts (008, Figure 10-29) and locking tabs. Remove the pipe (007) from the oil baffle.

  • Page 603: Oil Baffle

    AA00-5581-01AAA-523A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - prepare before removal Fig 10-29 Oil baffle CLOSE UP • Remove the camshaft and bearing shells, refer to 10.7.2 Supply unit camshaft and bearing shell - remove - 603 - Issue 001 2020-10 Winterthur Gas &...

  • Page 604: Supply Unit Camshaft And Bearing Shell - Remove

    AA00-5581-01AAA-520A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - remove 10.7.2 Supply unit camshaft and bearing shell - remove Periodicity Description Working hours 90000 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 605: Bearing Shells - Remove

    AA00-5581-01AAA-520A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - remove PROCEDURE Bearing shells - removal Loosen the two Allen screws. (002, Figure 10-30). Remove the filling piece (003) from bearing cover No. 2. Attach the two pre-tensioning jacks (004) to the elastic bolts at bearing cover No.

  • Page 606: Camshaft - Remove

    AA00-5581-01AAA-520A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - remove Put the two support (004 and 005, Figure 10-31) in position at No. 2 and No. 5 bearings. On the two supports (004, 005), tighten the nuts (003, 006).
  • Page 607 AA00-5581-01AAA-520A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - remove Page left intentionally blank - 607 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 608: Supply Unit Camshaft And Bearing Shell - Install

    AA00-5581-01AAA-720A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - install 10.7.3 Supply unit camshaft and bearing shell - install Periodicity Description Working hours 90000 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 609 AA00-5581-01AAA-720A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - install PROCEDURE Make sure that all items are clean and do not have damage. Apply to the top bearing shell half, the bottom bearing shell half and the camshaft.

  • Page 610: Camshaft - Install

    AA00-5581-01AAA-720A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - install Make sure that the pin (008, Figure 10-33) is in the bearing cover (009). Attach the bearing cover (009). Put the round nuts (004) on the elastic bolts (003). Tighten the round nuts with your hand.

  • Page 611: Oil Baffle - Install

    AA00-5581-01AAA-720A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - install Turn the segments (005, 004, 002) clockwise approximately 90°. Put the segment (001) in position on the camshaft. Attach the segment (001) to the segments (002, 005) with the taper pin (003) and the four screws (006).

  • Page 612: Supply Unit Bearing Bush - Remove

    AA00-5581-02AAA-520A-A X82-B Maintenance Manual Supply unit bearing bush - remove 10.7.4 Supply unit bearing bush - remove Periodicity Description Working hours 90 000 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 613: Bearing Bushes

    AA00-5581-02AAA-520A-A X82-B Maintenance Manual Supply unit bearing bush - remove PROCEDURE NOTE: The bearing bushes (006 and 007, Figure 10-35) in the housing (010) and the pump support (002) are matched items and thus, are not interchangeable. Do a check of the pinion (008) and shaft (009) for axial clearance and damage, refer to 3.3 Clearances - general...

  • Page 614: Supply Unit Bearing Bush - Install

    AA00-5581-02AAA-720A-A X82-B Maintenance Manual Supply unit bearing bush - install 10.7.5 Supply unit bearing bush - install Periodicity Description Working hours 90 000 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 615 AA00-5581-02AAA-720A-A X82-B Maintenance Manual Supply unit bearing bush - install PROCEDURE Put oil on the new bearing bushes (006 and 007, Figure 10-36). Put a small quantity of on the O-ring (005). Put the O-ring (005) on the pump support (002).

  • Page 616: Supply Unit Camshaft And Bearing Shell - Do The Follow-On Work

    AA00-5581-01AAA-724A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - do the follow-on work 10.7.6 Supply unit camshaft and bearing shell - do the follow-on work Periodicity Description Working hours 90000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours...

  • Page 617: Filling Piece

    AA00-5581-01AAA-724A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - do the follow-on work PROCEDURE Measure the axial clearances and compare the results with those given in Clearances - general. If the axial clearances are not in the specified range, loosen the round nuts on one of the bearing covers, refer to 10.7.2 Supply unit camshaft and bearing shell -...
  • Page 618 AA00-5581-01AAA-724A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - do the follow-on work Fig 10-38 Covers CLOSE UP • None - 618 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 619 AA00-5581-01AAA-724A-A X82-B Maintenance Manual Supply unit camshaft and bearing shell - do the follow-on work Page left intentionally blank - 619 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 620: Exhaust Valve Control Unit

    AA00-5612-00AAA-520A-A X82-B 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 621: Exhaust Valve Control Unit - Remove

    AA00-5612-00AAA-520A-A X82-B 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 10-39) from the VCU (006).

