WinGD RT-flex50DF Maintenance Manual

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Winterthur Gas & Diesel Ltd.

Winterthur Gas & Diesel AG

Winterthur Gas & Diesel S.A.

RT-flex50DF

Schützenstrasse 3

P.O. Box 414, 8401

Winterthur, Switzerland

Maintenance Manual

Tel. +41 (0)52 264 8844

Fax +41 (0)52 264 8866

www.wingd.com

Issue 003 2020-10

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Summary of Contents for WinGD RT-flex50DF

Page 1 Maintenance Manual RT-flex50DF Issue 003 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 Modification Service Engine Documentation RT-flex50DF Summary for Maintenance Manual Page No. Modification Title Subject Page or (MM) Date Manual new exch. 2015 Maintenance Manual, Issue 2015 Date of publication 2015-03-31 0002-1/A1 2015-09 Table of Contents New documents added: 0008-1/A2, 0803-1/A2, 2124-...
Page 4 Page No. Modification Title Subject Page or (MM) Date Manual new exch. Group 5 ToC 2018-01 WinGD input 5555-2/A1 added 2140-2/A1 2017-12 Update Exhaust Valve: Pge 7: Para 5, Steps 10 to 12 changed. WinGD Disassemble and Assemble 2751-2/A1 2017-12 WinGD input...
Page 5 Rear page New Rear Page Added Logo change 2020-05 WinGD Input Logo change Logo is updated from Wärtsilä to WinGD Date of publication 2020-05 0330-1/A1 2020-10 WinGD Input Clearance Table – Page 10: Illustration updated to include the scrapper ring...
Page 6 General Information Bedplate and Tie Rod Cylinder Liner and Cylinder Cover Crankshaft, Connecting Rod and Piston Driving Wheels and Shut-off Valve for Starting Air Supply Unit, Injection and Exhaust Valve Control Scavenge Air Receiver and Auxiliary Blower Cylinder Lubrication Piping Crank Angle Sensor Unit, Tools...
Page 7: Table Of Contents
RT-flex50DF Maintenance Table of Contents Table of Contents General Information Group 0 For Particular Attention ..............
Page 8 Maintenance RT-flex50DF Table of Contents Engine Stays with Friction Shims: Tension − Checks ........
Page 9 RT-flex50DF Maintenance Table of Contents Connecting Rod Loosening and Tensioning the Connecting Rod Studs ........
Page 10 Maintenance RT-flex50DF Table of Contents Regulating Linkage Adjustment: Heinzmann StG 10-01 Actuator ..........
Page 11: For Particular Attention
Group0 Maintenance General Information Group 0 For Particular Attention ..............0000−1/A1 Preface .
Page 12: General
0000−1/A1 Maintenance For Your Attention General This manual is for the operator and is for use only for the related type of diesel engine (the engine described in this manual). The data in this manual is confidential. Make sure that you read carefully the Operation Manual before you operate the engine.
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Page 14 0001−1/A1 Maintenance Preface The instructions in this Maintenance Manual are to help make sure that maintenance is done correctly at the specified intervals. It is a condition that the personnel who do important work have the applicable training and experience. Data about the operation of the engine and descriptions of the function of the different systems are part of the Operation Manual.
Page 15 0008−1/A1 Maintenance General General Configuration − Turbocharger at Aft End Turbocharger Auxiliary Blower 1 Auxiliary Blower 2 Cylinder Number DRIVING END FREE END Main Bearing Number WCH002808 Thrust Bearing Pads DATA FOR 5 CYLINDERS Rail Unit EXHAUST SIDE FUEL SIDE Supply Unit Clockwise Rotation Counterclockwise...
Page 16 0008−1/A1 Maintenance Flex Parts: Fuel Pump 1 Fuel Pump 2 Fuel Pump Actuator 1 Fuel Pump Actuator 2 FUEL SIDE Servo Oil Pump 2 Supply Unit Servo Oil Pump 1 DRIVING DRAWN FOR 5 CYLINDERS Crank Angle Sensors Sensor 2 Sensor 1 FUEL SIDE 013.150/05...
Page 17 0008−1/A2 Maintenance General General Configuration − Turbocharger on Exhaust Side DRAWN FOR 7 CYLINDERS Turbocharger Auxiliary Auxiliary Blower 1 Blower 2 Cylinder Number Main Bearing Number FREE END DRIVING END WCH03435 Thrust Bearing Pads Rail Unit EXHAUST SIDE FUEL SIDE Supply Unit Counterclockwise Clockwise Rotation...
Page 18 0008−1/A2 Maintenance Flex Parts: Fuel Pump 1 Fuel Pump 2 Fuel Pump Actuator 1 Fuel Pump Actuator 2 FUEL SIDE Servo Oil Pump 2 Supply Unit Servo Oil Pump 1 DATA FOR 5 CYLINDERS DRIVING Crank Angle Sensor Unit I - I DRIVING Supply Unit drive...
Page 19 0011−1/A1 Maintenance General Guidelines for Maintenance Safety Precautions and Warnings General ............General Safety Precautions .
Page 20 0011−1/A1 Maintenance Safety Measures and Warnings Precautions before the Start of Maintenance CAUTION Damage Hazard: Do not use water or cleaning fluid to clean the electronic components and control boxes on the engine and the rail unit. Damage can occur if water or cleaning fluid goes into these electronic components or control boxes.
Page 21 0011−1/A1 Maintenance Special Safety Procedures WARNING Injury Hazard: After engine operation in gas mode, gas fuel can stay in the gas inlet pipes. There is a risk of explosion. You must replace the gas fuel with inert gas (e.g. nitrogen). For the procedure, refer to the documentation of the gas valve unit manufacturer.
Page 22 0011−1/A1 Maintenance Safety Measures and Warnings Recommendations Read the data in 3301−1 Work Platform. Do the work carefully. Make sure that all parts and equipment are clean. Use only the applicable tools and equipment for the maintenance tasks. For data about the tools and equipment, refer to 9403−5 Tool List.
Page 23 0012−1/A1 Maintenance General Guidelines for Lifting Tools Wire Rope Slings, Span-sets, Eye Bolts, etc. General ............Lifting Equipment .
Page 24 0012−1/A1 Maintenance General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc. Lifting values (for data only): Table 1: Values Lifting capacity [kg] Eye bolts and eye nuts, single-strand double-strand (45°) thread size 1200 1800 1290 3200 2300 4600 3300 6300 4500 8600 6100...
Page 25 0012−1/A1 Maintenance General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc. 2.4.1 RUD Eye Bolts RUD eye bolts must be fully attached to the seating surfaces. Use the applicable star-profile wrenches to tighten RUD eye bolts with your hand (do not use an extension).
Page 26 0012−1/A1 Maintenance General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc. 2.4.2 RUD Swivel Lugs RUD swivel lugs must be fully attached to the seating surfaces. Use an open-ended wrench to tighten the RUD swivel lugs with your hand. Align the RUD swivel lug with the direction of force before a load is applied (Fig.
Page 27 0012−1/A1 Maintenance General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc. Data to Attach Ropes and Slings You must know the data that follow: A sling with one strand has the total of load weight For a sling with two strands, each strand has one half of the load weight For a sling with four strands of equal load, each strand has one quarter of the load weight.
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Page 29 0330−1/A1 Maintenance Clearance Table General ............Crankshaft and Thrust Bearing .
Page 30: Crankshaft And Thrust Bearing
0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing 013.025/05 Fig. 2 Fig. 1 2016 2/ 25 Winterthur Gas & Diesel Ltd.
Page 31 0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 1203 Thrust Bearing 1224 −0.5 Thrust bearing pad thickness − 0.6 Thrust bearing clearance axial (total) 0.8 to 1.3 Thrust bearing pad, lateral clearance total...
Page 32: Crankshaft And Main Bearing
0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing 018.600/09 MAIN BEARING MAIN BEARING No. 2 No. 1 AND FOLLOWING Fig. 3 Fig. 4 018.663/09 2016 4/ 25 Winterthur Gas & Diesel Ltd.
Page 33 0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 1132 Main bearing No. 1 Crankshaft outer ∅ − 0.07 Main bearing inner ∅ Bearing clearance vertical 0.3−0.6 1132...
Page 34: Crosshead Guide
0330−1/A1 Maintenance Clearance Table Crosshead Guide Note: Some parts can look different. HOLDING PLATE HOLDING PLATE 013.027/05 FUEL SIDE Fig. 5 2016 6/ 25 Winterthur Gas & Diesel Ltd.
Page 35 0330−1/A1 Maintenance Clearance Table Crosshead Guide Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 3326 Crosshead guide Guide way (column) transverse − 0.20 Guide shoe transverse − 0.30 Guide shoe clearance 0.20−0.90 Guide rail, lateral clearance total 0.80−1.60...
Page 36: Cylinder Liner
0330−1/A1 Maintenance Clearance Table Cylinder Liner Approximately 100 mm to 180 mm WCH03120 Fig. 6 2016 8/ 25 Winterthur Gas & Diesel Ltd.
Page 37 0330−1/A1 Maintenance Clearance Table Cylinder Liner Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 2124 Water guide jacket on cylinder cover + 0.3 Water guide jacket Ø + 0.1 Clearance total 0.40−0.80 + 1.10 Water guide jacket Ø...
Page 38: Piston Rod Gland
0330- 1/A1 Maintenance Clearance Table Piston Rod Gland 013.225/05 Fig. 7 2020 10/ 25 Winterthur Gas & Diesel Ltd.
Page 39: Piston Rod Gland
0330−1/A1 Maintenance Clearance Table Piston Rod Gland Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 2303 Piston rod gland Ring width radial min. 25 Ring width radial min. 20.20 Ring width radial min.
Page 40: Exhaust Valve
0330−1/A1 Maintenance Clearance Table Exhaust Valve VALVE SPINDLE GUIDE BUSH L = LENGTH 012.999/05 Fig. 9 Fig. 8 2016 12/ 25 Winterthur Gas & Diesel Ltd.
Page 41 0330−1/A1 Maintenance Clearance Table Exhaust Valve Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 2751 Valve spindle − 0.14 Spindle outer ∅ 54.40 − 0.17 2751 Guide bush + 0.03 Bore inner ∅ 55.35 + 0.03 Bore...
Page 42: Top And Bottom End Bearings To Connecting Rod
0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod 10 mm 10 mm 60 mm 60 mm Fig. 10 013.028/05 2016 14/ 25 Winterthur Gas & Diesel Ltd.
Page 43 0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 3303 Top end bearing 3326 Crosshead pin outer ∅ − 0.04 Bearing inner ∅...
Page 44: Piston Cooling And Crosshead Lubrication
0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubrication Fig. 11 013.029/05 2016 16/ 25 Winterthur Gas & Diesel Ltd.
Page 45 0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubrication Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 3603 Piston cooling and crosshead lubrication + 0.15 Sleeve inner ∅ + 0.12 − 0.08 Sleeve length −...
Page 46: Piston And Piston Rings
0330−1/A1 Maintenance Clearance Table Piston and Piston Rings DESIGN WITH THREE PISTON RINGS Fig. 12 2016 18/ 25 Winterthur Gas & Diesel Ltd.
Page 47 0330−1/A1 Maintenance Clearance Table Piston and Piston Rings Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 3406 Piston Head Head (tapered part) outer ∅ − 0.2 Head outer ∅ 497.7 − 0.2 3403 Piston ring grooves 3425...
Page 48: Driving Wheels For Supply Unit
0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit Fig. 14 WCH00139 Fig. 13 013.030/05 2016 20/ 25 Winterthur Gas & Diesel Ltd.
Page 49 0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 4103 Intermediate wheel Shaft outer ∅ Bearing clearance vertical 0.082−0.147 0.25 Axial clearance total 0.6−1.1 Tooth backlash 0.20−0.33 0.55...
Page 50: Supply Unit
0330−1/A1 Maintenance Clearance Table Supply Unit 013.031/05 1 3 2 7 Fig. 15 2016 22/ 25 Winterthur Gas & Diesel Ltd.
Page 51 0330−1/A1 Maintenance Clearance Table Supply Unit Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 5552 Supply unit Pinion outer ∅ − 0.019 + 0.10 Bearing (installed) inner ∅ + 0.085 Bearing clearance radial 0.085−0.119 Axial clearance...
Page 52: Fuel Pump
0330−1/A1 Maintenance Clearance Table Fuel Pump PLUNGER and CYLINDER 012.098/04 Fig. 17 013.032/05 Fig. 16 2016 24/ 25 Winterthur Gas & Diesel Ltd.
Page 53 0330−1/A1 Maintenance Clearance Table Fuel Pump Description Measured Nominal Maximum Clearance, Direction Dimension Dimension (mm) (mm) (usual, new) (because of worn components) 5556 Fuel pump Clearance (plunger / cylinder) A−B radial 0.028−0.030 0.037 Clearance (plunger / cylinder) B−C radial 0.018−0.020 0.027 Guide piston outer ∅...
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Page 55: Tightening Values Of Important Screwed Connections
0352−1/A1 Maintenance Tightening Values of Important Screwed Connections WCH03038 Fig. 1 2016 1/ 7 Winterthur Gas & Diesel Ltd.
Page 56 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections WCH03038 Fig. 2 2016 2/ 7 Winterthur Gas & Diesel Ltd.
Page 57 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections WCH030038 WCH03038 Fig. 3 2016 3/ 7 Winterthur Gas & Diesel Ltd.
Page 58 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections WCH03038 Fig. 4 2016 4/ 7 Winterthur Gas & Diesel Ltd.
Page 59 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections WCH03038 Fig. 5 2016 5/ 7 Winterthur Gas & Diesel Ltd.
Page 60 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections WCH03038 Fig. 6 2016 6/ 7 Winterthur Gas & Diesel Ltd.
Page 61 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2016 7/ 7 Winterthur Gas & Diesel Ltd.
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Page 63: Torque Values − Standard Screws And Elastic Studs
0352−2/A1 Maintenance Torque Values − Standard Screws and Elastic Stud Torque Values − Standard Screws and Elastic Studs Torque Values − Standard Screws It is recommended that the torque values given in the table below are for aII standard metric screws of grade 8.8. This applies to all threaded connections not shown in 0352−1.
Page 64: 0352−2/A1
0352−2/A1 Maintenance Torque Values − Standard Screws and Elastic Studs Elastic Studs − Replacement Procedure Read the data in the manual of the jointing compound manufacturer. Remove the unserviceable elastic stud. Remove the grease. Clean the sealing surfaces of the new elastic stud. Remove the grease and other unwanted material from the tap hole and the area where the elastic stud will be installed.
Page 65 0352−2/A1 Maintenance Torque Values − Standard Screws and Elastic Studs 10) For the elastic studs installed in the valve cage, cylinder liner and cylinder jacket fill the area around the elastic stud with jointing compound (see Fig.3 JOINTING COMPOUND SEALING SURFACES ELASTIC STUD Fig.
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Page 67: 0360−1/A1
0360−1/A1 Maintenance Masses (Weights) Components of each Group in kg Group Component Design 1115 Main bearing cover 1134 Main bearing shells (upper and lower) 46.8 1203 Holder for thrust bearing 44.6 1224 Thrust bearing pad 40.6 1717 Casing, upper part free end Casing, lower part free end...
Page 68 0360−1/A1 Maintenance Individual Components per Piece in kg Group Component Design 3103 Balance weight on crankshaft 3122 Flywheel light 1530−2030 heavy 8000 3140 Axial detuner Two parts 3303 Connecting rod 1399 3306 Connecting rod shaft 1426 Bottom bearing half for bottom end bearing with elastic bolts 3310 Bottom bearing shell half for bottom...
Page 69 0360−1/A1 Maintenance Individual Components per Piece in kg Group Component Design 5552 Supply unit with pumps, driving wheels 5−6 Cyl. engines 1750 7−8 Cyl. engines 2000 Servo oil pump (Dynex) 5−6 Cyl. engines Camshaft with gear wheel 7−8 Cyl. engines 5556 Fuel pump 5612...
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Page 71 0380−1/A1 Maintenance Maintenance Schedule Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) System oil − Laboratory analysis 3000 Main fuel and − Do a check of the filter elements for white 3000 lubricating oil metal particles (clean or replace the filter as filters necessary).
Page 72 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 1715−1 Engine Stays − Hydraulic type: Do a check of the oil pressure Monthly on the gauge 1903−1 Tie Rod − Do a check of the pre-tension. If necessary, 24000 to 30000 apply tension again.
Page 73 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 2708−1 Cylinder cover − Do a check of the combustion space for At each cylinder cover damage and worn areas removal − Estimated service life: Cylinder cover Engine lifetime (re-manufacture as necessary)
Page 74 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 2751−1 Exhaust valve − General inspection of valve housing, valve At each piston removal spindle and valve seat (when the exhaust valve is not disassembled) 2751−4 −...
Page 75 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) − Lubricate the tooth flanks of the pinion and 2000 flywheel. Related to visual inspections, but at the latest, each 2000 Op. h of the engine −...
Page 76 6000 5551−1 Servo oil pump − Replace the servo oil pump with new item or a 50000 (Dynex) pump re−manufactured by WinGD service provider 5552−1 Servo oil pump − Do a check of the pinion and driving wheels to 3000...
Page 77 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 5552−2 Fuel oil pump − Camshaft: Do a check of the running surface 3000 drive of cams, rollers and roller guides (first time after 500 Op. h) −...
Page 78 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) − Renew flow limiting valve 48000 − Estimated lifetime: Flow limiting valve 24000 Servo oil rail − Replace the hoses (each five years at a 30000 minimum) 5612−1...
Page 79 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) 6606−1 Scavenge air − Clean the scavenge air cooler (air side) during As necessary cooler operation each week. Later if np (pressure decrease through the SAC) increases compared to the shop test value at the same engine load (refer to the Operation Manual 6606−1)
Page 80 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Procedure Intervals and Service Life (operation hours) Pressure − Compare and calibrate according to the 6000 to 8000 gauges and master instruments pyrometers Pipe holders − Make sure that the fasteners are tight. Tighten As necessary the screws if necessary (first time after 100 Op.
Page 81 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) The maintenance intervals shown are for guidance and can be different in relation to the installation. The correct intervals apply to the points given below. These intervals, which are related to the duration of operation, can be longer or shorter: Environmental and operation conditions Diesel engine fuels and quality of lubricating oil (refer to the Operation Manual 0710−1 and 0750−1)
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Page 83: Engine Cross Section And Longitudinal Section (Tc At Driving End)
0803−1/A1 Maintenance Engine Cross Section and Longitudinal Section (TC at Driving End) Cross Section 8460−1 2728−1 8733−1 2124−1 2124−3 5612−1 4325−1 6420−1 6606−1 8447−1 3603−1 3326−1 6545−1 3326−2 8752−1 5556−1 5801−1 3301−1 5552−1 5552−5 4103−1 1112−1 WCH00676 Fig. 1: Cross Section 2016 1/ 2 Winterthur Gas &...
Page 84 0803−1/A1 Maintenance Engine Cross Section and Longitudinal Section (TC at Driving End) Longitudinal Section 2751−1 2751−4 2722−1 2708−1 2708−3 3425−1 3403−1 3403−4 2138−1 1903−1 6420−1 2303−1 6606−1 6708−1 3303−1 3303−5 3140−1 1132−1 1132−2 9223−1 1203−1 1224−1 3130−1 WCH00677 Fig. 2: Longitudinal Section 2016 2/ 2 Winterthur Gas &...
Page 85: Engine Cross Section And Longitudinal Section (Tc At Exhaust Side)
0803−1/A2 Maintenance Engine Cross Section and Longitudinal Section (TC at Exhaust Side) Cross Section 8460−1 8733−1 2728−1 5562−1 3603−1 8447−1 6606−1 3326−1 6708−1 3326−2 6420−1 8752−1 5556−1 5801−1 3301−1 3206−1 5552−1 5552−5 4103−1 1112−1 WCH00123 Fig. 1: Cross Section 2016 1/ 2 Winterthur Gas &...
Page 86 0803−1/A2 Maintenance Engine Cross Section and Longitudinal Section (TC at Exhaust Side) Longitudinal Section 2751−1 2751−4 2722−1 2708−1 2708−3 3425−1 2124−1 2124−3 3403−1 3403−4 1903−1 2138−1 4325−1 2303−1 3303−1 3303−5 3140−1 1132−1 1132−2 1203−1 1224−1 3130−1 4103−3 WCH03431 Fig. 2: Longitudinal Section 2016 2/ 2 Winterthur Gas &...
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Page 88: Bedplate And Tie Rod Group
Group1 Maintenance Bedplate and Tie Rod Group 1 Bedplate and Thrust Bearing: Foundation Bolts − Check ........1112−1/A1 Main Bearing Waisted Studs −...
Page 89 1112−1/A1 Maintenance Bedplate and Thrust Bearing Foundation Bolts − Check Tools: 1 Feeler gauge 94122 2 Pressure gauges 94934A 1 Pre-tensioner 94145 1 HP hose 94935 1 HP oil pump 94931 General You must do a check of the tension of the foundation bolts and studs at longer intervals e.g.
