WinGD X92 Maintenance Manual

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Winterthur Gas & Diesel Ltd.

Winterthur Gas & Diesel AG

Winterthur Gas & Diesel S.A.

Schützenstrasse 3

P.O. Box 414, 8401

Winterthur, Switzerland

Maintenance Manual

Tel. +41 (0)52 264 8844

Fax +41 (0)52 264 8866

www.wingd.com

X92

Issue 003 2021-12

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Summary of Contents for WinGD X92

Page 1 Maintenance Manual Issue 003 2021-12 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 E 2021−12 Winterthur Gas & Diesel Ltd., Printed in Switzerland – All rights reserved No part of this publication may be reproduced or copied in any form or by any means (electron- ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder.
Page 3 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 4 Pge 3, data added to 2722-1, Pge 6, data added to 5551-1, 5552-1 & 55561-1. Pge 7, data added to 5612-1. Pge 10, data added to WECS-9520 1132-2/A1 2017-01 WinGD Input Pge 1: Note added Main Bearing: Removal and Installation...
Page 5 Procedure to remove and install the Crosshead Bearing - Removal / Installation Temperature Monitor added to document. Full document / Clearance Checks update. 3425-1/A1 2016-02 WinGD Input Correction of ring type designation Wear of Piston Rings and Ring Grooves 5552-1/A2 2016...
Page 6 Subject Page or Date Manual new exch. 5564-1/A2 2017-11 EAAD087878 Injection Control Unit - Pge 1: Illustration replaced with X92 item. Removal and Installation 2124-2-A2 2017 EAAD088154 Cylinder Liner: New document: Includes optional tool to remove and install the Removal and water guide jacket.
Page 7 ........1715−1/A1 X92 / MM / 2020 Winterthur Gas & Diesel Ltd.
Page 8 ....... 3326−2/A1 X92 / MM / 2020 2017-01 2/ 4 Winterthur Gas &...
Page 9 ............. 7218−1/A1 X92 / MM / 2020 Winterthur Gas & Diesel Ltd.
Page 10 ............Pages 34 to 36 X92 / MM / 2020 2017-01 4/ 4 Winterthur Gas &...
Page 11 ......... . . 0803−1/A1 X92 / MM / 2015 Winterthur Gas & Diesel Ltd.
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Page 13 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 15 0001−1/A1 Maintenance Preface The instructions contained in this ”Maintenance Manual” are intended to help to ensure that the maintenance which must be carried out at specific intervals is correctly carried out. It is a precondition that the personnel charged with such important work possesses the necessary training and experience.
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Page 17 0008−1/A1 Maintenance General Engine Numbering and Designations General Turbocharger Auxiliary Blower 3 Auxiliary Blower 1 Auxiliary Blower 2 Cylinder Number DRIVING END FREE END Main Bearing Number WCH02724 Thrust Bearing Pads Rail Unit FUEL SIDE EXHAUST SIDE Supply Unit DATA SHOWN IS FOR A 9−CYLINDER ENGINE WCH02724 2015...
Page 18 0008−1/A1 Maintenance Fuel Supply: Fuel Supply Intermediate I - I Wheel (Supply Unit) Gear Wheel (to Supply Unit) WCH02727 Intermediate Intermediate Wheel Wheel (Supply Unit) WCH02727 Crankshaft Wheel Gear Wheel to Servo Oil Pumps WCH02727 Fuel Pump 5 Fuel Pump 4 Fuel Pump 3 Fuel Pump 6 Fuel Pump 2...
Page 19 0008−1/A1 Maintenance Crank Angle Sensors: Crank Angle Sensors FUEL SIDE WCH02874 DRIVING END WCH02879 WCH02874 Crankshaft Wheel 2015 3/ 3 Winterthur Gas & Diesel Ltd.
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Page 21 0011−1/A1 Maintenance General Guidelines for Maintenance Safety Precautions and Warnings General ............General Safety Precautions .
Page 22 0011−1/A1 Maintenance Fire Make sure that fire−fighting equipment is available in the engine room. Keep covers and casings of the engine closed until the engine is sufficiently cool. Clean the area around the relief valves free of oil, grease etc. This will prevent risk of fire cause by hot air or gas when the relief valves are open.
Page 23 0011−1/A1 Maintenance shut−down functions. Make sure that all the engine crew members are trained and knows about the use and importance of the alarm system. Sealing Materials Use hand gloves to remove the o−rings and other rubber or plastic based sealing materials.
Page 24 0011−1/A1 Maintenance Safety Measures and Warnings Safety notes Danger This warning is used when an operation, procedure, or use may cause personal injury or loss of life. Warning This warning is used when an operation, procedure, or use may cause a latently dangerous state of personal injury or loss of life.
Page 25 0011−1/A1 Maintenance Safety Measures and Warnings General safety warnings and cautions WARNING Injury hazard: Engine parts can fall down and injury to personnel can occur. Make sure that no personnel is standing below the crane and the area is clear. WARNING Injury hazard: Do not open the cocks suddenly because it can discharge hot fluids and gases.
Page 26 0011−1/A1 Maintenance WARNING Injury hazard: Do not stand near the crankcase doors, engine room casing doors or relief valves when the alarm is active for oil mist, high lube oil temperature, no piston colling oil flow or scavenge box fire. Injury to personnel can occur. CAUTION Damage hazard: Always replace the damaged sealing materials with new sealing materials.
Page 27 0011−1/A1 Maintenance Safety Measures and Warnings Personal safety and protection equipment Always use the below given personal protection equipment during repair and maintenance work on the engine. Safety helmet Ear protection. Cotton boiler suite. Safety shoes. Hand gloves. Safety goggles. Safety harness 2021 7/ 10...
Page 28 0011−1/A1 Maintenance Safety Measures and Warnings General safety guidelines for Hot work If you do hot work at or near the engine, obey the guidelines that follow to prevent risks of harm or damage to personal, to equipment, or to environment. Guidelines for hot work: General Hot work means any work requiring the use of electric arc or gas welding equipment, cutting burner equipment or other forms of naked flame, as well as heating or spark...
Page 29 0011−1/A1 Maintenance Guidelines for work with hydraulic tools Always use personal protection safety goggles and safety gloves while operating hydraulic tools. Check high pressure double walled hydraulic hoses for any damages before operation. Check all connection points from the pump to the hydraulic tool for leaks during pressure build−up.
Page 30 0011−1/A1 Maintenance Safety Measures and Warnings Safety Measures and Warnings General safety lifting instructions The engine crew members must obey the general safety lifting instructions before lifting the engine components: Always use the correct personal safety protective equipment. Plan the lifting sequence of engine components in all steps of the lifting procedure.
Page 31 0012−1/A1 Maintenance General Guidelines for Lifting Tools Use of Wire Rope Slings, Span-sets, Eye Bolts, etc. General ............Attachment elements .
Page 32 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. Lifting capacity (for information purposes only): Lifting capacity [kg] Eye bolts & eye nuts, single-strand double-strand (45°) thread size 1200 1800 1290 3200 2300 4600 3300 6300 4500 8600 6100 11 500 8300 Note: The details listed in the table above are based on DIN 580 &...
Page 33 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. 2.4.1 Remarks on the use of RUD-eye bolts they must be completely screwed down, lying fully on the seating surfaces. they are hand-screwed with their own star-profile wrenches (do not use any extension).
Page 34 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. 2.4.2 Remarks on the use of RUD-swivel lugs they must be completely screwed down, lying fully on the seating surfaces. they are hand-screwed with an open end wrench. Prior to loading the RUD-swivel lug adjust it in force direction (Fig. ’3’ and ’4’). Loading as shown in Fig.
Page 35 0012−1/A1 Maintenance Wire Rope Slings, Span-sets, Eye Bolts, etc. Attaching and disconnecting The following must be observed: Distribution of load: one strand carries the total of load weight two strands carry each one half of the load weight four strands carry each one quarter of the load weight if the load is distributed equally.
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Page 37 0330−1/A1 Maintenance Clearance Table General ............Crankshaft and Thrust Bearing .
Page 38 0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing WCH01221 Fig. 2 Fig. 1 2014 2/ 25 Winterthur Gas & Diesel Ltd.
Page 39 0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 1203 Thrust bearing 1224 − 0.5 Thrust bearing pad thickness − 0.6 Thrust bearing clearance axial (total) 0.8...1.2 Clearance between thrust pad and...
Page 40 0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing CRANKSHAFT HALF FREE END CRANKSHAFT HALF DRIVING END WCH02885 WCH02886 WIDE MAIN BEARINGS NARROW MAIN BEARINGS of crankshaft half at driving end of crankshaft half at free end FREE END DRIVING WCH02884 WCH02884 I - I II - II...
Page 41 0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 1132 Narrow main bearings of cranks- haft half at free end 1060 Crankshaft outer ∅ −...
Page 42 0330−1/A1 Maintenance Clearance Table Crosshead Guide FUEL SIDE Fig. 5 WCH02888 2015 6/ 25 Winterthur Gas & Diesel Ltd.
Page 43 0330−1/A1 Maintenance Clearance Table Crosshead Guide Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 3326 Crosshead guide + 0.25 Guide bar (column) transverse 1620 − 0.20 1620 Guide shoe transverse −...
Page 44 0330−1/A1 Maintenance Clearance Table Cylinder Liner WCH03095 Fig. 6 2015 8/ 25 Winterthur Gas & Diesel Ltd.
Page 45 0330−1/A1 Maintenance Clearance Table Cylinder Liner Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 2130 Water guide jacket on cylinder cover + 0.80 Water guide jacket upper part Ø 1290 + 0.60 Clearance total...
Page 46 0330−1/A1 Maintenance Clearance Table Piston Rod Gland Fig. 8 Fig. 9 Fig. 10 Fig. 11 99.7406 WCH02225 Fig. 7 2015 10/ 25 Winterthur Gas & Diesel Ltd.
Page 47 0330−1/A1 Maintenance Clearance Table Piston Rod Gland Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 2303 Piston rod gland Ring width radial min. 25 Ring width radial min. 22.20 Ring width radial min.
Page 48 0330−1/A1 Maintenance Clearance Table Exhaust Valve VALVE SPINDLE GUIDE BUSH 016.995/08 Fig. 13 016.994/08 Fig. 12 2015 12/ 25 Winterthur Gas & Diesel Ltd.
Page 49 0330−1/A1 Maintenance Clearance Table Exhaust Valve Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 2754 Valve spindle − 0.33 Spindle outer ∅ 89.40 − 0.37 2751 Guide bush + 0.035 Bore inner ∅...
Page 50 0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod Fig. 14 016.993/08 2015 14/ 25 Winterthur Gas & Diesel Ltd.
Page 51 0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 3303 Top end bearing 3326 Crosshead pin outer ∅ Bearing clearance vertical 0.65−0.95 1.15...
Page 52 0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubricating Link EXHAUST SIDE 016.996/08 Fig. 15 003.314/00 Fig. 16 2015 16/ 25 Winterthur Gas & Diesel Ltd.
Page 53 0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubricating Link Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 3603 Piston cooling and crosshead lubricating link outer ∅ Bearing clearance radial 0.03−0.09 0.20 Bearing...
Page 54 0330−1/A1 Maintenance Clearance Table Piston and Piston Rings 2015 18/ 25 Winterthur Gas & Diesel Ltd.
Page 55 0330−1/A1 Maintenance Clearance Table Piston and Piston Rings Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 3406 Piston head − 0 Head outer ∅ 916.1 − 0.2 3406 Piston ring grooves + 0.55 Height of the uppermost groove vertical...
Page 56 0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit INTERMEDIATE WHEELS FOR SUPPLY UNIT I - I Fig. 17 INTERMEDIATE WHEEL FOR SERVO PUMP UNIT Fig. 19 WCH03097 2015 20/ 25 Winterthur Gas & Diesel Ltd.
Page 57 0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 4103 Intermediate wheel Shaft outer ∅ Bearing clearance vertical 0.062−0.13 0.15 Axial clearance total 0.6−1.1 Tooth backlash...
Page 58 0330−1/A1 Maintenance Clearance Table Fuel and Servo Pump Units FUEL PUMP UNIT Fig. 20 SERVO PUMP UNIT WCH03098 Fig. 21 2015 22/ 25 Winterthur Gas & Diesel Ltd.
Page 59 0330−1/A1 Maintenance Clearance Table Fuel and Servo Pump Units Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 5552 Fuel pump unit Bearing clearance radial 0.153−0.237 0.33 Axial clearance total 0.30−0.65 0.81 Cam shaft outer ∅...
Page 60 0330−1/A1 Maintenance Clearance Table Fuel Pump PLUNGER & CYLINDER WCH02233 Fig. 23 WCH03099 2015 24/ 25 Winterthur Gas & Diesel Ltd.
Page 61 0330−1/A1 Maintenance Clearance Table Fuel Pump Description Measuring Nominal Maximum Clearance, Direction Dimension Dimension (method of (usual, new) (because of wear) measuring) [mm] [mm] 5556 Fuel pump Plunger (∅ 42, 44 and 46 mm) Clearance (plunger / cylinder) A−B radial 0.035−0.038 0.045 Clearance (plunger / cylinder) B−C...
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Page 63 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 2016−10 1/ 12 Winterthur Gas & Diesel Ltd.
Page 64 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections TIE RODS INTERMEDIATE WHEEL SUPPLY UNIT MAIN BEARING GEAR WHEEL CRANKSHAFT 2015 2/ 12 Winterthur Gas & Diesel Ltd.
Page 65 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections STARTING AIR VALVE HP PIPE INJECTION VALVE INJECTION VALVE MAINTENANCE TOOL SUPPLY UNIT 2015 3/ 12 Winterthur Gas & Diesel Ltd.
Page 66 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections HP FUEL PIPE FUEL PUMP SUPPLY UNIT SUPPLY UNIT 2015 4/ 12 Winterthur Gas & Diesel Ltd.
Page 67 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections HP SERVO OIL PIPE INJECTION CONTROL UNIT RAIL UNIT 2015 5/ 12 Winterthur Gas & Diesel Ltd.
Page 68 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections FUEL RAIL 2015 6/ 12 Winterthur Gas & Diesel Ltd.
Page 69 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections CYLINDER LINER ASSEMBLY EXHAUST VALVE CONTROL UNIT SERVO OIL RAIL CONNECTING ROD LIFTING TOOL 2015 7/ 12 Winterthur Gas & Diesel Ltd.
Page 70 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections RAIL UNIT MAINTENANCE (GENERAL) JACKS AND PUMPS PRE−TENSIONER CONNECTIG ROD PISTON SUSPENSION TOOL 2015 8/ 12 Winterthur Gas & Diesel Ltd.
Page 71 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 1500 (652) 20 Nm 60° See on page 1 position 3 0.75 ±0.04 Or hand-tight with open−end spanner 1500 700 bar 1500 bar M100 1500 All screws All screws See on page 1 position 8 with 600 bar with 1500 bar 1500...
Page 72 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 200 Nm 30° G¼“ G¼“ 1500 (1250) 100 Nm 300 Nm Tightening Sequence see p. 4 G1/2“ MOLYKOTE PASTE G−N MOLYSLIP COPASLIP NEVER SEEZ Regular Grade On threads and contact surfaces On threads and contact surfaces On threads and contact surfaces NO ADDITIONAL LUBRICATION LUBRICATING OIL SAE 30...
Page 73 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections G¼“ G¼“ Secured with Loctite 2701 G¼“ G¼“ G¼“ MOLYKOTE PASTE G−N MOLYSLIP COPASLIP NEVER SEEZ Regular Grade On threads and contact surfaces On threads and contact surfaces On threads and contact surfaces NO ADDITIONAL LUBRICATION LUBRICATING OIL SAE 30 On threads and contact surfaces...
Page 74 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections Designation: LUBRICATION OIL SAE 30 Designation: MOLYSLIP COPASLIP Short form: Short form: K factior: 0.16 Manufacturer: Molyslip Atlantic Ltd A1 Danebrook Court Oxford Office Village Langford Lane, Kidlington Oxfordshire OX5 1LQ England Designation: MOLYKOTE PASTE G−N Plus Designation:...
Page 75 0352−2/A1 Maintenance Torque Values and Elastic Stud Replacement Torque Values − Standard Screws and Elastic Studs Torque Values − Standard Screws We highly recommend the torque values given in the table below for aII standard metric screws of grade 8.8. This applies to all threaded connections not shown on page 0352−1.
Page 76 0352−2/A1 Maintenance Torque Values − Standard Screws and Elastic Studs Replacement of Elastic Studs Procedure Read the data in the manual of the jointing compound manufacturer. Remove the unserviceable elastic stud. Remove the grease and clean the sealing surfaces of the new elastic stud. Remove the grease and other unwanted material from the tap hole and the area where the elastic stud will be installed.
Page 77 0352−2/A1 Maintenance Torque Values − Standard Screws and Elastic Studs For the elastic studs installed in the valve cage, cylinder liner and cylinder jacket fill the area around the elastic stud with jointing compound (see Fig. 3). JOINTING COMPOUND SEALING SURFACES ELASTIC STUD Fig.
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Page 79 0360−1/A1 Maintenance Masses (Weights) Individual Weight of Components Group Component Execution Main bearing cover (1st) 1238 1117 1134 Main bearing shell 1224 Thrust bearing pad 1717 Casing (lower part) free end 2127 Casing (upper part) 1174 1719 Casing driving end 1720 Oil baffle, upper half 259590...
Page 80 0360−1/A1 Maintenance Individual Components per Piece in kg Group Component Execution 3306 Connecting rod complete 6900 With elastic stud and nut for bottom end bearing 3306 Bearing cover for bottom end complete bearing with elastic studs 3310 Bearing shell for bottom end bearing Lower upper 3312...
Page 81 0360−1/A1 Maintenance Individual Components per Piece in kg Group Component Execution 6506 Turbocharger ABB A175 5600 ABB A180 7500 ABB A185 10500 ABB A190 12000 ABB A 270L 3800 ABB 280L 8600 6545 Auxiliary blower with electric motor complete Electric motor Ca.
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Page 83 0380−1/A1 Maintenance Maintenance Schedule Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) System oil − Laboratory analysis 3000 Main fuel and − Do a check of the filter elements − specially for 3000 lubricating oil white metal particles (clean or replace as...
Page 84 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) 1715−1 Engine stays − Hydraulic type: Check oil pressure at the gauge monthly 1903−1 Tie rod − Check pretension, if necessary apply tension 30 000 again, first time after one year of ship delivery Estimated lifetime: Tie rod...