  • Page 622: Exhaust Valve Control Unit (Vcu) - Disassemble

    AA00-5612-00AAA-530A-A X82-B 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 623: Exhaust Valve Control Unit - Disassemble/Assemble

    AA00-5612-00AAA-530A-A X82-B Maintenance Manual Exhaust valve control unit (VCU) - disassemble PROCEDURE Remove the pan head screw (007, Figure 10-40). Fig 10-40 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 624: Exhaust Valve Control Unit (Vcu) - Assemble

    AA00-5612-00AAA-710A-A X82-B 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 625 AA00-5612-00AAA-710A-A X82-B Maintenance Manual Exhaust valve control unit (VCU) - assemble PROCEDURE Put a new oil filter (001, Figure 10-41) 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 626: Exhaust Valve Control Unit (Vcu) - Install

    AA00-5612-00AAA-720A-A X82-B 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 627: Exhaust Valve Control Unit - Install

    AA00-5612-00AAA-720A-A X82-B 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 10-42). Remove the blanks from the ports in the VCU (005).

  • Page 628: Distance X For Vcu

    AA00-5612-00AAA-720A-A X82-B Maintenance Manual Exhaust valve control unit (VCU) - install Make sure that the distance X (Figure 10-43) between the washer (001) and the holder (002) is in the correct range, refer to Table 10-1 - Distance X for VCU.
  • Page 629 AA00-5612-00AAA-720A-A X82-B Maintenance Manual Exhaust valve control unit (VCU) - install CLOSE UP • None - 629 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 630 AA00-5612-00AAA-720A-A X82-B Maintenance Manual Exhaust valve control unit (VCU) - install Page left intentionally blank - 630 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 631: 11 Group 6 - Scavenge Air Components

    X82-B Maintenance Manual 11 Group 6 - Scavenge air components 11.1 Scavenge air receiver 11.1.1 Scavenge air receiver - examine........

  • Page 632: Scavenge Air Receiver

    AA00-6420-00AAA-310A-A X82-B 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 633 AA00-6420-00AAA-310A-A X82-B 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. - 633 - Issue 001 2020-10...

  • Page 634: Scavenge Air Receiver - Visual Examination

    AA00-6420-00AAA-310A-A X82-B 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 635: Level Switches And Filters

    AA00-6420-00AAA-310A-A X82-B 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 636: Scavenge Air Receiver - Do A Check Of The Relief Valve

    AA00-6420-00AAA-360A-A X82-B 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 637: Relief Valve

    AA00-6420-00AAA-360A-A X82-B 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 638: Scavenge Air Receiver - Remove The Flaps

    AA00-6420-00AAA-520A-A X82-B 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 639: Flaps - Remove

    AA00-6420-00AAA-520A-A X82-B 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 640: Scavenge Air Receiver - Install The Flaps

    AA00-6420-00AAA-720A-A X82-B 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 641: Flaps - Install

    AA00-6420-00AAA-720A-A X82-B 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 642: Auxiliary Blower

    AA00-6545-00AAA-520A-A X82-B 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 643: Electric Motor (Driving End) - Move

    AA00-6545-00AAA-520A-A X82-B 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 644: Electric Motor (Driving End) - Remove

    AA00-6545-00AAA-520A-A X82-B 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 645: Electric Motor (Free End) - Move

    AA00-6545-00AAA-520A-A X82-B 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 646 AA00-6545-00AAA-520A-A X82-B 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 - 646 - Issue 001 2020-10...
  • Page 647 AA00-6545-00AAA-520A-A X82-B Maintenance Manual Auxiliary blower - remove Page left intentionally blank - 647 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 648: Auxiliary Blower - Install

    AA00-6545-00AAA-720A-A X82-B 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 649 AA00-6545-00AAA-720A-A X82-B 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 650: Auxiliary Blower - Move

    AA00-6545-00AAA-720A-A X82-B 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 651: Electric Motor (Free End) - Install

    AA00-6545-00AAA-720A-A X82-B 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 652: Auxiliary Blower (Driving End) Move

    AA00-6545-00AAA-720A-A X82-B 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 653: Electric Motor (Driving End) - Install

    AA00-6545-00AAA-720A-A X82-B 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 654: Scavenge Air Cooler

    AA00-6606-00AAA-520A-A X82-B 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 655 AA00-6606-00AAA-520A-A X82-B 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 - 655 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

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

    AA00-6606-00AAA-520A-A X82-B 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 657 AA00-6606-00AAA-520A-A X82-B 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 658 AA00-6606-00AAA-520A-A X82-B 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 659 AA00-6606-00AAA-520A-A X82-B 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 660 AA00-6606-00AAA-520A-A X82-B 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 661 AA00-6606-00AAA-520A-A X82-B Maintenance Manual Scavenge air cooler - remove Page left intentionally blank - 661 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 662: Scavenge Air Cooler - Install