Page 90: 1112−1/A1
1112−1/A1 Maintenance Bedplate and Thrust Bearing Tension Check Clean the threads of the foundation bolts (5, Fig. 4) and the seating surfaces. Apply Molykote G paste to the threads of the foundation bolts, or installed studs (5). Put the pre-tensioner (94145) in position on the foundation bolt (5) Open the vent screw (8).
Page 91 1112−1/A1 Maintenance Bedplate and Thrust Bearing Foundation Bolts − Loosen If all foundation bolts must have tension applied again, start with the studs at the driving end and continue from one side to the other side to the free end of the engine. Attach the pre-tensioning jack (94145) on the foundation bolt (5, Fig.
Page 92 1112−1/A1 Maintenance Bedplate and Thrust Bearing Foundation Bolts − Apply Tension You must apply tension to the foundation bolts (metal and synthetic) in two steps as follows: Attach the pre-tensioning jack (94145) as given in paragraph 2, step 1) to step 8). Apply a pressure of 900 bar to the foundation bolt.
Page 93: Main Bearing
1132−1/A1 Maintenance Main Bearing Waisted Studs − Loosen and Apply Tension Tools: 2 Double pre-tensioner 94114B 4 Coupling elements 94934G 1 Feeler gauge 94122 3 HP hose 94935 1 Pressure gauge 94934A 1 Hydraulic unit 94942 1 Distributing piece 94934C General The 1 main bearing cover (2,...
Page 94 1132−1/A1 Maintenance Main Bearing: Waisted Studs − Loosen and Apply Tension Connect the two double pre-tensioning jacks (94114B, Fig. 2) to the hydraulic unit (94942). 94934G 94114B 94942 94935 94934 94934A 018.675/09 Fig. 2 Waisted Studs − Loosen Install the double pre-tensioning jacks (94114B), refer to paragraph 2.
Page 95 1132−1/A1 Maintenance Main Bearing: Main Bearing: Waisted Studs − Loosen and Apply Tension Waisted Studs − Apply Tension After you install the main bearing cover (see 1132−2), apply tension to the waisted studs (3) as follows: Install the double pre-tensioning jacks (94114B) as given in paragraph 2. Start the hydraulic unit (94942).
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Page 97: Main Bearing − Removal And Installation
1132−2/A1 Maintenance Main Bearing Main Bearing − Removal and Installation Tools: 2 Manual ratchet (800 kg) 94016 (H1, H2) 1 Wire rope 94120A 1 Spur-geared chain block (2000 kg) 94017−001 (H3) 1 Support 94141 1 Shackle (4750 kg) 94018B 1 Work platform 94142 1 RUD eye bolt 94040−M20...
Page 98 1132−2/A1 Maintenance Main Bearing − Removal and Installation Note: Some parts can look different Main Bearing Covers No. 2 to No. 8 − Removal Tools − Installation Remove the oil pipe(1, Fig. 1) from the main bearing cover (2). Apply protection to all openings. WCH02325 Fig.
Page 99: 1132−2/A1
1132−2/A1 Maintenance Main Bearing − Removal and Installation WARNING Injury Hazard: Do not use the thrust device 94110 as a lifting device. Injury to personnel can occur. 94116B CAUTION 94110 Damage Hazard: Use the thrust device (94110) only for the removal of the main bearing covers.
Page 100 1132−2/A1 Maintenance Main Bearing − Removal and Installation 94335 Attach the deviation pipe (94117A, Fig. 5) to the column. Attach the tool (94335) between the reinforced double-I girders. Attach the manual ratchet (H1) to the shackle (94018B) and the lug (94116B). Lift the main bearing cover (3) until it is fully removed from the elastic studs.
Page 101 1132−2/A1 Maintenance Main Bearing − Removal and Installation VIEW ON FLYWHEEL Main Bearing Cover FROM AFT END No.1 − Removal Remove the pipe (6, Fig. Remove the casing (1). Remove the oil pipe (2) from the main bearing cover. Remove the top half of the oil baffle. Apply protection to the slinger rings on the crankshaft.
Page 102 1132−2/A1 Maintenance Main Bearing − Removal and Installation 17) Attach the manual ratchet (H1, Fig. to the main bearing cover and the attachment point (3) as shown. 18) Operate the manual ratchets (H1, H2) between the attachment rings in the gallery to move the main bearing cover (2) to the fuel side.
Page 103 1132−2/A1 Maintenance Main Bearing − Removal and Installation Note: When you remove the bottom bearing shell No. 1, you must use the jack Fig. 9) to hold the weight of the flywheel. To give protection to the flywheel teeth, put a copper or aluminum plate between the jack and the flywheel.
Page 104 1132−2/A1 Maintenance Main Bearing − Removal and Installation Crankshaft − Lift Measure and record the lateral bearing clearances (y1 and y2 Fig. 10 between the crankshaft (2) and the bottom bearing shell (3, 4) approximately 50 mm below the bearing. 50 mm Put the dial gauge (1) above the crankshaft (2) as shown.
Page 105 1132−2/A1 Maintenance Main Bearing − Removal and Installation Bearing Shell No. 1 − Removal CAUTION Damage Hazard: Do not remove two adjacent main bearing shells at the same time. Damage to the engine can occur. Note: The applicable main bearing cover is removed.
Page 106 1132−2/A1 Maintenance Main Bearing − Removal and Installation Operate the manual ratchet (H1, Fig. 12) to turn the bearing shell (1) to the position as shown. Note: If the bearing shell (1) does not move, the device (94119B) must be attached to the other side of the turning-out device (94118A).
Page 107 1132−2/A1 Maintenance Main Bearing − Removal and Installation Bearing Shell No. 2 to No. 8 − Removal WARNING 94117 Injury Hazard: Before you 94120A operate the turning gear, make sure that no 94119B personnel are near the flywheel or in the engine. CAUTION Damage Hazard: Do not remove two adjacent main...
Page 108 1132−2/A1 Maintenance Main Bearing − Removal and Installation 12) Operate the manual ratchet (H1, Fig. 15) to turn the bearing shell until you can attach the tool (94116A).Attach the tool (94116A) to the bearing shell (1). 13) Attach the tool (94116A) to the bearing shell (1).
Page 109 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Shells − Inspection CAUTION Damage Hazard: Do not use a scraper in the running area of the bearing shell. Damage to the bearing shell can occur. Use a soft cloth to clean the bearing shell. Do a check the bearing shell for damage such as breakouts or cracks.
Page 110 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Cover − Installation Make sure that the work area and all tools and equipment are clean and in good condition. Use the applicable equipment to get the bearing cover in the correct position above the crankshaft as follows: For bearing covers No.
Page 111: Thrust Bearing
1203−1/A1 Maintenance Thrust Bearing Axial Clearance − Checks Tools: 1 Inside micrometer 94101 1 Feeler gauge 94238 Procedure One Start the engine in the direction AHEAD to move the crankshaft fully forward. Stop the engine. Put the dial gauge (8, Fig.
Page 112 1203−1/A1 Maintenance Axial Clearance − Checks Procedure Two II-II Start the engine in the direction AHEAD to move the crankshaft fully forward. The crankshaft must touch the thrust pads (3, Fig.1). Stop the engine. Make sure that the crankshaft does not move.
Page 113: Thrust Bearing Pads − Removal And Installation
1224−1/A1 Maintenance Thrust Bearing Thrust Bearing Pads − Removal and Installation Tools: 1 Turning-out device 94155 1 Turning-out device 94155A (for 1-part gear wheel) (for 2-part gear wheel) 2 Spur-geared chain block (H1, H2) 94018−006 1 Eye bolt 94040−M12 Removal Read the data in 0012−1 General Guidelines for Lifting Tools.
Page 114 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation 11) Attach the eye bolt (94040−M12) to the thrust bearing pad (2 or 3, Fig. 12) Attach the chain blocks to the eye bolt (94040−M12). 13) Attach the turning-out device (94155 or 94155A). WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine.
Page 115 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation I - I II - II 94155 94155A 94040−M12 94155 94155A 5, 5a 012.959/05 2, 3 Fig. 2 012.960/05 11) Install the arbor supports (2, or 5, Fig. 1) as follows: Attach the eye bolt (94040−M12) to the applicable arbor support.
Page 116 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation CONFIGURATION OF THRUST BEARING PADS WITH FIXED PITCH PROPELLER 5−Cyl and 6−Cyl ENGINES CLOCKWISE ASTERN AHEAD ROTATING ENGINE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END PADS ON ENGINE SIDE COUNTERCLOCKWISE ASTERN AHEAD...
Page 117 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation CONFIGURATION OF THRUST BEARING PADS FOR CONTROLLABLE PITCH PROPELLER 5−Cyl and 6−Cyl ENGINE CLOCKWISE ASTERN AHEAD ROTATING ENGINE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END PADS ON ENGINE SIDE AHEAD COUNTERCLOCKWISE ASTERN...
Page 118 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation CONFIGURATION OF THRUST BEARING PADS FOR FIXED PITCH PROPELLER 7−Cyl and 8−Cyl ENGINE CLOCKWISE ASTERN AHEAD ROTATING ENGINE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END PADS ON ENGINE SIDE COUNTERCLOCKWISE ASTERN AHEAD...
Page 119: Engine Stays With Friction Shims Tension Checks
1715−1/A1 Maintenance Engine Stays with Friction Shims Engine Stays with Friction Shims Tension Checks Tools: 1 Feeler gauge 94122 2 Pressure gauge 94934A 1 Pre-tensioner jack 94145 1 HP hose 94935 1 HP oil pump 94931 General The engine stays (1, Fig.
Page 120 1715−1/A1 Maintenance Engine Stays with Friction Shims: Tension Checks Tension Checks Clean the threads of the bolts (2, Fig. 1) and the seating surfaces. Apply Molykote G paste to the threads of the bolts (2). Refer to 9403−2 9403−4 . Attach the pre-tensioner and the applicable equipment as shown in Fig.
Page 121: 1715−1/A2
1715−1/A2 Maintenance Hydraulic Engine Stays Oil Pressure Checks General Usually two hydraulic engine stays (1, Fig.1) are installed on the exhaust side and two on the fuel side of the engine. This can be different because of special installations. You must compare the oil pressures on the pressure gauges (8) of the hydraulic cylinders (3) at regular intervals.
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Page 123: 1903−1/A1
1903−1/A1 Maintenance Tie Rod Tension Checks and Replacement Procedure Tools: 1 Rod 94005 2 Coupling elements 94934G 2 Pre-tensioner 94180 3 HP hoses 94935 1 Connection block 94934 1 Hydraulic unit 94942 1 Hydraulic distributor 94934A General ............Tension Check .
Page 124 1903−1/A1 Maintenance Tension Checks and Replacement Procedure Tie Rods − Replace Preparation Remove the protection cover (1, Fig. from the tie rods (2). Clean the surface of the intermediate ring (5). Remove the set screws (7). Refer to 9403−4, then attach the two pre-tensioners (94180) to two tie rods (2), e.g.
Page 125 1903−1/A1 Maintenance Tension Checks and Replacement Procedure Apply Tension Note: Start with the tie rods in the middle of the engine (a−a, then b−b etc). Make sure that the set screws (7, Fig. 2) are removed. Put the two pre-tensioning jacks 94180 (94180, Fig.3) on the to two tie rods (2).
Page 126: Cylinder Liner And Cylinder Cover Group
Group2 Maintenance Cylinder Liner and Cylinder Cover Group 2 Cylinder Liner Measure the Cylinder Liner ............2124−1/A1 Removal and Installation .
Page 127: Measure The Cylinder Liner
2124−1/A1 Maintenance Cylinder Liner Measure the Cylinder Liner Tools: 1 Gauge 94225 1 Ladder 1 Tool cylinder liner measuring 94226 WARNING Danger: Gas Hazard. Poisonous gas can stay in the cylinder liner. There is Setting Screw a risk of suffocation. You must make sure that poisonous gas is removed before you go into the...
Page 128 2124−1/A1 Maintenance Measure the Cylinder Liner Put the gauge (94225, Fig. 1) in position on the top face of the cylinder liner (3) in line with the longitudinal axis of the engine. Make sure that the top hole (A) is above the ridge in the non-running surface of the cylinder liner (3).
Page 129: Removal And Installation
2124−2/A1 Maintenance Cylinder Liner Removal and Installation Tools: 3 Manual ratchets 94016−004 2 Flange couplings 94201C 3 Shackles 94018D 1 Shackle 94201D 1 Lifting device 94201 1 Chain 94202L consisting of: 1 Dismantling tool 94208 1 Lifting tool 94201A 1 Assembly tool 94345E 2 Holders 94201B...
Page 130 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Cylinder Liner − Removal Remove the screws (4, Fig. Remove the pipe connection (3) and the transition tubes (5) from the water guide jacket (2). Note: The transition tubes (5) are a push-fit into the pipe connections (3).
Page 131 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Lifting Tool − Install 94201 Put the two flange couplings (94201C, Fig. 3) in position on the cylinder liner (1). 94201B Apply Molyslip Copaslip paste to the threads of the screws (3). In each flange coupling, torque the four screws (3) to 140 Nm.
Page 132 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Cylinder Liner − Safe Storage 94202L 94202L Attach the shackle (94201D, Fig. 5) of the lifting tool (94201) as shown. 94201D Attach the chain (94202L) to the 94201 shackle (94201D) and the crane hook. Put the wooden underlay (2) in position as shown.
Page 133 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Water Guide Jacket − Removal Remove the cylinder liner, refer to the procedures in paragraph paragraph 2.2. Loosen the two screws (3, Fig. Remove the cylinder holders (4, 5). Attach the three shackles (94018D) to the lifting tool (94201).
Page 134 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Water Guide Jacket − Installation Install the insulation bandage, refer to paragraph 6. Attach the lifting tool (94201) to the cylinder liner, refer to paragraph 2.1. Lift, move and lower the cylinder liner into the water guide jacket (1, Fig.
Page 135 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Insulation Bandage − Removal Remove the cylinder liner, refer to the procedures in paragraph paragraph 2.2. Remove the water guide jacket, refer to paragraph 3. Use the assembly tool (94345E, Fig. to remove all the tension springs (2). Remove the plate (3).
Page 136 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Cylinder Liner − Installation Install the lifting tool (94201, .10) and the chain (94202) to the cylinder liner, refer to paragraph 2.1. Clean the seating surfaces of the cylinder liner (1) and the cylinder jacket.
Page 137: Remove Unwanted Material, Dress The Lubricating Grooves And Scavenge Ports
2124−3/A1 Maintenance Cylinder Liner Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports Tools: 1 Grinding device 94299 General During operation, the cylinder liner becomes worn and an edge of unwanted material collects immediately above the location where the top piston ring travel stops. Also, the lubricating grooves decrease in depth and the corner radii of the scavenge ports become smaller.
Page 138 2124−3/A1 Maintenance 94299 WCH02352 Unwanted material r = 8.0 mm 2.0 mm to 3.0 mm 1.0 mm Fig. 1 2016 2/ 4 Winterthur Gas & Diesel Ltd.
Page 139: 2124−3/A1
2124−3/A1 Maintenance Cylinder Liner: Re-dressing Lubricating Grooves and Scavenge Ports Lubricating grooves CAUTION Damage Hazard: Make sure that you keep the initial shape of the lubricating grooves when you remove sharp edges. If the depth of the lubricating grooves (1, Fig.
Page 140 2124−3/A1 Maintenance Cylinder Liner: Re-dressing Lubricating Grooves and Scavenge Ports II-II Rounded Edges WCH00106 Fig. 3 015.739/07 WCH03094 After the repair is completed, fully clean the lubricating grooves and the bore of the cylinder liner. Remove unwanted particles, which may have passed into the scavenge space through the ports.
Page 141 2138−1/A1 Maintenance Lubricating Quill Removal and Installation Tools: 1 HP oil pump 94931 1 Connection nipple (G¼ in.) 94934I 1 Hydraulic distributor with 94934H 1 HP hose 94935 pressure gauge 0 bar to 25 bar) 1 Dismantling tool 94213 General If it is not necessary to remove the cylinder liner (1, Fig.
Page 142: 2138−1/A1
2138−1/A1 Maintenance Lubricating Quill Nozzle Tip − Replace Remove the two bolts (2, Fig. 2) and the plate (1) from the distance sleeve (3). Put the distance sleeve (3) on (5) of the lubricating quill. Attach the plate (1) to the nozzle tip (4). Engage the collar on the plate with the recess on the lubricating quill (5).
Page 143 2138−1/A1 Maintenance Lubricating Quill Lubricating Quill − Function Check General You do a function check to make sure that the non-return valve (3, Fig. 3) operates correctly. The pressure that opens the non‐return valve is 5.0 bar. During the function check, keep the lubricating quill (2) in a horizontal position. For the function check, use an oil with a viscosity as given in the specifications that follow: SAE 50 at 40_C (approximately 200 cSt)
Page 144 2138−1/A1 Maintenance Lubricating Quill Installation CAUTION Damage Hazard: The surfaces of the cylinder liner and the nozzle tip make a metallic seal. The seat angles in the cylinder liner and on the nozzle tip are different. Do not use a gasket between the cylinder liner and the nozzle tip, or damage to the equipment can occur.
Page 145 2138−1/A1 Maintenance Lubricating Quill Remove the plugs from the oil pipe (5, Fig. Connect the pipe (5) to the lubricating quill (7) and the applicable pipe (8). Tighten the nuts (4, 6) of the screw-in union and angle union. Step a) to step c) is only necessary if the cylinder liner was installed. Remove the plugs from the six pipes (1).
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Page 147: 2140−1/A1
2140−1/A1 Maintenance Gas Admission Valve (GAV) Removal, Disassemble, Assemble, Checks, Installation Tools: 1 Assembly tool 94023A 1 Pressure reducing valve 94214B 1 Eye bolt 94040-M8 1 Handle 94214A 1 Disassembly / assembly tool 94214 1 Disassembly / assembly tool 94890 2 Screws 94214L 2 Nuts...
Page 148 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Apply Molykote G-Rapid Plus to the tool (94890, Fig. Remove the screws (3) on each side of the compensator (1). Put the tool (94890) in position on the compensator (1) as shown. Note: The tool (94890) is shorter than the installed length of the compensator (1).
Page 149 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Removal WARNING Danger: If a gas detector alarm is activated, keep away from the engine. The natural gas is flammable. There is a risk of fire or explosion. WARNING Injury Hazard: When you open valves and shut-off devices, hot fluids or gases can be released.
Page 150 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Disassemble Hydraulic Drive − Removal Loosen the four Allen screws (6, Fig. Carefully remove the cover (5) together with the rail valve (7). Remove the coupling nut (9) on the valve stroke sensor (10) Remove the valve stroke sensor (10) and the sleeve (9).
Page 151 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Valve Bush and Valve Guide − Remove If it is necessary to remove the valve bush (2, Fig. 4) and the valve guide (4), do step 1) to step 5): Remove the six Allen screws (1) from the valve bush (2).
Page 152 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Valve Spindle − Removal Apply Molykote G Rapid Plus to the rod Fig. 5) of the tool (94214). Attach the plate (94214F) to the bush (94214E) with the four screws (94214G).
Page 153 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Pressure Test 94214B Apply lubricating oil to the valve spindle (3, Fig. Put the valve spindle (3) in position in the valve guide (4). Install the pusher (94214D) to the bush (94214E) with the two M6x65 screws (9).
Page 154 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Valve Seat − Lap Remove the spring (5, Fig. 5), refer to paragraph 4.3. 94214A Attach the handle (94214A) to the valve spindle (3, Fig. 7) as shown. Apply lubricating oil to the valve spindle (3).
Page 155 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Manual Check − Free Movement Note: Do not use oil when you do step 1) and step 2) Make sure that the valve spindle and valve guide move freely as follows: Remove the oil from the running surface of valve spindle and valve guide.
Page 156 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Assemble Note: During this procedure, make sure that you do not cause damage to the surface of the valve housing and the O-rings (9, Fig. Clean all parts and bores. Make sure that the O-rings (9) are in good condition.