Page 85 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) 2722−1 Injection valve − Do an external check for tightness after engine stop, before (main fuel a longer standstill injector) − Do a function check (nozzle tip inspection, 6000 opening pressure) −...
Page 86 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) Exhaust valve Estimated lifetime: Exhaust valve (Nimonic) 108 000 (re-manufacture (cont’d) as necessary) Estimated lifetime: Exhaust valve seat 72 000 (re-manufacture as necessary) 3103−1 Crankshaft −...
Page 87 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) 3326 Guide shoe, − Do a check of the clearances 6000 to 8000 crosshead pin 3403−1 Piston − Remove and clean 36 000 3403−3 −...
Page 88 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) Starting air − Release the pressure / bleed the starting air after each manoeuvring shut-off valve inlet (manifold) pipe period 4325−1 − Disassemble and clean. Make sure that the 30 000 to 36 000 important parts: seat, springs and sealing rings are serviceable...
Page 89 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) 5562−1 Fuel pressure − Do a check of the shut-down function 3000 control valve (refer to the Operation Manual 4003−1) (PCV) − Do a function check (refer to the Operation 6000 Manual 5562−1) −...
Page 90 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) Turbocharger − Wash-clean the blower during operation Refer to the manufacturer’s documentation − Wash-clean or dry clean the turbine during Refer to the operation manufacturer’s documentation...
Page 91 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) Cylinder lube oil − Replace filter element upstream of the cylinder as necessary filter lubricating system 8135−1 Exhaust Waste − During a longer operation period at low engine In accordance with load, manually open the butterfly valve (refer to instructions of valve...
Page 92 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be done Intervals & Lifetime (operation hours) 9223−1 Crank angle − Replace the proximity sensor as necessary sensor (CAS) unit 9308−1 Oil mist detector − Read and obey the manufacturer’s instructions half yearly −...
Page 93 0803−1/A1 Maintenance Engine Cross Section 2751−1 2728−1 2722−1 2751−4 8460−1 2708−1 8733−1 3403−1 3403−4 5562−1 2124−1 5612−1 2124−3 1903−1 4325−1 6420−1 8447−1 8752−1 6606−1 6545−1 2303−1 6708−1 3326−1 3326−2 3303−2 3303−4 3301−1 3206−1 4103−1 1132−1 1132−2 1112−1 WCH02926 Fig. 1: Cross Section 2015 1/ 1 Winterthur Gas &...
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Page 95 ........1903−1/A1 X92 / MM / 2015 Winterthur Gas & Diesel Ltd.
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Page 97 1112−1/A1 Maintenance Bedplate and Thrust Bearing Foundation Bolts − Check Tools: 1 Feeler gauge 94122 2 Hydr. distributors 94934A 1 Pre-tensioning jack 94145 1 HP hose 94935 1 HP oil pump 94931 General The pre-tension of the foundation bolts (holding down studs) must be checked at longer intervals e.g.
Page 98 1112−1/A1 Maintenance Bedplate and Thrust Bearing Checking the pre-tension Clean the threads of the foundation bolts (2, Fig. 3) and the seating surfaces. Attach the pre-tensioning jack (94145, Fig. 1) to the foundation bolt (2, Fig. 3) Screw the foundation bolt (2) completely down with the opened vent screw (5), until there is only little or no clearance at ’x’.
Page 99 1132−1/A1 Maintenance Main Bearing Elastic Studs − Loosen and Apply Tension Tools: 2 Double pre-tensioning jacks 94114 4 Coupling elements 94934G 1 Feeler gauge 94122 3 HP hose 94935 1 Pressure gage 94934A 1 Hydraulic unit 94942 1 Distributing piece 94934C Note: Always use the hydraulic double pre-tensioning jacks (94114, Fig.1) to loosen and apply tension to:...
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Page 101 1132−2/A1 Maintenance Main Bearing Main Bearing − Removal and Installation Tools: 1 Manual ratchet (H1) 94016-012 2 Spur-geared chain block, 2500 kg (H2,H4) 94017-028 1 Dismantling tool 94118B 1 Spur-geared chain block, 2500 kg (H3) 94017-029 Dismantling tool 94118C 4 Shackles 8500kg 94019L 1 Lifting plate 94119...
Page 102 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Cover Removal (No. 2 to No. #) Put the the platform (94143, Fig.1) in position in the column. Use the feeler gauge 94123 to do a check of the bearing clearance, refer to 94117B 0330−1.
Page 103 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Install the lug (94116C, Fig. 3) on the main bearing cover (1). Make sure that the thrust device (94110, Fig. 4) is clean. 94116C WARNING Injury Hazard: The thrust device has a WLL of only 70 kg.
Page 104 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing 22) Put the chain of the manual ratchet (H1) through the roller support 94117, see Fig. 5. 23) Attach the hook of the chain to the lug 94116C on the bearing cover (1). 94117 94116C WCH03014...
Page 105 1132−2/A1 Maintenance Main Bearing − Removal and Installation 30) Attach the sling 94039-015 to the gallery (Fig. 7). 31) Attach the chain block 94017-029 (H3) to the sling 94039-015. 32) Attach deviation pipe 94117B and 94039−015 94117C to the column, see view I. 94019P 33) Attach the chain block 94017-028 (H2) with shackle 94019P to the column.
Page 106 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Cover No.1 − Removal Remove the cover (1, Fig. 8) and the holder (2). Remove the round nuts (2, Fig.9) ,refer to 1132−1. Remove the oil pipe (1) from the main bearing cover.
Page 107 1132−2/A1 Maintenance Main Bearing − Removal and Installation 10) Attach the shackle 94019K (Fig. 11) to the lug 94116C. 11) Attach the hook of the machine room crane to the shackle 94109K. Apply a light tension to the chain of the machine room crane.
Page 108 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Shell − Removal Preparation CAUTION Damage Hazard: Do not remove two adjacent main bearing shells at the same time. Damage to equipment can occur. Put the bracket 94141 (Fig. 12) on the two main bearing girders (1) parallel to the engine axis.
Page 109 1132−2/A1 Maintenance Main Bearing − Removal and Installation Bearing Shell No.2 to No. # − Removal CAUTION Damage Hazard: Use only the applicable tools. Do not attach external installations during the removal procedure. Make sure that the crankshaft is lifted to 0.3 mm.
Page 110 1132−2/A1 Maintenance Main Bearing Removal and Installation Use the manual ratchet (H1, Fig. 15) to turn the bearing shell (3) until the center of the bearing shell (1) is in a vertical position. Note: If the bearing shell (1) does not move freely during the removal procedure, you must attach the lifting plate (94119A,...
Page 111 1132−2/A1 Maintenance Main Bearing − Removal and Installation Bearing Shell No. 1 Note: The bearing cover and the top main bearing shell are removed. The crank is on the exhaust side at 94019G the TDC position. 94017−028 CAUTION Damage Hazard: Use only the applicable tools.
Page 112 1132−2/A1 Maintenance Main Bearing Removal and Installation 11) Install the lifting tool 94116A (Fig. 18) to the bearing shell (1). 12) Attach the spur-geared chain block (H2) the middle of the lifting tool 94116A. 13) Use the spur-geared chain block (H2) and the lifting tool 94116A to lift the bearing shell (1).
Page 113 1132−2/A1 Maintenance Main Bearing − Removal and Installation Main Bearing Shell − Inspection Use a soft cloth to clean the bearing shell. Do a check of the bearing shell for damage e.g. breakouts or cracks. Use Scotchbrite to remove small scratches and running marks. CAUTION Damage Hazard: Do not use a scraper in the running area of the bearing shell.
Page 114 1132−2/A1 Maintenance Main Bearing − Removal and Installation Note: Use the applicable equipment to carefully move the bearing shell into position (for No. 1, see Fig. 17 and for No2 to No. 8 see Fig. 14). Carefully move the bearing shell into the bearing girder (on the fuel side). Carefully install the Allen screws to the bearing shell.
Page 115 1132−2/A1 Maintenance Main Bearing − Removal and Installation 15) After each installation of a new bearing shell, measure the crank deflection, refer to 3103−1. 16) Do a check of the oil supply to the main bearing. Main Bearing − Lubrication After an overhaul of the bearing shells, more lubricant can be added to prevent damage to the surface of the bearing shells.
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Page 117 1132−2/A2 Maintenance Main Bearing Main Bearing − Removal and Installation Tools: 1 Manual ratchet (H1) 94016-012 2 Manual ratchet (H5, H6) 94016−015 2 Spur-geared chain block, 2500 kg (H2,H4) 94017-028 1 Dismantling tool 94118B 1 Spur-geared chain block, 2500 kg (H3) 94017-029 Dismantling tool 94118C...
Page 118 1132−2/A2 Maintenance Main Bearing − Removal and Installation Preparation WARNING Injury and Damage Hazard: Do not turn the crankshaft when the platforms, tools and/or supports, are installed. This will cause injury to personnel and damage to equipment. WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel or in the engine.
Page 119 1132−2/A2 Maintenance Main Bearing − Removal and Installation Main Bearing Cover (No. 2 to No. #) − Removal Note: This procedure is for engines where the supply unit is near the middle of the fuel side on engines with 9 to 12 cylinders. For engines 94143 with 6 to 8 cylinders, the procedure can look different...
Page 120 1132−2/A2 Maintenance Removal and Fitting of a Main Bearing Install the lug (94116C, Fig. 3) on the main bearing cover (1). Make sure that the thrust device (94110) is clean. 94116C WARNING Injury Hazard: The thrust device has a WLL of only 70 kg.
Page 121 1132−2/A2 Maintenance Removal and Fitting of a Main Bearing 20) Put the chain of the manual ratchet (H1) through the roller support 94117, see Fig. 21) Attach the manual ratchet (H1) to the lug (94116C) on the bearing cover (1). 94117 94116C WCH03782...
Page 122 1132−2/A2 Maintenance Removal and Fitting of a Main Bearing 28) Attach the sling (94039−015, Fig. 6) to 94019P the platform as shown. 29) Attach the shackle (94019P) to the top of the column as shown. 94039−015 30) Attach the chain block (H3) to the shackle (94019P) and the support (94116D).
Page 123 1132−2/A2 Maintenance Main Bearing − Removal and Installation 38) Remove the manual ratchet (H4) from the lug (94116C). 39) Attach the manual ratchet (H5, Fig. to the shackle (94019G) and the lug 94116C). 40) Attach the manual ratchet (H6) to the shackle (94019G).
Page 124 1132−2/A2 Maintenance Main Bearing − Removal and Installation 42) Remove the chain block (H3). 43) Attach the chain block (H6, Fig. 9) to the lug (94116C). WCH03782 Fig. 9 44) Operate the manual ratchets (H5, H6, Fig. 10) to move the bearing cover to the position shown.
Page 125 1132−2/A2 Maintenance Main Bearing − Removal and Installation 51) Connect the thrust device (94110, Fig. 11) to the HP oil pump (94931). 52) Apply 1040 bar pressure to the thrust THRUST DEVICE 94110 device. 53) Carefully loosen the screw (5). 94110 54) Slowly release the pressure to zero in the thrust device (94110) refer to...
Page 126 1132−2/A2 Maintenance Main Bearing − Removal and Installation Main Bearing Cover No.1 − Removal Remove the holder(1, Fig. 12) and the cover (2). Remove the round nuts (2, Fig. ,refer to 1132−1. Remove the oil pipe (1) from the main bearing cover.
Page 127 1132−2/A2 Maintenance Main Bearing − Removal and Installation 10) Attach the shackle (94019K, Fig. 15) to the lug (94116C). 11) Attach the hook of the engine room crane to the shackle (94109K). Apply a light tension to the chain of the engine room crane.
Page 128 1132−2/A2 Maintenance Main Bearing − Removal and Installation Main Bearing Shell − Removal Preparation CAUTION Damage Hazard: Do not remove two adjacent main bearing shells at the same time. Damage to equipment can occur. Put the bracket 94141 (Fig. 16) on the two main bearing girders (1) parallel to the engine axis.
Page 129 1132−2/A2 Maintenance Main Bearing − Removal and Installation Bearing Shell No.2 to No. # − Removal CAUTION Damage Hazard: Use only the applicable tools. Do not attach external installations during the removal procedure. Make sure that the crankshaft is lifted to 0.3 mm.
Page 130 1132−2/A2 Maintenance Main Bearing Removal and Installation Operate the manual ratchet (H1, Fig. 18) to turn the bearing shell (3) until the center of the bearing shell (1) is in a vertical position. Note: If the bearing shell (1) does not move freely during the removal procedure, you must attach the lifting plate (94119A,...
Page 131 1132−2/A2 Maintenance Main Bearing − Removal and Installation Bearing Shell No. 1 CAUTION 94019G Damage Hazard: Use only the applicable tools. Do 94017−028 not attach external installations during the removal procedure. 94119 Note: The bearing cover and the top main bearing shell are removed. The crank is on the exhaust side at the TDC position.
Page 132 1132−2/A2 Maintenance Main Bearing Removal and Installation 11) Attach the tool (94116A, Fig. 21) to the bearing shell (1). 12) Attach the chain block (H2) the middle of the lifting tool (94116A). 13) Operate the chain block (H2) and the tool (94116A) to lift the bearing shell (1).
Page 133 1132−2/A2 Maintenance Main Bearing − Removal and Installation Main Bearing Shell − Inspection CAUTION Damage Hazard: Do not use a scraper in the running area of the bearing shell. Damage to the bearing shell will occur. Use a soft cloth to clean the bearing shell. Do a check of the bearing shell for damage e.g.
Page 134 1132−2/A2 Maintenance Main Bearing − Removal and Installation Note: Use the applicable equipment to carefully move the bearing shell into position (for No. 1, see Fig. 20 and for No. 2 to No. # see Fig. 17). Carefully move the bearing shell into the bearing girder (on the fuel side). Carefully install the Allen screws to the bearing shell.
Page 135 1132−2/A2 Maintenance Main Bearing − Removal and Installation 15) After each installation of a new bearing shell, measure the crank deflection, refer to 3103−1. 16) Do a check of the oil supply to the main bearing. Main Bearing − Lubrication After an overhaul of the bearing shells, more lubricant can be added to prevent damage to the surface of the bearing shells.
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Page 137 1203−1/A1 Maintenance Thrust Bearing Axial Clearance Check Tools: 1 Inside micrometer 94101 Procedure One Start the engine in the direction AHEAD to move the crankshaft (2, Fig. 1) fully forward. Stop the engine. Put the dial gauge (1) in position on the oil baffle (3) and record the value.
Page 138 1203−1/A1 Maintenance Checking the Axial Clearance Procedure Two Start the engine in the direction AHEAD to move the crankshaft fully forward. The crankshaft (4, Fig. 2) must touch the thrust pads (1). Stop the engine. Make sure that the crankshaft (4) does not move.
Page 139 1224−1/A1 Maintenance Thrust Bearing Thrust Bearing Pads − Removal and Installation Tools: 1 Manual ratchet 94016−012 (H3) 1 Carrier 94155A 2 Spur geared chain block 2500 kg 94017−028 (H1) (H2) 1 Link 94321 1 Eye bolt 94045-M56 2 Shackle 94334A Preparation Read the data in 0012−1...
Page 140 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation Removal Remove and discard the lockwire (4, Fig. 2) from the elastic bolts (3). Remove the elastic bolts (3) and the sleeves (2). Attach the eye bolt (9405−M56) to the arbor support (1). Attach the chain block (H1) to the eye bolt (94045−M56).
Page 141 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation Attach the link (94321) to the chain blocks (H1, H2, Fig. Connect the manual ratchet (H3) to the link (94321). WCH02906 94321 94155A 94045−M12 WCH02906 Fig. 3 10) Remove the temperature sensors (1) from the thrust pad (2). 11) Install the carrier (94155A) on the gear wheel (3) as shown.
Page 142 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation 13) Attach the manual ratchet (H3, Fig. 4) to the eye bolt (94045-M12). WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or inside the engine. 14) Operate the turning gear to turn the crankshaft in the applicable direction.
Page 143 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation Installation Make sure that the thrust pads are clean. Apply clean engine oil to the thrust pads. Note: You must install the thrust pads that you removed before in the same positions.
Page 144 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation 14) Remove the chain block and the eye bolt. 15) Install the three elastic bolts (3, Fig. 2) to the arbor supports (1, 5). 16) Lock the three elastic bolts (3) with wire (4) as shown. 17) Install the temperature sensors (1, Fig.
Page 145 1224−1/A1 Maintenance Thrust Bearing Pads − Removal and Installation Completion Install the end casing (1, Fig. Install the beam (2). Remove all tools and equipment from the area. Fig. 7 WCH02906 2015 7/ 7 Winterthur Gas & Diesel Ltd.
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Page 147 1715−1/A1 Maintenance Engine Stays with Friction Shims Pre-tension Checks Tools: 1 Feeler gauge 94122 2 Pressure gauge 94934A 1 Pre-tensioning jack 94145 1 HP hose 94935 1 HP oil pump 94931 General The engine stays (see Fig.1) are related to the design of the ship. The engine stays are installed as follows: Four engine stays are installed on the exhaust side, or the fuel side.
Page 148 1715−1/A1 Maintenance Engine Stays with Friction Shims: Pre-tension Checks Pre-tension Checks Clean the threads of the bolts (2, Fig.1) and the seating surfaces. Refer to 9403−2 and 9403−4. Attach the pre-tensioning jack and the applicable equipment as shown in Fig. Apply a tension of 170 bar to the bolt (2).
Page 149 1715−1/A2 Maintenance Hydraulic Engine Stays Engine Stays − Checking the Oil Pressure General Two hydraulic engine stays (1) are installed on the exhaust side and two on fuel side of the engine. The oil pressures on the pressure gauges of the hydraulic cylinders must be checked and compared with each other at regular intervals.
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Page 151 1903−1/A1 Maintenance Tie Rod Pre-tension Checks and Tie Rod Replacement Tools: 1 Feeler gauge 94122 1 Pressure gauge 94934A 2 Pre-tensioning jacks 94180 3 HP hoses 94935 1 Connection block 94934 1 Hydraulic unit 94942 General We recommend that you check the tension of all the tie rods one year after commissioning.