    AA00-6606-00AAA-720A-A X82-B 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 663 AA00-6606-00AAA-720A-A X82-B 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 - 663 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 664: Scavenge Air Cooler (Example) - Prepare For Installation

    AA00-6606-00AAA-720A-A X82-B 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 665: Scavenge Air Cooler (Example) - Follow Up Front And Rear Side

    AA00-6606-00AAA-720A-A X82-B 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 666: Water Separator

    AA00-6708-00AAA-520A-A X82-B 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 667: Water Separator - View 1

    AA00-6708-00AAA-520A-A X82-B 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. - 667 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 668: Water Separator - View 2

    AA00-6708-00AAA-520A-A X82-B 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 669: Water Separator - View 3

    AA00-6708-00AAA-520A-A X82-B 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 670: Water Separator - View 4

    AA00-6708-00AAA-520A-A X82-B 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 671: Water Separator - View 5

    AA00-6708-00AAA-520A-A X82-B 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 672: Water Separator - Install

    AA00-6708-00AAA-720A-A X82-B 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 673: Water Separator - View 6

    AA00-6708-00AAA-720A-A X82-B 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 674: Water Separator - View 7

    AA00-6708-00AAA-720A-A X82-B 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 675 AA00-6708-00AAA-720A-A X82-B 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 676 AA00-6708-00AAA-720A-A X82-B 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 677: 12 Group 7 - Cylinder Lubrication

    X82-B Maintenance Manual 12 Group 7 - Cylinder lubrication 12.1 Cylinder lubrication system 12.1.1 Cylinder lubrication system - do a functional test......

  • Page 678: Cylinder Lubrication System

    AA00-7218-00AAA-340A-A X82-B 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 679 AA00-7218-00AAA-340A-A X82-B 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 680: Cylinder Lubrication System - Bleed

    AA00-7218-00AAA-231A-A X82-B 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 681 AA00-7218-00AAA-231A-A X82-B 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 682 AA00-7218-00AAA-231A-A X82-B Maintenance Manual Cylinder lubrication system - bleed Fig 12-2 Cylinder lubrication system - bleed - 682 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 683 AA00-7218-00AAA-231A-A X82-B Maintenance Manual Cylinder lubrication system - bleed CLOSE UP • None - 683 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 684: Cylinder Lubricating Pump - Remove

    AA00-7206-00AAA-520A-A X82-B 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 685 AA00-7206-00AAA-520A-A X82-B 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 686 AA00-7206-00AAA-520A-A X82-B Maintenance Manual Cylinder lubricating pump - remove Fig 12-3 Cylinder lubricating pump (MK-E, example) - remove CLOSE UP • None - 686 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 687 AA00-7206-00AAA-520A-A X82-B Maintenance Manual Cylinder lubricating pump - remove Page left intentionally blank - 687 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 688: Cylinder Lubricating Pump (Pulse) - Examine

    AA00-0000-00AAA-310A-A X82-B Maintenance Manual Cylinder lubricating pump (pulse) - examine 12.1.4 Cylinder lubricating pump (pulse) - 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 689 AA00-0000-00AAA-310A-A X82-B Maintenance Manual Cylinder lubricating pump (pulse) - examine PROCEDURE Prepare the cylinder lubricating pump for the check as follows: Close the stop-valve 4.30-5 to stop the servo oil supply to the cylinder lubricating pumps. Drain the servo oil system of the cylinder lubricating pumps with the screw plug on the last cylinder lubricating pump.

  • Page 690: Cylinder Lubricating Pump - Examine

    AA00-0000-00AAA-310A-A X82-B Maintenance Manual Cylinder lubricating pump (pulse) - examine Fig 12-4 Cylinder lubricating pump - examine Open the stop-valve 4.30-5 to start the servo oil supply to the cylinder lubricating pumps. Close the screw plug on the last cylinder lubricating pump.
  • Page 691 AA00-0000-00AAA-310A-A X82-B Maintenance Manual Cylinder lubricating pump (pulse) - examine Page left intentionally blank - 691 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 692: Cylinder Lubricating Pump - Install

    AA00-7206-00AAA-720A-A X82-B Maintenance Manual Cylinder lubricating pump - install 12.1.5 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 693 AA00-7206-00AAA-720A-A X82-B 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 694 AA00-7206-00AAA-720A-A X82-B Maintenance Manual Cylinder lubricating pump - install Page left intentionally blank - 694 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 695: 13 Group 8 - Pipes

    X82-B Maintenance Manual 13 Group 8 - Pipes 13.1 HP servo oil pipe 13.1.1 HP servo oil pipe - remove......... . .