Page 157 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation 18) Attach the cover (4, Fig. 9) to the valve housing (6). 19) Apply Never Seez High Temperature Stainless lubricant to the threads and surfaces of the six Allen screws (1). 20) Torque symmetrically the six Allen screws (1) to 10 Nm.
Page 158 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation Installation 94040−M8 Attach the eye bolt (94040−M8, Fig. to the housing of the GAV (4). Lift and move the GAV (4) to the applicable position at the cylinder liner. Make sure that all surfaces that will touch are clean.
Page 159 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation 10. Completion Make sure that the compensator (1, Fig. 12), the O-rings (7), the coupling flanges and the surface of connecting block and are clean and in good condition. Put the tool (94890) in position on the compensator (1) as shown.
Page 160 2140−1/A1 Maintenance Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation 15) Do a leakage check of the high-pressure hydraulic pipe. 16) Do a pressure test of the opening pressure, refer to Operation Manual. Note: For a functional check of the gas admission valve the engine must be stopped.
Page 161 2303−1/A1 Maintenance Piston Rod Gland Removal, Disassemble, Measure Worn Parts, Assemble, Installation Tools: 2 Distance holders 94345 2 Distance pieces 94345F−9 1 Clamp ring (2-part) 94345B 2 Distance pieces 94345F−11 1 Gauge 94345C 2 Distance pieces 94345F−13 2 Spring assembly tools 94345E 2 Work supports 94143 2 Work platforms...
Page 162 2303−1/A1 Maintenance Removal, Disassemble, Measure Worn Parts, Assemble, Installation Removal Operate the turning gear to move the piston to BDC. Lock the turning gear. Make sure that the two distance 94345 holders (94345, Fig. 1) are installed on to the piston rod foot (2). Remove the four inner bolts (3, Fig.
Page 163: 2303−1/A1
2303−1/A1 Maintenance Removal, Disassemble, Measure Worn Parts, Assemble, Installation Disassemble CAUTION Injury Hazard: The eight outer screws must be removed after the piston rod gland is disassembled. This will prevent injury to personnel. Remove the bolts (3, Fig. 4) and screws (4) from the housing (2).
Page 164 2303−1/A1 Maintenance Removal, Disassemble, Measure Worn Parts, Assemble, Installation II - II WCH03495 I - I 1, 2 3, 4 Fig. 6: Gland Box − General Views 1 Locking Plate 6 Bolt 2 Screw 7 Spring dowel pin 3 Locking Plate 8 2−part housing 4 Screw 9 Screw...
Page 165 2303−1/A1 Maintenance Removal, Disassemble, Measure Worn Parts, Assemble, Installation Assemble Attach two parts of the clamp ring (94345B, Fig. 7) to the piston rod (2). Put the ring support (4) and the 3-part scraper ring (5) on the clamp ring (94345B).
Page 166 2303−1/A1 Maintenance Removal, Disassemble, Measure Worn Parts, Assemble, Installation Installation Apply lubricating oil to the piston rod (2, Fig. 8) and to the all O-rings. 94350 Put the template (94345C) in position over the assembled rings. Make sure that all parts are in their correct 94345C positions.
Page 167 2708−1/A1 Maintenance Cylinder Cover Cylinder Cover and Water Guide Jacket − Removal and Installation Tools: 1 Tool 94265 2 Special eye bolts 94265A Preparation ............Cylinder Cover −...
Page 168: Cylinder Cover − Removal
2708−1/A1 Maintenance Cylinder Cover and Water Guide Jacket − Removal and Installation 94265 Cylinder Cover − Removal CAUTION Injury Hazard: The weight of the cylinder cover with the top water guide jacket and the exhaust valve is approximately 1640 kg. Use the correct equipment to lift 94265A and move the cylinder...
Page 169: 2708−1/A1
2708−1/A1 Maintenance Cylinder Cover and Water Guide Jacket − Removal and Installation 94265 Water Guide Jacket − Installation Clean all the sealing faces and O-ring grooves. Apply oil to the sealing faces of the top water guide jacket (3, Fig. Apply oil to the new O-rings (6, 7).
Page 170: Cylinder Cover − Installation
2708−1/A1 Maintenance Cylinder Cover and Water Guide Jacket − Removal and Installation Cylinder cover − Installation 94265 Make sure that the compression space is free from particles or dirt. Make sure that the seating surfaces on the cylinder cover (2, Fig.
Page 171: Completion
2708−1/A1 Maintenance Cylinder Cover and Water Guide Jacket − Removal and Installation Completion Install the expansion piece, refer to 2751−1, paragraph 4. Install the hydraulic pipe to the exhaust valve, refer to 8460−1. Install the HP fuel pipe, refer to 8733−1. Install the applicable HP pilot fuel pipes, refer to 8790−1.
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Page 173: Cylinder Cover Elastic Studs − Loosen And Apply Tension
2708−2/A1 Maintenance Cylinder Cover Cylinder Cover Elastic Studs − Loosen and Apply Tension Tools: 1 Hydraulic tensioning device 94215 1 Hydraulic distributor 94934A includes: 3 HP hoses 94935 8 Pre-tensioning jacks 94215A 1 Hose 94935C 2 Connection pieces with HP hoses 94215B 1 Hydraulic unit 94942...
Page 174 2708−2/A1 Maintenance Cylinder Cover Elastic Studs − Loosen and Apply Tension Connect the two connection pieces (94215B, Fig. 2) and their HP hoses to the hydraulic jacks (94215A). Connect the hydraulic unit (94942) to the connection pieces (94215B). 94215B 94215B 94215A 94934 94935...
Page 175 2708−2/A1 Maintenance Cylinder Cover Elastic Studs − Loosen and Apply Tension Apply Tension Turn the round nuts (4, Fig. 3) fully down. Use a feeler gauge to make sure that there is no clearance at the slot (5). Put one reference mark (Y) on the round nuts (4) and one reference mark (X) on the parts below.
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Page 177 2708−3/A1 Maintenance Cylinder Cover Grind Sealing Face Tools: 1 Cutting device 94270 1 Profile cutter 94270A General The sealing face in the cylinder cover for the primary injection valve is a metallic seal. Thus, this sealing face must be clean and have no damage. Sealing Face −...
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Page 179: Sealing Face For The Pilot Injection Valve Position − Grind
2708−4/A1 Maintenance Pilot Injection Valve Sealing Face for Pilot Injection Valve Position − Grind Tools: 1 Grinding device 94270−02 2 Stud bolts 94270F 1 Stencil 94270−2D Procedure Make sure that the stop sleeve (4) is attached to the spindle (1) of the device (94270−02).
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Page 181: Sealing Face For The Fuel Injection Valve Position − Grind
2708−5/A1 Maintenance Pilot Injection Valve Sealing Face for Fuel Injection Valve Position − Grind Tools: 1 Grinding device 94270−01 1 Stencil 94270−1D Procedure Make sure that the stop sleeve (3) is attached to the spindle (2) of the device (94270−01). Make sure that the O−rings (4) are serviceable.
Page 183: Sealing Face For The Prechamber − Grind
2708−6/A1 Maintenance Pilot Injection Valve Sealing Face for the Prechamber − Grind Tools: 1 Grinding device 94270−03 1 Stencil 94270−3D Procedure Make sure that the stop sleeve (2) is attached to the spindle (1) of the device (94270−03). Use the applicable grade of emery cloth related to the quantity of metal 94270−3 you want to remove.
Page 185: 2722−1/A1
2722−1/A1 Maintenance Injection Valve Removal and Installation Tools: 2 Hexagon head bolts 94270C 1 Bush 94289C 2 Stud bolts 94270D Removal CAUTION Injury Hazard: The weight of the injection valve is 12 kg. Use sufficient personnel to lift and move heavy items.
Page 186 2722−1/A1 Maintenance Injection Valve: Removal and Installation Storage Apply protection to the nozzle tip. Be careful when you move the injection valve. CAUTION Injury Hazard: White spirit is a harmful substance. Put on gloves and safety goggles when you use white spirit. Use white spirit to clean to the injection valve (e.g.
Page 187: Warning
2722−1/A1 Maintenance Injection Valve: Removal and Installation Injection valve − installation WARNING Injury and Damage Hazard: Do not use copper paste in this procedure. Copper paste can be a conductor of electricity. Injury to personnel and damage to equipment can occur. 94289C Do a check of the condition of the sealing face in the cylinder cover.
Page 188 2722−1/A1 Maintenance Injection Valve: Removal and Installation If the spring cage (5, Fig. 4) was disassembled, make sure that the 24 cup springs (2) are installed as shown. Flush Apply Never-Seez NSBT8 to the threads and the seating surface of the screws (3).
Page 189 2722−1/A2 Maintenance Injection Valve: Installation Injection Valve with FAST Injection Valve Installation of Injection Valve with FAST General ............Installation .
Page 190 2722−1/A2 Maintenance Injection Valve: Installation Injection Valve with FAST Installation Remove and discard the old O−rings. Install new O−rings (3, Fig.2). Put oil on the new O−rings Make sure that the work station is clean. Carefully position the injector valve assembly (4) into the chamber.
Page 191 2722−2/A1 Maintenance Injection Valve Checks, Disassemble, Assemble Tools: 1 Torque spanner 94012 1 Adaptor 94272B 1 Slugging wrench 94269A−46 1 HP hose 94275 1 Hydraulic cylinder 94269B 1 Tool 94289 1 Cable 94275A which includes: 1 Socket wrench insert 94269C−46 1 Bush 94289A 1 Valve holder...
Page 192: Injection Valve: Checks, Disassemble, Assemble
2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble 94272 Preparation WARNING Danger. Do not use welding or grinding equipment near the work area. Fuel and solvents are flammable. 94273 WARNING Injury Hazard. Calibration fluid is a harmful substance. Always read the manufacturer’s safety WCH03003 instructions before you use...
Page 193 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Procedure Checks WARNING Injury Hazard: Do not put your fingers near the holes in the nozzle tip. Fuel can go through your skin and cause injury or kill you. Start the test bench (94272). At regular intervals, use a master pressure gauge to do checks of the pressure gauges on the test bench.
Page 194 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve − Disassemble 94272 Make sure that the test bench (94272) and HP hose (94275) have no pressure. Remove the receiver (2, Fig. 1) from the valve holder (94273). 94275 Disconnect the HP hose (94275, Fig.
Page 195: 2722−2/A1
2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Nozzle Tip − Removal SCREWDRIVER Note: If it is necessary to replace only the nozzle tip, it is sufficient to remove only the sleeve (5, Fig. Put the screwdrivers into the recess in the nozzle body (2).
Page 196 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Pilot Valve − Removal 94289 Note: When you do the step below, it is not necessary to torque the coupling nut (2, Fig. Remove the nozzle tip, refer to paragraph 3.4. 94289B Attach the coupling nut (2) to the nozzle body (1).
Page 197 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve − Assemble WARNING Injury and Damage Hazard: Do not use copper paste in this procedure. Copper paste can be a conductor of electricity. Injury to personnel and damage to equipment can occur. Make sure that the sealing faces of the injection valve (2, Fig.
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Page 199 2728−1/A1 Maintenance Starting Air Valve Removal, Disassemble, Grind, Assemble, Installation Tools: 1 Assembly tool 94281 General ............Preparation .
Page 200: Starting Air Valve: Removal, Disassemble, Grind, Assemble, Installation
2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Removal Remove the control air pipe (5, Fig. from the starting air valve. Disconnect the electrical connection from the 3/2-way solenoid valve (1). Remove the four screws (6). Carefully remove the starting air valve from the cylinder cover (4).
Page 201: 2728−1/A1
2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Disassemble Put the starting air valve in a vice. Make sure that the vice jaws do not damage the starting air valve. Remove the two screws (2, Fig. Remove the cover (1) together with the 3/2-way solenoid valve (3).
Page 202 2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Grind If the seating faces of the housing (1, Fig. 5) and the valve spindle (2) have minimum damage, do as follows: Manually grind the seat faces of the housing (1) and the valve spindle (2).
Page 203 2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Initial Position Put the tool (94281, Fig. 7) in position on the housing. 10) Tighten equally the two nuts (1) until you get to the second position. Note: Do not get Molykote paste G on 94281 the thread of the valve spindle (3) where the insert of the self-locking...
Page 204 2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Installation Remove the protection from the cylinder cover (4, Fig. Put a new gasket (3) in the bore of the cylinder cover (4). Apply a thin layer of oil to the bore of the cylinder cover (4).
Page 205: Exhaust Valve
2751−1/A1 Maintenance Exhaust Valve Removal and Installation of Exhaust Valve, Replacement of Elastic Studs Tools: 1 Stud tool 94008A−M12 1 Connection block 94934 2 Pre-tensioning jacks 94252 1 Hydr. distributor 94934A 1 Valve protector 94262 2 Coupling elements 94934G 1 Suspension device 94265 3 HP hoses 94935...
Page 206 2751−1/A1 Maintenance Removal and Installation of Exhaust Valve, Replacement of Elastic Studs Removal Procedure Round Nuts − Removal Clean the threads of the elastic studs (1, 2) and the area around the round nuts (2). Put the two pre-tensioning jacks (94252) in position on the applicable elastic studs (1).
Page 207 2751−1/A1 Maintenance Removal and Installation of Exhaust Valve, Replacement of Elastic Studs 94265 Exhaust Valve − Removal WARNING Injury Hazard: The weight of the suspension tool (94265) is 33.4 kg. Use applicable equipment and personnel to move and install the suspension device.
Page 208 2751−1/A1 Maintenance Removal and Installation of Exhaust Valve, Replacement of Elastic Studs Installation Exhaust Valve − Install Clean all the sealing faces on the exhaust valve and in the cylinder cover Fig. Do a check for damage in the cylinder cover (1) and on the exhaust valve.
Page 209 2751−1/A1 Maintenance Removal and Installation of Exhaust Valve, Replacement of Elastic Studs Round Nuts − Install Clean all the sealing faces on the exhaust valve and in the cylinder cover. Apply a small quantity of oil to the threads of the elastic studs (3, Fig.
Page 210 2751−1/A1 Maintenance Removal and Installation of Exhaust Valve, Replacement of Elastic Studs Completion Clean the sealing faces on the expansion piece (1, Fig. 10) and the related sealing faces on the valve cage and exhaust manifold. Apply a thin layer of a heat-resistant lubricant to the sealing faces and related screws.
Page 211 2751−1/A1 Maintenance Removal and Installation of Exhaust Valve, Replacement of Elastic Studs Elastic Studs − Replace Use the stud tool (94008A−M12, Fig. 12) to remove the elastic stud (1). Remove all grease and clean the 94008A−M12 sealing face of the new elastic stud. Read the data in the documentation of the jointing compound manufacturer.
Page 212 2751−1/A1 Maintenance Removal and Installation of Exhaust Valve, Replacement of Elastic Studs Other Materials Products of other manufacturers that have the specifications given below, are also permitted. Materials that: Contain no acid, e.g. no acetic acid Are resistant to oil, marine diesel oil, heavy fuel oil and water at a permanent temperature of approximately 100_C.
Page 213: Disassemble And Assemble
2751−2/A1 Maintenance Exhaust Valve Disassemble and Assemble Tools: 1 Depth gauge 94126 1 Torque wrench General ............Disassemble .
Page 214 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Fig. Fig. Fig. Fig. Fig. 10 Fig. Fig. 9 Fig. Fig. 11 Fig. Fig. Fig. Fig. Fig. 11 Fig. 1 2016 2/ 8 Winterthur Gas & Diesel Ltd.
Page 215: 2751−2/A1
2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Disassemble WARNING Danger: Do not weld or grind materials in the area. The sparks from welding equipment and grinding tools can cause a fire. Make sure that the work area is clean and has no dust. Valve Drive −...
Page 216: Valve Spindle − Remove
2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Valve Spindle − Remove Remove the circlip (1, Fig. Push the piston (6) down. Remove the two parts of the valve cotter (2). Remove the piston (6) from the valve spindle (5). Remove the cup springs (3). When you do step 6) below, make sure that the valve spindle (5) does not move.
Page 217: Valve Spindle − Install
2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Valve Spindle − Install If the valve seat or spindle are new items, you must examine them. Refer to the instructions given in 2751−3, paragraph 5. Measure the dimensions of the valve spindle (7, Fig.
Page 218: Valve Drive − Assemble
2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Valve Drive − Assemble Attach the lifting equipment to the housing (2, Fig. Lift, then lower the housing (2) on to the valve cage (4). Attach the housing (2) to the valve cage (4) with the two Allen screws (3). Put the top housing (6) in position on the housing (2).
Page 219: Damper Setting
2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Damper Setting You set the damper (1, Fig. 9) only if you replace a valve spindle or valve seat, or after one of the seating faces was ground. Remove the damper (1). Make sure that the bores in the damper are clear.
Page 220: Throttle
2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Throttle Do a check of the throttle as follows: Remove the screw plug (2, Fig. 10) from the top housing (3). Remove the throttle (1). Make sure that the throttle (1) is clear. Put oil on the thread of the throttle (1).
Page 221: General
2751−3/A1 Maintenance Exhaust Valve Valve Seat − Replace / Grind Tools: 1 Feeler gauge 94122 1 Valve seat dismantling device 94261 1 Template 94279 1 Tool, grinding 94291 General ............Preparation .
Page 222 2751−3/A1 Maintenance Valve Seat − Replace / Grind Recommended Procedure Turn the valve cage (2, Fig. 1) until the valve seat (1) points up. Carefully put the valve cage on to an applicable wooden underlay (3). Install the top two halves of the tool (94261) into the groove of the valve seat (1).
Page 223: 2751−3/A1
2751−3/A1 Maintenance Valve Seat − Replace / Grind Valve Seat − Grind Use only the tool (94291, Fig. 3) to grind the valve seats. Read the data in the manufacturer’s documentation for the tool (94291). Put the valve seat (1) in the correct position on the tool (94291).
Page 224 2751−3/A1 Maintenance Valve Seat − Replace / Grind Valve Seat − Check You do this procedure to make sure that the sealing face of the valve spindle correctly touches the sealing face of the valve seat. Put a thin layer of engineer’s blue paste on the sealing face of the valve spindle (4, Fig.
Page 225 2751−3/A1 Maintenance Valve Seat − Replace / Grind Valve Seat − Installation Clean the bores and the sealing faces of the valve cage (3, Fig. 6) and the valve seat (2). Apply oil (or lubricants e.g. Never-Seez NBST-8, or Loctite anti-seize compound) to the bores and sealing 94261 faces of the valve seat (2) and the...
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Page 227: Grinding The Seating Surface On The Valve Head
2751−4/A1 Maintenance Exhaust Valve Grinding the Seating Surface on the Valve Head Tools: 1 Feeler gauge 94122 1 Tool, valve grinding device 94291 1 Template 94292 General a = between Use only the tool (94291, Fig. 1) to grind the 30°8' and 30°10' valve head.
Page 228 2751−4/A1 Maintenance Exhaust Valve: Grinding the Seating Surface on the Valve Head If the measured values are more than the limits given on the gauge (94292), you can repair the valve spindle (refer to the data below). If more than 3.0 mm is ground off, do the procedure that follows: Use a build-up welding procedure to repair the valve seating surface.
Page 229: Pilot Injection Valve: Removal, Disassemble, Check, Assemble, Installation