Page 152 1903−1/A1 Maintenance Pre-tension Checks and Tie Rod Replacement Tie Rods − Replacement Preparation Remove the protection cover (1, Fig. from the tie rods (4). Clean the surface of the intermediate ring (3). Refer to 9403−4, then attach the two pre-tensioning jacks (94180) to two tie rods that opposite each other (e.g.
Page 153 1903−1/A1 Maintenance Pre-tension Checks and Tie Rod Replacement Apply Tension DL must be 17 mm to 19 mm Note: Start with the tie rods in the middle of the engine a−a, then b−b etc). Put the two pre-tensioning jacks 1500 bar (94180, Fig.3) on the tie rods (2).
Page 154 ......... 2751−4/A1 X92 / MM / 2017−11 Winterthur Gas & Diesel Ltd.
Page 155 2124−1/A1 Maintenance Cylinder Liner Measuring Bore Wear Tools: 1 Inside micrometer 94101 1 Ladder 94224 1 Measuring gauge 94225 Measure the cylinder liner wear before you remove a piston. 94224 Remove the cylinder cover, (see 2708−1). Use the turning gear to move the piston to BDC.
Page 156 2124−1/A1 Maintenance Measuring Bore Wear 14) Use the formula below to calculate the wear rate: WR = (D1−D2) x 1000 WR = Wear rate [mm/1000 h] T1 = Total running hours [h] D1 = Max. Liner diameter in running surface (points B and below) [mm] D2 = Liner diameter in non-running surface (point A) [mm] 15) For the maximum permitted inner diameter, refer to 0330−1...
Page 157 2124−2/A1 Maintenance Cylinder Liner Removal and Installation Tools: 3 Shackle 94019L 3 Manual ratchet 94016−003 3 Shackle 94019H 3 Eye bolt 94045−M10 1 Lifting tool 94201 1 Chain 94202A 1 Assembly tool 94233 Wooden blocks Preparation ............Bottom Water Guide Jacket −...
Page 158 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Lifting Tool − Install Attach the two flanges (2, Fig. 2) (part of lifting tool 94201) to the cylinder liner (1) with the five screws (5). Use the engine room crane to lower the lifting tool 94201 on to the cylinder liner (1).
Page 159 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Cylinder Liner − Safe 94202A Storage Attach the chain 94212A to the lifting tool and the engine room as shown in 94201 Fig. Put the wooden underlays (4, 5) and the wooden chocks (3) in position as shown in Fig.
Page 160 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Insulation Bandage − Removal Make sure that the water guide jacket is removed (refer to paragraph Use the tool (94233, Fig. 6) to remove the tension springs (2). Remove the plate (3). Remove insulation bandage (1). Insulation Bandage −...
Page 161 2124−2/A1 Maintenance Cylinder Liner: Removal and Fitting Cylinder Liner and 94202A Water Guide Jacket − Installation 94201 Install the insulation bandage, refer to paragraph Attach the lifting tool (94201, Fig. 7) to the cylinder liner, refer to paragraph Attach the chain 94202A to the shackle on the lifting tool 94201.
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Page 163 2124−2/A2 Maintenance Cylinder Liner Removal and Installation Tools: 3 Shackle 94019L 3 Spur−geared chain block 94017−004 3 Shackle 94019H 3 Eye bolt 94045−M10 1 Lifting tool 94205 1 Chain 94202A 1 Assembly tool 94233 1 Chain 94205A 1 Lifting tool 94201 Wooden blocks Preparation...
Page 164 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation ........(with optional tool) Lifting Tool −...
Page 165 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation ........(with optional tool) Cylinder Liner −...
Page 166 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation ........(with optional tool) Insulation Bandage −...
Page 167 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation ........(with optional tool) Cylinder Liner and Water Guide Jacket −...
Page 168 2124−2/A2 Maintenance Cylinder Liner: Removal and Installation ........(with optional tool) 21) Remove the chain blocks (94017−004, Fig.
Page 169 2124−3/A1 Maintenance Cylinder Liner Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports Tools: 1 Wear ridge grinding device 94299 (optional) General During operation, the cylinder liner becomes worn. As a result a ridge arise 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 170 2124−3/A1 Maintenance Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports 94299 WCH02352 Fig. 1 Unwanted material r = 8 mm 2 mm to 3 mm 1 mm 2015 2/ 3 Winterthur Gas & Diesel Ltd.
Page 171 2124−3/A1 Maintenance Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports Lubricating grooves CAUTION When you remove sharp edges from the lubricating grooves, make sure that the shape stays the same as the original. If the depth of the lubricating grooves has decreased to less than 1.5 mm, do as follows: Use emery cloth or an oil stone to get the the lubricating grooves 5 back to their original depth (see...
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Page 173 2138−1/A2 Maintenance Lubricating Quill Removal and Installation Tools: 1 HP oil pump 94931 1 Connection nipple (G¼ inch) 94934I 1 Pressure gauge 0 bar to 20 bar 94934B 1 HP hose 94935 General If it is not necessary to remove the cylinder liner (1, Fig.
Page 174 2138−1/A2 Maintenance Lubricating Quill Lubricating Quill − Function Check General You do a function check to make sure that the non-return valve (1, Fig. 2) operates correctly. The pressure that opens the non-return valve is 5.0 bar. During the function check, keep the lubricating quill (2) in a horizontal position. For the function check, use an oil with a viscosity as given in the specifications that follow: SAE 50 at 40_C (approx.
Page 175 2138−1/A2 Maintenance Lubricating Quill Installation CAUTION Damage Hazard: The surfaces of the cylinder liner and the nozzle tip make a metallic seal. The seat angles in the cylinder liner and on the nozzle tip are different. Do not use a gasket between the cylinder liner and the nozzle tip, or damage to the equipment can occur.
Page 176 2138−1/A2 Maintenance Lubricating Quill Tighten the nuts (6, Fig. 4) of the screw-in union and angle union. Step a) to step c) is only necessary if the cylinder liner was installed. Remove the protection from the 10 pipes (3). Connect the 10 pipes (3). Attach the two holders (4) to the 10 pipes (3).
Page 177 2303−1/A1 Maintenance Piston Rod Gland Remove, Disassemble, Measure Worn Parts, Assemble, Install Tools: 2 Distance holders 94230 1 Distance piece (11 mm) 94231C 1 Clamp ring (2-parts) 94231A 1 Distance piece (9 mm) 94231D 1 Distance piece (12 mm) 94231B 2 Spring assembly tool 94233 1 Template...
Page 178 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install Remove Make sure that the piston rod gland (1) is in the correct position on the two hinged covers (5, Fig. Remove the two O-rings (3). Remove the four screws and nuts (4). Push the two parts of the housing (2) away from the piston rod (1).
Page 179 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install Disassemble Remove the parts that follow (see Fig. Tension springs (1, 5) Scraper rings (2, 6, 11, 12) Gaskets (3, 4, 8, 10) Spring dowel pins (9) Ring supports (7). WCH02943 Fig.
Page 180 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install II - II WCH02943 I - I WCH02943 Fig. 3 Fig. 3: Gland Box, General Views 1 Bolt M16x60 and nut M16 6 Dowel Pins 2 Spring Dowel Pin 7 Inner Bolt M16x100 3 Gland box housing, 2-part 8 Locking Plate 4 Support...
Page 181 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install Assemble Attach the two parts of the clamp ring (94231A, Fig. 4) to the piston rod. Put the three parts of the ring support (15) and the scraper rings (16) on the clamp ring 94231A.
Page 182 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install 14) Put the two parts of the distance piece (94231B 12 mm height, Fig. 4) on the gaskets (12, 14). 15) Put the four parts of the gaskets (12, 13) on the distance piece (94231B). Make sure that there is an equal distance between the four parts.
Page 183 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install Installation When you assemble the piston rod gland, make sure that all parts are in a serviceable condition. To install the piston rod gland, do the steps that follow: Apply lubricating oil to the opening in the cylinder jacket (3) and to the area of the O-rings (4) on the housing (1, Fig.
Page 184 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install CAUTION Damage Hazard: Each time you operate the turning gear, you must remove the platform (94142). This will prevent damage to equipment. After you use the turning gear, you can install the platform (94142) again.
Page 185 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install Note: Some parts can look different. 4, 5 6, 5 94234 94143 94142 WCH01172 018.654/09 Fig. 9 2015 9/ 10 Winterthur Gas & Diesel Ltd.
Page 186 2303−1/A1 Maintenance Remove, Disassemble, Measure Worn Parts, Assemble, Install Installation WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. CAUTION Damage Hazard: Each time you operate the turning gear, you must remove the platform (94142).
Page 187 2708−1/A1 Maintenance Cylinder Cover Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve Tools: Lifting tool 94215 1 Cylinder cover support 94266 Pre-tensioning jacks 94215A Suspension device 94265 Hydraulic equipment 9403−2 Preparation Stop the engine, see the procedure in Operation Manual 4002−2.
Page 188 2708−1/A1 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve Elastic Stud − Loosening and Tensioning Loosening Use the crane and put the lifting tool (94215, Fig.2) with the ten pre−tensioning jacks 94215A above the cylinder cover (3). Lower the lifting tool 94215 slowly until the four brackets (4) are on the cylinder 94215...
Page 189 2708−1/A1 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve Cylinder Cover, Water Guide Jacket, Exhaust Valve − Removal CAUTION Injury Hazard: The weight of the cylinder cover with the top water guide jacket and the exhaust valve is 2500 kg.
Page 190 2708−1/A1 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve 10) Prepare an applicable working area for the exhaust valve (2, Fig. 5). 11) Connect the crane hook to the bolt of the exhaust valve cage (1). 12) Use the engine room crane to lift exhaust valve cage (2) and put it on a wooden underlay.
Page 191 2708−1/A1 Maintenance Removal and Installation of Cylinder Cover, Water Guide Jacket, Exhaust Valve Cylinder Cover, Water Guide Jacket, Exhaust Valve − Installation For installation of the exhaust valve, refer to 2751−1 and 2751−2. Clean all contact faces and O-ring grooves. Apply oil to two new O-rings (3, Fig.
Page 192 2708−1/A1 Maintenance 15) Connect the air pipe to the cylinder cover. 16) Connect all other connections to the cylinder cover and to the exhaust valve. 17) Do a leak test after installing a cylinder cover. Turn on the cooling water pump at normal operating pressure.
Page 193 2708−3/A1 Maintenance Cylinder Cover Sealing Face − Grind Tools: 1 Grinding device 94270G 1 Stencil General 94270G The sealing face in the cylinder cover for the injection valve must be clean and have no damage. WARNING Injury Hazard: Heavy parts can fall down.
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Page 195 2722−1/A1 Maintenance Injection Valve Replacement Tools: No special tools required Removal of injection valve Remove HP fuel pipe (3) of the concerned injection valve (1), refer to 8733−1. Disconnect the leakage pipe (5) from the injection valve. Remove the screws (2) with their spring cage (3).
Page 196 2722−1/A1 Maintenance Installation of injection valve CAUTION Do not open vacuum packed injection valve be- fore the installation on the engine. Clean and check the condition of the sealing face ’SF’ in the cylinder cover and recut it if necessary according to 2708−3.
Page 197 2722−2/A1 Maintenance Injection Valve Disassemble, Check, Assemble Injection Valve Tools: 1 Torque spanner 94011A 1 Wrench extension 94022D−55 1 Wrench extension 94022D−70 1 Injector test bench compl. 94272 1 Nozzle removal tool 94278A 1 Nozzle installation tool 94278B General ............Preparation .
Page 198 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Preparation 94272D 94272E 94272 WARNING Fire Hazard. Do not use welding or grinding equip- ment near the work area. WARNING Health Hazard. Calibration fluid is harmful to your health. Read and follow the instruction manual of the test bench manufacturer.
Page 199 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Follow the instruction of the injector test bench manufacturer for testing the opening pressure and tightness. Check opening pressure as follows: Increase the oil pressure slowly until the opening pressure is reached and the injector sprays.
Page 200 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Disassemble Injection valve Make sure that the test bench has no 94022D−55 pressure. 94273 Remove the spray can from the valve holder 94273. Disconnect the HP hose 94272E is from the connecting piece 94272B, see Fig.
Page 201 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Nozzle tip − replace 94278A Removal It is not recommended but possible to replace the nozzle tip (1) with the nozzle WCH02740 needle (2) installed. Remove only clamping nut according to paragraph (4). Disassemble the injection valve, see paragraph 4.
Page 202 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST Installation Make sure that the nozzle needle (2, Fig. 5), is removed from the nozzle body (3). Attach the nozzle body (3, Fig. 5) with coupling nut (4) to the injection valve 94278B (5) on the injection test bench.
Page 203 2722−2/A1 Maintenance Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST SEATING FACE Assemble Injection valve − assemble SEATING FACE Clean the contact surface of nozzle body (2) and nozzle holder (10). Contact surface must be dry, clean and free of lubricants. Put the nozzle body (2) together with the inserted nozzle needle (5) in position on the nozzle holder (10).
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Page 205 2728−1/A1 Maintenance Starting Air Valve Removal, Disassemble, Grinding, Assemble, Installation General ............Preparation .
Page 206 2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Removal Disconnect the electrical connection from the 3/2-way solenoid valve (3). Remove the four screws (4). Carefully remove the starting air valve from the cylinder cover (5). Remove and discard the gasket (13). Put applicable protection over the opening in the cylinder cover (5).
Page 207 2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Grinding If the seating faces of the housing (2) and the valve spindle (10) have minimum damage, do as follows: Manually grind the seat faces of the housing (2) and the valve spindle (10). Make sure that you keep the radius to the values given in Fig.
Page 208 2728−1/A1 Maintenance Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation Assemble Clean all the parts of the starting air valve. Put a small quantity of oil on the all the parts. Put new oiled O-rings (6) and (11) in the housing (2). Put the the valve spindle (10) into the housing (2).
Page 209 2751−1/A1 Maintenance Exhaust Valve Exhaust Valve − Removal and Installation Tools: 2 Sling 94049A Preparation Drain the cylinder cooling water from the related cylinder (see 2708−1). Close the air inlet to the air spring at the control air supply. Remove the hydraulic pipe (4, Fig.
Page 210 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation Removal Put two slings (94049A, 2.5m) in position on the expansion piece (6, 200 kg) as shown in (Fig. Connect the slings to the hook on the 94049A crane. Use the crane to put a light tension on the slings.
Page 211 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation Installation Clean all the sealing surfaces of the exhaust valve and the cylinder cover. Examine the sealing surfaces of the exhaust valve and cylinder cover for damage. Remove the 2 mm metal gasket (15) from the cylinder cover (see Fig.
Page 212 2751−1/A1 Maintenance Exhaust Valve − Removal and Installation 15) Clean the sealing contact surfaces of the expansion piece (6) and the related faces on the valve cage (3) and exhaust pipe (14, see Fig. 7). 16) Apply a thin layer of heat-resistant lubricant to the sealing faces and the screws (12 and 10).
Page 213 2751−2/A1 Maintenance Exhaust Valve Disassemble and Assemble Tools: 2 Jack screws 94263 2 Eye bolts 94045−M12 1 Depth gauge 94126 2 Eye bolts 94045−M24 General ............Exhaust valve −...
Page 214 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble WCH02968 Fig. 1: Exhaust Valve 1 Valve cage 16 Piston 2 Bottom housing 17 Piston seal ring 3 Top housing 18 Cup springs 5 Inside piston 19 Eye nut M64 6 Outside piston 20 Elastic bolt 7 Valve spindle 23 Throttle...
Page 215 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Exhaust valve − disassemble CAUTION During this procedure, do the work in a clean area. Electrical welding is not permitted. Valve drive − disassemble Attach the crane hook to the eye bolt (19, Fig. 2). Remove the six nuts (21).
Page 216 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Guide bush − removal Remove the four cap screws (12, Fig. Remove the distance ring (10). Remove and discard the rod seal (11). Put the jack screws (tool 94263) into the two threads of the guide bush flange (9).
Page 217 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Valve spindle − installation Measure the dimensions of the valve spindle (7, Fig. Compare the values with those given in 0330−1 Exhaust Valve table. Do a check of the piston seal ring (17) for damage.
Page 218 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble 12) Lift and carefully lower the top housing (3) on to the bottom housing (2). 13) Put oil on to the threads of the elastic studs (20). 14) Put the six nuts (21) on to the elastic studs (20).
Page 219 2751−2/A1 Maintenance Exhaust Valve: Disassemble and Assemble Valve stroke sensor − installation Clean the parts that follow: The valve stroke sensor (28). The transmitter housing (27). bore collar housing (3) Put oil on the O-ring (41) and the valve stroke sensor (28). Carefully put the O-ring (41) and the Fig.
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Page 221 2751−3/A1 Maintenance Exhaust Valve Valve Seat − Replace / Grind Tools: 1 Feeler gauge 94122 1 Valve seat fitting and dismantling device 94261 1 Template 94279 1 Tool, grinding 94291 General ............Preparation .