  • Page 696: Hp Servo Oil Pipe

    AA00-8447-00AAA-520A-A X82-B 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 697 AA00-8447-00AAA-520A-A X82-B 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 698: Servo Oil Pipes - Remove

    AA00-8447-00AAA-520A-A X82-B Maintenance Manual HP servo oil pipe - remove Fig 13-1 Servo oil pipes - remove - 698 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 699 AA00-8447-00AAA-520A-A X82-B Maintenance Manual HP servo oil pipe - remove CLOSE UP • None - 699 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 700: Hp Servo Oil Pipe - Grind The Sealing Face

    AA00-8447-00AAA-655A-A X82-B 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 701 Distance X for HP servo oil pipe Engine type Distance X [mm] X35, X35-B X40, X40-B X40DF X52DF X62, X62-B X62DF X72, X72-B X72DF X82, X82-B X82DF X92, X92-B X92DF - 701 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 702: Hp Servo Oil Pipe - Grind And Adjust

    AA00-8447-00AAA-655A-A X82-B 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 - 702 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 703 AA00-8447-00AAA-655A-A X82-B Maintenance Manual HP servo oil pipe - grind the sealing face Page left intentionally blank - 703 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 704: Hp Servo Oil Pipe - Install

    AA00-8447-00AAA-720A-A X82-B 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 705 AA00-8447-00AAA-720A-A X82-B 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 706: Servo Oil Pipes - Install

    AA00-8447-00AAA-720A-A X82-B Maintenance Manual HP servo oil pipe - install Fig 13-3 Servo oil pipes - install - 706 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 707 AA00-8447-00AAA-720A-A X82-B Maintenance Manual HP servo oil pipe - install CLOSE UP • None - 707 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 708: Hydraulic Pipe Exhaust Valve

    AA00-8460-00AAA-520A-A X82-B 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 709 AA00-8460-00AAA-520A-A X82-B 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 710 AA00-8460-00AAA-520A-A X82-B Maintenance Manual Hydraulic pipe exhaust valve - remove Fig 13-4 Hydraulic pipe (exhaust valve) - remove I - I II - II 00956 - 710 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 711 AA00-8460-00AAA-520A-A X82-B Maintenance Manual Hydraulic pipe exhaust valve - remove CLOSE UP • None - 711 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 712: Hydraulic Pipe Exhaust Valve - Grind The Sealing Face

    AA00-8460-00AAA-655A-A X82-B 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 713 AA00-8460-00AAA-655A-A X82-B 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 714: Hydraulic Pipe (Exhaust Valve) - Grind Sealing Face

    AA00-8460-00AAA-655A-A X82-B Maintenance Manual Hydraulic pipe exhaust valve - grind the sealing face Fig 13-5 Hydraulic pipe (exhaust valve) - grind sealing face 00957 CLOSE UP • None - 714 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 715 AA00-8460-00AAA-655A-A X82-B Maintenance Manual Hydraulic pipe exhaust valve - grind the sealing face Page left intentionally blank - 715 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 716: Hydraulic Pipe Exhaust Valve - Install

    AA00-8460-00AAA-720A-A X82-B 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 717 Distance X for hydraulic pipe exhaust valve Engine type Distance X [mm] X35, X35-B X40, X40-B X40DF X52DF X62, X62-B X62DF X72, X72-B X72DF X82, X82-B X82DF X92, X92-B X92DF - 717 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 718 AA00-8460-00AAA-720A-A X82-B Maintenance Manual Hydraulic pipe exhaust valve - install Fig 13-6 Hydraulic pipe (exhaust valve) - install - 718 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 719 AA00-8460-00AAA-720A-A X82-B Maintenance Manual Hydraulic pipe exhaust valve - install CLOSE UP • None - 719 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 720: Hp Fuel Pipe

    AA00-8733-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - remove 13.3 HP fuel pipe 13.3.1 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 1.0 man-hours...
  • Page 721 AA00-8733-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - remove PROCEDURE Step 1.1 Step 1.4 to release the pressure in the fuel rail: In the plant, set to off the fuel booster pump. Close the shut-off valves to the fuel inlet and return pipes.
  • Page 722 AA00-8733-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - remove Fig 13-7 HP fuel pipe (fuel rail to injection valve) - remove I - I III - III 00959 - 722 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 723 AA00-8733-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - remove CLOSE UP • None - 723 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 724: Hp Fuel Pipe (Fuel Rail To Injection Valve) - Grind The Sealing Face

    AA00-8733-01AAA-655A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - grind the sealing face 13.3.2 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 1.0 man-hours...
  • Page 725 AA00-8733-01AAA-655A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - grind the sealing face PROCEDURE Put the template (001, Figure 13-8) on the back of emery cloth. Use the applicable grade of the emery cloth related to the quantity of metal you want to remove.
  • Page 726 AA00-8733-01AAA-655A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - grind the sealing face Fig 13-8 HP fuel pipe (fuel rail to injection valve) - grind 00961 CLOSE UP • Install the HP fuel pipe, refer to 13.3.3 HP fuel pipe (fuel rail to injection valve) - install...
  • Page 727 AA00-8733-01AAA-655A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - grind the sealing face Page left intentionally blank - 727 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 728: Hp Fuel Pipe (Fuel Rail To Injection Valve) - Install

