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Maintenance

TOC

Table of Contents

RT-flex50DF

2016

 4/ 4

Winterthur Gas & Diesel Ltd.

Regulating Linkage

Adjustment: Heinzmann StG 10-01 Actuator

5801

−

1/A1

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Scavenge Air Receiver and Auxiliary Blower

Group 6

Scavenge Air Receiver: Clean and do Checks

6420

−

1/A1

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Scavenge Air Receiver (TC at Exhaust Side): Clean and do Checks

6420

−

2/A1

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Auxiliary Blower: Maintenance

6545

−

1/A1

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Auxiliary Blower (TC at Exhaust Side): Maintenance

6545

−

2/A1

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Scavenge Air Cooler: Removal and Installation

6606

−

1/A1

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Scavenge Air Cooler: Cleaning Instructions

6606

−

1/A2

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Scavenge Air Cooler (TC at Exhaust Side): Removal and Installation

6606

−

2/A1

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Water Separator: Removal and Installation

6708

−

1/A1

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Water Separator Removal and Installation (TC at Exhaust Side)

6708

−

2/A1

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Cylinder Lubrication

Group 7

Cylinder Lubricating System 

7218

−

1/A1

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Piping

Group 8

Exhaust Waste Gate (Low-load Tuning

)

8135

−

1/A1

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HP Servo Oil Pipe: Removal, Grind, Installation

8447

−

1/A1

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Hydraulic Pipe for Exhaust Valve Drive: Removal, Grind, Installation

8460

−

1/A1

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HP Injection Pipe: 

Removal, Grind, Installation

8733

−

1/A1

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HP Fuel Pipe: Removal, Grind, Installation (TC at Aft End)

8752

−

1/A1

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HP Pipe Pilot Fuel: Removal and Installation

8790

−

1/A1

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Crank Angle Sensor Unit, Tools

Group 9

Crank Angle Sensor Unit: 

Proximity Sensor 

−

 Replace

 

9223

−

1/A1

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Cylinder Pressure Sensor: Removal and Installation

9258

−

1/A1

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Tools: Description

9403

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1/A1

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Hydraulic Jacks and Pumps: Configuration

9403

−

2/A1

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Hydraulic Pre-tensioning Jacks

Storage, Servicing and Maintenance

9403

−

3/A1

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General Application Instructions

9403

−

4/A1

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Tool List

9403

−

5/A1

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Standard Tools

Pages 1 to 43

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Recommended Special Tools

Pages 44 to 45

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Winterthur Gas & Diesel Ltd.

RT

−

flex50DF / MM / 2020

Summary of Contents for RT-flex50DF

Page 1: ...RT flex50DF Issue 003 2020 10 Winterthur Gas Diesel Ltd Schützenstrasse 3 Tel 41 0 52 264 8844 Winterthur Gas Diesel AG P O Box 414 8401 Fax 41 0 52 264 8866 Winterthur Gas Diesel S A Winterthur Switzerland www wingd com ...

Page 2: ...yright holder Winterthur Gas Diesel Ltd makes no representation warranty express or implied in this publication and assumes no responsibility for the correctness errors or omissions of information contained herein Information in this publication is subject to change without notice NO LIABILITY WHETHER DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL IS ASSUMED WITH RESPECT TO THE INFORMATION CO...

Page 3: ...AD085973 Piston Fig M to S and U changed description with the new lifting tool updated x 5555 1 A1 2015 Pilot Fuel Supply Unit Document moved from group 8 to group 5 and changed the name x 6420 2 A1 EAAD085839 Scavenge Air Receiver New document added turbocharger at exhaust side x 6545 2 A1 EAAD085896 Auxiliary Blower New document added turbocharger at exhaust side x 6606 2 A1 EAAD085896 Scavenge ...

Page 4: ...nmber Grind New procedure x 2751 1 A1 2018 02 Customer input Exhaust Valve Replacement of Elastic Studs Pge 6 Fig 10 Flow direction changed x 2751 2 A1 2018 02 WinGD Input Exhaust Valve Disassemble and Assemble Pge 7 Steps 6 to 10 changed x 2790 1 A1 2018 02 WinGD Input Pilot Injection Valve Removal Disassemble Check Assemble Installation Pge 1 ToC changed Pge 2 Procedure changed Pge 5 data added ...

Page 5: ...s New document x Group 6 ToC 2020 05 WinGD Input Group 6 ToC Scavenge Air Cooler Cleaning instructions added x 2722 1 A2 2020 05 WinGD Input Injection Valve Installation of Injection Valve with FAST New document x Group 2 ToC 2020 05 WinGD Input Group 2 ToC Injection Valve Installation of Injection Valve with FAST added x 9403 5 A1 2020 05 WinGD Input Tools List Page 8 Dismantling Tool added Page ...

Page 6: ...or Starting Air Crankshaft Connecting Rod and Piston Cylinder Liner and Cylinder Cover Bedplate and Tie Rod General Information Supply Unit Injection and Exhaust Valve Control Scavenge Air Receiver and Auxiliary Blower Cylinder Lubrication Piping Crank Angle Sensor Unit Tools ...

Page 7: ...5 Piston Cooling and Crosshead Lubrication 16 17 Piston and Piston Rings 18 19 Driving Wheels for Supply Unit 20 21 Supply Unit 22 23 Fuel Pump 24 25 Tightening Values of Important Screwed Connections 0352 1 A1 Torque Values Standard Screws and Elastic Studs 0352 2 A1 Masses Weights Individual Components per Piece in kg 0360 1 A1 Maintenance Schedule Inspection and Overhaul Intervals Guidelines 03...

Page 8: ...lot Injection Valve Position Grind 2708 4 A1 Sealing Face for the Fuel Injection Valve Position Grind 2708 5 A1 Sealing Face for the Prechamber Grind 2708 6 A1 Injection Valve Removal and Installation 2722 1 A1 Injection Valve Checks Disassemble Assemble 2722 2 A1 Injection Valve Installation of Injection Valve with FAST 2722 1 A2 Starting Air Valve Removal Disassemble Grind Assemble Installation ...

Page 9: ...rances and Tooth Condition 4103 1 A1 Starting Air Shut off Valve Clean and Function Check 4325 1 A1 Supply Unit Injection and Exhaust Valve Control Group 5 Supply Unit Servo Oil Pump and Servo Oil Pump Drive Removal and Installation 5552 1 A1 Camshaft and Bearing Shells Removal and Installation 5552 2 A1 Gear Wheel on Camshaft Removal and Installation 5552 3 A1 Supply Unit Removal and Installation...

Page 10: ...A1 Cylinder Lubrication Group 7 Cylinder Lubricating System 7218 1 A1 Piping Group 8 Exhaust Waste Gate Low load Tuning 8135 1 A1 HP Servo Oil Pipe Removal Grind Installation 8447 1 A1 Hydraulic Pipe for Exhaust Valve Drive Removal Grind Installation 8460 1 A1 HP Injection Pipe Removal Grind Installation 8733 1 A1 HP Fuel Pipe Removal Grind Installation TC at Aft End 8752 1 A1 HP Pipe Pilot Fuel R...

Page 11: ...ead Guide 6 7 Cylinder Liner 8 9 Piston Rod Gland 10 11 Exhaust Valve 12 13 Top and Bottom End Bearings to Connecting Rod 14 15 Piston Cooling and Crosshead Lubrication 16 17 Piston and Piston Rings 18 19 Driving Wheels for Supply Unit 20 21 Supply Unit 22 23 Fuel Pump 24 25 Tightening Values of Important Screwed Connections 0352 1 A1 Torque Values Standard Screws and Elastic Studs 0352 2 A1 Masse...

Page 12: ...r maintenance and operation must be serviceable and in good condition The extent of all supplies and services is set exclusively to the related supply contract 3 Data The specifications and recommendations of the classification societies which are essential for the design are included in this manual The data instructions graphics and illustrations etc in this manual are related to drawings from Wi...

Page 13: ...Intentionally blank ...

Page 14: ... not manufactured in accordance with production drawings from Wärtsilä Switzerland Ltd The Maintenance Manual has the primary data that follow D General Guidelines for Maintenance These give recommendations about precautions and applicable procedures D Clearance tables tightening values of screwed connections masses weights These give data about usual and maximum permitted clearances engine compon...

Page 15: ...d FREE END DRIVING END Thrust Bearing Pads FUEL SIDE EXHAUST SIDE Rail Unit Clockwise Rotation Counterclockwise Rotation Supply Unit Turbocharger Cylinder Number Auxiliary Blower 1 6 5 4 3 2 7 1 2 3 4 5 WCH002808 Main Bearing Number Auxiliary Blower 2 1 DATA FOR 5 CYLINDERS WCH002808 2016 General ...

Page 16: ...td 2 2 013 150 05 FREE END Crank Angle Sensors Sensor 2 Sensor 1 FUEL SIDE Fuel Pump Actuator 1 Fuel Pump Actuator 2 Fuel Pump 1 Fuel Pump 2 Servo Oil Pump 2 Servo Oil Pump 1 Supply Unit FUEL SIDE DRIVING END DRAWN FOR 5 CYLINDERS 2016 Flex Parts ...