Page 222 2751−3/A1 Maintenance Valve Seat − Replace / Grind Valve seat − removal Mark the position of the valve seat in the valve cage before you start the removal procedure. Recommended procedure Turn the valve cage until the valve seat points up (see Fig.1). Carefully put the valve cage on to an Fig.
Page 223 2751−3/A1 Maintenance Valve Seat − Replace / Grind Valve seat − grinding Use only the tool 94291 (see Fig. 3) to grind the valve seats. Read the data in the manufacturer’s manual 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 (9) ,see 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 (2) and the valve seat (1, Fig. 7). Apply oil (or lubricants e.g. Never-Seez NSBT, or Loctite anti-seize compound) on to the sealing faces of the valve seat (1) and the valve cage (2).
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Page 227 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 Use only the grinding device 94291 (see Fig. 1) to grind the valve head. a = between: 30°14' and 30°16' You must grind valve heads that have...
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 gage 94122, you can repair the valve spindle (see the data below). If more than 3 mm is ground off, do the procedure that follows: Use a build-up welding procedure to repair the valve seating surface.
Page 229 ........3425−1/A1 X92 / MM / 2017−01 Winterthur Gas & Diesel Ltd.
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Page 231 3103−1/A1 Maintenance Crankshaft Measuring Crank Deflection Tools: 1 Crankshaft equipment (dial gauge) 94305 1 Or a remote gauge 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 232 3103−1/A1 Maintenance Measuring Crank Deflection Note: Step is applicable only for a cold engine. If the engine has usual operation temperature, continue from step 2). Make sure that the tank heater and lubricating oil separator are set to off a minimum of eight hours.
Page 233 3103−1/A1 Maintenance Measuring Crank Deflection Date Evaluation 94305 nBDC nTDC Fig. 3 The difference between the indicated values shows the crank deflection during one full turn (Fig. Where values are measured, which are above the maximum permitted limits, you must find the cause (e.g. defective main bearing, engine stay changed because hull deformation, loose hold-down bolts, defective propeller shaft bearings, equipment 94305 etc).
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Page 235 3130−2/A1 Maintenance Vibration Damper Steel Spring Vibration Damper − Inspection 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 236 3130−2/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 237 3130−2/A1 Maintenance Inspection (GEISLINGER Vibration Damper) I - I FREE WCH03838 WCH03838 Fig. 2 Fig. 2: Vibration Damper, Free End 1 Vibration damper 4 Crankshaft 2 Damper casing 5 Coupling bolt 3 Oil supply pipe 2017−11 3/ 3 Winterthur Gas & Diesel Ltd.
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Page 239 3140−1/A1 Maintenance Axial Detuner Disassembly and Assembly Tools: 1 Manual chain block 94016-011 2 Eye bolt 94045-M30 1 Shackle 94019P 1 Chain 94325 2 Round slings 94038-011 1 Link 94321P Preparation ............Disassembly .
Page 240 3140−1/A1 Maintenance Axial Detuner: Disassembly and Assembly Disassembly Remove the two pipes (4, Fig. Remove the oil inlet pipe (5) and the two non-return valves (6). Remove the six bolts (3). Remove the four bolts (1). WCH02996 Fig. 2 Attach two eye bolts 94045-M30, (Fig.
Page 241 3140−1/A1 Maintenance Axial Detuner: Disassembly and Assembly 94019P 94038−011 94325 94045-M30 94321P 94016−011 Fig. 3 WCH02996 12) Do a check of the two part gaskets (2 and 3, Fig. 4). If the 2-part gaskets have damage or contamination, do step a) and step b). Carefully remove the tension springs (4, 5).
Page 242 3140−1/A1 Maintenance Axial Detuner: Disassembly and Assembly Assembly Apply clean engine oil to the new 2-part gaskets. Attach the new 2-part gaskets (2 and 3, Fig. 4) to the axial detuner. Make sure that the new 2-part gaskets (2, 3) can move freely around the axial detuner.
Page 243 3140−1/A1 Maintenance Axial Detuner: Disassembly and Assembly Completion Use a suitable lifting tool to put the top housing (5, 1200 kg) on top of the lower housing (9) with a slight distance to the crank case. Insert two screws to prevent the top housing from sliding. Connect the pipes (4 and 5, Fig.
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Page 245 3206−1/A1 Maintenance Turning Gear Teeth 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 yu must make sure that there is lubricant applied to these components.
Page 246 3206−1/A1 Maintenance Turning Gear: Teeth and Screwed Connections − Check Tooth Checks Lubricant 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 1 and Table 2. Table 1: Instructions −...
Page 247 3301−1/A1 Maintenance Crankcase Platforms Tools: 2 Platform, each platform includes three grids 94142 2 Support 94143 General You use the platform (94142, Fig. 1) and platform (94143) when you do work in the crank area and between the columns. The platforms help to prevent accidents in these areas.
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Page 249 3303−2/A1 Maintenance Connecting Rod Bottom End Bearing − Removal, Inspection and Installation Tools: 2 Manual ratchet, 2500 kg 94016−012 4 Eye bolt M24 94045-M24 2 Spur-geared chain block, 94017−029 1 Deviation pipe 94117B 2500kg 1 Shackle, 6500 kg 94019K 1 Chain 94327 4 Shackle, 8500 kg 94019L...
Page 250 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bearing Cover − Removal Remove the round nuts (1), refer to the 94038−015 procedure in 9403−4 paragraph 2. Operate the manual ratchets (H2, H3) to carefully lower the bearing cover (3). Do an inspection of the bearing shell (4, Fig.
Page 251 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bearing Shell − Removal 94327 Remove the two screws (1, Fig. 3). Install the four eye bolts 94045-M10. Attach chain 94327 to the four eye bolts 94045-M8. Lift the bearing shell (3) from the bearing cover (2).
Page 252 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Put the chain of the manual ratchet (H3, Fig. 5) around the connecting rod (3). Use the turning gear to turn the crank to the fuel side. At the same time, operate the manual ratchet (H3) to keep a light tension on the chain.
Page 253 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Top Bearing Shell − Removal Attach the manual ratchets 4016−012 (H1, H5, Fig. 6) and the shackle 94019P to the column. 94019P Attach the console frame 94326 (Fig. 7) to the bearing shell (3) with the four screws (1).
Page 254 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Top Bearing Shell − Installation Clean the seating surface of the bearing shell. Put the bearing shell on the console 94326 frame 94326 (Fig. 9), then tighten the four screws (2). Clean the seating surface of the connecting rod (4) and the bearing shell (3).
Page 255 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bottom Bearing Shell − Installation Attach the four eye bolts 94045-M10, 94327 (Fig. 11) to the bottom bearing shell (3). Attach the chain 94327 to the four eye bolts 94045-M10. Lift the bottom bearing shell (3).
Page 256 3303−2/A1 Maintenance Bottom End Bearing − Removal, Inspection and Installation Make sure that the bearing shell is clean. Put oil on the bearing shell as follows: If you start the engine immediately after completion of this procedure, use only bearing oil. If the engine has stopped for some days, use a mixture of high-viscosity oil (steam engine...
Page 257 3303−2/A2 Maintenance Connecting Rod Bottom End Bearing − Removal, Inspection and Installation Tools: 2 Manual ratchet, 2500 kg (H2, H3) 94016−012 4 Eye bolt M24 94045-M24 2 Manual ratchet, 3200 kg (H6, H7) 94016−015 6 Eye Bolt 94045−M10 1 Spur-geared chain block, 2500 kg (H1) 94017−029 1 Sling 94039−002...
Page 258 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Operate the turning gear to turn the crankshaft until the applicable crank (2, Fig. 1) is at TDC. Lock the turning gear. Attach the eye bolts (94045-M24) to the bearing cover (3). Attach the manual ratchets (H2, H3) and shackles (94019L) to the column.
Page 259 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bearing Cover − Removal 94019K Remove the round nuts (1), refer to the procedure in 9403−4 paragraph 2. 94039−015 Operate the manual ratchets (H2, H3) to carefully lower the bearing cover (3).) Do an inspection of the bearing shell (4,...
Page 260 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Attach the shackle (94019G, Fig. 3) to the support (94116D). 10) Attach the manual ratchet (H3) to the shackle (94019G) and the shackle (94019L). 11) Operate the manual ratchets (H2, H3) to move the bearing cover to the position shown.
Page 261 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation 15) Remove the manual ratchets (H2, H3). 16) Operate the manual ratchet (H6) to lower the bearing cover on to an applicable wooden support. 17) Remove the support (94116D, Fig. as follows: Attach the sling (94039−002) to the support (94116D).
Page 262 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Top Bearing Shell − Inspection WARNING 94322 300 mm Injury Hazard: Before you 94322A operate the turning gear, make sure that no personnel are near the flywheel. WCH03013 Unlock the turning gear. Operate the turning gear to turn the crank to the fuel side until the crosshead (1,...
Page 263 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Top Bearing Shell − Removal 94019P Attach the shackles (94019P) and the chain blocks (H8, H9, Fig. 9) to the column. Attach the console frame (94326) (Fig. 10) to the bearing shell (3) with the four screws (1).
Page 264 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Top Bearing Shell − Installation Clean the seating surface of the bearing shell. Put the bearing shell on the console frame (94326, Fig. 12), then tighten the 94326 four screws (2). Clean the seating surface of the connecting rod (4) and the bearing shell (3).
Page 265 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel. 15) Operate the turning gear to move the crank to TDC. At the same time, make sure that there is no load at points (X, Fig.
Page 266 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Bearing Cover − Installation Attach the support (94116D) to the column, refer to paragraph 2, step 7). Attach the manual ratchet (H6, Fig. to the bearing cover. Operate the manual ratchet (H6) to lift the bearing cover to the position shown.
Page 267 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation Remove the manual ratchet (H6). Operate the manual ratchets (H2, H3, Fig. 18) to lower the bearing cover on to the crankcase floor. Remove the manual ratchet (H3) from the support (94116D). 94016D 94019G 94019L...
Page 268 3303−2/A2 Maintenance Bottom End Bearing − Removal, Inspection and Installation 11) Make sure that the bearing shell is clean. 12) Put oil on the bearing shell as follows: If you start the engine immediately after completion of this procedure, use only bearing oil. If the engine has stopped for some days, use a mixture of high-viscosity oil (steam engine...
Page 269 3303−3/A1 Maintenance Connecting Rod Top End Bearing − Removal, Inspection and Installation Tools: 2 Manual ratchet, 3200kg 94016-015 1 Support 94322 2 Spur-geared chain block, 500 kg 94017-004 1 Bracket 94322B 1 Spur-geared chain block, 2500 kg 94017-028 1 Lifting tool 94324 2 Spur-geared chain block, 5000 kg 94017-040...
Page 270 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation If necessary, put oil on the two bolts (2, Fig.2). 94045-M56 Install the two holders 94333 with the four bolts (2) to the piston rod foot (3). 94333 Torque the four bolts (2) to 200 Nm. Tighten the two bolts (1).
Page 271 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation 94045−M56 Crosshead − Lift 94019P 94019K Disconnect the toggle lever (1, Fig. 4) from the connecting rod and suspend it 94017−004 to the column wall. Attach shackle 94019P to each side of the column and two shackles 94019K to 94019P.
Page 272 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation Bearing shell − Removal Inspect the bearing shell (2, Fig. 6) and go ahead to replace it, if necessary. Remove working platform 94143, see Fig. 4. 94039−015 Move the top of the connecting rod (1, Fig.
Page 273 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation Bearing Shell − Installation Clean the seating surface of the bearing shell (2, Fig. 6). Put oil on the surface of the bearing shell as follows: If you start the engine immediately after completion of this procedure, use only bearing oil.
Page 274 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation 17) Put the round nuts (2, Fig. 9) on the elastic studs (1). 18) Tighten the round nuts (2) equally with a round bar. 19) Measure the distance (X1, X2) between the edges of the bearing shells and the connecting rod (3).
Page 275 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation Completion WARNING Injury Hazard: Before you operate the turning gear, 94333 make sure that no personnel are near the flywheel, the propeller shaft or inside the engine. Make sure that the piston rod foot (1, Fig.
Page 276 3303−3/A1 Maintenance Top End Bearing − Removal, Inspection Installation Bearing Lubrication To decrease the risk of dry-running on new bearing shells, it is necessary to apply a mixture of high-viscosity oil (steam engine cylinder oil, ISO VG 1000/1500) and bearing oil. Remove the oil inlet pipe (2, Fig.
Page 277 3303−4/A1 Maintenance Connecting Rod Connecting Rod − Removal and Installation Tools: 1 Trolley 94015-008 1 Round sling, 2000 kg 94039-057 1 Manual ratchet, 3200 kg 94016-015 1 Deviation pipe 94117B 1 Spur-geared chain block, 7500 kg 94017-045 1 Deviation pipe 94117C 1 Spur-geared chain block, 7500 kg 94017-047...
Page 278 3303−4/A1 Maintenance Removal and Installation Removal WARNING 94019P Injury Hazard: The 94017−045 connecting rod weighs 6000 kg. To prevent injury, be careful when you move the connecting rod. WARNING 94016−015 Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel.
Page 279 3303−4/A1 Maintenance Removal and Installation 11) Use the turning gear to turn the crankshaft for almost 90 degree and at the same time guide the connecting rod with chain block (H4) out of the column door, see Fig. 4. 12) Attach hook of manual ratchet (H2) to the swivel lug of rod (3, Fig.
Page 280 3303−4/A1 Maintenance Removal and Installation Installation WARNING Injury Hazard: The connecting rod weighs 6000 kg. To prevent injury, be careful when you move the connecting rod. 94319 94039−057 WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel.
Page 281 3303−4/A1 Maintenance Removal and Installation Carefully move the lower end of the connecting rod (1) inside the column. Attach hook of manual ratchet (H2) to the upper end of rod (3, Fig. 7). Use chain block (H3) and manual ratchet (H2) to pull the connecting rod carefully onto the crank pin (2).
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Page 283 3303−5/A1 Maintenance Connecting Rod Top End Bearing Cover − Removal, Inspection and Installation Tools: 1 Spur-geared trolley 94015-008 1 Deviation pipe 94117B 1 Spur-geared chain block, 1500 kg 94017-015 1 Platform 94143 2 Spur-geared chain block, 2500 kg 94017-029 1 Pre-tensioner 94315 2 Shackle, 8500 kg 94019L...
Page 284 3303−5/A1 Maintenance Top End Bearing Cover − Removal, Inspection and Installation Removal 94325 Use the pre-tensioning jack 94315 to loosen the four round nuts (3, Fig. 94045−M36 refer to 9403−4. Remove the four round nuts (3) from the elastic bolts (2). Attach the two eye bolts (94045-M36) to the bearing cover (1).
Page 285 3303−5/A1 Maintenance Top End Bearing Cover − Removal, Inspection and Installation Attach deviation pipe 94319 to the beam of the gallery. 94319 10) Put round sling 94039-015 around the 94039−015 beam. 11) Attach chain block 94017-015 to the 94015−008 sling. 94017−029 12) Move the bearing cover (1) to the left until it hangs only on the left chain...
Page 286 3303−5/A1 Maintenance Top End Bearing Cover − Removal, Inspection and Installation Attach the round nuts (2, Fig. 6) to the elastic bolts (3). Use the pre-tensioning jack 94315 to tighten the four round nuts (2) refer to 9403−4. WCH02662 Fig. 6 Completion Attach the piston to the crosshead, refer to 3303−3, paragraph 6.
Page 287 3303−5/A2 Maintenance Connecting Rod Top End Bearing Cover − Removal, Inspection and Installation Tools: 1 Spur-geared trolley 94015−008 1 Lifting support 94116D 2 Manual ratchet, 2500 kg (H1, H2) 94016−012 1 Platform 94143 2 Spur-geared chain block, 2500 kg (H3, H4) 94017−029 1 Pre-tensioner 94315 1 Spur-geared chain block, 7500 kg (H5)
Page 288 3303−5/A2 Maintenance Top End Bearing Cover − Removal, Inspection and Installation 94325 Removal Use the pre-tensioning jack 94315 to 94045−M36 loosen the four round nuts (3, Fig. refer to 9403−4. Remove the four round nuts (3) from the elastic bolts (2). Attach the two eye bolts (94045-M36) to the bearing cover (1).
Page 289 3303−5/A2 Maintenance Top End Bearing Cover − Removal, Inspection and Installation Attach the shackle (94019P, Fig. 4) to the top of the column. Attach the shackle (94019L) to the chain (94325). Attach the chain block (H4) to the shackle (94019P). Attach the chain blocks (H3, H4) to the 94019P shackle (94019L).
Page 290 3303−5/A2 Maintenance Top End Bearing Cover − Removal, Inspection and Installation 14) Attach the manual ratchet (H2, Fig. to the shackle (94019G). 15) Operate carefully the manual ratchets (H1, H2) and the chain block (H3) to move the bearing cover through the column door.
Page 291 3303−5/A2 Maintenance Top End Bearing Cover − Removal, Inspection and Installation 18) Operate the manual ratchets (H1, H2, Fig. 8) to move the bearing cover directly below (H2). 19) Remove the manual ratchet (H1). 20) Operate the manual ratchet (H2) to lower the bearing cover on to an applicable surface.
Page 292 3303−5/A2 Maintenance Top End Bearing Cover − Removal, Inspection and Installation Install the support (94116D), refer to paragraph 2, step 5). Attach the manual ratchets (H1 and H2, Fig. 10) to the support (94116D). Attach the manual ratchet (H2) to the shackle on the chain (94325).