2790−1/A1 Maintenance Pilot Injection Valve Pilot Injection Valve: Removal, Disassemble, Check, Assemble, Installation Tools: 1 Torque spanner 94012 1 OBEL test bench 94272 1 Slugging wrench 94269A−55 1 Connecting piece 94272F 1 Socket wrench extension 94269C−55 1 Valve holder 94273 1 Hydraulic cylinder 94269B 1 HP hose...
Page 230 2790−1/A1 Maintenance Pilot Injection Valve: Removal, Disassembly, Check, Assemble, Installation Preparation Stop the engine, refer to the procedure in the Operation Manual 4002−2. Let the engine temperature decrease before you start the removal procedure. Set to off the pilot fuel pump. Close the valves from the fuel supply and pilot fuel supply.
Page 231: 2790−1/A1
2790−1/A1 Maintenance Pilot Injection Valve: Removal, Disassembly, Check, Assemble, Installation Put the plate (94270E, Fig. 2) on the pilot injection valve (2) as shown. Put the two screws (1) in the plate 94270E (94270E). Turn equally the screws until the they touch the valve holder (3).
Page 232 2790−1/A1 Maintenance Pilot Injection Valve: Removal, Disassembly, Check, Assemble, Installation Pilot Injection Valve − Check 94275 WARNING Danger: Do not put your SUPPLY fingers near the nozzle tip. 94273 Fuel can go through your skin and cause injury or kill you.
Page 233 2790−1/A1 Maintenance Pilot Injection Valve: Removal, Disassembly, Check, Assemble, Installation 10) Push the INJECT button. The pilot injection valve must operate correctly. 11) Do a check of the seating surface between the needle seat and the nozzle as follows: Keep the pressure of the test bench constant at approximately 350 bar. Monitor the pilot injection valve for 30 seconds.
Page 234 2790−1/A1 Maintenance Pilot Injection Valve: Removal, Disassembly, Check, Assemble, Installation Coupling Nut − Install Make sure that the sealing faces of the pilot injection valve: Are clean and dry Are in a satisfactory condition Have no lubricant. Apply a thin layer of Molykote paste G to the thread and the seating surface of the coupling nut (2, Fig.
Page 235 2790−1/A1 Maintenance Pilot Injection Valve: Removal, Disassembly, Check, Assemble, Installation Pilot Injection Valve Seal − Install 94289E Put a new seal (2, Fig. 6) on the injection valve (1). Use the tool (94289E) to install the seal (2) on to the injection valve (1). Remove the tool (94289E).
Page 236: Crankshaft, Connecting Rod And Piston Group
Piston Cooling and Crosshead Lubrication: Inner Pipe − Removal and Installation ... 3603−1/A1 RT-flex50DF / MM / 2016 Winterthur Gas & Diesel Ltd. 1/ 3 Winterthur Gas & Diesel Ltd.
Page 237 3103−1/A1 Maintenance Crankshaft Crank Deflection − Measure Tools: 1 Crankshaft equipment (dial gauge) 94305 General It is sufficient to measure the crank-web deflection in accordance with the intervals specified in the class rules. It can be necessary to measure the crank-web deflection in unusual conditions, for example: Important change of crank-web deflection results compared to the data before.
Page 238 3103−1/A1 Maintenance Measuring Crank Deflection Make sure that the tank heater and lubricating oil separator are set to off for a minimum of eight hours. Operate the turning gear to move the crank to the BDC 1st position (see Fig. Attach the dial gauge (94305) to the connecting rod.
Page 239 3103−1/A1 Maintenance Measuring Crank Deflection Data Analysis STROKE 94305 nBDC nTDC Fig. 3 If the measured values are above the maximum permissible limits, do the necessary measurements to find the cause of the problem. It can be: Where values are measured, which are above the maximum permitted limits, you must find the cause (e.g.
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Page 241 3130−1/A1 Maintenance Vibration Damper Inspection (Geislinger Vibration Damper) General Some engine designs can have a Geislinger manufactured vibration damper installed at the free end of the crankshaft. The service life of a vibration damper is related to the speed range in which the engine operates.
Page 242 3130−1/A1 Maintenance Inspection (GEISLINGER Vibration Damper) Check Engine Filters CAUTION Damage Hazard: If the oil supply to the damper is stopped, the engine must be stopped immediately. Damage to the vibration damper can occur. The oil supply must flow correctly before the engine is started again.
Page 243 3130−1/A1 Maintenance Inspection (GEISLINGER Vibration Damper) I - I FREE END SUPPLY 000.940/93 Note: Some parts can look different. WCH02925 Fig. 2: Vibration Damper (section view) 1 Damper casing 4 Oil supply pipe 2 Vibration damper 5 Coupling bolt 3 Cover 6 Vent nozzle 2016 3/ 3...
Page 245 3140−1/A1 Maintenance Axial Detuner Disassemble and Assemble Tools: 2 Manual ratchets 94016-001 2 RUD eye bolts 94040-M20 1 Manual ratchet 94016-002 1 Lifting tool 94335 Preparation CAUTION Injury Hazard: The weight of the top housing is approximately 400 kg. Use the correct equipment to lift and move the top housing. This will prevent injury to personnel.
Page 246 3140−1/A1 Maintenance Axial Detuner: Disassemble and Assemble Disassemble Remove the four screws (1, Fig. Remove the eight screws (3) from top cylinder half (2). On engines that have a vibration damper, loosen fully the eight screws and pull them out as far as possible.
Page 247 3140−1/A1 Maintenance Axial Detuner: Disassemble and Assemble Attach the lifting tool (94335, Fig. 3) between the double-I girders. Attach the manual ratchet (94016−002) to the lifting tool (94335). Attach the eye bolts (94040−M20) to the top cylinder half (1). Attach the manual ratchets (94016−001) to the eye bolts (94040−M20) as shown. I - I 94335 94016−002...
Page 248 3140−1/A1 Maintenance Axial Detuner: Disassemble and Assemble Note: The two gaskets (2, Fig. 4) are 2-part items. The gasket (5) is a 1-part item. Note: When you do step 7), make sure that you do not cause damage to the gaskets (2, 5 and tension springs (3, 4) Operate the manual ratchets (94016−001) to carefully lift the top cylinder half (1).
Page 249 3140−1/A1 Maintenance Axial Detuner: Disassemble and Assemble Assemble Apply clean engine oil to the gaskets (2, 5). Attach the new gaskets (2, 5) to the axial detuner. Make sure that the new gaskets (2, 5) can move freely around the axial detuner. Put the tension springs (3, 4) around the 2-part gaskets (2, 5).
Page 250 3140−1/A1 Maintenance Axial Detuner: Disassemble and Assemble Completion Attach the two pipes (2, Fig. 6) to the top cylinder half (4). Attach the top housing (1). Connect the two pipes (3) to the screw-in unions (2). I - I WCH03505 Fig.
Page 251 3206−1/A1 Maintenance Turning Gear Teeth and Screwed Connections Check General Before you operate the turning gear (1, Fig. 1) you must do a check of the condition of the tooth flanks on the pinion (2) and the flywheel (3). Also you must make sure that lubricant is applied to these components.
Page 252 3206−1/A1 Maintenance Turning Gear: Checking the Toothing Tooth Checks Lubrication Instructions Apply a very thin, equal layer of lubricant to the tooth flanks of the pinion (2, Fig. and the flywheel (3). Refer to Table and Table 2. Table 1: Instructions − Pyroshield Manufacturer Location Instruction...
Page 253 3301−1/A1 Maintenance Crankcase Work Platform Tools: 1 Platform 94142 2 Nut 94142A 1 Support 94143 General WARNING Injury and Damage Hazard: Do not turn the crankshaft when the platforms and/or supports are installed. This can cause injury to personnel and damage to equipment. You use the platform (94142, Fig.
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Page 255: 3301−2/A2
3301−2/A2 Maintenance Top Platform Configuration of Lifting Tools Tools: 1 Spur-geared chain block 94017 2 Bushes 94335B (WLL 2000 kg) 2 Screws 94335C 1 Lifting tool 94335 General For the removal and installation of heavy engine components, the lifting tool (94335) is attached between double I-girders (1).
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Page 257: Connecting Rod
3303−1/A1 Maintenance Connecting Rod Loosening and Tensioning the Connecting Rod Studs Tools: 1 Feeler gauge 94122 1 Connection block 94934 2 Pre-tensioning jacks 94314 1 Hydr. distributor 94934A 2 Distance bushes 94314A 3 HP hoses 94935 1 Pre-tensioning jacks 94315 1 Hydraulic unit 94942 General...
Page 258 3303−1/A1 Maintenance Loosening and Tensioning the Connecting Rod Studs Loosening the stud of bottom end bearing 94314 Clean the threads of studs 4 and the area around nuts 5. 94314A Put the distance bushes 94314A on the studs. Attach and tighten the pre-tensioning jacks 94314 with open vent screws 7 until there is only little or no clearance at ’x’...
Page 259 3303−1/A1 Maintenance Loosening and Tensioning the Connecting Rod Studs Tensioning the stud of bottom end bearing Clean the threads of studs 4 and the area around the nuts 5. Apply oil to the stud threads and screw on the nuts. Tighten the nuts with round bar ’RS’...
Page 260 3303−1/A1 Maintenance Loosening and Tensioning the Connecting Rod Studs Loosening the stud of top end bearing Note: For loosening the studs always follow the sequence shown in Fig. 4 i.e. a + a and b + b. Clean the threads of studs 1 and the 94315 area around the nuts 2.
Page 261 3303−1/A1 Maintenance Loosening and Tensioning the Connecting Rod Studs Tensioning the stud of top end bearing Note: For tensioning the studs always follow the sequence shown in Fig. 4 i.e. a + a and b + b for each step. Clean the threads of studs 1 as well as the area around nuts 2.
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Page 263: Bottom End Bearing − Removal, Inspection And Installation
3303−2/A2 Maintenance Connecting Rod Bottom End Bearing − Removal, Inspection and Installation Tools: 1 Work platform 94142 1 Spur-geared chain block H3 94017−022 4 Retaining pins 94323 2 RUD-eye bolt M8 94040−M8 1 Lifting tool 94335 2 Manual ratchets 1600 kg H1, H2 94016−007 1 Chain (double sling) 94666I...
Page 264 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Apply a light tension to the manual ratchets (H1 and H2, , Fig. Remove the manual ratchet (H1) from the column and attach it to the top attachment point as shown. Operate the manual ratchets (H1, H2) to move the bearing cover to the position shown.
Page 265 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation 94666I Bottom Bearing Shell − 94040−M6 Removal Remove the two Allen screws (3, Fig. Attach the two eye bolts (94040−M6) to the bearing shell. Attach the chain (94666I) to the eye bolts (94040−M30).
Page 266 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Operate the turning gear to move the crank (1, Fig. 5) down. 10) Install the work platform (94142), refer to the instructions given in 3301−1. 11) Hold the bearing shell and remove Allen screws (2).
Page 267 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bottom Bearing Shell − 94666I 94040−M6 Installation Attach the two eye bolts (94040−M6, Fig. 7) to the bottom bearing shell (1). Attach the chain (94666I) to the two eye bolts (94040−M30) and the chain block (H3).
Page 268 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Attach the manual ratchet (H2, Fig. to the attachment point in the column and the eye bolt (94040−M8). Attach the manual ratchet (H1) to the bottom attachment point in the column and the eye bolt (94040−M8).
Page 269 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Table 1: ISO G 1000/1500 Suppliers Supplier Type Viscosity at Viscosity at Weight at 40° C mm 100° C mm 15° C g/ml ENERGOL DC 1000 49.0 0.913 ENERGOL DCW 1000 40.0 0.913 CHEVRON...
Page 271: Top End Bearing − Removal And Installation
3303−3/A2 Maintenance Connecting Rod Top End Bearing − Removal, Inspection and Installation Tools: 1 Work platform 94142 1 Lifting tool 94335 4 Retaining pins 94323 1 Stop plate 94370H 1 Lifting plate 94324 2 Manual ratchet 1600 kg H1, H2 94016−007 2 Lifting rings 94332...
Page 272 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation Crosshead − Lift (Installed 94332 Piston) Note: During this procedure, the piston Fig. 2) is installed. Remove the four round nuts (5) of the connecting rod (7), refer to 9403−4. Attach the stop plate (94370H) to the bearing cover (4) and guide shoe (6).
Page 273 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation Operate the manual ratchets (H3 and Fig. 3) to lift the crosshead above the bottom holes in the guideways (1). Put the four retaining pins (94323) in the holes in the guideways (1). Operate carefully the manual ratchets (H3, H4) to lower the guide shoes on to the retaining pins (94323).
Page 274 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation Crosshead − Lift (Piston Removed) Remove the four round nuts (2, Fig. from the connecting rod (4), refer to 9403−4. Attach the stop plate (94370H) to the bearing cover (1) and guide shoe (6). Attach the lifting plate (94324) to crosshead pin with the round nuts from the piston rod foot.
Page 275 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation 94335 Bearing Shell − Removal Attach the lifting tool (94335, Fig. between the double-I girders. Operate the manual ratchets (H1, H2) 94017−022 to move the connecting rod a small distance to the fuel side. Remove the manual ratchet (H1) from the swivel lug (94048−M30) on the connecting rod.
Page 276 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation Bearing Shell − Installation Installation with Piston Installed Clean the seating surface of the bearing shell (1, Fig. Put oil on the surface of the bearing shell (1) as follows: If you start the engine immediately after completion of this procedure, use only bearing oil.
Page 277 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation 18) Operate the manual ratchets (H3 and Fig. 8) to lift the guide shoes a small distance. 19) Remove the four retaining pins (94323). Note: During step 20), make sure that the elastic studs are aligned with the holes in the crosshead pin.
Page 278 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation Installation with Piston Removed Clean the seating surface of the bearing shell (1, Fig. 10). Put oil on the surface of the bearing shell (1) as follows: If you start the engine immediately after completion of this procedure, use only bearing oil.
Page 279 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation 18) Operate the engine room crane to to lift the guide shoes (1, Fig. 11) a small distance. 19) Remove the four retaining pins (94323). Note: During step 20), make sure that the elastic studs are aligned with the holes in the crosshead pin.
Page 280 3303−3/A2 Maintenance Top End Bearing − Removal, Inspection and Installation Table 1: ISO G 1000/1500 Suppliers Supplier Type Viscosity at Viscosity at Weight at 40° C mm 100° C mm 15° C g/ml ENERGOL DC 1000 49.0 0.913 ENERGOL DCW 1000 40.0 0.913 CHEVRON...
Page 281: Removal And Installation
3303−4/A2 Maintenance Connecting Rod Removal and Installation Tools: 1 Work platform 94142 1 Lifting tool 94335 4 Retaining pins 94323 1 Stop plate 94370H 1 Lifting plate 94324 2 Manual ratchet 1600 kg H1, H2 94016−007 2 Lifting rings 94332 2 Manual ratchet 3200 kg H3, H4 94016−013 1 Spur-geared chain block 2000 kg H5 94017−022 3 Eye bolts M8 EB1, EB2, EB3...
Page 282 3303−4/A2 Maintenance Connecting Rod: Removal and Installation Attach the lifting tool (94335, Fig. 94335 between reinforced double-I girders, refer to 3301−2. Attach the chain block (H5) to the lifting tool (94335). Operate the manual ratchets (H1, H2) to move the connecting rod to the fuel side.
Page 283 3303−4/A2 Maintenance Connecting Rod: Removal and Installation 14) Operate the turning gear to move the crank counterclockwise to approximately 35_ after TDC (see Fig. 15) Attach the manual ratchet (H1) to the eye bolt (E3). 16) Attach the manual ratchet (H2) to the eye bolt (EB3).
Page 284 3303−4/A2 Maintenance Installation Make sure that the mark FUEL SIDE on the connecting rod (3, Fig. 6) points to the fuel side of the engine. Put oil on the bearing shell (2) and the crank pin (1). Attach the chain block (H5) to the eye bolt (EB2) Attach the manual ratchet (H2) to the eye bolt (EB3).
Page 285 3303−4/A2 Maintenance Connecting Rod: Removal and Installation Operate the turning gear to move the crank clockwise. At the same time, operate the chain block (H5, Fig. 8) to hold the connecting block. Attach the manual ratchet (H1) to the eye bolt (EB 2). 10) Remove the manual ratchet from the eye bolt (EB3).
Page 286 3303−4/A2 Maintenance Connecting Rod: Removal and Installation 16) Operate the turning gear to move the crank clockwise to BDC. Make sure that the connecting rod stays in the vertical position (see Fig. 10). 17) Attach the manual ratchet (H1) to the eye bolt (EB1).
Page 287: Top End Bearing − Bearing Cover Removal And Installation
3303−5/A2 Maintenance Connecting Rod Top End Bearing − Bearing Cover Removal and Installation Tools: 2 Lifting rings 94332 2 Manual ratchets H1, H2, 94016−007 1 Lifting tool 94335 2 Manual ratchets H3, H4 94016−001 1 Spur-geared chain block H4 94017−021 4 RUD-eye bolt EB1, EB2 94040−M8 1 Work platform...
Page 288 3303−5/A2 Maintenance Top End Bearing − Bearing Cover Removal and Installation Removal Loosen the elastic studs on the top end 94332 bearing and remove their round nuts, refer to 9403−4. Attach the eye bolts (EB1 and EB2, Fig. 3) to the bearing cover (3). Attach the lifting rings (94332) to cylinder block (1) with screws (2).
Page 289: 3303−5/A2
3303−5/A2 Maintenance Top End Bearing − Bearing Cover Removal and Installation 94335 Attach the lifting tool (94335, Fig. between the double-I girders. Attach the work platform (94142), refer to 3301−1. 10) Attach the manual ratchet (H3) to the top attachment point in the column. 11) Attach the chain (94666I) to the manual 94666I ratchet (H3) and the eye bolts (EB1,...
Page 290 3303−5/A2 Maintenance Top End Bearing − Bearing Cover Removal and Installation Installation Make sure that the bearing cover is clean and has no damage. Attach the chain (94666I) to the eye bolts (EB1 and EB2) and the chain block (H4) see Fig.
Page 291 3303−5/A2 Maintenance Top End Bearing − Bearing Cover Removal and Installation Completion 94333B WARNING Injury Hazard: Before you operate the turning gear, make sure that no 94333A personnel are near the flywheel, or in the engine. Remove the work platform (94142). Note: During step 2), make sure that you do not cause damage to the elastic studs, (1,...
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Page 293: Crosshead
3326−1/A1 Maintenance Crosshead Clearances Tools: 1 Feeler gauge 94238 General During an overhaul or after the installation of the crosshead, you must do as follows: FUEL SIDE Measure and record the clearances shown in Fig. 1 Fig. Compare the clearances with those given in 0330−1 Clearance Table Crosshead Guide.
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Page 295: Crosshead Pin − Removal And Installation
3326−2/A2 Maintenance Crosshead Crosshead Pin − Removal and Installation Tools: 1 Deviation pipe 94117A 2 Manual ratchet 800 kg, H4, H5 94016-001 1 Work platform 94142 2 Manual ratchet 1600 kg, H2, H3 94016-007 1 Lifting plate 94324 1 Manual ratchet 3200 kg, H1 94016-013 2 Lifting rings 94332...
Page 296 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation Crosshead Pin − Removal 94666 Attach the sling (94666, Fig. 1) to the attachment points (1) in the column. 94324 Attach the lifting plate (94324) and shackles to the crosshead pin (2) with 94324 the round nuts (3) removed from the piston rod foot.
Page 297 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation Put the wooden chock (1, Fig. 3) in the bottom corner of the column as shown. Operate the manual ratchets (H2, H3) to move the crosshead to the exhaust side a small distance. Make sure that 94666 the connecting rod cannot move back to the fuel side.
Page 298 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation 13) Attach the lifting rings (94332, Fig. 5) to the cylinder block (6) with the screws (5). 14) Torque the screws (5) to 200 Nm. 15) Attach the eye bolts (EB) to the guide shoes (1, 4).
Page 299 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation 19) Move the crosshead pin (1, Fig. 7) to the driving end as shown. 20) Operate the manual ratchet (H4) to lift the guide shoe (2). 013.243/05 21) Move the crosshead pin (1) to the free end.