Page 17: ...rust Bearing Pads FUEL SIDE Rail Unit Clockwise Rotation Counterclockwise Rotation Supply Unit Turbocharger Cylinder Number Auxiliary Blower 1 6 5 4 3 2 7 1 2 3 4 5 WCH03435 Main Bearing Number Auxiliary Blower 2 1 DRAWN FOR 7 CYLINDERS WCH03435 6 7 8 9 EXHAUST SIDE DATA FOR ONE A175 TURBOCHARGER FREE END 2016 General ...

Page 18: ... Angle Sensor Unit Fuel Pump Actuator 1 Fuel Pump Actuator 2 Fuel Pump 1 Fuel Pump 2 Servo Oil Pump 2 Servo Oil Pump 1 Supply Unit FUEL SIDE DRIVING END DATA FOR 5 CYLINDERS Supply Unit drive I I II DRIVING END WCH02993 Proximity sensor II I I 2016 Flex Parts ...

Page 19: ...otection data related to the operation and maintenance of diesel engines D All personnel must know the dangers functions and operation of cranes and lifting devices D The safety officer must make sure that all precautions are done to prevent dangerous conditions D The operator must select a supervisor to give work tasks to each person who does maintenance work D Make sure that fluids that drain or...

Page 20: ... cables of the electronic units Before you start the maintenance on the engine specially the running gear do the procedure that follows 1 Close the shut off valves on the starting air bottles 2 Close all the shut off valves in the control air supply unit 3 Open the drains on each starting air bottle to release all the pressure 4 On the starting air shut off valve operate the handwheel to move the ...

Page 21: ...ry the safety person can give the applicable aid Personnel who do work in the engine must put on the correct safety equipment Safety equipment to prevent suffocation must also be included The permitted load capacity of the equipment that follows must be sufficient for the parts to be lifted D The engine room crane D Lifting tools ropes slings and chains You must make sure that the lifting equipmen...

Page 22: ...e or more than that given in 0330 1 Clearance Tables the parts must be replaced 11 Use spare parts from the spares stock on board When you order new parts get the code numbers and description from the Spare Parts Catalog 12 When you tighten nuts bolts or screws make sure that you do not cause damage to the thread Turn the nut bolt or screw with your hand until the metal parts touch Use only the sp...

Page 23: ...orn and tools that have damage are defective and must be replaced For safety and correct handling of the engine room crane lifting tools or movement of loads the sequence that follows is recommend 1 Find the weight of load 2 Find the centers of gravity 3 Use the applicable attachments 4 Attach and remove the applicable lifting equipment 2 Lifting Equipment 2 1 Wire Rope Slings The WLL of the wire ...

Page 24: ...permitted in the direction of the ring therefore the eye bolts or eye nuts must be moved to the correct position If necessary use the distance rings If there are through holes you must put a washer on the opposite side under the nut or screw head When possible do not apply an angle of inclination of more than 45 in all directions in relation to the ring Do not apply lateral loads For different use...

Page 25: ...RUD eye bolt is tightened remove the star profile wrench Fig 1 This will make sure that the RUD eye bolt can turn freely Align the RUD eye bolt with the direction of force before a load is applied Note Do not apply loads in the directions shown in Fig 2 DIRECTION OF FORCE Ring Star profile wrench Screw Fig 1 Fig 2 013 444 05 DO NOT APPLY FORCE IN THESE DIRECTIONS DIRECTION OF FORCE General Guideli...

Page 26: ... POSSIBLE DO NOT APPLY FORCE IN THIS DIRECTION 2 5 Shackles Only those shackles that are in accordance with American Standard RR C 271A or that have the same or are more than these values must be used This includes the safety factor All calculations for components and tools where shackles are used are related to the given standards Usually the permitted load on the shackles is specified for one st...

Page 27: ... shafts etc A soft wooden board between the rope and the component prevents movement Use a cloth or a wooden pallet to prevent damage to ropes Sharp edges can cut steel strands Always make sure that the load is correctly attached to prevent a fall When a rope is wound around an item two times the friction increases You can use this procedure to help prevent movement of a shaft that has surface oil...

Page 28: ...Intentionally blank ...

Page 29: ...e columns Maximum Clearance Dimension are the possible results after a long period of operation The differences in the clearances must not be less than or more than those given On components where the clearance is adjustable changed thickness of shims discs spacers etc the values must be those given in Usual Clearance Where this is not possible you must replace worn parts with standard new parts o...

Page 30: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 2 25 Crankshaft and Thrust Bearing 2 013 025 05 1 Fig 1 Fig 2 2016 Clearance Table ...

Page 31: ...ription Measured Direction Nominal Dimension mm usual new Maximum Clearance Dimension mm because of worn components 1203 1224 Thrust Bearing Thrust bearing pad thickness 0 5 0 6 67 1 Thrust bearing clearance axial total 0 8 to 1 3 2 5 2 Thrust bearing pad lateral clearance total 6 Clearance Table 2016 ...

Page 32: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 4 25 Crankshaft and Main Bearing MAIN BEARING No 1 MAIN BEARING No 2 AND FOLLOWING 1 018 600 09 018 663 09 1 2 3 Fig 3 Fig 4 2016 Clearance Table ...

Page 33: ...mm because of worn components 1132 Main bearing No 1 Crankshaft outer 600 0 0 07 Main bearing inner 600 1 Bearing clearance vertical 0 3 0 6 0 9 1132 Main bearing No 2 and following Crankshaft outer 600 0 0 07 Main bearing inner 600 1 Bearing clearance vertical 0 2 0 5 0 8 All main bearing clearances are only correct with tie rods and main bearing studs tightened 2016 Clearance Table ...

Page 34: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 6 25 Crosshead Guide 013 027 05 4 4 HOLDING PLATE 5 6 7 3 5 2 1 x x FUEL SIDE HOLDING PLATE Fig 5 Note Some parts can look different 2016 Clearance Table ...

Page 35: ...rail lateral clearance total 0 80 1 60 2 0 5 Guide shoe lateral clearance total 0 10 0 60 6 Guide shoe bearing pin outer 528 0 0 044 Guide shoe bearing bore inner 528 0 101 0 044 7 Bearing clearance radial 0 064 0 145 0 25 To measure the clearances refer to 3326 1 The clearance 3 is only correct with tie rods tightened The clearance 5 refers to the space between the white metal of the guide shoe a...

Page 36: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 8 25 Cylinder Liner WCH03120 5 Approximately 100 mm to 180 mm 1 2 3 4 Fig 6 2016 Clearance Table ...

Page 37: ...linder cover Water guide jacket Ø 760 0 3 0 1 1 Clearance total 0 40 0 80 Water guide jacket Ø 750 1 10 0 9 2 Clearance total 1 20 1 60 2124 Water guide jacket on cylinder liner Water guide jacket Ø 750 0 20 0 40 3 Clearance total 0 30 0 50 Water guide jacket Ø 695 0 30 0 1 4 Clearance total 0 30 0 70 2124 Cylinder liner 5 Cylinder liner bore radial 500 503 50 Make sure that you measure at the cor...

Page 38: ...4 5 6 6 6 6 6 1 1 2 3 013 225 05 Fig 7 Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 10 25 Piston Rod Gland 2020 Clearance Table ...

Page 39: ...omponents 2303 Piston rod gland 1 Ring width radial 31 min 25 2 Ring width radial 22 min 20 20 3 Ring width radial 5 min 3 20 4 Ring clearance axial 0 05 0 19 0 40 5 Ring clearance axial 0 05 0 13 0 35 6 Ring clearance axial 0 10 0 17 0 40 Ring wear The difference in value between the nominal dimension and maximum worn area is equal for all rings i e also for smaller rings 2016 Clearance Table ...

Page 40: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 12 25 Exhaust Valve 1 3 L 2 3 L 3 2 1 012 999 05 VALVE SPINDLE GUIDE BUSH L LENGTH Fig 8 Fig 9 2016 Clearance Table ...

Page 41: ...red Direction Nominal Dimension mm usual new Maximum Clearance Dimension mm because of worn components 2751 Valve spindle 1 Spindle outer 55 0 14 0 17 54 40 2751 Guide bush 2 Bore inner 55 0 03 0 55 35 3 Bore inner 55 0 03 0 56 20 Make sure that you measure at the correct points 2016 Clearance Table ...

Page 42: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 14 25 Top and Bottom End Bearings to Connecting Rod 10 mm 10 mm 60 mm 5 6 5 6 2 3 2 3 013 028 05 1 4 Fig 10 60 mm 2016 Clearance Table ...