    AA00-8733-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - install 13.3.3 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 1.0 man-hours...
  • Page 729 AA00-8733-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - install PROCEDURE Put oil on the new O-ring (005 and 010, Figure 13-9). NOTE: The HP fuel pipes are as follows: • HP fuel pipe (001) •...
  • Page 730 AA00-8733-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - install Fig 13-9 HP fuel pipe (fuel rail to injection valve) - install CLOSE UP • None - 730 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 731 AA00-8733-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel rail to injection valve) - install Page left intentionally blank - 731 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 732: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Remove

    AA00-8752-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove 13.3.4 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 1.5 man-hours...
  • Page 733 AA00-8752-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove • The trace heating must be set to off. - 733 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 734: Hp Fuel Pipe Fuel Pump To Fuel Rail - Prepare

    AA00-8752-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove PROCEDURE NOTE: The procedures to remove the HP fuel pipes (002, 004, 005, 007, 009 and 010, Figure 13-10) are almost the same. The procedure that follows applies to the HP fuel pipes (005, 007, 009).

  • Page 735: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Prepare

    AA00-8752-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove Legend Fuel rail HP fuel pipe (qty 6) HP fuel pipes (qty 2) Pipe bracket Pipe brackets HP fuel pipe (qty 1) HP fuel pipes (qty 2)
  • Page 736 AA00-8752-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove Remove the four screws (010) from the flange (009). Carefully move the flange (009) up. Carefully remove the HP fuel pipe (011). Remove the four screws (001) from the flange (002).
  • Page 737 AA00-8752-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove Fig 13-12 HP fuel pipe (fuel pump to fuel rail) - remove - 737 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 738 AA00-8752-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove CLOSE UP • Install the HP fuel pipe, refer to 13.3.6 HP fuel pipe (fuel pump to fuel rail) - install - 738 - Issue 001 2020-10...
  • Page 739 AA00-8752-01AAA-520A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - remove Page left intentionally blank - 739 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 740: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Grind The Sealing Face

    AA00-8752-01AAA-655A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - grind the sealing face 13.3.5 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 741 AA00-8752-01AAA-655A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - grind the sealing face PROCEDURE Put the template (009, Figure 13-13) on the back of the emery cloth (30 to 80 CAMI) (008). Use a pencil or a ball pen to make the inner shape.

  • Page 742: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Sealing Face - Grind

    AA00-8752-01AAA-655A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - grind the sealing face Fig 13-13 HP fuel pipe (fuel pump to fuel rail) - sealing face - Grind Minimum 0.5 mm 00966 CLOSE UP • Install the applicable HP fuel pipe, refer to 13.3.6 HP fuel pipe (fuel pump to fuel rail) -...
  • Page 743 AA00-8752-01AAA-655A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - grind the sealing face Page left intentionally blank - 743 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 744: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Install

    AA00-8752-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install 13.3.6 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 1.5 man-hours...
  • Page 745 AA00-8752-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install PROCEDURE The views I-I, II-II, III-III and IV-IV in Figure 13-14, are shown in Figure 13-15 - 745 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 746: Hp Fuel Pipe (Fuel Pump To Fuel Rail) - Views

    AA00-8752-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install Fig 13-14 HP fuel pipe (fuel pump to fuel rail) - views on the new O-ring (005, Figure 13-15) and O-ring (002). Remove all of the protection from the sealing faces (011, 020).
  • Page 747 AA00-8752-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install NOTE: You can adjust the claw with an open-ended wrench. Make sure that there is a distance of Y = 14.0 mm between the end of the HP fuel pipe (026) and the claw (024).
  • Page 748 AA00-8752-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install Fig 13-15 HP fuel pipe (fuel pump to fuel rail) - install I - I IV - IV III - III 00967 - 748 - Issue 001 2020-10...
  • Page 749 AA00-8752-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install CLOSE UP • None - 749 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 750 AA00-8752-01AAA-720A-A X82-B Maintenance Manual HP fuel pipe (fuel pump to fuel rail) - install Page left intentionally blank - 750 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 751: 14 Group 9 - Monitoring Instruments

    X82-B Maintenance Manual 14 Group 9 - Monitoring instruments 14.1 Crank angle sensor unit 14.1.1 Crank angle sensor unit (flywheel) - proximity sensor - remove... . 14.1.2 Crank angle sensor unit (flywheel) - proximity sensor - install....