Page 293 3303−5/A2 Maintenance Top End Bearing Cover − Removal, Inspection and Installation 12) Attach the chain block (H3, Fig. 12) to the shackle (94019P) and the shackle on the chain (94325). 13) Operate carefully the chain block (H3) and the manual ratchets (H1, H2) to 94019P move the bearing cover through the column door.
Page 294 3303−5/A2 Maintenance Top End Bearing Cover − Removal, Inspection and Installation 16) Operate the chain blocks (H3 and H4, Fig. 14) to move the bearing cover (1) to a position directly above the elastic bolts (2). 17) Operate carefully the chain blocks (H3, H4) to lower the bearing cover (1) on to the crosshead pin.
Page 295 3326−1/A1 Maintenance Crosshead Crosshead Pin − Removal / Installation / Clearance Checks Tools: 1 Spur-geared trolley 94015-008 1 Working platform 94143 2 Manual ratchet 94016−015 1 Working platform 94144 2 Spur-geared chain blocks 94017-004 1 Edge protector 94319 2 Spur-geared chain blocks 94017-040 1 Support 94322...
Page 296 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 94324 Crosshead Pin − 94143 Removal WARNING 94337 Injury Hazard: The weight of the lifting tool (94324) is approx. 104 kg; the weight of the lifting tool (94337) is approx.
Page 297 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 16) Attach the shackle (94019L, Fig. 3) to the column. 17) Attach the manual ratchet (94016-015) to the shackle (94019L) on the column. 94144 18) Attach the manual ratchet (94016-015) to the working platform (94143).
Page 298 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 94045-M56 WARNING Injury Hazard: The weight of the crosshead pin is 4830 kg. Use only approved equipment and sufficient personnel to lift and move the crosshead pin. 31) Attach the two lifting eye bolts WCH03035 (94045-M56, Fig.
Page 299 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Note: For engines with two-piece 94017-051 94017-040 crankshaft, use the one support (94322A) and one support (94322) to disassemble the crosshead which is in the middle. For engines with one-piece crankshaft, use the two supports (94322A) for each crosshead.
Page 300 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Do the steps a) to d) for the second support on the other side of the column. 49) Use the spur-geared chain block (94017-051, Fig. 12) and the two spur-geared chain blocks (94017−040) 94017-051 to carefully lower the crosshead to the...
Page 301 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 56) Use the spur-geared chain block (94017-040, Fig. 15) to lift the guide shoe (1 or 2). 57) Remove the chain (94325, Fig. 14), the 94017-040 shackle (94019N) and manual ratchet (94016-015).
Page 302 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 71) Attach the deviation pipe (94319, Fig. 18) to the support on the gallery. Note: After removal or assembly work, the deviation pipe (94319) has to be removed from the engine. 94319 94017-040 72) Attach the sling (94039-057) to the...
Page 303 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Guide Shoes − Removal Record the positions of the guide shoes. The shims of the guide shoes can have different dimensions (0.3 mm, 0.5 and 1 mm thickness). This will help you during the installation procedure.
Page 304 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Guide shoes − Installation Note: When you the steps below, make sure that you install the guide shoes in their original positions. 94017-040 94017-047 Attach the spur-geared chain block (94017−047, Fig.
Page 305 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks WARNING Injury Hazard: The weight of the crosshead pin is 4830 kg. Use only approved equipment and sufficient personnel to lift and move the crosshead 94017-051 pin. Attach the spur-geared chain block (94017-040, Fig.
Page 306 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 20) Attach the eye bolts (94045−M20, Fig. 25) and chain (94325) to the other side of the crosshead pin. 21) Attach the eye bolt (94045−M56) to an applicable position on the column. 22) Use the manual ratchet (94016−015) to pull the crosshead pin (3) into the guide shoe (1).
Page 307 3326−1/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Note: During the step below, make sure that the elastic bolts in the connecting rod align with the holes in the crosshead pin. 37) Carefully lower the crosshead pin (2, Fig.
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Page 309 3326−2/A1 Maintenance Crosshead Crosshead Pin − Removal / Installation / Clearance Checks Tools: 1 Spur-geared trolley 94015-008 1 Platform 94143 2 Manual ratchet (H1) (H6) 94016−015 1 Platform 94144 2 Chain block (H2) (H7) 94017-004 1 Edge protector 94319 2 Chain block (H3) (H8) 94017-040 1 Support 94322...
Page 310 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Crosshead Pin − 94324 Removal 94143 WARNING 94337 Injury Hazard: The weight of the lifting tool (94324) is approx. 104 kg; the weight of the lifting tool (94337) is approx.
Page 311 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Disconnect the toggle lever (1, Fig. from the crosshead pin (2). Let the toggle lever hang in the column. Attach the shackle (94019L) to the column. 94144 10) Attach the manual ratchet (H1) to the shackle (94019L) on the column and 94019L the platform (94143).
Page 312 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 94045-M56 WARNING Injury Hazard: The weight of the crosshead pin is 4830 kg. Use only approved equipment and sufficient personnel to lift and move the crosshead pin. 23) Attach the two eye bolts (94045-M56, WCH03035 Fig.
Page 313 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Note: For engines with two-piece crankshaft, use one support (94322A) and one support (94322) for the middle crosshead. For engines with one-piece crankshaft, use the two supports (94322A) for each crosshead.
Page 314 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 42) Operate carefully the chain block (H5, Fig. 11) and the two chain blocks (H3, H8) to lower the crosshead to the position shown. Note: Make sure that the primary load stays on the geared chain block (H5).
Page 315 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 49) Operate the chain block (H8, Fig. 14) to lift the guide shoe (1). 50) Remove the chain (94325, Fig. 13), the shackle (94019N) and manual ratchet (H1). 51) Attach the chain chain (94325) the shackle (94019N) and manual ratchet (H1, Fig.
Page 316 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks 64) Attach the deviation pipe (94319, Fig. 17) to the support on the gallery. 65) Attach the sling (94039-057) around the beam in the gallery. 66) Attach the chain block (H4) to the 94319 round sling (94039-057).
Page 317 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Guide Shoes − Removal Record the positions of the guide shoes. The shims of the guide shoes can have different dimensions (0.3 mm, 0.5 and 1 mm thickness). This will help you during the installation procedure.
Page 318 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Guide Shoes − Installation Note: When you do the steps below, make sure that you install the guide shoes in their original positions. Attach the chain block (H4, Fig. 20) to the eye bolt on the guide shoe.
Page 319 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks WARNING Injury Hazard: The weight of the crosshead pin is 4830 kg. Use only approved equipment and sufficient personnel to lift and move the crosshead pin. Operate the chain blocks (H4, H9) to move the crosshead pin through the door frame.
Page 320 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Note: The guide shoe (2, Fig. 25) can look different. 24) Attach the two holding plates (1) to the guide shoe (2) with the tab washers and bolts. 25) Make sure that there is no clearance between the holding plates (1) and crosshead pin (3).
Page 321 3326−2/A1 Maintenance Crosshead Pin − Removal / Installation / Clearance Checks Note: During step 37), make sure that the elastic bolts in the connecting rod align with the holes in the crosshead pin. 37) Carefully lower the crosshead pin (2, Fig.
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Page 323 3403−1/A1 Maintenance Piston Removal and Installation Tools: 1 Lifting tool 94209 1 Insertion funnel 94342 2 Distance holders 94230 1 Cover plate 94345 1 Piston suspension device 94341 1 Device 94350 2 Distance plates 94341A/B Preparation 94209 WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the...
Page 324 3403−1/A1 Maintenance Piston: Removal and Installation 12) Remove the four inner bolts (2, Fig. from the support (1). WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or inside the Fig. 3 WCH02943 engine.
Page 325 3403−1/A1 Maintenance Piston: Removal and Installation Removal Make sure that the device (94350, Fig.6) is installed correctly on the top platform. Use the crane to carefully lift the piston (1) from the cylinder. Make sure that the piston rod foot (6) (does not touch the support of the piston rod gland (7).
Page 326 3403−1/A1 Maintenance Piston: Removal and Installation Installation Put oil on the bore of the cylinder liner Fig. 8) and the surfaces of the insertion funnel (94342). 94342 Put the insertion funnel (94342) in position on the cylinder liner (1). Use the turning gear and turn the crank to TDC.
Page 327 3403−1/A1 Maintenance Piston: Removal and Installation WARNING Injury Hazard: You must put on safety goggles and gloves when you do work on hot components. Oil can come out as a spray and cause injury. 16) Do a function check of the cylinder lubricating system.
Page 328 3403−1/A1 Maintenance Piston: Removal and Installation 20) Put oil on the four bolts (2,Fig.3). 21) Attach the piston rod gland (2, Fig.4) in the cylinder block with the four bolts (2, Fig.3) and new locking plates. 22) Torque the four bolts (2, Fig.3) to 150 Nm.
Page 329 3403−3/A1 Maintenance Piston Disassemble and Assemble Tools: 3 Pre-tensioning jacks 94340 3* Jacking screws 94364A 2* Jacking screws 94364B 3* Jacking screws 94364C * Use available screws from piston assembly Preparation Read the data in 0012−1 General Guidelines for Lifting Tools. Remove the piston, refer to 3403−1, paragraph and paragraph 2.
Page 330 3403−3/A1 Maintenance Piston: Disassemble and Assemble Disassemble 94364A CAUTION Damage Hazard: When you disassemble the piston, make sure that you do not damage the pipes or nozzles on the spay plate. Put the three jacking screws (94364A, 94364A Fig. 2) fully into the three tap holes in the top of the piston rod (2).
Page 331 3403−3/A1 Maintenance Piston: Disassemble and Assemble Assemble Note: Do not install pipes or nozzles that have damage. Apply Loctite N0. 0270 to the thread of the pipe (2, Fig. Use the applicable tool to install the pipe (2) to the spray plate (3). Use a center punch to lock the pipe (2) in position.
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Page 333 3403−4/A1 Maintenance Piston Top Surface − Check Tools: 1 Feeler gauge 94122 1 Template 94366 1 Template 94366A General ............Procedure −...
Page 334 3403−4/A1 Maintenance Piston 94366A Procedure − Piston Installed WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the 10 mm flywheel, or in the engine. WCH02678 Use the turning gear to move the piston Fig.
Page 335 3425−1/A1 Maintenance Piston Rings Wear of Piston Rings and Ring Grooves Tools: 1 Inside micrometer 94101 1 Permascope MP0 94356 1 Feeler gauge 94122 (with instruments to 1 Piston ring tool 94338 measure chrome-ceramic layers) 1 Calliper gauge General ............Chrome-ceramic Layer −...
Page 336 3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves 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 inside the engine. Read the data in the suppler documentation for the tool Permascope MP0 (94356). Calibrate the Permascope MP0 (94356).
Page 337 3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Rate of Deterioration The deterioration of the chrome-ceramic layer is related to the operation conditions. If a piston ring that has some deterioration of the chrome-ceramic layer is found (see Fig.
Page 338 3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Service Life − Calculate Use the formula below to calculate the deterioration rate of a piston ring: (D1−D2) x 1000 WR = T2−T1 Where: WR = Rate of deterioration (mm/1000 hrs) D1 = First recorded thickness of the chrome-ceramic layer (mm) D2 = Second recorded thickness of the chrome-ceramic layer (mm) T2 = Hours (hrs)
Page 339 3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Piston Ring Grooves Do a check of all dimensions and record them (see 0330−1 Pistons 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 340 3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Piston Rings − Removal CAUTION Damage Hazard: Do not open the piston rings too far. This will cause damage to the piston rings. Use the tool (94338, Fig. 3) to remove the top, middle and bottom piston rings (1). Make sure that you do not cause damage to the chrome-ceramic surface.
Page 341 3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves 2.3.2 Alternative Procedure with Piston Ring Piece Measure the thickness of the piece of piston ring (1, Fig. 94122 WCH02244 Fig. 5 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 the piston ring and the groove.
Page 342 3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves Used Piston Rings − Installation For the ring types and their locations, see Table Table 3: Standard Piston Ring Locations Ring Type Material Application Top Piston Ring 1 x GTP1CC26 (gas tight) Chrome-ceramic Layer For new and fully honed Middle Piston Ring...
Page 343 3425−1/A1 Maintenance Piston Rings: Wear of Piston Rings and Ring Grooves New Piston Rings − Installation CAUTION Damage Hazard: Do not open the piston rings too far. This will cause damage to the piston rings. Note: Make sure that the mark TOP, on the piston ring, points up. Note: For the ring types and their locations, see Table Measure and record the thickness of the chrome-ceramic layer on each piston ring.
Page 344 ....... 4325−1/A1 X92 / MM / 2015 Winterthur Gas & Diesel Ltd.
Page 345 4103−1/A1 Maintenance Drive Wheels Running and Backlash Clearances and Tooth Condition Tools: 1 Feeler gauge 94122 1 Dial gauge 1 Micrometer 1 Lead wire 1.5 mm diameter General On new engines during the running-in period, you must do a visual check of the gear wheels after approximately one and two operation hours.
Page 346 4103−1/A1 Maintenance Running and Backlash Clearances and Tooth Condition Gear tooth backlash checks Refer to 0330−1, Driving Wheels for Supply Unit (Group 4103) for data about the gear tooth backlash values. There are three procedures to measure the backlash. Feeler gage (94122) Measure the clearance between the tooth flanks (10, Fig.
Page 347 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 349 4325−1/A1 Maintenance Shut-off Valve for Starting Air Cleaning and Function Check General ............Preparation .
Page 350 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check Disassembly Remove the eight screws (26, Fig.2) from the cover (9). Turn the handwheel fully in. This will move the cover (9) out of the spindle (13). Remove the handwheel (25), the cover (9) and the spring (11). Use an AF 60 swan neck spanner to remove the spindle nut (14).
Page 351 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check 12 14 WCH03093 To Ball Valve 35−8353_E0_2 Fig. 2 2015 3/ 6 Winterthur Gas & Diesel Ltd.
Page 352 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check Assembly Make sure that all bores are clear. Apply a thin layer of Molykote paste to the spring (17) and to the sliding surface of the valve guide (16) and the valve body (18). Put the O-ring (31) and valve body (18) into the housing (33).
Page 353 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check 22) Attach the silencer (29) to the control valve (19, Fig. 23) Put the assembled shut-off valve (500 kg) in position as shown in Fig. 24) Attach the flange (7, Fig.
Page 354 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check Use the handwheel (25, Fig. 5) to move the shut-off valve to the position AUTOMAT. Make sure that the lever (34) engages with the groove in the spindle. Make sure that no air flows from the bore of the screw plug (27). When no air flows, the automatic function of the shut-off valves operates correctly.
Page 355 Servo Oil Rail: Exhaust Valve Control Unit − Pilot valve : Removal and Installation ... 5612−1/A1 X92 / MM / 2020−06 Winterthur Gas & Diesel Ltd. 1/ 11 Winterthur Gas & Diesel Ltd.
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Page 357 5551−1/A1 Maintenance Servo Pump Unit Servo Oil Pump − Removal and Installation Tools: 1 Sling (1000 kg) 94039−005 2 Spur-geared chain block (500 kg) 94017−004 2 Sling (1000 kg) 94039−002 1 Manual ratchet (800 kg) 94016−003 1 Lifting tool 94651 1 Deviation pipe 94319 2 Shackle (6500 kg)
Page 358 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Removal Preparation Read the data in 0012−1 General Guidelines for Lifting Tools. Stop the engine (see the Operation Manual 4002-2). Set to off the main bearing oil pump. Remove the applicable HP servo oil pipes (1, Fig.
Page 359 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Pump No. 3 CAUTION Injury Hazard: The weight of the servo oil pump is 230 kg. Make sure that you use the correct equipment to lift and move the servo oil pump. This will prevent injury to personnel. Attach the two shackles (94019K, Fig.
Page 360 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Pump No. 1 CAUTION Injury Hazard: The weight of the servo oil pump is 230 kg. Make sure that you use the correct equipment to lift and move the servo oil pump. This will prevent injury to personnel. Attach the two shackles (94019K, Fig.
Page 361 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Pump No. 2 CAUTION 2x 94017-004 Injury Hazard: The weight of the servo oil pump is 230 kg. Make sure that you use the correct equipment to lift and move the servo 941319 oil pump.
Page 362 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Bearing Bushes Injury Hazard: The weight of the pinion and shaft is 55 kg. Make sure that you use the correct equipment and sufficient personnel to lift and move the pinion and shaft. This will prevent injury to personnel.