Page 43: ...ad pin outer 528 0 0 04 4 Bearing inner 528 1 Bearing clearance vertical 0 20 0 40 0 60 2 Lateral clearance total 0 40 0 60 3 Lateral clearance total 0 20 0 40 3303 Bottom end bearing Crankshaft outer 600 0 0 07 Bearing inner 600 4 Bearing clearance vertical 0 30 0 50 0 65 5 Lateral clearance total 0 20 0 40 6 Lateral clearance total 0 30 0 50 Make sure that you measure at the correct points For m...

Page 44: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 16 25 Piston Cooling and Crosshead Lubrication 013 029 05 2 1 Fig 11 2016 Clearance Table ...

Page 45: ...ection Nominal Dimension mm usual new Maximum Clearance Dimension mm because of worn components 3603 Piston cooling and crosshead lubrication Sleeve inner 56 0 15 0 12 Sleeve length 115 0 08 0 10 1 Radial clearance total 0 30 0 39 0 42 2 Clearance vertical 0 08 0 20 0 25 Inside telescopic pipe outer 56 0 18 0 24 2016 Clearance Table ...

Page 46: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 18 25 Piston and Piston Rings 8a 8 1 10 2 9 5 3 4 DESIGN WITH THREE PISTON RINGS 6 7 B A B A Fig 12 2016 Clearance Table ...

Page 47: ...rtical 15 0 33 0 28 5 Groove depth radial 17 50 3425 Piston rings 3 Top ring height vertical 17 0 0 03 4 Lower ring height vertical 15 0 0 03 Point A Point B 6 Top ring clearance vertical 0 33 0 41 0 60 0 75 7 Ring clearance vertical 0 28 0 36 0 58 0 75 8 Ring width radial 18 0 0 25 8a Ring width radial 16 5 0 25 3403 Piston skirt 9 Skirt outer 499 4 0 0 2 min 497 7 3403 Piston rod 10 Rod outer 20...

Page 48: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 20 25 Driving Wheels for Supply Unit 4 5 1 2 3 013 030 05 WCH00139 Fig 13 Fig 14 2016 Clearance Table ...

Page 49: ... Clearance Dimension mm because of worn components 4103 Intermediate wheel 1 Shaft outer 160 2 Bearing clearance vertical 0 082 0 147 0 25 3 Axial clearance total 0 6 1 1 1 5 4 Tooth backlash 0 20 0 33 0 55 5 Tooth backlash 0 28 0 42 0 65 When you measure the tooth backlash look at the tooth crown of the tooth flanks in the longitudinal direction 2016 Clearance Table ...

Page 50: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 22 25 Supply Unit 013 031 05 6 8 5 4 1 3 2 7 Fig 15 2016 Clearance Table ...

Page 51: ...upply unit 1 Pinion outer 80 0 0 019 Bearing installed inner 80 0 10 0 085 2 Bearing clearance radial 0 085 0 119 3 Axial clearance total 0 25 0 54 0 7 5552 Camshaft unit 4 Camshaft outer 120 0 0 022 5 Bearing clearance radial 0 10 0 19 6 Axial clearance total 0 2 0 5 0 7 7 Tooth backlash 0 12 0 22 8 Minimum clearance 2 Minimum clearance between cam and roller with fuel pump cut out 2016 Clearance...

Page 52: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 24 25 Fuel Pump 012 098 04 3 8 7 6 1 2 4 5 171 mm A B C 013 032 05 PLUNGER and CYLINDER 30 mm Ø30 35 mm 38 mm Ø36 mm Fig 16 Fig 17 2016 Clearance Table ...

Page 53: ...0 0 027 Guide piston outer 130 Bottom housing inner 130 2 Clearance radial 0 070 0 125 0 149 3 Piston lower spring carrier axial 0 02 0 06 0 08 5556 Roller guide Bush outer 60 Roller inner 60 4 Clearance radial 0 06 0 09 0 10 Pin outer 50 Bush inner 50 5 Clearance radial 0 025 0 08 0 10 Pin outer 50 Guide piston bore inner 50 6 Clearance radial 0 009 0 050 0 080 7 Axial clearance of bush total 0 2...

Page 54: ...Intentionally blank ...

Page 55: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 1 7 Tightening Values of Important Screwed Connections WCH03038 Fig 1 2016 ...

Page 56: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 2 7 WCH03038 Fig 2 2016 Tightening Values of Important Screwed Connections ...

Page 57: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 3 7 WCH030038 Fig 3 WCH03038 2016 Tightening Values of Important Screwed Connections ...

Page 58: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 4 7 Fig 4 WCH03038 2016 Tightening Values of Important Screwed Connections ...

Page 59: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 5 7 Fig 5 WCH03038 2016 Tightening Values of Important Screwed Connections ...

Page 60: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 6 7 WCH03038 Fig 6 2016 Tightening Values of Important Screwed Connections ...

Page 61: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 7 7 2016 Tightening Values of Important Screwed Connections ...

Page 62: ...Intentionally blank ...

Page 63: ...ed the torque value must be decreased by 20 of the values given in the table These torque values do not apply to turbocharger installations Refer to the documents of the turbocharger manufacturer for the correct torque values Standard thread Grade 8 8 Fine thread Grade 8 8 Torque Value Nm M3 M3 x 0 35 0 9 M4 M4 x 0 5 2 1 M5 M5 x 0 5 4 2 M6 M6 x 0 75 7 2 M8 M8 x 1 18 M10 M10 x 1 25 35 M12 M12 x 1 2...

Page 64: ...tap hole and the area where the elastic stud will be installed 7 If necessary apply an adhesive primer to the shank of the elastic stud Make sure that no adhesive primer goes on to the threads 8 Use only a stud driver or two nuts locked together to fully install the stud into the tap hole 9 Torque the elastic stud to the applicable value given in the table below TORQUE Nm 400 300 200 10 100 20 30 ...

Page 65: ...elated manufacturer s instructions to mix and apply the jointing compounds hardeners and adhesive primers Materials from other manufacturers are permitted but must have the qualities given below D The materials must not contain acid D The materials must be resistant to oil marine diesel oil heavy fuel oil and water at a temperature of 100_C D A short age hardening time is necessary i e not more th...

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Page 67: ...using to supply unit drive 545 1903 Tie rod Tie rod nut Intermediate ring M80x6 thread 254 4 9 7 2 2106 Elastic stud in cylinder block M56 28 4 2124 Cylinder liner complete Cylinder liner to GAV50 Mk2 complete 2345 2344 2130 Water guide jacket upper Water guide jacket lower 80 5 98 2140 Gas admission valve 30 4 2303 Piston rod gland 86 9 2708 Elastic stud for valve cage Cylinder cover without acce...

Page 68: ...r crosshead for top end bearing 148 3315 Bearing shell crosshead for top end bearing 43 3326 Crosshead with guide shoes Crosshead pin Guide shoe Free End side Guide shoe Driving End side 1440 1040 188 184 3403 Piston two part with piston rod and piston rod gland Piston head Piston skirt Piston rod Spray plate with oil pipe 881 204 39 571 41 5 3603 Inside telescopic pipe to piston cooling and cross...

Page 69: ...556 Fuel pump 162 5612 Exhaust valve control unit 43 4 6 6506 Turbocharger ABB A165 ABB A175 ABB A265 2300 2600 2700 6545 Auxiliary blower with electric motor Electric motor 1434 184 to 283 6606 Scavenge air cooler SACA46 SF TROPICAL SACA44 SD 1142 2760 6708 Water separator 220 7 7206 Cylinder lubricating pump 5 8 Cyl engines 13 2 8 8139 Expansion piece exhaust valve 35 8790 Supply unit for pilot ...

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Page 71: ...mmended Estimated service life Bedplate foundation bolts Engine Lifetime Crankcase Do a visual examination 100 Op h after overhaul works Look for white metal particles from bearings and for other problems 1500 to 3000 1132 2 Main bearing An inspection of the bearing shell is only necessary if the bearing clearance crankshaft deflection wire check oil analysis or crankcase inspectionindicates exces...

Page 72: ... antipolishing ring At each piston removal 2124 3 Grind off wear ridge in bore At each piston removal Refinish the lubricating grooves As necessary Clean the scavenge ports and refinish their edges As necessary Estimated service life Cylinder liner Up to 90000 2138 1 Lubricating Quill Pulse Lubrication Do a function and tightness check At each piston removal Do a function check of the non return v...

Page 73: ...valve plate and pilot valve and check function 6000 to 8000 Replace the injection valve 24000 2728 1 Starting air valve Do a check of the pipes upstream of the starting air valve during operation If the pipes are too hot disassemble the starting air valve Weekly Remove and disassemble one starting air valve From the condition calculate the time of overhaul for remaining valves 12000 Make sure that...

Page 74: ...ry 2790 1 Pilot injection valve Do an external check for tightness After engine stop before a longer standstill Replace the nozzle spare parts set and perform function check 12000 Replace the O rings and sealing rings every time when the pilot injector is removed from the holder Replace the pilot injection valve complete 24000 Replace the pre chamber 18000 3 3103 1 Crankshaft Measure the crank def...