Page 300 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation 23) Attach the lifting tool (94335, Fig. 94335 between the double-I girders. 24) Attach the chain block (H6) to the lifting tool (94335). 25) Turn the crosshead pin 90_. 26) Attach the chain block (H6) to the crosshead pin.
Page 301 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation Attach the chain block (H6, Fig. 10) to the guide shoe. Operate the manual ratchet (H1) and the chain block (H6) to remove the guide shoe from the engine. Do step 2) to step 6) for the guide shoe attached to the manual ratchet (H5).
Page 302 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation Turn the crosshead pin (1, Fig. 12) 90° . Move the crosshead pin (1) to the driving end. Lower and align the guide shoe (2) with the crosshead pin (1). 10) Move the crosshead pin (1) fully through the guide shoe (2).
Page 303 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation 16) Attach the manual ratchet (H2, Fig. to the eye bolt on the connecting rod. 17) Operate the manual ratchet (H2) to move the connecting rod (1) sufficiently to remove the wooden chock (2) and attach the eye bolt (EB).
Page 304 3326−2/A2 Maintenance Crosshead Pin − Removal and Installation Clearance Checks Do the clearance checks, refer to 3326−1. Completion Install the round nuts to the elastic studs on the connecting rod, refer to 9403−4. Install the top bearing cover, refer to 3303−5 paragraph 3. Attach the piston to the crosshead, refer to 3303−5 paragraph 4.
Page 305: Piston
3403−1/A1 Maintenance Piston Removal and Installation Tools: 1 Working platform 94142 1 Spacer 94344A 2 Nuts 94142A 2 Chains 94344B 1 Support 94143 2 Distance holders 94345 1 Dismantling tool 94208 1 Piston supporting device 94350 1 Lifting hook 94209 1 Inserting cone 94342 2 Lifting bosses...
Page 306 3403−1/A1 Maintenance Piston: Removal and Installation Removal Remove the work platform (94142) and the support (94143). Operate the turning gear to move the crank (1, Fig. 3) approximately 90° to BDC. Remove the four round nuts (2, Fig. 3) from the piston rod foot (1), refer to 9403−4.
Page 307 3403−1/A1 Maintenance Piston: Removal and Installation Operate the turning gear to move the crank to BDC. 10) Put the spacer (94344A, Fig. 5) on the crosshead pin (1). 94344A Fig. 5 WCH03082 11) Operate the turning gear to move the crosshead up sufficiently so there is no tension on the chains (94344B, Fig.
Page 308 3403−1/A1 Maintenance Piston: Removal and Installation 14) Before you move the crank to TDC, make sure that: The four inner bolts (1, Fig. 8) are 94345 removed. The distance pieces (94345) are in line with the gland box. Fig. 8 Note: When you do step 15), the piston moves up and the the distance pieces (94230) move the gland box...
Page 309 3403−1/A1 Maintenance Piston: Removal and Installation 24) Make sure that the piston support 94350 tool (94350, Fig. 12) is in the correct position on the top platform. 25) Loosen the four screws (3). 26) Move fully out the two supports (1). 27) Lift and lock the plates (2) in the vertical position.
Page 310 3403−1/A1 Maintenance Piston: Removal and Installation Installation Make sure that the items that follow are clean and in a satisfactory condition: All parts of the piston rod gland The piston ring grooves and the piston rings All surfaces of the piston. Make sure that the O-rings in the piston 94209 rod gland are in a satisfactory...
Page 311 3403−1/A1 Maintenance Piston: Removal and Installation 21) Make sure that each clearance in the piston rings is opposite the clearance in the piston ring above/below. Note: When you do step 21), make sure that you do not damage the cylinder liner (2) or the support for the piston rod gland.
Page 312 3403−1/A1 Maintenance Piston: Removal and Installation 38) Put oil on the four elastic studs (2, Fig. 17). 39) Attach the four round nuts (3) to the elastic studs (2). 40) Tighten the four round nuts (3), refer to 9403−4. Fig. 17 41) Attach the engine room crane to the tool (94209, Fig.
Page 313 3403−1/A1 Maintenance Piston: Removal and Installation Completion Install the cylinder cover, refer to 2708−1. Set to on the bearing lubrication pump. Look through the scavenge ports on the fuel side. Make sure that the running surface of the cylinder liner stays dry. Note: A defective O-ring in the piston rod gland can cause an increase of the dirty oil level in the scavenge air space.
Page 315: Changing The Compression Shims
3403−2/A1 Maintenance Piston Changing the Compression Shims Tools: 1 Working platform 94142 2 Lifting bosses 94333A 2 Suspension chains 94333B Compression shim − Removal and Installation 94333B 94333A I - I 94333A 94142 013.553/05 Fig. 1 013.552/05 Note: Pay attention to: General Guidelines for Lifting Tools 0012−1.
Page 316 3403−2/A1 Maintenance Piston: Changing the Compression Shims The crank may be turned max. 30_ towards T.D.C. Pay attention to the warning plate provided on the holders! 94333B CAUTION 94333A Carefully turn the crank down until waisted studs 7 are out of piston rod foot 3 (Fig.
Page 317: 3403−2/A1
3403−2/A1 Maintenance 94333B 013.693/05 94333A COMPRESSION SHIMS: ONLY FOR ENGINES WITHOUT ADDITION HP CROSSHEAD LUBRICATION PUMP ONLY FOR ENGINES WITH ADDITION HP CROSSHEAD LUBRICATION PUMP 013.694/05 3/ 3 Winterthur Gas & Diesel Ltd.
Page 319: Disassemble And Assemble
3403−3/A1 Maintenance Piston Disassemble and Assemble Tools: 1 Suspension device 94341 1 Hydr. distributor 94934A 2 Pre-tensioning jacks 94346 2 Coupling elements 94934G 1 Piston supporting device 94350 3 HP hoses 94935 2 Jacking screws 94364 1 Hydraulic unit 94942 1 Connection block 94934 1 Torque wrench...
Page 320 3403−3/A1 Maintenance Piston: Disassemble and Assemble Disassemble CAUTION Damage Hazard: When you disassemble the piston, make sure that you do not damage the pipes or nozzles on the spray plate. Put the two jacking screws (94364A, Fig. 2) fully into the two tap holes in the top of the piston rod (3).
Page 321 3403−3/A1 Maintenance Piston: Disassemble and Assemble CAUTION Damage Hazard: If it becomes necessary to remove the the elastic studs, do not use a pipe wrench. This could cause damage to the bolt shank. 14) Remove the piston skirt (5, Fig. 4) from the piston rod (6) as given in step a) to step c):...
Page 322 3403−3/A1 Maintenance Piston: Disassemble and Assemble Assemble Note: Do not install pipes or nozzles that have damage. Apply LOCTITE No. 0270 to the thread of the pipe (2, Fig. Use the applicable tool to install the pipe (2) to the spray plate (4). Use a center punch to lock the pipe (2) in position.
Page 323 3403−3/A1 Maintenance Piston: Disassemble and Assemble 12) Refer to Fig. 1 for the sequence to apply tension to the elastic studs. 13) Apply tension to the 12 elastic studs (1, Fig. 14) Tighten the round nuts (1) on the elastic bolts (2). 15) Install the piston, refer to 3403−1, paragraph 3.
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Page 325: Top Surface Check
3403−4/A1 Maintenance Piston Top Surface Check Tools: 1 Feeler gauge 94122 1 Template 94366A 1 Template 94366B General Each time you remove a piston, you must do a check of the top surface of the piston head for damage (burn scars). The causes of burn scars are as follows: Poor combustion Worn nozzles...
Page 326 3403−4/A1 Maintenance Piston − Top Surface Check 94366A Procedure − Piston Installed WARNING Injury Hazard: Before you operate the turning gear, make sure that no 10 mm personnel are near the flywheel, or inside the 009.901/02 engine. Fig. 2 Operate the turning gear to move the piston to BDC.
Page 327: Piston Rings And Ring Grooves: Rate Of Wear
3425−1/A1 Maintenance Piston Rings Piston Rings and Ring Grooves − Rate of Wear Tools: 1 Inside micrometer 94101 1 Permascope MP0 94356 1 Feeler gauge 94122 (with instruments to 1 Piston ring tool 94338 measure chrome-ceramic layers) 1 Calliper gauge General .
Page 328: 3425−1/A1
3425−1/A1 Maintenance Piston Rings and Grooves − Rate of Wear Three Piston Rings Piston Ring − Rate of Wear Chrome-ceramic Layer − Measure (Piston Installed) WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Read the data in the suppler documentation for the Permascope MP0 (94356).
Page 329: Rate Of Wear
3425−1/A1 Maintenance Piston Rings and Grooves − Rate of Wear Three Piston Rings Rate of Wear The rate at which the the chrome-ceramic layer becomes worn is related to the operation conditions. If a piston ring that has some wear of the chrome-ceramic layer is found (see Fig.
Page 330: Service Life − Calculate
3425−1/A1 Maintenance Piston Rings and Grooves − Rate of Wear Three Piston Rings Service Life − Calculate Use the formula below to calculate the rate of wear of a piston ring: (D1−D2) x 1000 WR = T2−T1 Where: WR = Rate of Wear (mm/1000 hrs) T2 = Time (hrs) T1 = First recorded operation hours (hrs) D1 = First recorded thickness of the chrome-ceramic layer (mm)
Page 331: Piston Ring Grooves
3425−1/A1 Maintenance Piston Rings and Grooves − Rate of Wear Three Piston Rings Piston Ring Grooves Do a check of all dimensions and record them (see 0330−1 Piston and Piston Rings). These records are important for an analysis of the running gear and must include the data that follow: All dimensions The date of the overhaul...
Page 332: Piston Rings − Removal
3425−1/A1 Maintenance Piston Rings and Grooves − Rate of Wear Three Piston Rings Piston Rings − Removal CAUTION Damage Hazard: Do not open the piston rings too far. This will cause damage to the piston rings. Note: If the same piston rings will be installed again, record their positions. Use the tool (94338, Fig.
Page 333 3425−1/A1 Maintenance Piston Rings and Grooves − Rate of Wear Three Piston Rings 3.3.2 Alternative Procedure with Piston Ring Piece Measure the thickness of the piece of piston ring (1, Fig. 94122 WCH02244 Fig. 6 Put the piece of piston ring (1) into the piston ring groove. Use the feeler gauge (94122) to measure the clearance (X1) between the face of piston ring and the groove.
Page 334: Used Piston Rings − Installation
3425−1/A1 Maintenance Piston Rings and Grooves − Rate of Wear Three Piston Rings Used Piston Rings − Installation For the ring types and their locations, see Table Table 3: Standard Piston Ring Locations Ring Type Material Application Top Piston Ring 1 x GTP1CC17 (gas tight) chrome-ceramic layer For new and fully honed cylinder liners...
Page 335: New Piston Rings − Installation
3425−1/A1 Maintenance Piston Rings and Grooves − Rate of Wear Three Piston Rings New Piston Rings − Installation CAUTION Damage Hazard: Do not open the piston rings too far. This will cause damage to the piston rings. Note: Make sure that the mark TOP, on the piston ring, points up. Note: For the ring types and their locations, refer to Table Note: Make sure that you use tool (94338,...
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Page 337: 3603−1/A1
3603−1/A1 Maintenance Piston Cooling and Crosshead Lubrication Inner Pipe − Removal and Installation Tools: 1 Lifting tool 94337 1 Centering piece 94337A 1 Flange 94337B Removal 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 applicable crank approximately 30_ after TDC.
Page 338 3603−1/A1 Maintenance Piston Cooling and Crosshead Lubrication: Removal and Installation of Inside Pipe Loosen the screws (6, Fig. Loosen the screws (2). Lower the ring holder (3) together with sleeve (1). Operate the turning gear to move the crank to BDC. Remove the inner pipe (4) together with the sleeve (1) and the ring holder (3).
Page 339 3603−1/A1 Maintenance Piston Cooling and Crosshead Lubrication: Removal and Installation of Inside Pipe Installation Operate the turning gear to move the applicable crank to BDC. If necessary, remove the flange (94337B, Fig. 3) from the inlet pipe (11). Attach the lifting tool (94337, Fig.
Page 340: Driving Wheels And Shut-Off Valve For Starting Air
Group4 Maintenance Driving Wheels and Shut-off Valve for Starting Air Group 4 Driving Wheels Running and Backlash Clearances and Tooth Condition ........4103−1/A1 Starting Air Shut-off Valve: Clean and Function Check .
Page 341 4103−1/A1 Maintenance Drive Wheels Running and Backlash Clearances and Tooth Condition Tools: 1 Feeler gauge 94122 1 Dial gauge 1 Micrometer 1 Lead wire Ø 1.5 mm General ............Checks .
Page 342 4103−1/A1 Maintenance Running and Backlash Clearances and Tooth Condition Gear Tooth Backlash Checks Refer to 0330−1, Driving Wheels for Supply Unit (Group 4103) for data about the gear tooth backlash values. There are three procedures to measure the backflash. Feeler Gauge 94122 Measure the clearance between the Drive Wheel tooth flanks (10,...
Page 343 4103−1/A1 Maintenance Running and Backlash Clearances and Tooth Condition Use the micrometer to measure the lead wire. Calculate as follows: The full tooth backlash: f = f1 + f2 The obliquity: Df = a1 − b1 or a3 − b3. The permitted difference of the tooth profile parallelity is between 0.0% and 0.2% across the width of the tooth.
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Page 345: 4325−1/A1
4325−1/A1 Maintenance Starting Air Shut-off Valve Clean and Function Check General ............Preparation .
Page 346 4325−1/A1 Maintenance Starting Air Shut-off Valve: Clean and Function Check Disassemble Remove the six screws (6, Fig. 2) from the cover. Turn the handwheel (3) fully in. This will move the cover from the spindle (5). Remove the handwheel (3) and the cover. Remove the spring (8) together with the valve (9) and the spindle (5).
Page 347 4325−1/A1 Maintenance Starting Air Shut-off Valve: Clean and Function Check 1.0 mm WCH03534 Fig. 2 2016 3/ 6 Winterthur Gas & Diesel Ltd.
Page 348 4325−1/A1 Maintenance Starting Air Shut-off Valve: Clean and Function Check Assembly Make sure that all the bores are clear. Remove grease from the surface of the spindle (5, Fig. Apply a thin layer of Molykote paste to the stopper (11), the spring (14) and the valve body (9).
Page 349 4325−1/A1 Maintenance Starting Air Shut-off Valve: Clean and Function Check 24) Attach the inlet flange and pipe (not shown) to the shut-off valve with the eight M24x50 bolts (9). 25) Torque the eight M24x50 screws to the value given in 0352−2, paragraph 1. 26) Connect the check pipe (10) to the pipe connection.
Page 350 4325−1/A1 Maintenance Starting Air Shut-off Valve: Clean and Function Check Operate the handwheel to move the shut-off valve to the position AUTOMAT.. Make sure that no air flows from the bore of the screw plug (5, Fig. 3). When no air flows, the automatic function of the shut-off valves operates correctly.
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Page 352: Supply Unit, Injection And Exhaust Valve Control Group
Group5 Maintenance Supply Unit, Injection and Exhaust Valve Control Group 5 Supply Unit Servo Oil Pump and Servo Oil Pump Drive − Removal and Installation ..... 5552−1/A1 Camshaft and Bearing Shells −...
Page 353 5552−1/A1 Maintenance Supply Unit Servo Oil Pump and Servo Oil Pump Drive − Removal and Installation Tools: 2 Sling 94657 General ............Preparation .
Page 354 5552−1/A1 Maintenance Supply Unit: Servo Oil Pump and Servo Oil Pump Drive Removal and Installation 94657 Removal CAUTION 2, 3 Injury Hazard: The weight of the servo oil pump is approximately 150 kg. Use the correct equipment to lift and move the servo oil pump.
Page 355 Maintenance 5552−1/A1 Supply Unit: Servo Oil Pump and Servo Oil Pump Drive Removal and Installation Pinion − Removal Note: The bores for the bearing bushes Fig. 3) in the housing (5) and the pump supports (1) are matched items and thus, are not interchangeable.
Page 356 5552−1/A1 Maintenance Supply Unit: Servo Oil Pump and Servo Oil Pump Drive Removal and Installation Nozzles Removal Note: To remove the nozzle (9, Fig. you must first remove the applicable servo oil pump and pinion. Note: The nozzle (4) can be removed easily after removal of cover (6).
Page 357 Maintenance 5552−1/A1 Supply Unit: Servo Oil Pump and Servo Oil Pump Drive Removal and Installation 94657 Servo Oil Pump − Installation 2, 3 CAUTION Injury Hazard: The weight of the servo oil pump is approximately 150 kg. Use the correct equipment to lift and move the servo oil pump.
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Page 359: Camshaft And Bearing Shells − Removal And Installation
5552−2/A1 Maintenance Supply Unit Camshaft and Bearing Shells − Removal and Installation Tools: Devices (roller lifting tools) 94430 1 Centring device 94566B (related to the number of cylinders) 1 Limiter 94566C 1 Support 94566 1 Assembly template 94567 1 Support 94566A 1 Torque amplifier 94020...
Page 360 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Remove the servo oil pump (1, Fig. and the nozzle (2), refer to 5552−1. 012.980/05 Fig. 2 Make sure that the bearing covers at positions No. 2, No 3 and No. 4 (Fig.
Page 361 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Bearing Covers − Removal Note: 7−cylinder and 8−cylinder engines have six bearings. Note: The position of the torque amplifier in Fig. 4 is for reference. Attach the limiter (94566C) with the screws (6) (from the cover) to the 94566C housing below fuel pump No.
Page 362 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Bearing Shells − Removal Put the template (94567, Fig. 5) on the top bearing shell. 94567 Put the wooden underlay (1) in position below the camshaft (2) as shown. Use the wooden underlay (1) as a lever to move the camshaft (2) up a small distance.
Page 363 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Note: When you attach the supports (94566 and 94566A, Fig. 7), use the screws from the bearing cover and the screws from the housing cover. Attach the supports (94566, 94566A) to the housing (1).
Page 364 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Camshaft and Bearing I - I Shells − Installation Make sure that all items are clean and do not have damage. Apply oil to the bearing shells, the ring halves and the camshaft.
Page 365 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Bearing Covers − Installation Note: The position of the torque amplifier in Fig. 9 is for reference. Start the procedure to tighten the screws (1) at bearing No. 1. Attach the limiter (94566C) with the 94566C screws (6) (from the cover) to the...
Page 366 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Completion Make sure that the radial and axial clearances are in the limits given in refer to 0330−1, Supply unit. If the axial clearances are not in the specified range, loosen the screws on one of the bearing covers, Fig.
Page 367 5552−3/A1 Maintenance Supply Unit Camshaft Gear Wheel − Removal and Installation Removal Remove the camshaft (4, Fig. 1), refer to 5552−2. Put the camshaft (4) on to a wooden underlay. Remove the screws (3). Use two M10 jack-screws to remove the camshaft (4) from the gear wheel (2). Remove the screw (5).
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Page 369: 5552−4/A1
5552−4/A1 Maintenance Supply Unit Removal and Installation Tools: 1 Lifting tool (complete with eye bolts 94557 Devices 94430 2 Manual ratchets 94016−013 (related to number of cylinders) 2 Chain 94202L Preparation Read the data in 0012−1 General Guidelines for Lifting Tools Remove the HP fuel pipes, refer to 8752−1.
Page 370 5552−4/A1 Maintenance Removal and Fitting of Supply Unit Removal 94202L Remove the dowel pins (3, Fig. 94202L Remove the screws (7). Attach the two chains (94202L) to the engine room crane. Attach the manual ratchets (H1, H2) to the chains (94202L) and the lifting tool (94557).
Page 371 5552−4/A1 Maintenance Removal and Fitting of Supply Unit Installation In paragraph 2, do step 3) to step 8) to attach the lifting tool (94557, Fig. 2) to the supply unit (1). Clean the sealing surfaces of the supply unit (1). Apply a non-hardening sealing compound to the sealing surfaces of the supply unit (1).
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Page 373: Lubrication Of Supply Unit During Maintenance