  • Page 752: Crank Angle Sensor Unit

    AA00-9223-01AAA-520B-A X82-B Maintenance Manual Crank angle sensor unit (flywheel) - proximity sensor - remove 14.1 Crank angle sensor unit 14.1.1 Crank angle sensor unit (flywheel) - proximity sensor - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 753 AA00-9223-01AAA-520B-A X82-B Maintenance Manual Crank angle sensor unit (flywheel) - proximity sensor - remove PROCEDURE Operate the turning gear to get the crank angle mark (003, Figure 14-1) of the flywheel (001) opposite the applicable proximity sensor (005). Put a mark on the applicable cable to identify its position.

  • Page 754: Proximity Sensor (Flywheel) - Remove

    AA00-9223-01AAA-520B-A X82-B Maintenance Manual Crank angle sensor unit (flywheel) - proximity sensor - remove Fig 14-1 Proximity sensor (flywheel) - remove 5125C 5124C 00971 - 754 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 755 AA00-9223-01AAA-520B-A X82-B Maintenance Manual Crank angle sensor unit (flywheel) - proximity sensor - remove CLOSE UP • Install the applicable proximity sensor, refer to 14.1.2 Crank angle sensor unit (flywheel) - proximity sensor - install - 755 - Issue 001 2020-10...

  • Page 756: Crank Angle Sensor Unit (Flywheel) - Proximity Sensor - Install

    AA00-9223-01AAA-720B-A X82-B Maintenance Manual Crank angle sensor unit (flywheel) - proximity sensor - install 14.1.2 Crank angle sensor unit (flywheel) - proximity sensor - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 757 AA00-9223-01AAA-720B-A X82-B Maintenance Manual Crank angle sensor unit (flywheel) - proximity sensor - install PROCEDURE Attach the proximity sensor (005 Figure 14-2) 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 758: Proximity Sensor (Flywheel) - Install

    AA00-9223-01AAA-720B-A X82-B Maintenance Manual Crank angle sensor unit (flywheel) - proximity sensor - install Fig 14-2 Proximity sensor (flywheel) - install 5125C 5124C -0.2 00972 - 758 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 759 AA00-9223-01AAA-720B-A X82-B Maintenance Manual Crank angle sensor unit (flywheel) - proximity sensor - install CLOSE UP • None - 759 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 760: Crank Angle Sensor Unit (Supply Unit) - Proximity Sensor - Remove

    AA00-9223-01AAA-520A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - remove 14.1.3 Crank angle sensor unit (supply unit) - proximity sensor - remove Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 761 AA00-9223-01AAA-520A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - remove PROCEDURE Operate the turning gear to get a tooth (004, Figure 14-3) of the intermediate wheel opposite the applicable proximity sensor (001). If necessary, put a mark on the applicable cable to identify its position.

  • Page 762: Proximity Sensor - Remove

    AA00-9223-01AAA-520A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - remove Fig 14-3 Proximity sensor - remove III - III ST5133C ST5136C ST5132C ST5135C ST5131C ST5134C 5131 - 36C 00969 - 762 - Issue 001 2020-10...
  • Page 763 AA00-9223-01AAA-520A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - remove CLOSE UP • Install the applicable proximity sensor, refer to 14.1.4 Crank angle sensor unit (supply unit) - proximity sensor - install - 763 - Issue 001 2020-10 Winterthur Gas &...

  • Page 764: Crank Angle Sensor Unit (Supply Unit) - Proximity Sensor - Install

    AA00-9223-01AAA-720A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - install 14.1.4 Crank angle sensor unit (supply unit) - proximity sensor - install Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
  • Page 765 AA00-9223-01AAA-720A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - install PROCEDURE Attach the proximity sensor (001, Figure 14-4) 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 766: Proximity Sensor - Install

    AA00-9223-01AAA-720A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - install Fig 14-4 Proximity sensor - install III - III -0.2 ST5133C ST5136C ST5132C ST5135C ST5131C ST5134C 5131 - 36C 00970 - 766 - Issue 001 2020-10...
  • Page 767 AA00-9223-01AAA-720A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - install CLOSE UP • None - 767 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 768 AA00-9223-01AAA-720A-A X82-B Maintenance Manual Crank angle sensor unit (supply unit) - proximity sensor - install Page left intentionally blank - 768 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 769: 15 Tools

    X82-B Maintenance Manual 15 Tools 15.1 General for tools............

  • Page 770: 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 771 AA00-0000-00AAA-018O-A X82-B Maintenance Manual General for tools Page left intentionally blank - 771 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.