Page 75: ...ting rod top end bearing and bottom end bearing 70000 Estimated service life Connecting rod bottom end bearings 90000 replacement if required Estimated service life Connecting rod top end bearings 90000 replacement if required 3326 1 Guide shoe crosshead pin Do a check of the clearances 6000 to 8000 3403 1 Piston Remove and clean 18000 to 36000 on condition Do a check of the tightness on the pisto...

Page 76: ...f the running clearance and tooth backlash 6000 to 8000 Estimated service life driving wheels Engine lifetime Starting air shut off valve Release the pressure in the starting air inlet manifold pipe After each maneuvering period 4325 1 Disassemble clean and do a check important parts are seat springs and sealing rings 30000 to 36000 Do an overhaul of the common start valve SPC Control Valve Group ...

Page 77: ...e filter cartridges must be replaced earlier if the pressure difference indicator shows high pressure increase 1000 regardless of the operating mode Clean the wire gauze and filter housing 1000 Estimated service life Pilot fuel pump 24000 5556 1 Fuel pump Do a check of the fuel oil leakage from the fuel pump cover the O ring in the non return valve can become weak weekly Re manufacture fuel pump o...

Page 78: ...or Make sure that the regulating linkage moves freely Lubricate parts that can move 3000 6 6420 1 Scavenge air receiver Do a check of the scavenge air receiver and clean the air flaps 4000 to 6000 Clean the receiver 4000 to 6000 Make sure water drain pipes and orifices are not blocked 1500 to 3000 Turbocharger Wash clean the compressor during operation According to manufacturer manual Wash cleanin...

Page 79: ...345 1 Daily Make sure that the condensate collector is not blocked refer to the Operating Manual 8345 1 1500 to 3000 Do a check of the the water separator elements if necessary clean them 1500 to 3000 Remove the water separator for overhaul As necessary 7 7218 1 Cylinder Lubricating pump Re manufacture cylinder lubricating pump or overhaul on board 45000 Filter replacement Replace the filter eleme...

Page 80: ...4 1 Supply unit fuel drain pipes Make sure that the pipes are not blocked 6000 8752 1 HP fuel pipe Grind the sealing faces As necessary 8903 Gas supply pipe Shut off and vent valves Do a tightness check of the ball valves and the shaft sealing 6000 Do a visual check of the compensators 6000 Estimated service life Engine lifetime 9 9223 1 Crank angle sensor proximity sensors on gear wheel at drivin...

Page 81: ...fications see 0770 1 D Engine load D Fuel lubricating oil and cooling water treatment refer to the Operation Manual 0720 1 and 0760 1 D Do an overhaul in accordance with the Maintenance Manual D The correct spare parts are used D Monitor the engine D The engines are in accordance with the specifications of Winterthur Gas Diesel Ltd Refer to 0803 1 A1 0803 1 A2 for the cross section and longitudina...

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Page 83: ...tion 6606 1 6420 1 3301 1 8733 1 2728 1 3326 1 5556 1 5801 1 4103 1 1112 1 3326 2 8752 1 8447 1 8460 1 5552 1 to 5552 5 5612 1 WCH00676 6545 1 4325 1 2124 1 to 2124 3 3603 1 Fig 1 Cross Section Engine Cross Section and Longitudinal Section TC at Driving End 2016 ...

Page 84: ...303 1 1132 2 2722 1 2751 1 to 2751 4 3403 1 to 3403 4 2708 1 to 2708 3 3140 1 9223 1 3303 1 to 3303 5 3130 1 3425 1 1903 1 1224 1 1132 1 2138 1 1203 1 WCH00677 6606 1 6708 1 6420 1 Fig 2 Longitudinal Section Engine Cross Section and Longitudinal Section TC at Driving End 2016 ...

Page 85: ...ross Section 6606 1 6420 1 3206 1 3301 1 8733 1 2728 1 5562 1 3603 1 3326 1 5556 1 5801 1 4103 1 WCH00123 6708 1 1112 1 3326 2 8752 1 8447 1 8460 1 5552 1 to 5552 5 Fig 1 Cross Section Engine Cross Section and Longitudinal Section TC at Exhaust Side 2016 ...

Page 86: ...03431 2303 1 1132 2 2722 1 4325 1 2124 1 to 2124 3 4103 3 2751 1 to 2751 4 3403 1 to 3403 4 2708 1 to 2708 3 3140 1 3303 1 to 3303 5 3130 1 3425 1 1903 1 1224 1 1132 1 2138 1 1203 1 Fig 2 Longitudinal Section Engine Cross Section and Longitudinal Section TC at Exhaust Side 2016 ...

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Page 88: ...Tension 1132 1 A1 Main Bearing Removal and Installation 1132 2 A1 Thrust Bearing Axial Clearance Checks 1203 1 A1 Thrust Bearing Pads Removal and Installation 1224 1 A1 Engine Stays with Friction Shims Tension Checks 1715 1 A1 Hydraulic Engine Stays Oil Pressure Checks 1715 1 A2 Tie Rod Tension Checks and Replacement Procedure 1903 1 A1 Winterthur Gas Diesel Ltd RT flex50DF MM 2016 ...

Page 89: ...vals e g during overhauls refer to 0380 1 In the area of the thrust bearing attach the foundation bolt as follows D With the foundation bolts 1 Fig 1 and sleeves 2 or D With the installed foundation studs 4 Fig 2 The remaining area is attached with the foundation bolts 1 Fig 3 without the sleeves Note Do the procedure given in 9403 4 General Application Instructions for the hydraulic pre tensionin...

Page 90: ...he vent screw 8 9 Apply a pressure of 1500 bar to the foundation bolt 5 Keep the pressure constant Note Do not move the piston 1 of the pre tensioner 94145 above the red groove 2 10 Use a feeler gauge to do a check for clearance through the slot 4 between the nut 7 and the bedplate 6 11 If there is a clearance do step a to step c If there is no clearance continue from step 12 a Make sure that the ...

Page 91: ...to get the clearance 4 4 Connect the pre tensioning jack 94145 to the HP oil pump 94931 5 Open the vent screw 9 6 Close the relief valve 10 7 Operate the HP oil pump 94931 until oil that has no air flows from the vent screw 9 8 Close vent screw 9 9 Operate the HP oil pump 94931 to get a pressure of 1530 bar Note Do not move the piston 1 of the pre tensioning jack 94145 above the red groove 2 10 Tu...

Page 92: ...ion bolts metal and synthetic in two steps as follows 1 Attach the pre tensioning jack 94145 as given in paragraph 2 step 1 to step 8 2 Apply a pressure of 900 bar to the foundation bolt 3 Apply a pressure of 1500 bar to the foundation bolt Keep the pressure constant 4 Do step 10 to step 13 2016 Bedplate and Thrust Bearing ...

Page 93: ...nstall the double pre tensioning jacks 94114B 2 Clean the threads of the waisted studs 9 Fig 1 and the faces of the round nuts 7 3 Apply oil to the threads of the waisted studs 9 Note Do the procedure given in 9403 4 General Application Instructions for pre tensioning jacks 2 Pre tension Jacks Install 1 Put the double pre tensioning jacks 94114B in position on the studs 9 2 Open all vent screws 1 ...

Page 94: ... flows out close the vent screws 7 Fig 3 on the pre tensioning jacks 94114B 4 Operate the hydraulic unit until a pressure of approximately 1530 bar shows Note Do not move the piston 5 of the pre tensioning jack 94144B above the red groove 2 5 Use the round bar 4 to turn the round nuts 3 back approximately of a turn to get the clearance 5 Fig 1 6 Stop the hydraulic unit 94942 and release the pressu...

Page 95: ... 1ST STEP 2ND STEP y x 4 013 432 05 009 758 02 y TIGHTENING ANGLE x Fig 4 7 On the hydraulic unit 94942 increase the pressure to 1500 bar Keep the pressure constant 8 Use the round bar 4 Fig 3 to tighten fully all the nuts 3 Use the feeler gauge 94122 to do a clearance check through the slot 5 9 On the hydraulic unit 94942 decrease the pressure to zero 10 Remove the double pre tensioning jacks 941...

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Page 97: ...Jacks Installation 6 4 2 Crankshaft Lift 8 4 3 Bearing Shell No 1 Removal 9 4 4 Bearing Shell No 2 to No 8 Removal 11 5 Main Bearing Shells Inspection 13 6 Bearing Shell and Bearing Cover Installation 13 6 1 Bearing Shell Installation 13 6 2 Main Bearing Cover Installation 14 1 Preparation WARNING Injury and Damage Hazard Do not turn the crankshaft when the work platforms tools and or supports are...

Page 98: ...emove the oil pipe 1 Fig 1 from the main bearing cover 2 2 Apply protection to all openings 3 Attach the work platform 94142 Fig 2 4 Use the feeler gauge 94123 to do a check of the bearing clearance refer to 0330 1 2016 Main Bearing Removal and Installation 1 Fig 1 2 Fig 2 94142 WCH02325 Note Some parts can look different ...