5552−5/A1 Maintenance Supply Unit Lubrication of Supply Unit during Maintenance Tools: 1 Lubricating tool 94844 1 Adapter 1 Reduction nipple 1 Adapter General The engine has a manual lubrication system. This system prevents damage to the bearings and bushes of the supply unit (5, Fig.
Page 374 5552−5/A1 Maintenance Lubrication of Supply Unit during Maintenance I - I 94844 II - II WCH03859 Fig. 1 2018−02 2/ 2 Winterthur Gas & Diesel Ltd.
Page 375: 5555−1/A1
5555−1/A1 Maintenance Pilot Fuel Supply Unit Lubrication General If you operate the engine in gas mode continuously, it is recommended that you have one more pilot fuel supply unit as a replacement. The supply unit is an electric motor that has a flexible coupling to the pump and a duplex filter.
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Page 377: Pilot Fuel Pump Removal And Installation
5555−2/A1 Maintenance Pilot Fuel Pump Removal and Installation Tools: 1 HP oil pump 94931 1 HP hose 94935 1 Pressure gauge 94934A 1 Assembly tool 94573 Removal ............Installation .
Page 378: 5555−2/A1
5555−2/A1 Maintenance Pilot Fuel Pump: Removal and Installation WCH03857 Fig. 1 11) On the assembly tool (94573, Fig. 2), turn fully back the special nut (2). 12) Apply Molykote G−Rapid Plus to the surfaces (4). 13) Attach the adapter piece (6) to the shaft of the pilot fuel pump (1). 14) Torque the adapter piece (6) to 45 Nm.
Page 379 5555−2/A1 Maintenance Pilot Fuel Pump: Removal and Installation 94573 WCH03848 I - I Fig. 2 Installation Push as far as possible the special nut (2, Fig. 3) on the shaft of the pilot fuel valve (1). Make sure that the couping is at 90° to the shaft of the pilot fuel valve. Measure the distance from the special nut (2) to the end face of the pump (1).
Page 380 5555−2/A1 Maintenance Pilot Fuel Pump: Removal and Installation 12) Push the special nut (2) forward until the distance from the end face of the pilot fuel pump is 61.5 mm. 13) Release the pressure in the HP oil pump (8). 14) Remove the hose (9) from the closing valve (5).
Page 381 5555−2/A1 Maintenance Pilot Fuel Pump: Removal and Installation I - I Note: Some parts can look different. WCH03848 II - II 3.0 mm X−3.0 mm WCH03848 Fig. 4 24) Attach the sleeves together with the screws (3) and nuts (2). 25) Torque the screws (3) and nuts (2) to 36 Nm.
Page 382 5555−2/A1 Maintenance Pilot Fuel Pump: Removal and Installation WCH03857 Fig. 5 2018 6/ 6 Winterthur Gas & Diesel Ltd.
Page 383 5556−1/A1 Maintenance Fuel Pump Removal, Disassemble, Assemble, Installation Tools: 1 Fitting and dismantling device 94551 1 Checking gauge 94556 1 Cover 94552 2 Screwdrivers 1 Spacer 94555 2 M12 jacking screws Applicable lifting gear Preparation ............Fuel Pump −...
Page 384: Fuel Pump: Removal, Disassemble, Assemble, Installation
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Preparation WARNING Fire Hazard. Do not weld or grind materials in the area. Sparks can cause a fire to occur. WARNING Injury Hazard. Put on gloves and eye protection. Fuel can come out as a spray and cause injury.
Page 385: Fuel Pump − Removal
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Fuel Pump − Removal Remove the connecting element (3, Fig. 1) between the regulating rack (4) and the actuator (2). Operate the turning gear until the cam base touches the roller (5, Fig.
Page 386: Disassemble
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Disassemble Guide Pin − Removal 94551 Attach the fuel pump to the work bench. Make sure that the top of the fuel pump points down. Attach the tool (94551, Fig. 3) as shown.
Page 387: Toothed Rack − Removal
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Remove the Allen screws (3, Fig. Remove the bottom housing (1) from top housing. 10) If necessary, replace the bush (2) as follows: Remove the bush. Apply Loctite No. 648 to the thread of the bush.
Page 388: Pump Cylinder − Removal
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Remove the screws (2, Fig. Remove the circlip (4) and the stop ring (5). Remove the flange (6) together with the rod seal ring (3). Push out the toothed rack (1). Fig. 7 013.679/05 Pump Cylinder −...
Page 389: Non-Return Valve − Removal
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Non-return Valve − Removal Put the two applicable screwdrivers in the nut of the valve block (1, Fig. Use the two screwdrivers as levers to push out the valve block (1). Make sure that you do not cause damage to the nut of the valve block.
Page 390: Pump Cover − Installation
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Pump Cover − Installation Make sure that all the joint faces are clean and in a satisfactory condition. Lubricate the O-rings (5, 12). Attach the O-rings (5) to the valve block (4). Put the valve body (9) and compression spring (10) into the valve block (4).
Page 391: Pump Plunger And Bottom Housing − Installation
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Pump Plunger and Bottom Housing − Installation Install the top spring carrier (5, Fig. and the compression spring (2). Put the plunger (3) into the bottom spring carrier (6). Apply clean diesel oil to the pump plunger (3).
Page 392: Plunger Position − Check
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Plunger Position − Check 94556 Move the toothed rack (1, Fig. 16) to 94555 the position shown. Put the spacer (94555) in the position shown. Remove the screw plug (not shown) from the check bore (2). Install fully the gauge (94556) into the check bore (2).
Page 393 5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation 21) Operate the applicable lifting tools to put the guide piston (3, Fig. 18) into the housing. Make sure that the groove is opposite the bore for the guide pin (2). 22) Remove the eye bolts (EB). 013.671/05 Fig.
Page 394: Fuel Pump − Installation
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation 26) Make sure that the toothed rack (5, 94552 Fig. 20) can move. 27) Put new O-rings (4) on the bottom housing (2). Fuel Pump − Installation 28) Clean the seating surfaces of the supply unit housing and the fuel pump.
Page 395: Completion
5556−1/A1 Maintenance Fuel Pump: Removal, Disassemble, Assemble, Installation Completion Install the applicable HP fuel pipe(s), refer to 8752−1. Install the fuel inlet and outlet pipes. Make sure that the valves to the fuel pumps are open. Set to on the power supply to the actuators. Open the fuel inlet valve, refer to the Operation Manual, Control Diagram 4003−2 and the Pipe Diagram 4003−11.
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Page 397 5562−1/A1 Maintenance Fuel Pressure Control Valve Removal, Check, Installation Tools: 1 HP oil pump 94931 1 HP hose 94935 1 Hydraulic distributor 94934A 1 PCV test block with tube 94556 General ............Preparation .
Page 398: Fuel Pressure Control Valve: Removal, Check, Installation
5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Check, Installation Removal Make sure that the fuel rail (4, Fig. has no pressure. Disconnect the electrical connection from the solenoid valve (2). Remove the fuel return pipe (5) from the PCV (1). Remove the four screws (8).
Page 399: 5562−1/A1
5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Check, Installation PCV Check Preparation Put the protection (4, Fig. 2) around the PCV test block (94556). Put the test block (94556) in a bench 94935 vice. 94556 Make sure that the sealing surfaces of the PCV and the test block (94556) are clean and have no damage.
Page 400: Adjustment Procedure
5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Check, Installation Adjustment Procedure CAUTION Damage Hazard. Do not connect the solenoid valve. Damage to the PCV can occur. Operate the HP oil pump (94931, Fig. Tighten the SAV (6) to get a value of 100 bar. Do a check for leaks.
Page 401: Installation
5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Check, Installation Installation Make sure that the seating surfaces of the PCV (1, Fig. 3) and the valve block (3) are clean and have no damage. Put the PCV (1) in position on the valve block (3).
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Page 403: 5562−1/A2
1) from the fuel rail (2) to do this procedure. Note: For the full PCV overhaul instructions, speak to or send a message to WinGD. Stop the engine Make sure that the PCV (1) is open. Note: If HFO is used, the drain port will be hot when the PCV is open.
Page 404 5562−1/A2 Maintenance Fuel Pressure Control Valve: Manual Release Valve − Clean Carefully remove the rubber cap (Fig. Rubber Solenoid Plastic Collar Record the installed position of the plastic collar. Remove the nut, plastic collar and solenoid. Solenoid Tube Hole Remove the solenoid tube. Use your finger to push the lever.
Page 405 5562−1/A2 Maintenance Fuel Pressure Control Valve: Manual Release Valve − Clean 11) Carefully remove the pusher (Fig. Note: It is possible that the pusher will stay on the PCV body. 12) Remove the plunger and spring from the PCV. Block Clean and Apply NeverSeez Remove the grease from all components (pusher, plunger, spring...
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Page 407: 5562−2/A1
5562−2/A1 Maintenance Fuel Overpressure Safety Valve Checks and Setting Tools: 1 OBEL test bench 94272 2 Hydraulic distributors 94934A 1 Valve holder 94272A 2 HP hoses 94935 1 HP oil pump 94931 General Maintenance of the relief valve (1, Fig. 1) is not usually necessary, but you must do a function check at regular intervals.
Page 408 5562−2/A1 Maintenance Fuel Overpressure Safety Valve: Checks and Setting Relief Valve Test Test and Calibration Fluid − Physical Conditions You use the test bench (94272) and the test and calibration fluid (e.g. Shell Calibration Fluid S.9365) to test the relief valve. Table gives the mandatory data for the test and calibration fluid.
Page 409 5562−2/A1 Maintenance Fuel Overpressure Safety Valve: Checks and Setting 94934A 94935 94272A 013.484/05 94272 94931 94934A 013.486/05 Fig. 2 Installation Apply Never-Seez NSBT-8 to the thread of valve housing (4, Fig. Attach new O-rings (3) to the relief valve (1). Put the relief valve into the intermediate piece of the fuel pressure control valve 3.06.
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Page 411: 5562−3/A1
5562−3/A1 Maintenance Flow Limiting Valve Replacement Tools: 2 Eye bolts (M10) 94045-M10 1 Surface plate 94585A 1 Blind flange 94585B General It is not usually necessary to do maintenance on the flow limiting valve (FLV) , but during operation the piston and cylinder in the FLV can become worn. This causes fuel leakage.
Page 412 5562−3/A1 Maintenance Flow Limiting Valve: Replacement Removal CAUTION Injury Hazard: The weight of the FLV is approximately 35 kg. Use the correct equipment to lift and move the FLV. This will prevent injury to personnel. WCH03116 Remove the four bolts (1, Fig.
Page 413 5562−3/A1 Maintenance Flow Limiting Valve: Replacement FLV − Align and Installation Valve Block − Align Make sure that the lip seal (3, Fig. 2) is removed from the FLV. Clean the surface plate (94585A, Fig. Attach the FLV to the surface plate (94585A).
Page 414 5562−3/A1 Maintenance Flow Limiting Valve: Replacement 10) Connect the leakage pipes (2) and 3, Fig. 6) to the FLV (1). 11) Install the HP injection pipes, refer to 8733−1. 12) After you start the engine,do a check for leaks. WCH03116 Fig.
Page 415: Fuel Pump Actuator Connection To Fuel Pump
5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump Fuel Pump Actuator Connection to Fuel Pump General The Heinzmann WEA−40 electrical actuator connects to the regulating rack of the high−pressure fuel pump to regulate the fuel flow to the engine and thus the common rail pressure.
Page 416 5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump Actuator and Fuel Pump − Align Make sure that the actuator is electrically disconnected (Open knife terminals if applicable of corresponding power supply in E85). Make sure that the connecting element (1, 1) is disconnected from the lever (2).
Page 417 5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump 48 mm Fig. 1 2020 3/ 4 Winterthur Gas & Diesel Ltd.
Page 418 5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump Actuator and Fuel Pump − Calibration The end position of the actuator are not factory set. Thus, calibration is always necessary after a fuel pump actuator is replaced. Refer Figure 2 In E85, turn OFF the related power supply.
Page 419 5612−1/A1 Maintenance Exhaust Valve Control Unit − Pilot valve: Removal and Installation Servo Oil Rail Exhaust Valve Control Unit − Pilot valve : Removal and Installation General ............Preparation .
Page 420 5612−1/A1 Maintenance Exhaust Valve Control Unit − Pilot valve: Removal and installation Removal and installation Make sure that the servo oil rail (3, Fig. 1) has no pressure. Disconnect the electrical connection from the pilot valve (1). Replace and install the new pilot valve, and make sure that O−ring are in the correct position.
Page 421: Regulating Linkage
5801−1/A1 Maintenance Regulating Linkage Adjustment Tools: 2 Spacers 94555A General After the installation of a new fuel pump (1, Fig. 1) or actuator (2), do a check of the regulating linkage. If necessary, adjust the regulating linkage (refer to paragraph 2). Maintenance of the connection between the fuel pump and the actuator is not necessary.
Page 422 5801−1/A1 Maintenance Regulating Linkage: Adjustment Regulating Linkage − Adjust Disconnect the electrical connection from the actuator (4, Fig. Loosen the screw (6). Remove the screw (2) and its self-locking nut. Lift the lever (9). Make sure that the regulating linkage moves freely. Apply grease to the linkage joints.
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Page 424: Scavenge Air Receiver And Auxiliary Blower
Group6 Maintenance Scavenge Air Receiver and Auxiliary Blower Group 6 Scavenge Air Receiver: Clean and do Checks ..........6420−1/A1 Scavenge Air Receiver (TC at Exhaust Side): Clean and do Checks .
Page 425: Scavenge Air Receiver: Clean And Do Checks
6420−1/A1 Maintenance Scavenge Air Receiver Scavenge Air Receiver − Clean and do Checks General For the intervals to clean the scavenge air receiver (1, Fig. 1), refer to 0380−1, Scavenge air receiver. You must also clean and do a check of the scavenge air receiver after each piston overhaul.
Page 426 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Relief Valve − Check WARNING Injury Hazard! Do not disassemble the relief valve. Parts can eject at high speed and cause injury. If there is damage or a malfunction, speak to the manufacturer of the relief valve or Wärtsilä Switzerland Ltd.
Page 427 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Flaps Removal Remove the screws (8, Fig. 3) and the tab washers (9). Remove the two flat bars (10) and the stop plate (7). Remove the screws (5) and tab washers (6). Remove the guide (2), spacer (1) flap (4) and axle (3).
Page 428 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Scavenge Air Receiver − Clean and do Checks Open the cover (3, Fig. Lock the cover (3) in position with the pin (2). This prevents unwanted movement. Clean the scavenge air receiver. Do the checks that follow: Note: The level switches LS4071A and LS4075A (2, Fig.
Page 429: 6420−2/A1
6420−2/A1 Maintenance Scavenge Air Receiver (TC at Exhaust Side) Scavenge Air Receiver − Clean and do Checks General For the intervals to clean the scavenge air receiver (1, Fig. 1), refer to 0380−1, Scavenge air receiver. You must also clean and do a check of the scavenge air receiver after each piston overhaul.
Page 430 6420−2/A1 Maintenance Scavenge Air Receiver − Clean and Checks Relief Valve − Check WARNING Injury Hazard! Do not disassemble the relief valve. Parts can eject at high speed and cause injury. If there is damage or a malfunction, speak to the manufacturer of the relief valve or Wärtsilä Services Switzerland Ltd.
Page 431 6420−2/A1 Maintenance Scavenge Air Receiver − Clean and Checks Flaps − Removal and Installation Removal Remove the screws (7, Fig. 3) and the tab washers (8). Remove the two flat bars (9) and the stop plate (6). Remove the screws (4) and tab washers (5). Remove the guide (1), spacer (10) flap (3) and axle (2).
Page 432 6420−2/A1 Maintenance Scavenge Air Receiver − Clean and Checks Scavenge Air Receiver − Clean and do Checks Open the covers (2 and 5, Fig. Lock the covers (2, 5) in position with the pins (3, 4). This prevents unwanted movement. Clean the scavenge air receiver.
Page 433: 6545−1/A1
6545−1/A1 Maintenance Auxiliary Blower Maintenance Tools: 2 Manual ratchet (WLL 1600 kg) 94016−007 4 Slings (WLL 1000 kg) 94657 1 Support (WLL 800 kg) 94658 General Two auxiliary blowers (1, Fig. 1) are attached to the scavenge air receiver (2). For more data about the auxiliary blower, refer to the Operation Manual 6545−1 Auxiliary Blower and Switch Box.
Page 434: Preparation
6545−1/A1 Maintenance Auxiliary Blower: Maintenance Removal 94657 94658 94657 Preparation Read and obey the data given in 0012-1, General Guidelines for Lifting Tools. Stop the engine. Set to off the power supply. Disconnect the electrical connection from the electric motor (2, Fig.
Page 435 6545−1/A1 Maintenance Auxiliary Blower: Maintenance CAUTION Damage Hazard: Do not put 94016−007 94658 the electric motor on the floor without an applicable support because damage to the impeller can occur. Operate the two manual ratchets (94016−007, Fig. 3) to carefully remove the electric motor (2) From from the casing (3).
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Page 437 6545−2/A1 Maintenance Auxiliary Blower (TC at Exhaust Side) Maintenance Tools: 2 Covers (5 cylinders) 94656A 2 Covers (6 to 8 cylinders) 94656B General The two auxiliary blowers (2 and 3, Fig. 1) are attached to the scavenge air receiver (1). For more data about the auxiliary blower, refer to the Operation Manual 6545−2 Auxiliary Blower and Switch Box.
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Page 439: 6606−1/A1
6606−1/A1 Maintenance Scavenge Air Cooler Removal and Installation Tools: 2 Manual ratchet (H1, H2) (WLL 800 kg) 94016−001 1 Support RIGHT 94663B 1 Manual ratchet (H3) (WLL 250 kg) 94016A−001 2 Lugs 94663C 4 Swivel lugs 94048−M16 2 Safety chains 94663D 1 Support 94661...
Page 440 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation EXPANSION FIXED Removal SIDE SIDE Remove the screws (4, Fig. 2)11 on the fixed side. Remove the cover (1) on the expansion side. Attach the three swivel lugs (94048−M16) to the front of the SAC. Attach the left and the right supports STEP (94663A, 94663B) to the receiver with...
Page 441 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Engine Room 18) Operate the engine room crane to Crane carefully pull out the SAC (Fig. 19) Attach the swivel lugs (94048−M16, ) to the rear of the SAC (1). 20) Attach the chain (94666I) to the two swivel lugs (94048−M16) on the rear of the SAC (1).
Page 442 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 26) Operate the engine room crane and the manual ratchet (H2, Fig. 5) to move the SAC fully away from the platform. 27) Operate the engine room crane to lift Engine Room the front of the SAC.
Page 443 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Installation Engine Room Clean the sealing surfaces of the SAC, Crane the scavenge air receiver and the frame. Attach the four swivel lugs (94048−M16, Fig. 4) and the two chains (94666I) to the SAC. Attach the manual ratchet (H2, Fig.
Page 444 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 17) Continue to operate the engine room crane and the manual ratchet (H3). 18) Attach the manual ratchet (H1, Fig. to the front chain (94666I). 19) Operate the manual ratchet (H1) to hold the weight of the SAC.
Page 445 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation FUEL SIDE Completion Install the inlet pipe (7, Fig. Install the outlet pipe (2, 7). Install the drain pipe (5). Install the vent pipe (6). Open the butterfly valves (1) of the SAC (3).
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Page 447 6606−1/A2 Maintenance Scavenge Air Cooler Cleaning Instructions General ............Cleaning the air side .