  • Page 772: Standard Tools

    AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools 15.2 Standard tools 032 - 043 001 - 006 028 - 031 008 - 011 047 - 051 013 - 026 053 - 059 - 772 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 773 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools 070 - 075 077 - 084 - 773 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 774 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools 116 - 119 - 774 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 775 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools 152 - 159 148 - 151 - 775 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 776 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools 165 - 173 Ø - 776 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 777 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 777 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 778 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 778 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 779 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 779 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 780 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 780 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 781 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 781 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 782 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 782 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 783 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools 323 - 328 334 - 339 - 783 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 784 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 784 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 785 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 785 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 786 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 786 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 787 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 787 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 788 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 788 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 789 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 789 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 790 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools 598 - 600 608 - 611 566 - 568 579 - 581 584 - 586 589 - 590 603 - 605 630 - 632 643 - 645 660 - 662 675 - 677 - 790 - Issue 001 2020-10 Winterthur Gas &...
  • Page 791 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 791 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 792 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 792 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 793 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools - 793 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 794 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 000 1 94000 Tool general combination wrench 001 2 94000-36 2 Pieces Combination wrench SW36 002 2 94000-41 2 Pieces Combination wrench SW41 003 2 94000-46 2 Pieces...
  • Page 795 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 047 2 94005I 1 Piece Ø 6.5 / Ø1 5.5 mm 048 2 94005A 1 Piece Ø 6 mm 049 2 94005B 1 Piece Ø 9.5 mm...
  • Page 796 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 092 3 94935C 1 Piece Oil pipe drain With couling socket, nipple and hose clip; Maximum operating pressure 2000 bar 093 3 94934G 4 Pieces Coupling element...
  • Page 797 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 136 3 94050D 1 Piece Pressure gauge 0 bar to 16 bar 137 3 TN 94171 2 Pieces Screw coupling 138 3 TN 94172 1 Piece Screw coupling...
  • Page 798 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 183 2 94101B 1 Piece Extension Length of 480mm 184 2 94101A 1 Piece Extension Length of 500 mm Tool bedplate alignment (JIS) 186 2 94101 1 Piece...
  • Page 799 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 209 3 94116A 1 Piece Lifting tool for removal and installation of main bearing shell special X = 286 mm (WLL 130 kg) 210 3 94119 1 Piece...
  • Page 800 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark Tool column working support 238 2 94143 1 Piece Tool column working support X = 920 to 1170 mm; Z = 240 mm Tool column working support...
  • Page 801 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 274 3 94345F 2 Pieces Distance piece To install the rings to the top gland group; X = 432.5 mm 275 3 94345B 1 Piece Clamping ring 2-parts...
  • Page 802 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 304 3 94275B 1 Piece Hose Leakage oil hose; X = approximately 2000 mm 305 3 94269B 1 Piece Hydraulic cylinder 306 3 94269A-70 1 Piece Slugging wrench/ ring...
  • Page 803 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark Tool valve cage pre-tensioning 341 2 94252 2 Pieces Pre-tensioner for exhaust valve cage; X = 300 mm Tool valve seat assembly 343 2 94261 1 Piece...
  • Page 804 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark X = ∅ 96 mm 380 2 94340 2 Pieces Pre-tensioner Tool connec. rod bearing inspection 382 2 94335 1 Piece Stop plate X = 300 mm, with screw M24x50, for inspection of top end bearing Tool connec.
  • Page 805 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 414 3 94208 4 Pieces Lifting plate with screws M12x25 for removal and installation of the antipolishing ring; X = 55 mm; Y = 107 Tool piston assembly Dismantling...
  • Page 806 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 447 3 94342 1 Piece Inserting cone X = 1035 mm, Y = 155 mm, Mass approximately 51 kg, 448 3 94343 2 Pieces Locking device X = 655 mm...
  • Page 807 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 481 3 94430 1 Piece Roller lifting tool To cut out and cut in the fuel pump; includes: elastic bolts and round nut; X = 197 mm...
  • Page 808 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 94552 1 Piece Lifting tool with Allen screws M14x40; for removal and installation of the fuel pump; X = ∅ 120 mm 512 2 94592 1 Piece Fitting and dismantling device for fuel pump;...
  • Page 809 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 548 2 94587 2 Pieces Tool rail unit maintenance for servo oil return (4 for each cylinder); X = ∅ 20 mm 549 2 94589 1 Piece...
  • Page 810 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 580 3 94653H−M83 1 Piece Cover X = 735 mm, Cover to scavenger air receiver inlet 581 3 94653G−M83 1 Piece Cover X = 705 mm, Cover to TC oulet...
  • Page 811 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 1 Piece Tool sac assembly 614 4 TN 94203 1 Piece Support X = 682 mm 615 4 TN 94204 1 Piece Chain X = 3148 mm...
  • Page 812 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 656 4 TN 94210 1 Piece Plate X = 170 mm 657 3 TN 94211 1 Piece Support X = 697 mm, (WLL 870 kg) Mass approximately 34 kg...
  • Page 813 AA00-0000-00AAA-941A-C X82-B Maintenance Manual Standard tools Pos. Ind. Part No. Quantity Description Remark 698 2 94720C 1 Piece Tool pulse accumulator charging measurement set complete for checking / refilling of hydraulic accumulator Tool exhaust manifold assembly 700 2 94810 1 Piece...