Page 99: ...ew 1 and the thrust piece 5 9 Attach the thrust device 94110 as given in the instructions on the name plate 2 10 Turn back fully the spindle 11 Attach the slugging wrench AF60 12 Attach the thrust device 94110 to the main bearing cover 4 13 Put the four screws 3 in the positions shown 14 Torque the four screws 3 to 24 Nm 15 Use the slugging wrench to turn the special screw 1 and expand the main be...

Page 100: ...itudinal direction below the crosshead 10 Attach the chain block H3 11 Operate the manual ratchets H1 H2 and the chain block H3 to move the main bearing cover 3 to the column door 12 Remove the manual ratchets H1 H2 13 Operate the chain block H3 to remove the main bearing cover 3 from the crankcase Note When you do step 15 make sure that you do not cause damage to the bearing shell 2 and the surfa...

Page 101: ...B on the main bearing cover 11 Operate the manual ratchet H1 to lift the main bearing cover from the elastic studs 12 Attach the manual ratchet H2 to the trolley 94117 and the lug 94116B on the main bearing cover 13 Apply tension to the chain of the manual ratchet H2 to hold the weight of the main bearing cover 14 Carefully operate the manual ratchet H2 to increase the tension At the same time car...

Page 102: ... the bearing shell 2 and the surfaces of the main bearing cover 3 21 Operate the chain block H3 to lower the main bearing 1 on the wooden underlay 4 Main Bearing Shell Removal 4 1 Hydraulic Jacks 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 Do not remove two adjacent main bearing shel...

Page 103: ... teeth put a copper or aluminum plate between the jack and the flywheel 5 Put the support 94141 in position on the two main bearing girders 2 parallel to the engine axis 6 Put the hydraulic jacks 94936 on to the support 94141 7 Connect the HP oil pump 94931 to the hydraulic jacks 94936 013 213 05 013 214 05 I I 94934A 94931 94934 94935 94936 1 2 94141 1 Fig 9 Main Bearing Removal and Installation ...

Page 104: ...the value on the dial gauge is 0 2 mm 6 Make sure that there is no clearance between the adjacent bearing cover and the crankshaft 2 7 Keep the pressure constant 8 Measure the lateral bearing clearances y1 and y2 Compare these values with the values recorded in step 1 9 If the value of the lateral bearing clearance is more than 0 1 mm lower the crankshaft and do step a to step c a Install the hydr...

Page 105: ... 0 2 mm Refer to paragraph 4 1 and paragraph 4 2 2 Attach the manual ratchet H1 Fig 11 to the platform 3 Remove the Allen screws 1 from the bearing girder 4 Attach the device 94119B to the manual ratchet H1 5 Attach the turning out device 94118A to the main bearing shell 3 6 Put the wire ropes 3 along the outer edges of the bearing shell to the other side and attach them to the device 94119B as sh...

Page 106: ...Attach the manual ratchet H2 to the trolley 94116 Fig 13 and the tool 94116A as shown Note During step 11 make sure that each end of the bearing shell 1 does not touch the bearing girder 11 Operate the manual ratchet H1 to lift the bearing shell 1 At the same time operate the manual ratchet H2 to keep tension on the chain 12 Carefully remove the manual ratchet H1 13 Move the trolley 94116A manual ...

Page 107: ...he exhaust side approximately 90_ after TDC 4 Lock the turning gear to prevent movement 5 Attach the work platform 94143 6 Lift the crankshaft refer to paragraph 4 1 and 4 2 7 Remove the two Allen screws 2 from the bearing shell 8 Attach the device 94117 Fig 14 to the column with its dowel pin and spring clip 9 Attach the turning out device 94118A to the bearing shell 10 Put the ropes of the turni...

Page 108: ... 16 to the column 19 Attach the lifting ring 94332 and the shackle 94018B to the cylinder block with the two screws 3 20 Torque the screws 3 to 200 Nm 21 Attach the lifting tool 94335 between reinforced double I girders 22 Attach the manual ratchet H2 to the shackle 94018B and the transportation tool 94116A Note During step 22 make sure that each end of the bearing shell 1 does not touch the beari...

Page 109: ...ools D The crankshaft pin D The girder bore for the bearing shell D Bearing shells 6 1 Bearing Shell Installation 1 Apply a very thin layer of Molykote paste G to the rear face of the bottom bearing shell before each installation 2 Make sure that the crankshaft pin and the running surface of the bearing shell are clean and fully lubricated with clean engine oil Note The bearing shells have differe...

Page 110: ...r to 1132 1 7 Tighten the round nuts 4 8 Remove the protection from the oil bores 9 Clean the pipe 2 10 Install the pipe 2 to the bearing cover 5 11 Do step a and step b if the cover 1 was removed a Install the cover 1 b Install the pipe 6 12 Remove all tools and equipment from the work area 13 Measure the bearing clearance and compare the value measured in paragraph 2 step 4 with the value given ...

Page 111: ... 8 in position on the oil baffle top part 9 and record the value 8 Remove the dial gauge 8 9 Compare the values with those given in the engine documents on the Check Dimensions page see also 0330 1 Clearance Table Crankshaft and Thrust Bearing If the measured values are more than the nominal values given the thrust pads are worn 10 After maintenance on the area of the thrust bearing do step a to s...

Page 112: ...and the value given in the engine documents is related to the wear of the thrust pads 7 Fig 1 8 Start the engine in the direction ASTERN to move the crankshaft fully forward The crankshaft must touch the thrust pads 3 Fig 1 9 Stop the engine 10 Make sure that the crankshaft does not move 11 Use the micrometer 94101 Fig 2 to measure the distance between the coupling flange 1 and the oil baffle top ...

Page 113: ...ch the chain blocks H1 H2 Fig 2 to the attachment points in the gallery 4 If necessary remove the cover 7 Fig 1 to get access to the arbor support 2 5 Record the positions of the thrust bearing pads 6 Remove the four bolts 1 from the applicable the arbor supports 2 or 5 7 Attach the eye bolt 94040 M12 to the applicable arbor support 2 or 5 8 Attach the chain block H1 or H2 to the applicable arbor ...

Page 114: ...can move 18 To prevent crankshaft movement do as follows a Get a piece of hardwood that has the same dimensions as a thrust bearing pad b Put the hardwood in the position of the removed thrust bearing pads 2 Installation 1 Make sure that the thrust bearing pads are clean 2 Apply clean engine oil to the thrust bearing pads Note You must install thrust bearing pads that you removed before in the sam...

Page 115: ...ther arbor supports f Do a check of the clearances between the arbor supports and the thrust bearing pads see 0330 1 Clearance Table Crankshaft and thrust bearing Note When you replace new thrust bearing pads or thrust bearing pads that have new metal you must make sure that the thickness final dimension corresponds exactly with the neighbouring pads Note When you replace a full set of thrust bear...

Page 116: ...M DRIVING END PADS AT DRIVING END AHEAD ASTERN CLOCKWISE ROTATING ENGINE COUNTERCLOCKWISE ROTATING ENGINE AHEAD ASTERN 012 833 05 PROPELLER THRUST AHEAD PROPELLER THRUST ASTERN Fig 3 Astern Pads Ahead Pads CONFIGURATION OF THRUST BEARING PADS WITH FIXED PITCH PROPELLER 5 Cyl and 6 Cyl ENGINES 2016 Thrust Bearing Pads Removal and Installation ...

Page 117: ...VIEW FROM DRIVING END PADS AT DRIVING END SUPPORT SURFACE AHEAD ASTERN AHEAD ASTERN COUNTERCLOCKWISE ROTATING ENGINE 012 835 05 PROPELLER THRUST AHEAD PROPELLER THRUST ASTERN Fig 4 Astern Pads Ahead Pads CONFIGURATION OF THRUST BEARING PADS FOR CONTROLLABLE PITCH PROPELLER 5 Cyl and 6 Cyl ENGINE 2016 Thrust Bearing Pads Removal and Installation ...

Page 118: ...OM DRIVING END PADS AT DRIVING END AHEAD ASTERN CLOCKWISE ROTATING ENGINE COUNTERCLOCKWISE ROTATING ENGINE AHEAD ASTERN 012 834 05 PROPELLER THRUST AHEAD PROPELLER THRUST ASTERN Fig 5 CONFIGURATION OF THRUST BEARING PADS FOR FIXED PITCH PROPELLER 7 Cyl and 8 Cyl ENGINE Astern Pads Ahead Pads 2016 Thrust Bearing Pads Removal and Installation ...

Page 119: ... fuel side D Two engine stays are installed at the free end D Two engine stays are installed at the driving end The engine stays have friction shims 3 You must do a tension check of the bolts 2 at the specified intervals refer to 0380 1 Engine stays with friction shims Note To do the tension checks on the engine stays you use the same jack 94145 as that used for the the foundation bolts The namepl...