Page 363 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Put oil on the new bearing bushes (2 and 3, Fig. 10) Put a new O-ring (5) on the pump support (4). 11) Put a small quantity of oil on the O-ring (5) 12) Carefully put the pinion (7) and shaft (6) in position in the casing (8).
Page 364 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Put the sling (94039-002, Fig. 8) around the servo oil pump (1). Attach the sling (94039-002) to the shackle (94019P). Attach the spur-geared chain blocks 94017-004 (1, 2) to the shackle (94019P). Use the spur-geared chain blocks (1, 2) together to lift the servo oil pump into a position level with the supply unit.
Page 365 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Pump No. 1 CAUTION Injury Hazard: The weight of the servo oil pump is 230 kg. Make sure that you use the correct equipment to lift the servo oil pump. This will prevent injury to personnel.
Page 366 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Pump No. 2 Attach the manual ratchet (94016−003, Fig. 11) to the shackle (94019P). Do steps 1) to 6) of chapter install the servo oil pump (1). 94017−004 Use the spur-geared chain blocks (1, 2) together to lift the servo oil pump into a position level with the supply unit.
Page 367 5551−1/A1 Maintenance Servo Oil Pump − Removal and Installation Completion Attach the applicable oil inlet pipes (2, Fig.12) to the servo oil pumps. Install the applicable HP servo oil pipes (1) to the servo oil pumps, refer to 8447−1 paragraph 5). Connect the applicable electrical connections (3, 4, 5).
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Page 369 5552−1/A1 Maintenance Supply Unit Camshaft and Bearing Shells − Removal and Installation Tools: Pre-tensioning jack 94557 1 Screwjack 94567B Support 94566 1 Connection block 94934 Support 94566A 1 Pressure gauges 94934A Roller lifting tool 94569B 3 HP hoses 94935 Assembly template 94567 1 Hydraulic unit 94942...
Page 370 5552−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Make sure that the bearing covers at positions No. 3 to No. 8 (Fig. 2) and the casing (1), have marks to identify them as a set. Note: The bearing at position No. 2 has the two thrust bearing ring halves (3). Install the roller lifting tools (94569B) to lift up the rollers and guide pistons of the fuel pumps.
Page 371 5552−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Bearing Shells − Removal Loosen the two Allen screws (2, Fig. and remove the filling piece (1) from bearing cover No.2. Use the pre-tensioning jacks (94557) to loosen the round nuts (4) of the bearing covers No.2, to No.7, refer to 9403−4.
Page 372 5552−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Camshaft − Removal Put the two supports (94566) in the positions at No.2 and No.5 (Fig. On the two supports (94566), tighten the nuts (4). Make sure that the camshaft stays in position before you remove the last bearing cover.
Page 373 5552−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Put the screwjack (94567B, Fig. 5) in position. Turn the screwjack (94567B) to lift the camshaft between 0.05 mm and 0.15 mm. Put the assembly template (94567A) on the bottom elastic bolt (7). 10) Put the round nut (8) on the elastic bolt (7).
Page 374 5552−1/A1 Maintenance Camshaft and Bearing Shells − Removal and Installation Completion Refer to 0330−1 Clearance Table, Group 5552 for the axial clearances. If the axial clearances are not in the specified range, loosen the round nuts on one of the bearing covers (see paragraph 2, step 2). Put the bearing cover in position again, see paragraph 4, step 17) ,step 18), step 19) and step 22) to step 25).
Page 375 5552−1/A2 Maintenance Supply Unit Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) Tools: Pre-tensioning jack 94557 1 Screwjack 94567B Support 94566 1 Connection block 94934 Support 94566A 1 Pressure gauges 94934A Roller lifting tool 94569B 3 HP hoses 94935 Assembly template 94567...
Page 376 5552−1/A2 Maintenance Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) Make sure that the bearing covers at positions No. 3 to No. 10 (Fig. 2) and the casing (1), have marks to identify them as a set. Note: The bearing at position No.
Page 377 5552−1/A2 Maintenance Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) Oil Baffle − Removal Note: The oil baffle has four parts. Remove the four bolts (6, Fig. 3) and locking tabs (7). Remove the pipe (5) from the oil baffle. Remove and discard the O-ring (8).
Page 378 5552−1/A2 Maintenance Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) Bearing Shells − Removal Loosen the two Allen screws. (2, Fig. Remove the filling piece (1) from bearing cover No. 2 (1). Use the pre-tensioning jacks (94557) to loosen the round nuts (4) of bearing covers No.
Page 379 5552−1/A2 Maintenance Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) Camshaft − Removal Put the two supports (94566) in the positions at No.2 and No.5 (Fig. On the two supports (94566), tighten the nuts (4). Make sure that the camshaft stays in position before you remove the last bearing cover.
Page 380 5552−1/A2 Maintenance Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) Put the screwjack (94567B, Fig. 6) in position. Turn the screwjack (94567B) to lift the camshaft between 0.05 mm and 0.15 mm. Put the assembly template (94567A) on the bottom elastic bolt (7).
Page 381 5552−1/A2 Maintenance Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) Oil Baffle − Installation Note: When you do this procedure, make sure that the locking tabs are on the screws before assembly. Clean the four segments and the interfaces of the oil baffle.
Page 382 5552−1/A2 Maintenance Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) 10) Turn the segments (1, 2, 5) clockwise approximately 90°. 11) Put the segment (6) in position on the camshaft. 12) Attach the segment (6) to the segments (1, 5) with the taper pin (3) and the four screws (4).
Page 383 5552−1/A2 Maintenance Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System) Completion Refer to 0330−1 Clearance Table, Group 5552 for the axial clearances. If the axial clearances are not in the specified range, loosen the round nuts on one of the bearing covers (see paragraph 3, step 3).
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Page 385 5552−2/A1 Maintenance Fuel Pump Unit Lubrication of Fuel Pump Unit During Maintenance Works Tools: 1 Lubricating device 94844 General Lubricating device 94844 has been provided to prevent the bearing shells of the fuel pump unit from being damaged (dry running) due to turning the engine during overhaul works.
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Page 387 5556−1/A1 Maintenance Fuel Pump Disassemble, Assemble Tools: 1 Circlip pliers 94007−A41 1 Guide bracket 94593 1 Handle 94009−M10 Which includes: 1 Manual ratchet 94016−003 1 Ring 94593A 1 2-part clamping ring 94550 2 Ring (2-part) 94593B 1 Spindle press 94551 2 Guide rods 94593C 1 Lifting tool...
Page 388 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Preparation Stop the engine. Set to off the fuel supply Set to off the main oil supply. Make sure that the fuel return valve is open, refer to the control diagram 4003−2 and 4003−11 in the Operation Manual. Close the fuel inlet valve, refer to the control diagram 4003-2 and 4003-11 in the Operation Manual.
Page 389 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble CAUTION Damage Hazard: Do not operate the engine with a fuel pump removed. This will decrease the supply of oil, i.e. there could be a decrease of lubrication to the other fuel pumps. Damage to equipment can then occur.
Page 390 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble 94552 Fuel Pump − Disassemble Split of the housings Remove the two limiters 94592B, (Fig. 3) and the screws 94592E. Turn the fuel pump until the roller (1) points up. Attach the limiters 94592B to each side of the fuel pump with the screws 94592E.
Page 391 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Use the M16 eye bolt (1, Fig. 5) to move the spindle (2) up. Attach the spindle press 94551 to the lower housing (3). 94551 Use the eye bolt (1) to carefully lift the lower housing (4) together with the guide piston (3), the lower spring carrier (5) and the pump plunger (8).
Page 392 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Guide Piston − Disassemble Attach the two M10 eye bolts (1, Fig. into the guide piston (5). Remove the guide piston (5) from the housing. Remove the circlip (6). Remove the pin (7). Push out the roller pin (3) then remove the roller (4), bush (8) and the two pressure discs (2).
Page 393 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Pump Cylinder - Removal Note: The pump cylinder (7, Fig. 8) and pump plunger are not interchangeable and must stay together as a unit. Turn the fuel pump until the pump cover (2) points up. Remove the screws (1) symmetrically.
Page 394 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Fuel Pump − Assemble Clean all parts of the fuel pump Examine all parts of the fuel pump for damage. Replace damaged parts with new items. Replace all O-rings and rod seal rings. Use a low-pressure air supply to make sure that the bores in the housings and the pump cylinder (1, Fig.
Page 395 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Put oil on lower part of the non return valve (3). Carefully put the assembled non-return valve (3, Fig. 12) into the upper housing (5). Put the pump cover (2) in position on the upper housing (5). 10) Apply Never Seez NSBT to the threads and to the contact surface of the heads of the 12 bolts (1).
Page 396 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Upper Housing − Assemble Turn the fuel pump into the position shown in Fig. Put the toothed rack (2) in position. Note: Make sure that the toothed rack (2) moves easily. Put oil on the rod seal ring (5). Put the rod seal ring (5) into the intermediate flange (8).
Page 397 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble 16) Move the toothed rack (3, Fig. 17) to the middle position. 17) Put the compression spring (1) in position in the upper housing (2). Lower Housing − Assemble Attach the spindle press (94551) to the lower housing (9, 18).
Page 398 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble 94551 Fuel Pump − Last Assembly Attach the ring (94593A, Fig. 19) to the lower housing (1). Attach the two-part ring (94593B) to the 94593A upper housing (2). Make sure that the guide rods (94593C) are aligned with the bores in the ring (94593A).
Page 399 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Lower the lower housing (1, Fig. 21) on to the upper housing (3) until the spring 94551 carrier (6) is approximately 10 mm to 20 mm above the spring (5). Align the actuators (7) on the pump plunger (4) with the slots in the regulating sleeve (2).
Page 400 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble 94551 Function Check Turn the eye bolt on the spindle press (94551, Fig. 23) to move the roller (1) down 59 mm. Note: The distance of 59 mm is equal to a hub stroke of 55 mm. Turn the eye bolt on the spindle press (94551) back to the initial position.
Page 401 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Fuel Pump − Install 94016−003 WARNING 94552 Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Use the turning gear to turn the camshaft until the applicable cam is at BDC.
Page 402 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble 15) Make sure the connecting link (3, Fig. 26) moves freely. 16) Apply Molykote paste G to the connecting link (3). 17) Connect the connecting link (3) to the toothed rack (2) with the screw (8) and a new self-locking nut (9).
Page 403 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Oil Flow Check WARNING Injury Hazard: Do not operate the engine. Injury to personnel can occur. WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel, or in the engine. Note: The oil flows through the throttle Fig.
Page 404 5556−1/A1 Maintenance Fuel Pump: Disassemble, Assemble Storage Do the procedure that follows to put the fuel pump into storage: Make sure that the storage area is clean and dry. Put oil on the fuel pump to prevent contamination. Put the pump in a vertical position. Put petroleum jelly (e.g.
Page 405 5556−2/A1 Maintenance Fuel Pump Removal of a Seized Pump Plunger Tools: 1 Piston reset tool 94595D 2 Screws 94595E 1 Hydraulic ram 94595 1 HP oil pump 94931 1 Short push rod 94595B 1 Pressure gauge 94932 1 Long push rod 94595C 1 HP hose 94935...
Page 406 5556−2/A1 Maintenance Fuel Pump: Removal of a Seized Pump Plunger Hydraulic Ram − Preparation 94595 Open the vent screw (5, Fig. 2) and push the piston (2) to the top of the cylinder of the hydraulic ram 94595. If you cannot move the piston (2) with 94595D your hand, do step a) to step c): WCH02281...
Page 407 5556−2/A1 Maintenance Fuel Pump: Removal of a Seized Pump Plunger Removal with Tool 94595B Connect the hydraulic ram (94595, 94595 Fig. 4 to the HP oil pump (94931). 94595B Close the relief valve (5). Make sure that the vent screw (10) is open.
Page 408 5556−2/A1 Maintenance Fuel Pump: Removal of a Seized Pump Plunger Removal with Tool 94595C Remove the short push rod (94595B) 94595 from the hydraulic ram 94595. 94595C Put the long push rod (94595C, Fig. into the hydraulic ram 94595. Install the hydraulic ram (94595) to the fuel pump (see paragraph 3).
Page 409 5562−1/A1 Maintenance Fuel Pressure Control Valve Removal and Installation General To avoid any risk of failures related to the fuel pressure control valve (PCV), Wärtsilä recommends only performing the below mentioned maintenance. PCV maintenance onboard is limited to: Replacement of the complete PCV (1, Fig. 1). Replacement of the 3/2-way solenoid valve (2).
Page 410 5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal and Installation Removal Remove all pipes from fuel pressure control valve (1, Fig. Use the manual ratchets and connect the PCV (48.3 kg) to the crane. Loosen the screws (8). Use the crane to move the PCV in arrow direction, taking care that intermediate ring (3) and connection piece (4) do not fall down.
Page 411 5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal and Installation Cleaning the filter Remove the oil inlet pipe ’OE’ and the union (1, Fig. 3). Loosen the filter (3) and clean it. If necessary replace it. Oil the filter (3), screw it into the cover (2) and apply a torque of 10 Nm. WCH00763 FUEL OIL Fig.
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Page 413 5562−1/A2 Maintenance Fuel Pressure Control Valve PCV On-board Repair Kit General The on-board repair kit is necessary for the repair of a defective pressure control valve (PCV). The on-board repair kit has the parts that follow: Table 3: PCV On−board Repair Kit Position Number Material 3/2-way Solenoid...
Page 414 5562−1/A2 Maintenance Fuel Pressure Control Valve: On-board Repair Kit No spare parts are supplied. WCH02792 Intermediate Ring Flange Connecting Piece WCH03791 Screw Plug Gasket Fig. 1 2017 2/ 3 Winterthur Gas & Diesel Ltd.
Page 415 5562−1/A2 Maintenance Fuel Pressure Control Valve: On-board Repair Kit Order Number Use the data that follow to send an order for the on-board repair kit. Pressure Setting 3/2-way Solenoid Control Oil Filter High Pressure Part (bar) DX55780 DX 55777 DX 55769 Procedure PCV −...
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Page 417 5562−2/A1 Maintenance Relief Valve Removal, Check, Installation Tools: 1 OBEL test bench 94272 2 Pressure gauge 94934A 1 Valve holder 94272A 2 HP hoses 94935 1 HP oil pump 94931 General ............Removal .
Page 418 5562−2/A1 Maintenance Relief Valve: Removal, Check, Installation Removal Stop the engine (refer to the Operation Manual 0310−1). Make sure that the fuel rail has no pressure. Use a spanner (AF80, Fig. 1) to remove the relief valve (1) from the connecting piece (4).
Page 419 5562−2/A1 Maintenance Relief Valve: Removal, Check, Installation 94934A 94935 94272A 013.484/05 94272 94931 94934A 013.486/05 Fig. 2 Installation Apply Never-Seez NSBT to the thread of valve housing (2, Fig. Install the relief valve (1) in the connecting piece (3). Torque the relief valve (1) to 300 Nm. AF80 Fuel Rail WCH02959...
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Page 421 5564−1/A2 Maintenance Injection Control Unit Removal and Installation Tools: 1 Eye bolt 94045−M10 1 Chain 94327 General ............Preparation .
Page 422 5564−1/A2 Maintenance Injection Control Unit: Removal and Installation Removal WARNING Fire Hazard: Do not weld or grind materials in the work area. Sparks can cause a fire. WARNING Injury Hazard: Put on gloves and safety goggles before you do work on hot components.
Page 423 5564−1/A2 Maintenance Injection Control Unit: Removal and Installation Remove the six bolts (2, Fig. 4) from the ICU (1). Use long hex head drivers 94022A−8L Attach the eye bolt (94045−M10) to the ICU (1). CAUTION Injury Hazard: The weight WCH02792 of the ICU is 127 kg.
Page 424 5564−1/A2 Maintenance Injection Control Unit: Removal and Installation Installation Make sure that the lip seal (2, Fig. 6) is in position in the bottom of the ICU (3). Remove the protection from the inlet port on the fuel rail (1). Attach the chain (94327) to the hook of the engine room crane.
Page 425 5564−1/A2 Maintenance Injection Control Unit: Removal and Installation 14) Remove the protection from the pipes and openings and from the openings in the ICU. 15) Install the pipes (2, 3 and 4, Fig. 9) to the ICU. 16) Connect the electrical connection to the fuel quantity sensor (5).
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Page 427 504−00−100−14 W−X72/DF 504−00−100−14 W−X82/DF 504−00−100−16 W−X92/DF 504−00−100−15 CW − Clockwise rotation CCW − Counter clockwise rotation Note: Make sure that the cable glands of the actuator are correctly tightened. Make sure that the gasket on the top cover of the actuator terminal box is in the correct position the bolts are tight.
Page 428 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 ap- plicable of corresponding power supply in E85). Make sure that the connecting element (1, 1) is disconnected from the lever (2).
Page 429 5583−1/A1 Maintenance Fuel Pump Actuator: Connection to Fuel Pump 48 mm Fig. 1 2020 3/ 11 Winterthur Gas & Diesel Ltd.