Page 448: 6606−1/A2
6606−1/A2 Maintenance Scavenge Air Cooler ENGINE PLANT Fig. 1: Location of Wash-water System Parts 1 Fresh water supply pipe 16 Receiver 2 Ball valve 17 Water separator 3 Ball valve 18 Scavenge air cooler (SAC) 4 Compressed air supply pipe 19 Shut-off valve (vent) 5 Shut-off valve 20 Shut-off valve...
Page 449 6606−1/A2 Maintenance Scavenge Air Cooler SAC Air Side − Clean during Operation The equipment necessary to clean the air side of the SAC is installed on the engine. The quantity of contamination in the SAC is related to the condition of the airflow into the SAC and the maintenance of the air suction filter on the turbocharger.
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Page 451: 6606−2/A1
6606−2/A1 Maintenance Scavenge Air Cooler A44−SD (TC at Exhaust Side) Removal and Installation 7 Cyl. Tools: 1 Manual ratchet (WLL 3200 kg) (H1) 94016−013 1 Support LEFT 94663A 2 Chain block (WLL 3000 kg) (H2, H3) 94018−006 1 Support RIGHT 94663B 2 Eye bolts 94040−M30...
Page 452 6606−2/A1 Maintenance Scavenge Air Cooler: Removal and Installation 7 Cyl. Removal Remove the screws (7, Fig. Remove the flange (8). Remove the collar (9). Remove and discard the O-ring (6). Remove the screws (3) and the four clamps (4). Remove the collar (2). Remove the flange (1).
Page 453 6606−2/A1 Maintenance Scavenge Air Cooler: Removal and Installation 7 Cyl. 17) Operate the manual ratchet (H1, Fig. to pull the SAC a distance of FREE approximately 750 mm. At the same time, use the chain block (H3) to keep the SAC horizontal. 18) Attach the left and right supports (94663A-IL, 94663B-IL) to the receiver (1) with the screws.
Page 454 6606−2/A1 Maintenance Scavenge Air Cooler: Removal and Installation 7 Cyl. 23) Operate the manual ratchet (H1, Fig. to pull out the SAC a maximum distance of 195 mm (View II) to the guide end of the supports (94663A−IL, 94663B−IL). 24) At the driving end, attach the lifting plate (94663−IL) to the swivel lugs (94048−M30).
Page 455 6606−2/A1 Maintenance Scavenge Air Cooler: Removal and Installation 7 Cyl. 29) Operate the chain blocks (H2 and H3, Fig. 6) to lower carefully the SAC (2). 30) Attach the hook (1) of the engine room crane to the wire rope sling (94666) 31) Operate the engine room crane to lift the SAC (2) a small distance.
Page 456 6606−2/A1 Maintenance Scavenge Air Cooler: Removal and Installation 7 Cyl. 37) Remove the manual ratchet (H1, Fig. 38) Remove the lifting plate (94663−IL). 39) Operate the engine room crane to move and lower the SAC to an applicable area. 40) Remove the lifting plate (94663−IL), swivel lugs (94048−M30), wire rope sling (94666) and eye bolt (94040−M30).
Page 457 6606−2/A1 Maintenance Scavenge Air Cooler: Removal and Installation 7 Cyl. Attach the manual ratchet (H1, Fig. to the lifting plate (94663−IL). 10) Operate the manual ratchet (H1) to lift the SAC as shown. 11) Attach the chain block (H2) to the eye bolt (94040−M30).
Page 458 6606−2/A1 Maintenance Scavenge Air Cooler: Removal and Installation 7 Cyl. 19) Attach the support (94661-IL, Fig. to the applicable platform support at the driving end. 20) Attach the manual ratchet (H1) to the support (94661-IL). 21) Move the SAC on to the supports (94663A, 94663B).
Page 459 6606−2/A1 Maintenance Scavenge Air Cooler: Removal and Installation 7 Cyl. Put a new O-ring (6, Fig. 16) in position. Put the collar (9) in position. Put the flange (8) in position. Attach the flange (8) to the SAC with the M16x60 screws (7). Torque the M16x60 screws (7) to the value given in 0352−2.
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Page 461: 6708−1/A1
6708−1/A1 Maintenance Water Separator Removal and Installation Tools: 1 Manual ratchet (WLL 800 kg) 94016−001 (H3) 1 Lifting plate 94667A 2 Manual ratchet (WLL 250 kg) 94016−005 (H1, H2) 1 Support 94667B 2 Shackles (WLL 1000 kg) 94018A (S1, S2) 1 Lifting lug 94667C 1 Lifting plate...
Page 462 6708−1/A1 Maintenance Water Separator: Removal and Installation Removal Remove the 18 screws (2, Fig. Remove the 18 intermediate rings (1). I - I II - II WCH00709 III - III Fig. 2 2016 2/ 10 Winterthur Gas & Diesel Ltd.
Page 463 6708−1/A1 Maintenance Water Separator: Removal and Installation Attach the lug (94667C, Fig. 3) and the support (94667B) as shown. Attach the manual ratchet (H3) to the support (94667B) and the lug (94667C). Operate the manual ratchet (H3) to pull out the water separator until you can attach the lifting plate (94667A).
Page 464 6708−1/A1 Maintenance Water Separator: Removal and Installation 12) Operate the manual ratchet (H2, Fig. to hold the weight of the water H1 H2 separator. H1 H2 13) Operate the manual ratchet (H2) to pull out the water separator. At the same time, operate the manual ratchet (H1) to release the tension.
Page 465 6708−1/A1 Maintenance Water Separator: Removal and Installation 17) Operate the manual ratchet (H1, Fig. to fully remove the water separator. At the same time, operate the manual ratchet (H2) to release the tension. 94667 18) Turn water separator 90_. 19) Attach the engine room crane to the Engine Room middle eyelet of the shackle (S1).
Page 466 6708−1/A1 Maintenance Water Separator: Removal and Installation Attach the plate (94667, Fig. 8) and the shackle (S1) to the water separator. Engine Room Crane Attach the engine room crane to the shackle (S1) on the middle eyelet of the plate (94667). Operate the engine room crane to lift the water separator.
Page 467 6708−1/A1 Maintenance Water Separator: Removal and Installation 14) Remove the manual ratchet (H1, Fig. 10) from the end attachment H1 H2 point (1). 15) Attach the manual ratchet to the attachment point (2). Fig. 10 H1 H2 16) Operate the manual ratchets (H1 and 11) to move the water separator into the frame as shown.
Page 468 6708−1/A1 Maintenance Water Separator: Removal and Installation 21) Remove the manual ratchet (H2) and attach it to the shackle (S2). as shown Fig. 22) Remove the shackle (S1) and the plate (94667). 94667 Fig. 13 WCH00709 Note: During step 23), operate the manual ratchets (H1, H2) to keep tension on the manual ratchets (H1, H2).
Page 469 6708−1/A1 Maintenance Water Separator: Removal and Installation 28) Put a new rubber cord (3, Fig. 16) in the position shown. Bond together the ends of the rubber cord. 29) Make sure that the rubber cords (3, 4) are seated correctly. 30) Put oil on the threads of the 18 M16x55 screws (2).
Page 470 6708−1/A1 Maintenance Water Separator: Removal and Installation Completion Install the supports and bottom plates that you removed before. Remove the pin (1, 18) to unlock the inspection cover (2). Close the inspection cover (2). Install the pin (1) in the stowage position.
Page 471 6708−2/A1 Maintenance Water Separator (TC at Exhaust Side) Removal and Installation − 7 Cylinder Engine Tools: 2 Manual ratchet (H3) 800 kg 94016-001 1 Lifting tool 94667G 2 Chain blocks (H1, H2) 1500 kg 94018−003 1 Limiter 94667H 1 Lifting and removal gear (bracket) 94667E 1 Holder 94667I...
Page 472 6708−2/A1 Maintenance Water Separator: Removal and Installation 7 Cyl. Removal Note: The water separator has two parts. To remove the front or rear water separator, remove the screws (7, Fig. 2) and the plate. Remove the 32 screws (9). Remove the 32 intermediate rings (8). II - II I - I III - III...
Page 473 6708−2/A1 Maintenance Water Separator: Removal and Installation 7 Cyl. H1 H2 Attach the the two chain blocks (H1 and H2, Fig. 3) to the rail (1). Attach the bracket (94667E) to the water separator (2). Attach the holder (94667I) as shown. Attach the manual ratchet (H3) to the holder (94667I) and the bracket 94667I...
Page 474 6708−2/A1 Maintenance Water Separator: Removal and Installation 7 Cyl. 17) Operate the manual ratchet (H3, Fig. to fully remove the water separator. At the same time, operate the chain blocks (H1, H2) to keep the height of the water separator constant. 18) Remove the manual ratchet (H3), the lifting tool 94667G) and the holder (94667I)
Page 475 6708−2/A1 Maintenance Water Separator: Removal and Installation 7 Cyl. Make sure that the seating surfaces on the water separator, and the frame (1, Fig. 7) are clean. Make sure that the guide bars (2) and the areas where the rubber cords go are clean.
Page 476 6708−2/A1 Maintenance Water Separator: Removal and Installation 7 Cyl. Move the water separator to the scavenge air receiver. 10) Attach the bracket (94667E, Fig. 9) to the front of the water separator. 11) Attach the chain block (H2) to the bracket (94667E).
Page 477 6708−2/A1 Maintenance Water Separator: Removal and Installation 7 Cyl. 20) Remove the manual ratchet (H1, H2 and H3, Fig. Fig. 12 21) Put a new rubber cord (4, Fig. 13) in the position shown. Bond together the ends of the rubber cord, 22) Make sure that the rubber cords (1, 4) are seated correctly.
Page 478 6708−2/A1 Maintenance Water Separator: Removal and Installation 7 Cyl. CAUTION Injury Hazard: The front cover weighs approximately 61 kg. Use applicable equipment to lift and move the cover. 26) Attach the front cover (1, Fig. 14) and the rear cover (4) to the scavenge air receiver.
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Page 480: Cylinder Lubrication Group
Group7 Maintenance Cylinder Lubrication Group 7 Cylinder Lubricating System ............7218−1/A1 RT−flex50DF / MM / 2016 Winterthur Gas &...
Page 481: Cylinder Lubricating System
7218−1/A1 Maintenance Cylinder Lubricating System Cylinder Lubrication System ........Cylinder Lubrication System −...
Page 482: Cylinder Lubrication System
7218−1/A1 Maintenance Cylinder Lubricating System Note: Some parts can look different. DRIVING END WCH02910 Fig. 1 2016 2/ 6 Winterthur Gas & Diesel Ltd.
Page 483: Function Check
7218−1/A1 Maintenance Cylinder Lubricating System Function Check WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. If necessary, bleed the cylinder lubricating system, refer to paragraph 3. Make sure that the applicable piston is in the TDC position.
Page 484: 7218−1/A1
7218−1/A1 Maintenance Cylinder Lubricating System Cylinder Lubricating System − Bleed Bleed the cylinder lubricating pump (10, Fig. 1) and the oil pipes each time you do maintenance on the cylinder lubrication system. Cylinder Lubricating Pump Note: When you bleed the cylinder lubrication system, always start at the first cylinder at the free end.
Page 485: Duplex Filter
7218−1/A1 Maintenance Cylinder Lubricating System Duplex filter For data about the duplex filter (1, Fig. 2) refer to the Operation Manual 7218−1, paragraph 2. Clogged Filter Element − Replace Close the ball valve (6). Remove the cover from the rail unit. Move the lever (5) to select the clean filter element.
Page 486 7218−1/A1 Maintenance Cylinder Lubricating System Note: Some parts can look different. FREE END WCH03020 WCH03018 Fig. 2 2016 6/ 6 Winterthur Gas & Diesel Ltd.
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Page 488: Group
Group8 Maintenance Piping Group 8 ..........Exhaust Waste Gate (Low-load Tuning) 8135−1/A1 .
Page 489 8135−1/A1 Maintenance Exhaust Waste Gate (Low-Load Tuning) General The Low-load Tuning (LLT) uses a specially designed turbocharger system and specified engine parameters. These parameters are related to fuel injection and exhaust valve control and get the best decreased part-load BSFC in LLT. Spring pressure keeps the actuator (3, Fig.
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Page 491: 8447−1/A1
8447−1/A1 Maintenance HP Servo Oil Pipe Removal, Grind, Installation Tools: 1 Grinding tool 94841 Emery cloth As necessary 1 Stencil 94841A 1 Hand drill Preparation Stop the engine, refer to the Operation Manual 0310−01. Make sure that the servo oil service pump is set to off. Put an oil tray under the applicable intermediate piece (3, Fig.
Page 492 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind, Installation On the flange (1, Fig. 2), loosen the I - I screws (2). Push down the flange (1) to get air in the HP servo oil pipe (3). On the flange (7), loosen the screws (8).
Page 493 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind, Installation Carefully remove the HP servo oil pipe (3 and 4, Fig. Apply protection to the sealing faces (SF) to prevent damage. Sealing Faces − Grind To get a smooth finish on the HP servo oil pipe (1, Fig.
Page 494 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind, Installation 18) Align accurately the hand drill and the grinding tool (94841, Fig. 3) with the hydraulic pipe (1) as shown. 19) Use light pressure and start grinding. 20) Regularly remove the unwanted material from the grinding tool (94841). 21) Make sure that the circular marks around the sealing face of the pipe are concentric.
Page 495 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind, Installation I - I Installation HP Servo Oil Pipes (11, 12) Remove all of the protection from: The sealing faces (SF) in the valve housing (22, Fig. 5) and the HP servo oil pipes (11, 12) The intermediate piece (16) WCH02974...
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Page 497: 8460−1/A1
8460−1/A1 Maintenance Hydraulic Pipe for Exhaust Valve Drive Removal, Grind, Installation Tools: 1 Grinding tool 94841 Emery cloth (as necessary 1 Template 94841A 1 Hand drill Preparation ............Removal .
Page 498 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind, Installation Preparation WARNING Injury Hazard: The servo oil system has high pressure. Replace a defective hydraulic pipe only when the engine has stopped. WARNING Injury Hazard: You must put on gloves and safety goggles when you do work on hot components.
Page 499 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind, Installation Removal III - III CAUTION Damage Hazard: Make sure that you do not damage the sealing faces or the hydraulic pipe. Remove the screws (3, Fig. 3) from the flange (2). Carefully move the flange (2) away from the top housing (1).
Page 500 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind, Installation Sealing Faces − Grind To get a clean and smooth finish on the hydraulic pipe (1, Fig. 5), do step 1) to Template step 20): Put the template (94841A) on the back of the emery cloth. Use the applicable grade of the emery cloth related to the quantity of metal you want to remove.
Page 501 8460−1/A1 Maintenance Hydraulic Pipe: Removal, Grind, Installation Adjustment Remove the protection from the hydraulic pipe (4, Fig. Make sure that the claw (3) is correctly attached to the hydraulic pipe (4). Do a check of the O-rings (1, 2). If the O-rings are unserviceable, replace them.
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Page 503 8733−1/A1 Maintenance HP Injection Pipe Removal, Grind, Install Tools: 1 Grinding tool 94870 1 Grinding tool / countersunk screw M4 94870B 1 Screw-on sleeve 94870A 1 Locknut 94870C 1 Template 94870D 1 Hand drill Preparation Stop the engine (refer to the Operation Manual 0310−1).
Page 504 8733−1/A1 Maintenance HP Injection Pipe: Removal, Grind, Install Sealing Faces − Grind Use a medium to coarse grade emery cloth (30 CAMI to 80 CAMI) to remove deep 94871D notches of more than 0.1 mm. Use a fine or ultra-fine grade emery cloth (100 CAMI to 600 CAMI) to get a smooth finish.
Page 505: 8733−1/A1
8733−1/A1 Maintenance HP Injection Pipe: Removal, Grind, Install Installation CAUTION Damage Hazard: Make sure that you do not damage the sealing faces or the HP injection pipes. If necessary, attach the electrical trace heating cable. To the HP injection pipe Fig.
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Page 507 8752−1/A1 Maintenance HP Fuel Pipe Removal, Grind, Installation Tools: 1 Grinding tool 94870−1 1 Locknut 94870G 1 Screw-on sleeve 94870E 1 Template 94870H 1 Grinding tool / countersunk screw M8 94870F 1 Hand drill Preparation ............Removal .
Page 508 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation Preparation WARNING Injury Hazard: The fuel system has high pressure. Replace a defective HP fuel pipe only when the engine has stopped. You must obey the data given in the Operation Manual 0520-1. WARNING Injury Hazard: Always put on gloves and safety goggles when you do work on hot components.
Page 509 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation I - I Removal Remove the applicable pipe clamps (1 and 2, Fig. Remove the four screws (5, Fig. from the flange (4). Carefully move the flange (4) up. Loosen the two screws (10) on the applicable intermediate piece (6).
Page 510: Hp Fuel Pipe: Removal, Grind, Installation (Tc At Aft End)
8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation Sealing Faces − Grind Use a medium to coarse grade emery cloth (30 to 80 CAMI) to remove deep notches of 94870H more than 0.1 mm. Use a fine or ultra-fine grade emery cloth (100 to 600 CAMI) to get a smooth finish.
Page 511 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation 18) Do a quality check of the sealing surface (SF). If necessary use new emery cloth of the same grade and do step 3) to step 17) again. 19) Replace the emery cloth with a smoother grade, then do step 3) to step 17) again.
Page 512 8752−1/A1 Maintenance HP Fuel Pipe: Removal, Grind, Installation I - I Apply Never-Seez NSBT to the threads of all the screws (1, 5, 9 and 11, Fig. CAUTION Injury Hazard: The weight of the HP fuel pipe is approximately 15 kg. Use approved equipment or sufficient personnel to lift and move the HP fuel pipe.
Page 513: 8790−1/A1
8790−1/A1 Maintenance HP Pipe Pilot Fuel Removal and Installation Preparation WARNING Injury Hazard: The pilot fuel system has high pressure. Replace a defective HP pilot fuel pipe only when the engine has stopped. You must obey the data given in the Operation Manual 0520-1. WARNING Injury Hazard: Always put on gloves and safety goggles when you do work on hot components.
Page 514 8790−1/A1 Maintenance HP Pipe Pilot Fuel: Removal and Installation Removal Pilot Fuel Pipe (1, 9) Put an oil tray under the applicable pilot fuel pipe (1 or 9, Fig. Open the screw plug (6). If there is no fuel, The pilot fuel pipes (1, 9) are fully drained.
Page 515 8790−1/A1 Maintenance HP Pipe Pilot Fuel: Removal and Installation Installation Pilot Fuel Pipe (4, 5) Remove all protection from the openings and sealing faces. Apply oil to the applicable coupling nuts (12 and 13, Fig. Make sure that the sealing faces (SF, Fig.
Page 516: Crank Angle Sensor Unit, Tools
Group9 Maintenance Crank Angle Sensor Unit, Tools Group 9 Proximity Sensor − Replace Crank Angle Sensor Unit: ........9223−1/A1 Cylinder Pressure Sensor: Removal and Installation .
Page 517: Crank Angle Sensor Unit
9223−1/A1 Maintenance Crank Angle Sensor Unit Proximity Sensor − Replace General For the function of the Crank Angle Sensor Unit, read the data in the Operation Manual 9223−1. For the Inspection and Overhaul Intervals, refer to 0380−1 Crank Angle Sensor Unit.
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Page 519 9258−1/A1 Maintenance Cylinder Pressure Sensor Removal and Installation Tools: 1 Disassemble and assemble tool 94022H General For data about the balance control of the cylinder pressure, refer to the Operation Manual, 4002−1, paragraph 3.10. For the signal failure test, refer to the Operation Manual 4002−2, paragraph 3.5 Cylinder Balancing (Diesel Mode) and 3.6 Cylinder Balancing (Gas Mode).
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Page 521 9403−1/A1 Maintenance Tools Description General The tools necessary for the maintenance of the engine are divided into the two groups that follow: 9403−5 Standard Tools 9403−5 Recommended Special Tools. When you send an order for tools or replacements, you must include the data that follows: The engine type The tool number...
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Page 523: 9403−2/A1
9403−2/A1 Maintenance Hydraulic Jacks and Pumps Configuration Tools: 1 HP oil pump (2800 bar) 94931 9 Pre-tensioning jack 94145 2 Hydraulic unit (2500 bar) 94942 10 Hydr. jack 500 kN (50 t) 94936 3 High pressure hose (2600 bar) 94935 11 Double pre-tensioning jack 94114B 4 Connection block...