Page 120: ...ep a and step b If there is a clearance do step 6 a Operate the vent screw 1 to release the pressure to zero b Remove the tools and equipment 6 If there is clearance the tension of the bolt has changed since the last check and you must do step a to step d below a Use a round bar 7 to tighten the nut 3 b Use the feeler gauge 94122 to make sure there is no clearance c Operate the vent screw 1 to rel...

Page 121: ...re of less than 10 bar defective O rings valves that have leaks defective screwed connections or accumulator you must do the procedure that follows 1 Decrease to 10 bar the pressure in the other hydraulic cylinder 2 Repair the defective engine stay as soon as possible 3 Adjust the oil pressure of the engine stays to the correct setting Refer to the instructions in the manufacturer s manual 1 1 Fig...

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Page 123: ...Fig 1 from all tie rods 2 2 Clean the surfaces of the intermediate ring 4 Note Start with the tie rods a a in the middle of the engine then b b etc 3 Attach the two pre tensioners 94180 to two tie rods 2 a a Fig 1 4 Apply a tension of 1500 bar to the tie rods 2 refer to 9403 4 5 If possible tighten the round nuts 3 6 If the round nut 3 cannot move do step a to step b a Put a round bar 94005 throug...

Page 124: ...2 from the cylinder jacket 5 3 3 Installation 1 Apply Molykote paste G to the bottom thread of the M80x6 tie rod 2 2 Make sure that the bush 6 is installed 3 Attach an applicable eye bolt to the tie rod 2 4 Attach the crane to the eye bolt 5 Lower the tie rod 2 into the cylinder jacket 5 6 Turn the tie rod 2 until the bottom is flush with the nut 9 7 Clean the top surfaces of the cylinder jacket 5...

Page 125: ...d the length of the tie rods 2 at L 5 Apply a tension of 1500 bar 6 Record the length of the tie rods 2 at L1 Note The extension DL of the tie rod 2 must be between 13 0 mm and 14 5 mm DL L1 L 7 Remove the pre tensioning jacks 94180 8 Install the set screws 7 9 Apply acid free grease to the threads of the tie rods 2 that show 10 Attach the protection covers 1 Fig 2 11 Do step 1 to step 10 for the ...

Page 126: ...ning of Sealing Face for Injection Valve 2708 3 A1 Sealing Face for the Pilot Injection Valve Position Grind 2708 4 A1 Sealing Face for the Fuel Injection Valve Position Grind 2708 5 A1 Sealing Face for the Prechamber Grind 2708 6 A1 Injection Valve Removal and Installation 2722 1 A1 Injection Valve Checks Disassemble Assemble 2722 2 A1 Injection Valve Installation of Injection Valve with FAST 272...

Page 127: ... Hazard Hot parts can cause injury to personnel Be careful when you do work in areas where there are hot parts Note Measure the the cylinder liner before you remove a piston 1 Remove the cylinder cover refer to 2708 1 2 Operate the turning gear to move the piston to BDC 3 Put on a harness that is attached to a safety person If necessary the safety person can pull you out of the cylinder liner if t...

Page 128: ...he value 12 Do step 11 above for the remaining holes below A and B 13 Move the gauge 90_ in line with the transverse axis of the engine 14 Do the steps above again to measure the bore in the positions F up to A 15 Use the formula below to calculate the rate of wear WR D1 D2 x 1000 T1 Where WR Rate of Wear mm 1000 hours T1 Total running hours h D1 Maximum liner diameter of running surface point B a...

Page 129: ...Removal 4 3 Water Guide Jacket Removal 5 4 Water Guide Jacket Installation 6 5 Insulation Bandage Removal 7 6 Insulation Bandage Installation 7 7 Cylinder Liner Installation 8 8 Completion 8 1 Preparation 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Drain the cylinder cooling water from the related cylinder 3 Remove the cylinder cover 1 Fig 1 together with the water guide jacke...

Page 130: ...tubes 5 from the water guide jacket 2 Note The transition tubes 5 are a push fit into the pipe connections 3 3 Loosen the screws 2 and 5 Fig 2 4 Remove the cylinder holders 3 6 Note The cylinder holders 3 6 keep the the cylinder liner 1 in position 2016 Cylinder Liner Removal and Fitting I I WCH03059 Fig 1 1 2 4 3 5 WCH030059 WCH03086 Fig 2 1 2 3 4 4 6 5 ...

Page 131: ...lip paste to the threads of the special screws 2 6 Attach the two holders 94201B to the flange couplings 94201C with the special screws 2 7 Torque the special screws 2 to 140 Nm 8 Connect the crane hook to the shackle of the lifting device 94201 Fig 4 9 Operate the engine room crane to carefully lift the cylinder liner together with the water guide jacket 10 Move the cylinder liner cylinder liner ...

Page 132: ...ylinder liner 90_ and put more wooden underlays 2 in position 9 Put the two wooden chocks 1 in position to prevent movement 10 Remove the lifting tool 94201 from the cylinder liner 11 Remove the insulation bandage refer to paragraph 4 12 To remove the cylinder liner from water guide jacket refer to paragraph 3 2 3 Lifting Tool Removal 1 Remove the two special screws 2 Fig 6 2 Remove the screws 1 t...

Page 133: ... liner 9 Operate the manual ratchets 94016 004 to lower the water guide jacket 1 10 If the water guide jacket 2 does not come away from the cylinder liner do step a and step b a Put three applicable M12 screws in the threaded holes of the holder 7 b Turn equally the three M12 screws to push down the water guide jacket 11 Operate the manual ratchets 94016 004 to lower the water guide jacket on to a...

Page 134: ...s 94018A on the lifting tool 94201 Note Make sure that you do not cause damage the top of the cylinder liner 7 Operate the manual ratchets 94016 004 to lift the water guide jacket 1 to the applicable position on the cylinder liner Make sure that you keep the water guide jacket level 8 Attach the water guide jacket 1 Fig 8 to the cylinder liner with the three screws 9 9 Attach the cylinder holders ...

Page 135: ...ove insulation bandage 1 6 Insulation Bandage Installation 6 Put the insulation bandage 1 around the water channel on the cylinder liner Note Make sure that the insulation bandage 1 has an overlap of approximately 30 mm 7 Put the plate 3 in position over the insulation bandage 1 8 Use the assembly tool 94345E to attach all the tension springs 2 9 Make sure that there is a clearance of 10 mm betwee...

Page 136: ... the holes in the cylinder jacket 7 Fully lower the cylinder liner 1 8 Replace the O rings 2 and 6 Fig 11 9 Attach the pipe connections 8 and the transition tube 3 to the water guide 7 with the screws 4 10 Remove the lifting tool 94201 8 Completion 1 Install all lubricating quills refer to 2138 1 2 Operate the flex lube pump on the related cylinder liner until oil flows from all the lubricating gr...

Page 137: ...ion 1 Remove the cylinder cover refer to 2708 1 2 Remove all lubricating quills refer to 2138 1 3 Put applicable protection below the cylinder liner This keeps unwanted particles out of the bore 3 Unwanted Material Remove CAUTION Damage Hazard Make sure that you do not cause damage to the running surface of the cylinder liner when you operate the grinding tool 1 Read the data in the Instruction Ma...

Page 138: ...Maintenance 2124 3 A1 Winterthur Gas Diesel Ltd 2 4 2 94299 1 WCH02352 r 8 0 mm Unwanted material TDC 2 0 mm to 3 0 mm 3 2 Fig 1 1 0 mm 2016 ...

Page 139: ...he the lubricating grooves 1 back to their original depth I I I I I I 2 0 mm R1 R2 3 1 1 Fig 2 5 Scavenge ports CAUTION Damage Hazard When you polish the scavenge ports make sure that you do not cause damage to the running surface of the cylinder liner Note The scavenge ports 1 Fig 3 are as seen in new cylinder liners 1 Use emery cloth to polish the surfaces of the scavenge ports 1 Make sure that ...

Page 140: ... clean the lubricating grooves and the bore of the cylinder liner 3 Remove unwanted particles which may have passed into the scavenge space through the ports 4 Manually operate the cylinder lubrication until oil flows from all the lubricating points This will flush away unwanted metal dust Cylinder Liner Re dressing Lubricating Grooves and Scavenge Ports 2016 ...

Page 141: ...ust be removed 1 If necessary remove the holders 3 2 Disconnect the six pipes 1 3 Seal the pipes 1 with applicable plugs to prevent contamination Fig 1 WCH02869 DRIVING END 4 5 7 6 1 2 3 1 3 2 Removal Procedure 1 Loosen the nuts 4 of the screw in union and the angle union and disconnect the pipe 5 from the lubricating quill 3 Note Make sure that you do not damage the oil pipe 5 2 Seal the oil pipe...

Page 142: ...o the nozzle tip 4 Engage the collar on the plate with the recess on the lubricating quill 5 4 Turn equally the two bolts 2 to remove the nozzle tip 4 from the holder 5 5 Remove the distance sleeve 3 6 Attach a new new nozzle tip 4 to the holder 5 7 Make sure that the nozzle tip 4 is correctly attached to the holder 5 8 Do the procedure in paragraph 4 Fig 2 94213 I I 1 2 3 I I 1 2 3 4 5 A B WCH038...