Page 430 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 431 5583−1/A2 Maintenance Faults in High Pressure Fuel System Faults in High Pressure Fuel System Defective Fuel Pump Actuator ........Fault Identification .
Page 432 5583−1/A2 Maintenance Faults in High Pressure Fuel System 1.3.1 One Actuator is Defective− 0% F.O delivery Do a check of the control signals from the ECS and the electrical cables. If necessary, replace the electrical ca- bles. Disconnect the electrical cable from the actuator.
Page 433 5583−1/A2 Maintenance 1.3.3 All Actuators are Defective To install the distance pieces (6, Fig. 1) to the toothed racks (3), see steps a) and b): For engines with two fuel pumps, install the distance pieces (6) to get: One fuel pump in the 0% fuel position and the other fuel pump in the 100% position.
Page 434 5612−1/A1 Maintenance Exhaust Valve Control Unit − Pilot valve: Removal and Installation Servo Oil Rail Exhaust Valve Control Unit − Pilot valve : Removal and Instal- lation General ............Preparation .
Page 435 5612−1/A1 Maintenance Exhaust Valve Control Unit − Pilot valve: Removal and installation Removal and installa- tion 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 436 ..........6708-1/A1 X92 / MM / 2020 Winterthur Gas & Diesel Ltd.
Page 437 6420−1/A1 Maintenance Scavenge Air Receiver Clean and do Checks Scavenge Air Receiver − Clean and do Checks ..... . Flaps .
Page 438 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Scavenge Air Receiver − Clean and do Checks Read the data in 0388−1 Scavenge Air Receiver for the applicable Inspection and Overhaul Intervals to clean the scavenge air receiver. You must also clean and do a check of the scavenge air receiver after each piston overhaul.
Page 439 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Flaps Removal Open the covers (4, Fig. 1) to get access to the flaps. Lock the covers (4) in position with the pins (3). This will prevent unwanted movement. Remove the three screws (7, Fig.
Page 440 6420−1/A1 Maintenance Scavenge Air Receiver − Clean and do Checks Remove the pins (2, Fig. 10) Close the covers (1). 11) Install the pin (2) in the stowage position. Relief Valve − Check WARNING Injury Hazard! If the disc springs are compressed, do not disassemble the relief valve.
Page 441 6545−1/A1 Maintenance Auxiliary Blower Removal and Installation Tools: 3 Spur-geared chain block 94017-028 2 Shackle 94019L 2 Spur-geared chain block 94017-029 2 Round sling, 2000 kg 94039-013 3 Shackle 94019H 1 Shackle 94019K General ............Removal .
Page 442 6545−1/A1 Maintenance Auxiliary Blower: Maintenance Removal Preparation Stop the engine. Set the power supply to off. Disconnect the electrical connection from the electric motor (2). Read and obey the data given in 0012-1 General Guidelines for Lifting Tools. Removal − driving end Attach chain block 94017-029 (H1) with shackle 94019L to the strut (4), see Fig.
Page 443 6545−1/A1 Maintenance Auxiliary Blower: Maintenance 10) Attach chain block 94017-028 (H3) with 94017−029 shackle 94019H to the lug in the gallery 94019H as shown in Fig. 3. 11) Attach chain block 94017-029 (H4) with 94019H shackle 94019H to the next lug on the gallery.
Page 444 6545−1/A1 Maintenance Auxiliary Blower: Maintenance Removal − free end Attach chain block 94017-029 (H1) with shackle 94019L to the strut (4), see 94019H (H3) Fig. 4. 94017−029 Attach chain block 94017-028 (H2) with shackle 94019K to the strut (5). Attach chain block H1 and H2 to the lugs of lifting tool 94651.
Page 445 6545−1/A1 Maintenance Auxiliary Blower: Maintenance 11) Attach chain block 94017-029 (H3) with shackle 94019H to the lug in the gallery as shown in Fig. 4 and Fig. 5. 12) Attach chain block 94017-029 (H4) with shackle 94019H to the next lug on the gallery.
Page 446 6545−1/A1 Maintenance Auxiliary Blower: Maintenance Installation Put two round slings 94039-013 around the electric motor (1, 1200 kg) and attach the slings to the hook of the engine room crane. For the installation of the free end motor use also lifting tool 94651.
Page 447 6606−1/A1 Maintenance Scavenge Air Cooler Removal and Installation Tools: 2 Trolley, 5000 kg 94015F 1 Left Support 94663A 1 Manual ratchet, 800 kg 94016−003 1 Right Support 94663B 2 Manual ratchet, 3200 kg 94016-015 1 Support 94663L 1 Spur-geared chain block, 2500 kg 94017−028 1 Ring, 5500 kg 94666A 1 Shackle, 8500 kg...
Page 448 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Removal (SAC at Free End ) At the front of the SAC (4, Fig. 2) remove the four screws (1). Remove the two rollers (2) from the SAC (4). Remove the screws (6), then remove the flange (3). Remove the collar (5) Remove and discard the O-ring (7).
Page 449 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 11) Attach the three lugs (94048−M42, FRONT OF SAC Fig. 3) the front of the SAC (1). 12) Attach the left and right supports (94663A, 94663B) to the receiver with the screws (2). 13) Torque the screws (2) to 136 Nm.
Page 450 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation WARNING Injury Hazard! The mass of the SAC is approximately 4053 kg. To prevent injury, be careful when you move the SAC. 23) Operate the the manual ratchet 94016−003 until the rear of the SAC is on the left and right supports 94663A/B 94015F (see...
Page 451 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 28) Operate the the manual ratchet 94016−003 until the SAC is clear of the left and right supports (see Fig. 29) Continue to operate the manual ratchet 94016−006 until the trolley (94201) touches the end stop (1).
Page 452 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Installation (SAC at Driving End) 94015F 94666A 94016−015 Make sure that all the surfaces of the 94015F SAC (1, Fig. 7) and the related 94017−028 surfaces in the receiver are clean and have no damage.
Page 453 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation 13) At the driving end, put a new O-ring (7, Fig. 9) in position. 14) Put the collar (5) in position. 15) Attach the flange (3) to the SAC (4) with the screws (6). 16) Tighten all the screws (6), see also tightening instruction 0352−1 17) At the free end, put a new O-ring (10) in position.
Page 454 6606−1/A1 Maintenance Scavenge Air Cooler: Removal and Installation Installation (SAC at Free End) To install the SAC at the free end, refer to paragraph 4. Completion Install the drain pipes (3, 4, Fig.10). Install the vent pipe (1) Install the outlet pipe (6). Install the inlet pipe (2).
Page 455 6606−1/A2 Maintenance Scavenge Air Cooler Cleaning Instructions General ............Cleaning the air side .
Page 456 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 457 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 459 6708−1/A1 Maintenance Water Separator Removal and Installation Tools: 1 Spur-geared chain block, H1 94017−004 2 Shackle, WLL 3250 kg 94018A WLL 500 kg 3 Tool 94667 1 Spur-geared chain block H2 94016−031 1 Holder 94667G WLL 500 kg 1 Holder 94667H 2 Manual ratchet H3, H4 94016−003...
Page 460 6708−1/A1 Maintenance Water Separators: Removal and Installation Install the tool (94667, Fig. 4) to the rear of the water separator. Install the holder (94667G) to the rear of the water separator. 10) Attach the manual ratchet (H4) to the holder (94667G) and the tool (94667). 94667G This will help you during the installation procedure.
Page 461 6708−1/A1 Maintenance Water Separators: Removal and Installation Attach the spur−geared chain block (H2, Fig. 7) to the tool (94667). 10) Apply a light tension to the spur-geared chain block (H2). 11) Loosen the spur−geared chain block (H1). At the same time, tighten the spur-geared chain block (H2) to move the water separator under the engine room crane.
Page 462 6708−1/A1 Maintenance Water Separators: Removal and Installation Operate the manual ratchet (H3, to pull the water separator (1) sufficiently so that you can attach the tool (94667). Attach the tool (94667) to top of the water separator (1). Attach the spur−geared chain block (H1) to the tool (94667).
Page 463 6708−1/A1 Maintenance Water Separators: Removal and Installation 13) Remove the manual ratchet (H4, Fig. 11) from the rear of the water separator (1). Note: Do not remove the manual ratchet (H4) from the holder (94667G). 14) Apply a light tension to the spur-geared chain block (H2).
Page 464 6708−1/A1 Maintenance Water Separators: Removal and Installation Remove the spur-geared chain blocks (H1, H2 Fig. 13) from the water separator (1). Remove the tool (94667) from the top of the water separator (1). Attach the spur-geared chain block (H1) to the tool (94667) on the front of the water separator (1).
Page 465 6708−1/A1 Maintenance Water Separators: Removal and Installation Front Water Separator In paragraph 3.1, do steps 1) to the front water separator, then continue with step 2) below. Align the front and rear water separators (1 and 4, Fig. 15). Install the two top screws (3) and the two bottom screws (2) to keep the water separators together.
Page 466 6708−1/A1 Maintenance Water Separators: Removal and Installation 11) Install the cover (3, Fig. 17) to the receiver. 12) Install the bottom plate (2). 13) Install the beam (1). 14) Install the cover (1, Fig. 18) to the receiver (2). 15) Remove all tool and equipment from the work area.
Page 467 ............. 7218−1/A1 X92 / MM / 2015 Winterthur Gas & Diesel Ltd.
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Page 469 7218−1/A1 Maintenance Cylinder Lubrication System Cylinder Lubricating System ........Cylinder Lubricating System −...
Page 470 7218−1/A1 Maintenance Cylinder Lubricating System WCH02856 WCH02856 Fig. 1: Cylinder Lubrication Pump − Location 2015 2/ 6 Winterthur Gas & Diesel Ltd.
Page 471 7218−1/A1 Maintenance Cylinder Lubricating System Function Check If necessary, bleed the cylinder lubricating system (see paragraph 3). WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel. Make sure that the applicable piston is in the TDC position. If the piston is not in the TDC position, do the steps that follow: Engage the turning gear.
Page 472 7218−1/A1 Maintenance Cylinder Lubricating System Cylinder Lubricating System − Bleed Bleed the cylinder lubrication pump and oil pipes each time you do maintenance on the cylinder lubricating system. Cylinder Lubrication Pump To bleed the cylinder lubrication pump (4, Fig. 1), do the steps that follow: Note: When you bleed the cylinder lubricating system, always start at the first cylinder at the free end.
Page 473 7218−1/A1 Maintenance Cylinder Lubricating System Duplex Filter For data about the duplex filter (1, Fig. 2), see the Operation Manual 7218-1, paragraph 3. Clogged Filter Element − Replace Close the ball valve (2). Remove the cover from the rail unit. Move the lever (3) to select the clean filter element.
Page 474 7218−1/A1 Maintenance Cylinder Lubricating System Note: Some items can look different FREE END WCH02359 WCH02364 Fig. 2: Duplex Filter 2015 6/ 6 Winterthur Gas & Diesel Ltd.
Page 475 ........... 8752−1/A1 X92 / MM / 2015 Winterthur Gas & Diesel Ltd.
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Page 477 8135−1/A1 Maintenance Exhaust Waste Gate (Low-load Tuning) General The Low-load Tuning (LLT) uses a specially designed turbocharger system and specified engine parameters. These parameters are related to fuel injection and exhaust valve control and get the best decreased part-load BSFC in LLT. For more data about the exhaust waste gate and LLT, see the Operation Manual 8135−1.
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Page 479 8447−1/A1 Maintenance HP Servo Oil Pipe Removal, Grind Sealing Faces and Installation Tools: 1 Grinding tool 94871 Preparation ............Removal −...
Page 480 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind Sealing Faces and Installation Loosen the screw plug (14, Fig. 2) to I - I drain the HP servo oil pipes (4, 10). On the flange (2), loosen the four screws (3). Push down the flange (2) to get air into the HP servo oil pipe (4).
Page 481 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind Sealing Faces and Installation 3. Sealing Faces − Grind Do a check of the O-ring (3, Fig. 3). If the O-ring is unserviceable, remove and discard it. Loosen the claw (4). Put an applicable piece of material (e.g. a cloth) into the opening of the HP servo oil pipe (1).
Page 482 8447−1/A1 Maintenance HP Servo Oil Pipe: Removal, Grind Sealing Faces and Installation 5. Installation I - I Remove all of the protection from the sealing faces (SF) in the valve housing (15, Fig. 4), the intermediate piece (11) and the servo oil pump. Apply oil to the the threads of all the screws (3, 5, 7, 9 and 12) Carefully put the HP servo oil pipe (10)
Page 483 8460−1/A1 Maintenance Hydraulic Pipe − Exhaust Valve Drive Removal, Grind Sealing Faces and Installation Tools: 1 Grinding tool 94841 Emery cloth (as necessary) 1 Template 94841A 1 Hand drill Preparation ............Removal .
Page 484 8460−1/A1 Maintenance Hydraulic Pipe for Exhaust Valve Drive: Removal, Grind Sealing Faces and Installation Preparation WARNING Injury Hazard: The servo oil system has high pressure. Replace a defective hydraulic pipe only when the engine has stopped. Stop the engine (see the Operation Manual 4002-2). Set to off the service pump.
Page 485 8460−1/A1 Maintenance Hydraulic Pipe for Exhaust Valve Drive: Removal, Grind Sealing Faces and Installation Removal CAUTION I - I Damage Hazard: Make sure that you do not damage the sealing faces or the hydraulic pipes. Remove the six screws (2, Fig.
Page 486 8460−1/A1 Maintenance Hydraulic Pipe for Exhaust Valve Drive: Removal, Grind Sealing Faces and Installation Sealing Faces − Grind To get a clean and smooth finish on the hydraulic pipe, do step 1) to step 20): Put the template (94841A, Fig. 5) on 94841A the back of the emery cloth.
Page 487 8460−1/A1 Maintenance Hydraulic Pipe for Exhaust Valve Drive: Removal, Grind Sealing Faces and Installation Installation I - I If necessary. replace the O-rings (1, 2, 8 and 12, Fig. Make sure that the claws (4, 13) are correctly attached to the hydraulic pipe (7).
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Page 489 8733−1/A1 Maintenance HP Injection Pipe Removal, Grinding and Installation Tools: 1 Grinding tool 94871 1 Template 94871A 1. Preparation Stop the engine (see the Operation Manual 4003−1 paragraph 3.4). Make sure that there is no pressure in the fuel rail as follows: Set to off the fuel booster pump (plant).
Page 490 8733−1/A1 Maintenance HP injection Pipe: Removal, Grinding and Installation 3. Sealing Faces − Grind To get a clean and smooth finish on the HP 94871A injection pipe do the procedure that follows: Put the template (94871A, Fig. 2) on the back of emery cloth. Use the applicable grade of the emery cloth related to the quantity of metal you want to remove.
Page 491 8733−1/A1 Maintenance HP injection Pipe: Removal, Grinding and Installation 4. Installation If necessary, replace the O-rings (5, 10, 11 and 12 Fig. Make sure that the claws (7, 13) are correctly attached to the HP injection pipe (2). Note: You can adjust the claws (7, 13) with an open-ended wrench.
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Page 493 8752−1/A1 Maintenance HP Fuel Pipe Removal, Grinding and Installation Preparation ............Removal .
Page 494 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation Preparation WARNING Injury Hazard: The fuel system has high pressure. Replace a defective HP fuel pipe only when the engine has stopped. You must obey the data given in the Operation Manual 0520-1. WARNING Injury Hazard: Always put on gloves and safety goggles when you do work on hot components.
Page 495 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation Loosen the four screws (3, Fig. 3) on I - I the flange (2) a maximum of three turns. 10) Move the flange (2) down and make sure that air goes into the HP fuel pipe (1).
Page 496 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation Removal CAUTION I - I Damage Hazard: Make sure that you do not damage the sealing faces or the HP fuel pipes. Remove the applicable pipe brackets (3, 8 Fig. Remove the four screws (3, Fig.
Page 497 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation Remove the four screws (1, 7) from the flange (2). I - I Carefully move the flange (2) away from the connecting block (3). WCH02957 Fig. 7 10) Remove the four screws (2, 8) from IV - IV the flange (1).
Page 498 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation 14) Remove the four screws (2, Fig. from the flange (3). 15) Carefully move the flange (3) up. CAUTION Injury Hazard: The weight of the HP fuel pipe is approximately 28 kg. Use approved equipment or sufficient personnel to lift and move the HP fuel pipe.
Page 499 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation Sealing Faces − Grind Use a medium to coarse grade emery cloth (30 to 80 CAMI) to remove deep notches of more than 0.1 mm. 94870H Use a fine or ultra-fine grade emery cloth (100 to 600 CAMI) to get a smooth finish.
Page 500 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation 15) Remove the grinding tool (94870F, Fig. 12) from the screw-on sleeve. 16) Use a low-pressure air supply to remove unwanted material from the HP fuel pipe. 17) Do a quality check of the sealing surface. If necessary use new emery cloth of the same grade and do the grinding procedure again 18) Replace the emery cloth with a smoother grade, then do step 1) to step 16) again until you get a smooth finish.
Page 501 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation CAUTION I - I Damage Hazard: Make sure that you do not damage the sealing faces (SF) or the HP fuel pipe. Do not apply lateral force to the HP fuel pipe and the flanges.
Page 502 8752−1/A1 Maintenance HP Fuel Pipe: Removal and Installation CAUTION Injury Hazard: The weight I - I of the HP fuel pipe is approximately 32 kg. Use approved equipment or sufficient personnel to lift and move the HP fuel pipe. 11) Do a check for damage of the O-rings (2, 6, 7 and 10 Fig.
Page 503 ............Pages 34 to 36 X92 / MM / 2015 Winterthur Gas & Diesel Ltd.