Page 524 9403−2/A1 Maintenance Hydraulic Jacks and Pumps: Arrangement and Application 018.664/09 Fig. 2 013.539/05 Apply tensioning / loosen tie rods, elastic studs G Set-up of pre-tensioning jacks 94215a (i.e. to exhaust valve cages, top and bottom end collection the hydraulic oil) bearings to connecting rod, piston rod screws and elastic studs to piston crown.
Page 525 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks Storage, Servicing and Maintenance General The pre-tensioning jacks are part of the engine tool kit. When the pre-tensioning jacks are not in use, make sure that: The dust plugs are installed in the open connections Grease is applied to the applicable areas The pre−tensioning jacks are in their toolboxes The toolboxes stay in a clean dry area away from contamination.
Page 526 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 1 (continued) Tool Position of Pre-tensioning Jack Part Back-up Ring O-ring Number (not cut) Dimension (mm) o∅ x i∅ x t i∅ x s 94340 Elastic studs for the piston rod − piston 58 x 51.8 x 1.4 50.39 x 3.53...
Page 527 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Overview of Pre-tensioning Jacks Table 2 Tool 94114B − Double Pre-tensioning Jack (Main Bearing − Elastic Studs) 1 Piston 7 O-ring 2 Double cylinder 8 Back-up ring 3 Round nut 9 O-ring 4 Holder 10 Adapter 5 Vent screw...
Page 528 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 3: Tool 94145 − Pre-tensioning Jack (Foundation Bolt and Engine Stay) 1 Piston 6 Back-up ring 2 Cylinder 7 O-ring 3 Vent screw 8 Back-up ring 4 Adapter 9 O-ring 5 Connection piece 94145−KJ Kit with back-up and O-rings for pre-tensioning Jack...
Page 529 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 4: Tool 94180A − Pre-tensioning jack (Tie Rod − M80x6) 1 Piston 6 Back-up ring 2 Cylinder 7 O-ring 3 Vent screw 8 Back-up ring 4 Adapter 9 O-ring 5 Connection piece 10 Eyelet 94180A−KJ Kit with back-up and O-rings for double pre-tensioning Jack...
Page 530 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 5: Tool 94215A − Pre-tensioning Jack (Elastic Stud − Cylinder Cover) 1 Piston 6 Back-up ring 2 Cylinder 7 O-ring 3 Vent screw 8 Back-up ring 4 Adapter 9 O-ring 5 Connection piece 10 Holder 94215A−KJ Kit with back-up and O-rings...
Page 531 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 6: Tool 94252 − Pre-tensioning Jack (Elastic Stud − Exhaust Valve Cage) 1 Piston 6 Back-up ring 2 Cylinder 7 O-ring 3 Vent screw 8 Back-up ring 4 Adapter 9 O-ring 5 Connection piece 10 Holder 94252−KJ Kit with back-up and O-rings...
Page 532 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 7: Tool 94314 − Pre-tensioning Jack (Elastic Stud − Bottom End Bearing) 1 Piston 6 Back-up ring 2 Cylinder 7 O-ring 3 Vent screw 8 Back-up ring 4 Adapter 9 O-ring 5 Connection piece 10 Distance bush 94314−KJ Kit with back-up and O-rings...
Page 533 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 8: Tool 94315 − Pre-tensioning Jack (Elastic Stud − Top End Bearing) 1 Piston 6 Back-up ring 2 Cylinder 7 O-ring 3 Vent screw 8 Back-up ring 4 Adapter 9 O-ring 5 Connection piece 10 Holder 94315−KJ Kit with back-up and O-rings...
Page 534 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 9: Tool 94340 − Pre-tensioning Jack (Elastic Stud − Piston Rod Foot) 1 Piston 6 Back-up ring 2 Cylinder 7 O-ring 3 Vent screw 8 Back-up ring 4 Adapter 9 O-ring 5 Connection piece 94340−KJ Kit with back-up and O-rings for pre-tensioning Jack...
Page 535 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance Table 10: Tool 94346 − Pre-tensioning Jack (Elastic Stud − Piston Crown) 1 Piston 6 Back-up ring 3 Cylinder 7 O-ring 4 Vent screw 8 Back-up ring 5 Adapter 9 O-ring 6 Connection piece 94346−KJ Kit with back-up and O-rings for pre-tensioning Jack...
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Page 537: Hydraulic Pre-Tensioning Jacks
9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks General Instructions Hydraulic Pre-tensioning Jacks for: Version 1: Version 2: Foundation bolt and engine stay 94145 Main bearing 94114B Elastic studs − cylinder cover 94215A Tie rod 94180A Elastic studs − exhaust valve 94252 Connecting rod − top end bearing 94315 Piston rod −screw connection 94340...
Page 538 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Instructions Loosen Version 1 − Preparation Make sure that the vent screw (1, Fig. 1) is open. Put the hydraulic jack on to the elastic stud (6). Turn the hydraulic jack until it is tight. Make sure that there is no clearance at X. Version 2 −...
Page 539 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Instructions Apply Tension Turn the round nut (7) fully down (Fig. 1 Fig. 2). Make sure that there is no clearance at the slot (5). Put one reference mark (Y) on the nut and one reference mark (X) on the part below (see Fig.
Page 540 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Instructions Table 1: Hydraulic Jacks − Values and Comparison Position of Group Jack Tightening Comparison Number of Lubricating Pre-tensioning Value (bar) (_( mm) Turns to Set Agent Jack the Jack / Round Nut Main bearing 1132−1 94114B 1500...
Page 541: Tool List
9403−5/A1 Maintenance Tool List Standard Tools 94000 Combination wrenches, set compl. consisting of: 6 wrenches AF36 to AF60 for ordering single wrenches state AF 94000−36 Example: ..94000−36 94000−60 94000−60 WCH02800 94001 Open end wrenches 94001−65 1 Piece .
Page 542: 9403−5/A1
9403−5/A1 Maintenance Standard Tools 94006 Socket head keys, set compl. consisting of: 7 Socket head keys AF11 to AF27 for ordering single wrenches state AF 94006−11 Example: ..94000−11 94006−27 94000−27 000.377/93 94007 Tongs 94007−C8 1 Piece .
Page 543: Standard Tools
9403−5/A1 Maintenance Standard Tools 94013 1 Torque spanner (Range of adjustment 50−225 Nm) WCH02642 94014 1 Torque spanner (Range of adjustment 8−40 Nm) 013.558/05 94015 1 Torque spanner (Range of adjustment 140−620 Nm) 94016−001 Manual ratchets WLL 800 kg, 2,5 m stroke 94016−007 Manual ratchets WLL 1600 kg 2,5 m stroke...
Page 544 9403−5/A1 Maintenance Standard Tools Shackle 94018B WLL 4750 kg Shackle 94019F WLL 1000 kg 94019G WLL 2000 kg 94019H WLL 3250 kg 94019I WLL 4750 kg WCH03047 94019K WLL 6500 kg 94020 1 Power amplifier (with transmission factor 1:4) WCH02642 94021 1 Pipe to power amplifier...
Page 545 9403−5/A1 Maintenance Standard Tools 94025 1 Tool box with socket wrench set ½” 000.368/93 94026 1 Tool box with hex. head drivers ½” 000.368/93 94027 4 Extensions for intermediate wheel assembly 250 mm 94032 1 High pressure grease gun for lubricating grease nipples on fuel pump regulating linkage 000.370/93 94040...
Page 546 9403−5/A1 Maintenance Standard Tools 94101 Inside micrometer (Measuring range 50−1000 mm) with case 94101A Inside micrometer (Measuring range 50−1010 mm) with case WCH02629 94110 1 Thrust device for removal and fitting of main baring cover 590 mm 018.664/09 94114B 2 Double pre-tensioning jacks for elastic studs to main bearing 222 mm 018.664/09...
Page 547 9403−5/A1 Maintenance Standard Tools 94117 1 Assembling and dismantling device for removal and fitting of main bearing shell 191 mm 018.662/09 94117A 1 Deviation pipe for removal and fitting of: − main bearing cover, shell − crosshead pin X = 340 mm WCH00265 94118A 1 Turning-out device...
Page 548 9403−5/A1 Maintenance Standard Tools KF 94074 1 Dismantling tool for removal of bearing shell 94122 1 Feeler gauge 000.361/93 94123 1 Special feeler gauge for main bearing 620 mm 000.395/93 94126 1 Depth gauge measuring range 760 mm 000.394/93 94141 1 Support for removal of main bearing shells 735 mm...
Page 549 9403−5/A1 Maintenance Standard Tools 94142 Work platform X = 1088 mm 94142A Nuts M20 WCH03524 76 mm 94143 1 Working support X = 450−540 mm WCH03524 94145 1 Pre-tensioning jack for foundation bolts and engine stays 130 mm 013/567/05 2020 9/45 Winterthur Gas &...
Page 550 9403−5/A1 Maintenance Standard Tools 94155 1 Turning-out device with screws M20x90 for turning out thrust bearing pads (with 1-part gear wheel) X = 161.4 mm 013.568/05 94155A 1 Turning-out device with screws M20x45 013.569/05 for turning out thrust bearing pads (with 2-part gear wheel) X = 161.4 mm 94180...
Page 551 9403−5/A1 Maintenance Standard Tools 94201 1 Lifting device for installation and transporting a cylinder 94201D 94201A Liner X = 927 mm Weight approx. 120 kg (WLL 4200 kg) consisting of: 94201A, B, C, D 94201A 1 Lifting tool X = 963 mm Mass approx.
Page 552 9403−5/A1 Maintenance Standard Tools 94213 Dismantling tool X = 83 mm WCH02256 94214 Dismantling and assembling tool for gas admission valve consisting of: 94214C 1 Dismantling and assembling tool for gas admission valve 94214D 1 Pusher 94214E 1 Bush 94214C 94214F 1 Angle steel 94214D...
Page 553 9403−5/A1 Maintenance Standard Tools 94215B 94215 1 Hydraulic tensioning device for cylinder cover studs, consisting of: 94215D 94215B 2 Connection pieces 94215D 4 Hoses 94215E X = 800 mm 94215E 4 Hoses X = 1000 mm 013.574/05 701.013.574 94215A 94215A 1 Pre-tensioning jacks 177 mm 016.765/08...
Page 554 9403−5/A1 Maintenance Standard Tools 94252 2 Pre-tensioning jacks for exhaust valve cage 194 mm 009.952/02 94259 1 Pressure element for exhaust valve 189 mm 016.765/08 94261 1 Valve seat fitting and extracting device 000.415/93 490 mm 94262 1 Valve protector (only to be used for transporting a complete exhaust valve) 450 mm...
Page 555 9403−5/A1 Maintenance Standard Tools 94265 1 Suspension device for cylinder cover and exhaust valve cage 604 mm including: 94265A 2 special eye nuts X = 238 mm (WLL 2100 kg) 013.577/05 003.971/96 KF 94124 1 Support for cylinder cover and exhaust valve assembly X = 990 mm Y = 1719 mm...
Page 556 9403−5/A1 Maintenance Standard Tools 94270 1 Cutting device 94270A for overhauling injection valve seat in cylinder cover X = 390 mm including: 94270A 1 Profile cutter WCH02803 94270C 2 Hexagon head bolts for dismantling and assembly an injection valve X = 180 mm WCH02263 94270D 2 Stud bolts...
Page 557 9403−5/A1 Maintenance Standard Tools 94272 1 Injector test bench for setting and testing of: − injection valve − safety valve − relief valve X = 1458 mm Mass approx. 161 kg including: 94269A−46 1 Slugging wrench for testing on test bench (AF46 to injection valve) WCH03069 X = 214.5 mm...
Page 558 9403−5/A1 Maintenance Standard Tools 94272 Continued 94289E 1 Assembly tool X = 150 mm Y = 100 mm WCH03069 94273 1 Valve holder to OBEL test bench for fastening injection valve X = 568 mm Y = 546 mm WCH03070 94275 94275 1 HP hose...
Page 559 9403−5/A1 Maintenance Standard Tools 94270−02 Grinding device To grind the pilot injection valve bore X = 289 mm 94270−2D Stencil 94270−2D WCH03864 94270−01 Grinding device To grind the pilot injection valve bore X = 358mm 94270−1D Stencil 94270−1D WCH00865 94270−03 Grinding device To grind the pilot injection valve bore X = 172 mm...
Page 560 9403−5/A1 Maintenance Standard Tools 94289A 1 Bush for assembling injection valve 45 mm WCH00897 94289B 1 Bush for dismantling injection valve 30 mm WCH00897 94289C 1 Bush for assembling O-rings of injection valve 65 mm WCH00896 94292 1 Template for checking wear on disc of exhaust valve spindle 160 mm 013.582/05...
Page 561 9403−5/A1 Maintenance Standard Tools 94315 2 Pre-tensioning jacks for connecting rod studs to top end bearing, 132 mm 94323 4 Retaining pins to prop up crosshead guide shoes when removing or fitting a connecting rod or a crosshead 75 mm 1.013.584 013.584/05 94324...
Page 562 9403−5/A1 Maintenance Standard Tools 94331 1 Holder for removal and fitting of a connecting rod, including: 2 Screws M24x380 with washers 2 Discs ∅ 90 mm 726 mm 013.586/05 94332 2 Lifting rings for removal and fitting of: − main bearing −...
Page 563 9403−5/A1 Maintenance Standard Tools 94335 1 Lifting tool for removal and installation of heavy 94335B engine components 94335C 964 mm including: 016.622/0 94335B 2 Bushes 94335C 2 Screws 94337 1 Lifting tool for removal and fitting of inside pipe to piston cooling and crosshead lubrication 137 mm...
Page 564 9403−5/A1 Maintenance Standard Tools 94340 2 Pre-tensioning jacks for piston foot fastening and crosshead screw connection 88 mm 013.594/05 94341 1 Lifting tool for removal and installation of piston 612 mm WCH03301 94342 1 Inserting cone 407 mm 2020 24/45 Winterthur Gas &...
Page 565 9403−5/A1 Maintenance Standard Tools KF 94156 1 Fitting and dismantling device For piston assembly X = 141 mm Y = 153 mm Z = 417 mm KF 94157 1 Dismantling and assembling tool For piston assembly X = 616 mm Y = 221 mm 94344 2 Dismantling tool...
Page 566 9403−5/A1 Maintenance Standard Tools 94345 2 Distance holders for removal and installation of piston rod gland and piston 495 mm 013.596/05 701.013.596 94345B 1 Clamp ring 52 mm 000.402/93 94345C 1 Gauge for fitting scraper rings 270 mm 701.013.597 013.597/05 2020 26/45 Winterthur Gas &...
Page 567 9403−5/A1 Maintenance Standard Tools 94345D 1 Cover plate for covering bore in cylinder block (when piston and gland are removed), including: O-ring 4 Screws M16x200 with nuts 432 mm 013.598/05 701.013.59 94345E 2 Assembly tools for tensioning springs to piston rod gland and insulation bandage 150 mm 004.284/98...
Page 568 9403−5/A1 Maintenance Standard Tools 94364 2 Jacking screws M10 for separating piston skirt from piston 170 mm WCH02950 94366A 1 Template for shape of top of piston crown (for use with piston in situ) 549 mm 009.973/02 94366B 1 Template for shape of top of piston crown (with 3 piston rings) 557 mm...
Page 569 9403−5/A1 Maintenance Standard Tools 94551 1 Fitting and dismantling device for removal and fitting of guide pin to fuel pump 255 mm 008.762/00 94552 1 Cover with Allen screws M12 for removal and fitting of fuel pump 116 mm 701.013.603 013.603/05 94555 Spacer...
Page 570 9403−5/A1 Maintenance Standard Tools 94557 1 Lifting tool for transporting a complete supply unit of 5 & 6 cylinder engines 922 mm (WLL 2250 kg) of 7 & 8 cylinder engines X = 1182 mm (WLL 2500 kg) 013.604/05 94566 1 Support for removal and fitting of camshaft 510 mm...
Page 571 9403−5/A1 Maintenance Standard Tools 94566C 1 Limiter for tightening or loosening bearing covers to supply unit 320 mm 013.608/05 94567 1 Assembly template for removal and fitting of bearing shells to supply unit 68 mm 701.013.609 013.609/05 94575 1 Adjusting scale (for Heinzmann StG 10-01 Actuator) for regulating linkage 120 mm...
Page 572 9403−5/A1 Maintenance Standard Tools 94569 Blank flange to fuel pump with 4 Screws M12x50 and 1 O-ring 42.52x2.62 mm 93 mm 94569A Blank flange 016.650/08 to valve housing at fuel rail with 4 Screws M12x80 92 mm 94583 1 PCV test block with tube for pressure check of pressure control valve X = 954 mm...
Page 573 9403−5/A1 Maintenance Standard Tools 94585D 3 Screw plug G 3/8“ to close the servo oil unions DIN 908 KF 94242 2 Lifting eye bolt DIN 580 to lift the servo oil unions 94585E 4 Capping end to close the opening in exhaust valve control unit WCH0259 94589...
Page 574 9403−5/A1 Maintenance Standard Tools In case of a turbocharger breakdown Cover to exhaust manifold outlet: 94653A−A165 for ABB A165, X = 600 mm, 12 holes 94653A−A175 for ABB A175, X = 820 mm, 16 holes Cover to turbocharger inlet: 94653B−A165 for ABB A165, X = 600 mm, 12 holes 94653B−A175 for ABB A175, X = 630 mm, 16 holes...
Page 575 9403−5/A1 Maintenance Standard Tools 94657 Round sling (straight length 1250 mm, with TC at Driving End) for removal and installation of auxiliary blower (WLL 1000 kg) 94658 Support (with TC at Driving End) for removal and installaton of auxiliary blower X = 1893 mm (WLL 800 kg) WCH03036 Tools for removal and fitting of...
Page 576 9403−5/A1 Maintenance Standard Tools 94663C Lugs 115 mm 94663D Safety chains X =1222 mm (SAC285) (WLL 1000 kg) 016.822/08 94666 1 Wire rope sling Ø 14 mm with 2 shackles for removal and fitting of a crosshead pin Ø and a scavenge air cooler 800 mm (WLL 3000 kg at ( 0−45_) 012.316/04...
Page 577 9403−5/A1 Maintenance Standard Tools 94663A−IL Support LEFT including: 1 Lug 1 Safety chain 94663C−IL (DP) 8 Screws M16x40 94663A−IL 600 mm 94663B−IL Support RIGHT 94663D including: 1 Lug 94663B−IL 1 Safety chain 8 Screws M16x40 600 mm 94663C−IL Lugs (only for SAC261, SAC265) 155 mm 94663D−IL Safety chains...
Page 578 9403−5/A1 Maintenance Standard Tools 94667B 1 Support for pulling out water separator X = 1054 mm 540 mm WCH00663 94667C 1 Lifting lug for pulling out water separator 100 mm WCH00663 94667D 1 Support for installation of water separator including: 4 nuts M16 X = 1000 mm 400 mm...
Page 579 9403−5/A1 Maintenance Standard Tools Tools for removal and fitting of water separator engines with 1 scavenge air cooler (underslung SAR design; TC at ES) 94667E 1 Lifting and withdrawing gear including: 1 Shackle 4 Screws M12x25 X = 330 mm (WLL 400 kg and 6000 N) 016.829/08 94667F...
Page 580 9403−5/A1 Maintenance Standard Tools 94667I 1 Holder including: 1 Shackle 4 Screws M12x40 X = 216.7 mm (WLL 6000 N) 018.229/09 94831 1 Blank flange for blanking off starting air pipe during emergency operation 200 mm 004.017/96 94841 Grinding tool 94841 94841A for hydraulic pipe...
Page 581 9403−5/A1 Maintenance Standard Tools 94870 1 Regrinding device for sealing surfaces on HP fuel piping (8733−1) 101 mm including: 94870A 1 Screw-on sleeve (AF 32) 94870B 1 Grinding tool with countersunk screw M4 94870C 1 Lock nut M18x1.5 016.776/08 016.740/08 (AF 27) 94870D 1 Template...
Page 582 9403−5/A1 Maintenance Standard Tools 94924 Hook spanner for crank angle sensor 205 mm 94925 Hook spanner for crank angle sensor 242 mm 008.771/00 Hydraulic parts and pump 94931 HP oil pump 94934F working pressure max. 2800 bar 94934F Adapter piece 010.001/02 94934 1 Connection block...
Page 583 9403−5/A1 Maintenance Standard Tools 94934I 1 Connection nipple (G¼”) WCH00724 94935 4 HP hoses 2600 bar with closing valves and coupling sockets X = 2130 mm 005.954/00 94935C 1 Hose for set-up of pre-tensioning jacks Length = 2000 mm 701.013.621 013.621/05 94936 2 Hydraulic jacks 500 kN (50 t)
Page 584: Recommended Special Tools
9403−5/A1 Maintenance Recommended Special Tools 94226 1 Tool cylinder liner measuring complete with extension and case (Measuring range 150−600 mm) 018.223/09 94291 Valve grinding device complete 94291A for valve spindle and valve seat 94291A Grinding discs (C-M No. 11373-01-01) WCH03339 WCH03339 94299 1 Grinding device...
Page 585 9403−5/A1 Maintenance Recommended Special Tools 94349 1 Pressure testing device for piston 255 mm 010.005/02 94356 1 Equipment case with instruments for measuring thickness of chrome- ceramic-layer on piston rings WCH01216 94929 2 Connecting cables with plugs for emergency cylinder lubrication Connector (plug ’C’) Plug ’B’...
Page 586 Winterthur Gas & Diesel in brief Winterthur Gas & Diesel Ltd. (WinGD) is a leading developer of two-stroke low-speed gas and diesel engines used for propulsion power in merchant shipping. WinGD’s target is to set the industry standard for reliability, efficiency and environmental friendliness.

WinGD RT-flex50DF Maintenance Manual

Table of Contents

−1/A1 Clearance Table

Bedplate and Tie Rod Group

Cylinder Liner and Cylinder Cover Group

Cylinder Cover and Water Guide Jacket − Removal and Installation

Disassemble and Assemble

General

2 Piston Ring − Rate of Wear

3 Piston Ring Grooves

4 Piston Rings − Storage

Driving Wheels and Shut-Off Valve for Starting Air

Supply Unit, Injection and Exhaust Valve Control Group

Table of Contents

1 Preparation

2 Fuel Pump − Removal

3 Disassemble

4 Fuel Pump − Assemble

5 Fuel Pump − Installation

6 Completion

7 Storage

Removal, Check, Installation

Servo Oil Rail Exhaust Valve Control Unit − Pilot Valve : Removal and Installation

Scavenge Air Receiver and Auxiliary Blower

Cylinder Lubrication Group

Cylinder Lubricating System

1 Cylinder Lubrication System

2 Cylinder Lubrication Pump

3 Cylinder Lubricating System − Bleed

4 Duplex Filter

Crank Angle Sensor Unit, Tools

Quick Links

Chapters

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Questions and answers

Summary of Contents for WinGD RT-flex50DF