Page 143: ...o the lubricating quill 2 3 Attach the HP hose to the nipple 94934I and to the hydraulic distributor and pressure gauge 94934H 4 Install the the hydraulic distributor and pressure gauge 94934H to the HP oil pump 94931 5 Hold the lubricating quill 2 up and operate the pump 94931 until oil that flows has no air 6 Open the relief valve 4 and decrease the pressure to 2 0 bar 7 Close the relief valve 4...

Page 144: ...ccur Note When you install the lubricating quill replace all components i e nozzle tip non return valve and holder see Fig 4 1 Make sure that the sealing surfaces 3 are clean and have no damage 2 Make sure that the marks MK are in line If the marks are not in line send the lubricating quill to Wärtsilä 3 Apply oil to the threads and surfaces of the screws 4 4 Put the lubricating quill 1 in positio...

Page 145: ... necessary if the cylinder liner was installed a Remove the plugs from the six pipes 1 b Connect the six pipes 1 c If necessary attach the holders 3 to the six pipes 1 10 Bleed the oil pipes 8 refer to 7218 1 paragraph 3 2 11 If necessary bleed the cylinder lubricating oil pump refer to 7218 1 paragraph 3 1 12 Do a function check of the cylinder lubricating system see 7218 1 paragraph 1 2 Fig 5 WC...

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Page 147: ... overhaul and spare part kits speak to or send a message to Wärtsilä Services Switzerland Ltd 1 Read the data in the D Operation Manual 0210 1 Safety Precautions and Warnings D Operation Manual 2140 Gas Admission Valve GAV D Operation Manual 8014 1 Gas Fuel System D Operation Manual 4003 12 Diagram Gas Fuel 2 For the inspection intervals refer to the Maintenance Schedule 0380 1 Gas Admission Valve...

Page 148: ...10 Tighten the four screws 5 11 Tighten the two bolts 6 at the same time to compress the compensator 1 12 Continue to tighten the bolts 6 until you can remove the compensator 1 13 Carefully remove the tool 94890 together with the compensator 1 14 Do a check of the condition of the six O rings 7 on the flange couplings if necessary replace the O rings 15 Remove the tool 94890 from the compensator 1...

Page 149: ...ipes These pipes must be moved to get more access to the GAV 1 Put an oil tray under the GAV 5 Fig 2 2 Make sure that the power supply to the rail valve 10 is set to off 3 Disconnect the electrical connections to the rail valve 10 and the valve stroke sensor 6 4 Loosen the four screws 2 Note During step 5 make sure that you do not damage the sealing face of the pipe 1 5 Remove the pipe 1 6 Remove ...

Page 150: ...e coupling nut 9 on the valve stroke sensor 10 4 Remove the valve stroke sensor 10 and the sleeve 9 5 Remove the piston 8 and the O ring 4 6 Loosen symmetrically the six screws 1 7 Carefully remove the cover 3 together with the O rings 2 8 Discard the O rings 2 Fig 2 WCH03493 I I II II 1 10 9 WCH03493 5 3 7 6 4 2 8 I I WCH03493 II II 2016 Gas Admission Valve Removal Disassemble Assemble Checks Ins...

Page 151: ...screws 1 from the valve bush 2 2 Put the two screws 94214L and the screws 94214M into the valve bush 2 as shown 3 Turn equally the nuts 94214M to remove the guide bush 2 and the valve guide 4 from the housing 5 4 Remove and discard the two O rings 3 5 Do the checks given in paragraph 7 2016 Gas Admission Valve Removal Disassemble Assemble Checks Installation Fig 3 1 2 WCH03493 WCH03493 94214L 9421...

Page 152: ... two M6x65 screws 9 11 Turn the special screw 8 fully in 12 Turn the rod 1 to compress the spring 5 and push the valve cotter 2 out of the spring carrier 11 13 Remove the valve cotter 2 14 Remove the pusher 94214D 15 Turn the valve spindle 3 out 16 Turn the rod 1 back to release the tension in the spring 5 17 Remove the tool 94214C 18 Remove the spring 5 19 Remove the valve spindle 3 20 Clean the ...

Page 153: ... reducing valve 94214B to the bush 94214E 9 Connect a pressurized air supply to the pressure reducing valve 94214B 10 Set the pressure reducing valve 94214B to 10 bar 11 Apply WD40 to the area of the sealing faces 6 7 or an approved alternative as a spray to the area of the valve seat and the soft metal seal 12 The test is satisfactory if a Up to five bubbles each second come from the valve seat b...

Page 154: ...rosion use engineers blue D Valve stem and valve guide for hard running marks D Valve cotters for damage or cracks D Compression spring for fretting or cracks D O rings in the housing for damage from disassembly D Valve spindle for scratches or other damage use engineers blue D Soft metal sealing i e fluted seal ring in the nozzle for damage or corrosion D Nozzle for corrosion or particles D Servo...

Page 155: ...he valve spindle moves freely e Put the valve guide and valve spindle in the vertical position f Make sure that the valve spindle moves down freely 2 Make sure that the servo piston moves freely in its housing 7 3 Valve Seat Leakage Check 1 Connect a pressurized air supply to the pressure reducing valve 94214B 2 Connect the pressure reducing valve 94214B to the valve guide 3 Set a low pressure set...

Page 156: ...re Stainless lubricant to the threads and surfaces of the six Allen screws 6 8 Torque symmetrically the six Allen screws 6 to 10 Nm 9 Measure the distance A between the end of the valve spindle 14 and the cover 17 The distance must be 8 5 mm 10 Clean the piston hole in the cover 2 11 Apply lubricating oil to the piston 3 12 Put the piston 3 fully into the cover 2 13 Measure the piston stroke B 14 ...

Page 157: ...sensor 2 This gives a clearance CL of 1 0 1 mm 24 Apply Never See NSBT to the threads of the sleeve 3 25 Hold the valve stroke sensor 2 in position 26 Put the sleeve 3 in position on the valve stroke sensor 2 27 Torque the sleeve 3 to 20 Nm 28 Clean the surfaces of the cover 9 and the cover 4 29 Put the cover 9 together with the rail valve 11 on the cover 4 Do not cause damage to the O ring 8 30 A...

Page 158: ...ace of the oil pipe 1 has no damage If there is damage grind the sealing faces refer to 8460 1 9 Adjust the claw 11 with an open ended wrench until there is a distance of 5 5mm between the claw and the end of the pipe 1 10 Attach the flange 3 and the high pressure hydraulic pipe 1 to the GAV 4 11 Apply oil to the threads and surfaces that touch of the four Allen screws 2 12 Torque the four Allen s...

Page 159: ...the compensator 1 is sufficiently compressed for installation 7 Make sure that the O rings 7 are in their correct positions Note During step 8 make sure that the O rings 7 stay in position 8 Put the compensator 1 and tool 94890 in position between the connecting block 4 and the flange 2 9 Make sure that the holes in the compensator 1 align with the holes in the flanges 2 10 Loosen the two bolts 6 ...

Page 160: ...gine must be stopped 17 Set to on the service pump to get the servo oil pressure to approximately 100 bar refer to the Operation Manual 4002 2 18 For a stroke signal test of the GAV refer to the Operation Manual 4002 2 paragraph 3 14 GAV Manual Valve Test 19 To start the engine and to change to gas mode refer to the Operation Manual 0275 1 and 4002 2 A1 Gas Fuel Pressure 2016 Gas Admission Valve R...

Page 161: ...age 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 The removal of the piston rod gland is done at the same time as the piston removal Examine the piston rod gland for wear and damage during each overhaul of the piston refer to 0380 1 Piston rod gland If ne...

Page 162: ...e holders 94345 Fig 1 are installed on to the piston rod foot 2 4 Remove the four inner bolts 3 Fig 2 from the support 4 5 Make sure that the piston rod gland is in the correct position on the two hinged covers 3 of the tool 94350 016 571 08 94345 94345B 94350 3 Fig 2 Fig 3 3 2 1 2016 Removal Disassemble Measure Worn Parts Assemble Installation 1 2 94345 013 223 05 Fig 1 ...

Page 163: ...parts that follow see Fig 5 D Tension springs 8 D Scraper rings 2 7 D Gaskets 5 6 D Pin 1 D Ring supports 3 4 5 Worn Parts Measure Note Refer to 0330 1 Clearance Table Piston Rod Gland for the maximum permitted dimensions of worn parts If necessary replace the worn parts 1 Compare the wear of the parts that follow D Scraper rings 2 7 D Gaskets 5 6 2 If necessary replace the tension springs 8 3 If ...

Page 164: ...IDE I I 1 2 3 4 5 6 II II WCH03495 7 6 9 1 2 3 4 10 8 Fig 6 Gland Box General Views 1 Locking Plate 6 Bolt 2 Screw 7 Spring dowel pin 3 Locking Plate 8 2 part housing 4 Screw 9 Screw 5 Support 10 O Rings 2016 Removal Disassemble Measure Worn Parts Assemble Installation ...