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Page 505 9223−1/A1 Maintenance Crank Angle Sensor Unit Proximity Sensor − Replace General Crank Angle Sensors Two crank angle sensor (CAS) units that operate independently are installed on the supply unit drive in the center of the engine. Each CAS unit has three proximity sensors (1, Fig.
Page 506 9223−1/A1 Maintenance Crank Angle Sensor Unit: Proximity Sensor − Replace Crank Angle Marks Two more proximity sensors (4, Fig. 2) are used to find the crank angle marks (3, 5) on the flywheel (1) for TDC and BDC. For the function of the Crank Angle Sensor Unit, read the data in 9223−1 General Application Instructions.
Page 507 9223−1/A1 Maintenance Crank Angle Sensor Unit: Proximity Sensor − Replace I - I WCH02896 Fig. 3 Proximity Sensors (ZS5124 and ZS5125) − Replace Put a mark on the applicable cable to identify its position. Disconnect the applicable electrical connection from the proximity sensor (1, Fig.
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Page 509 9308−1/A1 Maintenance Relief Valve on Cylinder Cover Blow-off Pressure Check Tools: 1 OBEL test bench 94272 1 Valve holder 94272C 1 HP oil pump 94931 2 Pressure gauge 94934A 1 HP hose 94935 General Some cylinder covers have an indicator valve installed together with a relief valve. Other cylinder covers have only an indicator valve.
Page 510 9308−1/A1 Maintenance Relief Valve: Blow-off Pressure Check Relief Valve Check There are two alternative procedures to do a check of the relief valve: Procedure One Read the data in the manual for the test 94272C bench (94272). Use the test and calibration fluid, or a low viscosity oil as a test fluid.
Page 511 9308−1/A1 Maintenance Relief Valve: Blow-off Pressure Check Make sure that the relief valve (2) is set to blow-off at 235 bar. This relates to a firing pressure of between 166 bar to 169 bar. Open the relief valve (6) on the HP oil pump to release the pressure in the hose (94935).
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Page 513 9403−1/A1 Maintenance Tools Explanation General The tools required for maintenance of the engine are divided into two groups: Standard tools Recommended special tools When ordering additional tools or replacements, the tool No. as well as the tool description including engine type must be indicated (see 9403−5). Detailed instructions on the arrangement and application, overview, storing, servicing and maintenance of the hydraulic pre-tensioning jacks are given in 9403−2...
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Page 515 9403−2/A1 Maintenance Hydraulic Jacks and Pumps Arrangement and Application Tools: HP oil Pump, 2800 bar 94931 8 Coupling element 94934G Adapter piece 94934F 9 Flexible hose 94935A Hydraulic unit, 2000 bar 94942 10 Oil pipe drain 94935C HP hose 94935 11 Adapter piece 94934L Pressure gauge...
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Page 517 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks Storing, Servicing and Maintenance General The hydraulic pre-tensioning jacks as engine tool kit are to be stored in their tool boxes when not in use. Grease them after use and close the connections with dust plugs.
Page 518 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Overview of pre-tensioning jacks Tool 94110 Thrust device for main bearing cover 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring...
Page 519 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94114 Double pre-tensioning jack for elastic bolts to main bearing 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Double cylinder 11 Backing bush 5 Back-up ring 12 Tension sleeve...
Page 520 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94145 Pre-tensioning jack for foundation bolts and engine stays 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring 94145−KJ Kit with back-up and O-rings...
Page 521 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94180 Pre-tensioning jack for tie rods 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 13 Round nut 5 Back-up ring Sealing ring O-ring 94180−KJ Kit with back-up and O-rings...
Page 522 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94215A Pre-tensioning jack for elastic bolts to cylinder cover 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring 94215A−KJ Kit with back-up and O-rings...
Page 523 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94252 Pre-tensioning jack for elastic bolts to exhaust valve cage and lower connecting rod studs 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring...
Page 524 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94315 Pre-tensioning jacks for elastic bolts to upper connecting rod bearing 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring...
Page 525 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94320 Pre-tensioning jack for turning gear 1a,1b Piston 7 Vent screw 2 Back-up ring 8 Adapter Piece Sealing ring O-ring 9 Closing valve 4a,4b Cylinder 10 O-ring 5 Back-up ring 13 Round nut Sealing ring O-ring...
Page 526 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94340 Pre-tensioning jack for piston and piston rod foot to crosshead 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter Piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring O-ring...
Page 527 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94557 Pre-tensioning jacks for elastic bolts to top end bearing (sup- ply unit) 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 5 Back-up ring Sealing ring...
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Page 529 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks General Instruction Hydraulic pre-tensioning jacks for: Variant 1: Variant 2: Foundation bolt and engine stay 94145 Main bearing 94114 Tie rod 94180 Cylinder cover 94215A Exhaust valve cage and 94252 bottom connecting rod studs 94315 Piston, piston rod foot 94340 Supply unit (fuel pump unit)
Page 530 9403−4/A1 Maintenance Loosen Version 1 − Preparation Make sure that the vent screw 6 is open (see Fig. Put the hydraulic jack on to the elastic stud 5. Turn the hydraulic jack until it is tight. Make sure that there is no clearance at X. Version 2 −...
Page 531 9403−4/A1 Maintenance Apply Tension Turn the round nut 4 fully down (Fig. 1 Fig. 2). Make sure that there is no clearance at the slot 10. Put one reference mark (Y) on the nut and one reference mark on the part below (X) (see Fig.
Page 532 9403−4/A1 Maintenance Table 1 − Hydraulic Jacks − Values and Comparison Application Group Jack Tightening Comparison Reset of jack / Lubricating value [bar] [_(, mm] round nut agent [turns] Foundation bolts 1112−1 94145 1500 − No lubricant step 1000) ¼ Main bearing 1132−1 94114...
Page 533 9403−5/A1 Maintenance Tool List Standard Tools 94000 Combination wrenches, set compl. consisting of: 26 wrenches AF6 to AF32 for ordering single wrenches state AF 94000−6 Example: ..94000−6 94000−32 94000−32 94000 Combination wrenches 94000−34 1 Piece .
Page 534 9403−5/A1 Maintenance Standard Tools 94007 Circlip pliers 94007−C8 1 Piece ..Type C 8 94007−C19 1 Piece ..Type C 19 94007−C40 1 Piece ..Type C 40 000.376/93 94007−C85 1 Piece...
Page 535 9403−5/A1 Maintenance Standard Tools 94016−003 Manual ratchets WLL 800 kg, stroke 5.5 m 94016−012 Manual ratchets WLL 2500 kg, stroke 5.5 m 94016−015 Manual ratchets WLL 3200 kg, stroke 5.5 m 012.233/04 94017−004 Spur-geared chain block WLL 500 kg, stroke 5.0 m 94017−028 Spur-geared chain block WLL 2500 kg, stroke 5.0 m...
Page 536 9403−5/A1 Maintenance Standard Tools 94020A Chain WLL = 14 000 kg X = 1071 mm WCH003046 Hex head drivers 94022A−2 AF2.5 94022A−19 AF19 WCH02893 94022A−8L AF8, L = 190 mm 94022A−10L AF10, L = 102 mm WCH03107 Socket wrench inserts ¾” 94022B−36 AF36 94022B−41...
Page 537 9403−5/A1 Maintenance Standard Tools 94039−002 Round sling WLL = 1000 kg X = 1.5 m 94039−005 Round sling WLL = 1000 kg X = 3.0 m 94039−013 Round sling WLL = 2000 kg X = 2.5 m 94039−015 Round sling WCH03043 WLL = 2000 kg X = 3.5 m...
Page 538 9403−5/A1 Maintenance Standard Tools 94050 Tool for pressure measurement for pneumatic elements 94050B 1 Pressure gauge 0−100 bar 94050C 1 Adapter 94050G 1 Pressure gauge 0−10 bar 94050H 2 Stop valve WCH02814 94051 Tool for pressure measurement for pneumatic elements 94051A 1 Pressure generator 700 bar 94051B...
Page 539 9403−5/A1 Maintenance Standard Tools 94114 Double pre-tensioner for elastic studs to main bearing X = 447 mm Mass approx. 173 kg WCH02821 94116A Lifting tool for removal and fitting of main bearing shell X = 266 mm (WLL 150 kg) WCH02247 94116C Lifting lug...
Page 540 9403−5/A1 Maintenance Standard Tools 94118A Turning-out device For 6−7 cylinder engines for removal and fitting of main bearing shell special at driving end X = 286 mm 94118B Turning-out device For 8 − 12 cylinder engines for removal and fitting of the main bearing shell X= 301 mm 94118C...
Page 541 9403−5/A1 Maintenance Standard Tools 94123 Bearing feeler gauge for main bearing X = 620 mm Blade thickness 0.1 ... 1.1 mm 000.395/93 (11-part) 94126 Depth gauge with case X = 310 mm WCH02250 94141A Bracket for removal and installation of main bearing shells FCV1 X = 500mm...
Page 542 9403−5/A1 Maintenance Standard Tools 94142 Platform X = 920 ... 1170 mm Z = 240 mm (max. loading 250 kg) WCH02827 94143 Platform (6 to 12 cylinder 2−part crankshaft Quantity three grids each X = 2320 mm Z = 1095 mm Mass approx.
Page 543 9403−5/A1 Maintenance Standard Tools 94155 Carrier For pushing out the thrust pads X = 412 mm Y = 255 mm Z = 430 mm WCH02824 94155A Carrier For pushing out the thrust pads X = 150 mm Y = 268 mm Z = 386 mm 94180 Pre-tensioning jacks...
Page 544 9403−5/A1 Maintenance Standard Tools 94201 Lifting device for fitting and transporting a cylinder Liner 94201D 94201A X = 1443 mm Mass approx. 478 kg (WLL 11100 kg) includes: 94201A 1 Lifting tool X = 1372 mm Mass approx. 297kg 94201B 2 Holder X = 1370 mm 94201B...
Page 545 9403−5/A1 Maintenance Standard Tools 94213 Dismantling tool X = 142 mm WCH02256 94215A 10 Pre-tensioner for cylinder cover studs X = Ø 228 mm Mass approx. 37.1 kg WCH02830 94219 Cylinder pressure measuring tool (indicator) including a wooden box X = 165 mm WCH03750 94224 Ladder...
Page 546 9403−5/A1 Maintenance Standard Tools 94230 Distance holders for removal and fitting of piston rod gland and piston, including 4 hexagon head screw M24x60 X = 750.5 mm WCH02589 94231A Clamping rings X = ∅ 405 mm 94231B Distance pieces Thick 12 X = 455.5 mm 94231C Distance pieces...
Page 547 9403−5/A1 Maintenance Standard Tools 94252 Pre-tensioner for exhaust valve cage / Lower connecting rod X = ∅ 301.6 mm Mass approx. 50.9 kg WCH02591 94259 Special screw for exhaust valve X = 328.5 mm 016.765/08 94261 Valve seat fitting and dismantling device X = 850 mm Mass approx.
Page 548 9403−5/A1 Maintenance 94270G Grinding device To grind the bore of the injection valve (with FAST) seat in the cylinder cover X = 404 mm includes: Stencil 94270G Stencil WCH03837 16/ 41 Winterthur Gas & Diesel Ltd.
Page 549 9403−5/A1 Maintenance Standard Tools 94272 OBEL test bench 94272E for setting and testing of: − injection valve − safety valve 94272D X = 1458 mm Mass approx. 186 kg including: 94269A−70 1 Slugging wrench for loosening and tightening of coupling nut to injection valve with FAST WCH02327...
Page 550 9403−5/A1 Maintenance Standard Tools 94278A Nozzle disassembly tool for injection nozzle disassembly X = ∅ 60 mm WCH02740 94278B Nozzle assembly tool for injection nozzle assembly X = ∅ 64 mm WCH02740 94279 Template for checking wear on exhaust valve seat X = 175 mm WCH02381...
Page 551 9403−5/A1 Maintenance Standard Tools 94315 Pre-tensioning jacks for connecting rod studs to top end bearing, X = 193.6 mm WCH02831 94319 Deviation pipe X = 400 mm Y = 207 mm Z = 89.4 mm WCH03403 94320 Pre-tensioning jack for screwed connection of turning gear, and round nut 94320A X = 200 mm including:...
Page 552 9403−5/A1 Maintenance Standard Tools 94322 Support For connecting rod assembly Only for 8 −12 cylinder engines. X = 632 mm WCH02834 94322A Support For connecting rod assembly (only 1 piece for 8 −12 cyl. Engines) X = 510 mm WCH02833 94322B Bracket For connecting rod assembly...
Page 553 9403−5/A1 Maintenance Standard Tools 94325 Chain For lifting the top end bearing cover/shell For pulling the crosshead pin 2 slings à 424 mm Mass approx. 4 kg (WLL 1500 kg) WCH02432 94326 Console Frame for removal and fitting of bottom end bearing shell X = 405 mm Mass approx.
Page 554 9403−5/A1 Maintenance Standard Tools 94334 Bracket for removal and fitting of a connecting rod (for bearing pin ∅ 1120 mm) X = 1730 mm Mass approx. 236 kg WCH02270 94334A Connecting element with shackle X = 120 mm (WLL 6700 kg) WCH02270 94335 Stop plate...
Page 555 9403−5/A1 Maintenance Standard Tools 94337 Lifting tools with 6 screws M20x110 for the connecting rod X = 594 mm WLL: 4300 kg WCH03835 94338 Piston ring tensioning device X = 550mm Y = 303 mm WCH03481 94340 Pre-tensioner for piston rod foot fastening X = ∅...
Page 556 9403−5/A1 Maintenance Standard Tools 94342 Insertion funnel for fitting a piston X = 1053 mm Y = 226 mm Mass approx. 125 kg WCH02272 94342A Dismantling and assembling tool for fitting a piston X = 126 mm WCH02839 Mass approx. 2.54 kg 94348 Tap M27 for cleaning carbon deposits in...
Page 557 9403−5/A1 Maintenance Standard Tools 94410 Adjusting devices (qty 6 for 2−part, qty 9 for 1−part) for alignment of intermediate wheel X = 230 mm 94410A Adjusting devices (qty 6 for 2−part, qty 3 for 1−part) WCH02276 for alignment of intermediate wheel X = 405 mm 94411A Chain...
Page 558 9403−5/A1 Maintenance Standard Tools 94552 Lifting tool with head screws M14x40 for removal and fitting of a fuel pump X = ∅ 120 mm (WLL 600 kg) WCH03064 94553 Guide rod to fuel pump X = 470 mm WCH02281 94555 Distance piece to fuel pump X = 95 mm...
Page 559 9403−5/A1 Maintenance Standard Tools 94566A Support for camshaft assembly, including clamping nut X = 925 mm Y1 = 165 mm Mass approx. 22.4 kg 016.788/08 2015 27/ 41 Winterthur Gas & Diesel Ltd.
Page 560 9403−5/A1 Maintenance Standard Tools 94566N Clamping nut For support 94566 and 94566A X = AF 32 6 Cyl. 2 piece 7 and 8 Cyl.4 pieces WCH02842 9 to 12 cyl. 6 pieces 94567 Assembly template for removal and fitting of bearing shells to fuel pump unit X = 90 mm 016.788/08...
Page 561 9403−5/A1 Maintenance Standard Tools 94569 Blank flange to fuel pump X = ∅ 120 mm 6 Cyl. 3 piece 7 and 8 Cyl.5 pieces 9 to 12 cyl. 6 pieces 94569C Screws for 94569 M14x25, 4 pcs. Per flanges 016.788/08 94569E O-Ring for 94569 1 pcs.
Page 562 9403−5/A1 Maintenance Standard Tools 94570A Blind flange X = 320 mm WCH02847 6 Cyl. 1 piece 7 to 12 Cyl.2 pieces 94570B Blind flange 8 holes WCH02848 X = 210 mm 94570C Blind flange X = 140 mm WCH02849 6 Cyl. 1 piece 7 to 12 Cyl.
Page 563 9403−5/A1 Maintenance Standard Tools 94593 Guide bracket for Pre-tensioning device X = ∅ 370 mm 94593C Mass approx. 23.5 kg 94593D 94593A 1 Ring 94593A 94593B 1 Ring (2-part) 94593B 94593C 2 Guide rods 94593E 94593D 4 Screws M12x130 with special nuts WCH02281 94593E...
Page 564 9403−5/A1 Maintenance Standard Tools 94651 Lifting Tool for auxiliary blower, WLL = 2000 kg X = 977 mm WCH03270 For turbocharger malfunctions: 94653A−A180 Cover to exhaust manifold outlet: for ABB A180, X = 872 mm, 24 holes 94653B−A180 Cover to turbocharger inlet: for ABB A180, X = 872 mm, 24 holes 94653C−A180 Cover to scavenge air receiver:...
Page 565 9403−5/A1 Maintenance Standard Tools Support left includes safety chain 94663D and safety lug 94663C 94663A−B24 for scavenge air cooler SAC B24-SF 94663D X = 682 mm, WLL 2200 kg, 59.5 kg 94663A−B25 for scavenge air cooler SAC B25-SF X = 682 mm, WLL 2200 kg, 59.5 kg 94663A−B27 for scavenge air cooler SAC B27-SF X = 682 mm, WLL 2400 kg, 59.5 kg...
Page 566 9403−5/A1 Maintenance Standard Tools 94666A Ring For Chains (double sling) X = 134 mm WCH02854 94667 Lifting tool for removal of water separator, including: 4 Hexagon head screw M12x30 X = 300 mm (WLL = 320 kg WCH02287 94667G Holder for pulling of water separator X = 420 mm WCH02287...
Page 567 9403−5/A1 Maintenance Standard Tools 94831 Blind flange for blanking off starting air pipe during emergency operation X = ∅ 275 mm WCH02289 94841 Grinding tool 94841 for hydraulic pipe X = ∅ 85 mm, R100 94841A Stencil 94841A Y = 55 mm WCH02853 94844 Lubrication device...
Page 568 9403−5/A1 Maintenance Standard Tools 94871 Grinding tool 94871 94871A for hydraulic pipe X = ∅ 60 mm, R30.5 94871A Stencil Y = 50 mm WCH02756 94930 SW-download package to WECS−9520 for flexView operator consisting of: 1 USB−memory stick 1 CAN cable (ca. 10 m) 1 UBS to CAN adapter 1 Connection diagram 1 Requirements...
Page 569 9403−5/A1 Maintenance Standard Tools 94934H Pressure gauge 0−25 bar WCH03836 94934C Distributing piece WCH03836 94934I Connection nipple To do a test of the lubrication quill WCH03836 94934J Tredo joint To connect the nipple 94934I WCH03836 94934K Adapter piece 94934K 94934L For adapter piece 94934L 94934L Adapter piece...
Page 570 9403−5/A1 Maintenance Standard Tools 94935C Hose for set-up of pre-tensioning jacks Length = 2000 mm 013.621/05 94936 Hydraulic jacks working range 933 kN to 1002 kN (95 t to 100 t) 005.952/00 94942 Hydraulic unit working pressure max. 2000 bar 013.622/05 Recommended Special Tools 94215...
Page 571 9403−5/A1 Maintenance Standard Tools 94234 Platform for piston rod gland removal inside the engine X = ∅ 962mm Mass approx. 43.6 kg WCH02382 94266 Cylinder cover support X = 2074 mm WCH03106 94291 Valve grinding device complete 94291A for valve spindle and valve seat 94291A Grinding discs (C-M No.
Page 572 9403−5/A1 Maintenance 94349 Plate for piston pressure testing X = 380 mm Mass approx. 46.3 kg WCH02841 94356 Equipment case with instruments for measuring thickness of chrome- ceramic-layer on piston rings WCH01216 94366A 1 Template for shape of top of piston head (for use with piston installed) X = 1074 mm WCH02678...
Page 573 9403−5/A1 Maintenance Recommended Special Tools 94595D 1 Piston reset device X = 255 mm WCH02281 94595E Screw M30x400 X = 418.7 mm WCH02281 94116D Lifting support for removal and installation only at positions where FSU platforms prevent access. X = 2051 mm (WLL 2000 kg) WCH03787 94357...
Page 574 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 X92 Maintenance Manual

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