  • Page 814: Recommended Tools

    AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools 15.3 Recommended tools - 814 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 815 AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools - 815 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 816 AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools - 816 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 817 AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools - 817 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 818 AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools - 818 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 819 AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools Pos. Ind. Part No. Quantity Description Remark Tool general cupboard 001 2 94300 1 Piece Tool cupboard Y = 1120 mm Tool general chain block 1 Piece Spur-geared chain block 004 3 94018-006 2 Pieces Spur-geared chain block platform with crane rail;...
  • Page 820 AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools Pos. Ind. Part No. Quantity Description Remark Tool turning gear pre-tensioning 037 2 94320B 1 Piece Assembly and transport yoke Y = 1305 mm Tool con. rod/crosshead assembly 039 2 94324C 1 Piece Fixing device...
  • Page 821 AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools Pos. Ind. Part No. Quantity Description Remark 071 3 94655 1 Piece Cover X = 580 mm, Cover to scavenger air receiver inlet and TC with suction pipe Tool tc failure ABB A180 073 3...
  • Page 822 AA00-0000-00AAA-941B-C X82-B Maintenance Manual Recommended tools Page left intentionally blank - 822 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 823 X82-B Maintenance Manual 16 Tightening instructions 16.1 Tightening instructions...........
  • Page 824 AA00-0000-00AAA-018N-A X82-B 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. - 824 - Issue 001 2020-10 Winterthur Gas &...
  • Page 825 Rev. B TIGHTENING INSTRUCTIONS Page 1 / 9...
  • Page 826 Rev. B TIGHTENING INSTRUCTIONS Page 2 / 9...
  • Page 827 Rev. B TIGHTENING INSTRUCTIONS Page 3 / 9...
  • Page 828 Rev. B TIGHTENING INSTRUCTIONS Page 4 / 9...
  • Page 829 Rev. B TIGHTENING INSTRUCTIONS Page 5 / 9...
  • Page 830 Rev. B TIGHTENING INSTRUCTIONS Page 6 / 9...
  • Page 831 Rev. B TIGHTENING INSTRUCTIONS Page 7 / 9...
  • Page 832 Rev. B TIGHTENING INSTRUCTIONS Page 8 / 9...
  • Page 833 Rev. B TIGHTENING INSTRUCTIONS Page 9 / 9...
  • Page 834 X82-B Maintenance Manual 17 Maintenance overview 17.1 Maintenance overview........... .
  • Page 835 AA00-0000-00AAA-280C-A X82-B 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. - 826 - Issue 001 2020-10 Winterthur Gas & Diesel Ltd.
  • Page 836 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 837 Intervals & Lifetime Component Work to be carried out [operating hours] Injection valve (main fuel injector, Function check (nozzle tip inspection, opening pressure). 6000 group 27xx) 1000 after injector parts are Make sure that the opening pressure is correct replaced Exchange nozzle tip (FAST type) 18000 Estimated lifetime: Nozzle spare parts set (e.g.
  • Page 838 Replace servo oil pump either with new one or a pump overhauled by a Servo oil pump (Group 55xx) 66000 (Bosch) WinGD service provider Replace servo oil pump either with new one or a pump remanufactured by 50000 (Dynex) a Wärtsilä workshop...
  • Page 839 Intervals & Lifetime Component Work to be carried out [operating hours] the non-return valve can become weak) Remanufacturing of fuel pump or overhaul on board 18000 - 22000 Fuel pressure control valve (PCV, Check shut-down function (see Operation Manual 4003-1) 3000 group 55xx) Function check (see Operation Manual 5562-1)
  • Page 840 Intervals & Lifetime Component Work to be carried out [operating hours] Remove water separator for general overhaul as necessary Checking gas (nitrogen) pre-charge pressure, directly after installation of a Lubricating pump (Group 72xx) every three month new accumulator then at least one week after start-up Remanufacturing 40000 Cylinder lube oil filter...
  • Page 841 Notes to Maintenance Intervals & Lifetime; All data provided on the pages above are for information purposes only, explicitly non-binding and subject to change without further notice. Detail maintenance schedule is included in Maintenance Manuals for specific engine type. Intervals for inspection or overhauls and estimated lifetimes are estimates only. They are based on past experience and valid for engines fully according to currently applicable Winterthur Gas &...

Table of Contents