Page 165: ...n the distance piece 94315F 11 Make sure that there is an equal distance between the three parts 9 Use the assembly tool 94345E to attach the tension spring 6 to the ring support 4 10 Move the two distances pieces 94345F 11 up 11 Do step 8 and step 10 for the next two ring supports and 3 part scraper rings 12 Put the distance piece 94345F 13 in position 13 Put the two 4 part gaskets 7 and the two ...

Page 166: ...o 3403 1 9 Put new locking plates 3 and the inner bolts 4 in position 10 Tighten the inner bolts 4 11 Lock the inner bolts 3 with the locking plates 4 WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine Note Make sure that the piston rod gland moves freely into the cylinder jacket and does not tilt 12 Operate the turning gear...

Page 167: ... cylinder refer to the Operation Manual 8017 1 paragraph 3 7 Close the valves from the gas supply Make sure that there is no pressure in the gas pipes 8 Close the valves from the fuel supply and pilot fuel supply Make sure that there is no pressure in HP fuel pipes 9 Remove the hydraulic pipe to the exhaust valve refer to 8460 1 10 Remove the HP fuel pipe refer to 8733 1 11 Remove the applicable H...

Page 168: ... with the exhaust valve cage 5 and the top water guide jacket 3 4 Lower the cylinder cover 2 together with the exhaust valve cage 5 and the top water guide jacket 3 on to the wooden supports 3 Water Guide Jacket Removal 1 Use the applicable tools to remove the screws 4 2 Operate the engine room crane to lift the cylinder cover 2 approximately 10 mm Make sure that the top water guide jacket 3 stays...

Page 169: ...al eye bolts 94265A on the cylinder cover 2 7 Operate the engine room crane to move the cylinder cover 2 and exhaust valve into position above the top water guide jacket 3 8 Make sure that the holes in the cylinder liner 2 align with the holes for the bolts in the top water guide jacket 3 9 Carefully operate the engine room crane to lower the cylinder liner 2 on to the top water guide jacket 3 10 ...

Page 170: ... room crane and the special eye bolts 64265A 8 Operate the engine room crane to lift and move the cylinder cover 2 together with the exhaust valve cage 4 and top water guide jacket 3 into position above the cylinder liner Note During step 9 make sure that the cylinder cover aligns correctly with the elastic studs of the cylinder liner 6 9 Operate carefully the engine room crane to lower the cylind...

Page 171: ...all injectors 7 Connect all connections to cylinder cover and exhaust valve 8 Connect the starting air pipe 9 Open the valves you closed before one valve each time and do a check for leaks 10 Connect all other connections to the cylinder cover and exhaust valve 11 Fill the cylinder cooling water system 12 Set to on the cooling water pump 13 Make sure that cooling water is at the usual operation pr...

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Page 173: ...ng jacks 2 If the cylinder cover must be replaced refer to 2751 1 2 Pre tensioning Jacks Attach 1 Clean the threads of the eight elastic studs 5 Fig 1 and the area around the round nuts 4 Note You can attach the pre tensioning jacks 94215A with the vent screws 3 open or connect the hose 94935C to the adaptor 1 If you connect the hose 94935C to the adaptor put an oil tray in an applicable position ...

Page 174: ...ning jacks refer to paragraph 2 2 Operate the hydraulic unit 94942 3 Close the vent screws 1 Fig 1 when oil that has no air flows out 4 Operate slowly the hydraulic unit to increase the pressure to between approximately 1550 bar to 1560 bar Note Do not move the pistons 1 Fig 3 above the limit of the red groove 2 5 Use the round bar 6 to turn the round nuts 4 back approximately two full turns 6 Rel...

Page 175: ...e red groove 2 10 Use the round bar 6 to tighten the round nuts 4 11 Use a feeler gauge to make sure that there is no clearance at the slot 5 12 On the hydraulic unit decrease the pressure to zero 13 Remove all pre tensioning jacks 14 Compare the angle between the reference marks X and Y The tightening angle must be 530 If there is a large difference you must investigate the cause and do the proce...

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Page 177: ...ease on the profile cutter 94270A This will make sure that shavings do not fall into the combustion chamber 3 Make sure that the two set screws 5 are tight 4 Carefully put the cutting device 94270 and the profile cutter 94270A into the valve bush 2 in the cylinder cover 3 5 Attach the guide flange 1 to the valve bush 2 with the two screws 5 6 Put a ring spanner on the top of the cutting device 942...

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Page 179: ... the Allen screw 7 8 Torque the Allen screw 7 to 8 0 Nm 9 Apply a thin layer of oil to the O rings 2 10 Attach the device 94270 02 to the cylinder cover with the stud bolts 94270F as shown 11 Attach an electric drill to the spindle 1 12 Operate the electric drill at a maximum of 500 rpm Note During step 12 do not grind more than 1 0 mm from the bottom of the bore 3 13 Apply a light pressure and st...

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Page 181: ... shape 5 to the device 94270 01 with the clamp 6 and the the Allen screw 7 8 Torque the Allen screw 7 to 4 0 Nm 9 Apply a thin layer of oil to the O rings 4 10 Attach the device 94270 01 to the cylinder cover as shown 11 Attach an electric drill to the spindle 2 12 Operate the electric drill at a maximum of 500 rpm 13 Apply a light pressure and start grinding 14 Regularly remove the unwanted mater...

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Page 183: ...the shape 3 6 Attach the shape 3 to the device 94270 03 with the clamp 4 and the the Allen screw 5 7 Attach the device 94270 03 to the cylinder cover as shown 8 Attach an electric drill to the spindle 1 9 Operate the electric drill at a maximum of 500 rpm 10 Apply a light pressure and start grinding 11 Regularly remove the unwanted material from the device 94270 03 and the bore 6 12 Make sure that...

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Page 185: ...le 1 Fig 1 3 Make sure that the cooling for the injection valve is stopped refer to the Operation Manual 8016 1 paragraph 3 4 Remove the screws 2 together with the spring cage 3 from the injection valve 4 5 Put the two bolts 94270C Fig 2 in the positions as shown 6 Turn fully the two bolts 94270C until they touch the thread end in the valve bush 1 7 Turn equally the two bolts 94270C to lift the in...

Page 186: ...azard White spirit is a harmful substance Put on gloves and safety goggles when you use white spirit 3 Use white spirit to clean to the injection valve e g Shellsol TD Shellsol T or Solvent FP68 4 Put the injection valve in an applicable package 5 Put the injection valve in a clean dry area that has no contamination 2016 Injection Valve Removal and Installation ...

Page 187: ...rts set for the injection valve 3 Put the five new O rings 2 in position as follows a Put the bush 94289C in position as shown b Apply oil to the five O rings c Put the five O ringsin their correct positions d Remove the bush 94289C 4 Carefully put the the injection valve 1 into the valve bush 5 The dowel pin 3 makes sure that the injection valve is in the correct position 5 Put the two stud bolts...

Page 188: ...Seez NSBT8 to the threads and the seating surface of the screws 3 9 Tighten equally the screws 3 until the spring guide 6 is flush with the spring cage 5 10 Connect the cable 1 that you removed before to the terminal box 95 41 to 95 47 11 Install the HP fuel pipe refer to 8733 1 paragraph 4 2016 Injection Valve Removal and Installation WCH02401 Fig 4 1 7 6 5 3 4 2 Flush ...

Page 189: ...f a spring pack is not according to the requirements and it is the only available spring pack the same tightening instructions are to be followed The old spring pack must be repaired or replaced as soon as you get the new spring pack Note It is not recommended that diesel oil gas oil is used if the injection valve is put into storage after these checks The injection valve can get corrosion 2020 In...

Page 190: ...jector valve assembly 4 into the chamber 6 Apply a thin layer of Never Seez on the threads of two M12 Hexagon socket head cap screw 2 7 Tighten the screws in two steps a Equally tighten the screws spring guides are flush with each other b Check the screws are tightened to at least 35 Nm 8 Connect the injector cable in the terminal box Fig 2 2 3 1 4 1 8 0 2 2020 Injection Valve Installation Injecti...

Page 191: ...e D To assemble The properties of the calibration fluid e g Shell Calibration Fluid S 9365 Univar Calibration Fluid 1487 are as follows D The density at 15_C is 827 kg m3 ISO 12185 D The kinematic viscosity at 40_C is 2 6 mm2 s ASTM D445 D The pour point is 27_C ISO 3016 If calibration fluid is not available you can use clean diesel oil gas oil If clean diesel oil gas oil is used install the injec...

Page 192: ...oved from valve holder 94273 Fig 1 in the receiver 2 4 Use a brass wire brush to remove combustion particles from the external parts of the nozzle 5 Put the injection valve 1 in position in the valve holder 94273 Make sure that the injection valve points down 6 Attach the injection valve 1 to the valve holder with the spring cages 3 and Allen screws 4 7 Attach the HP hose 94275 to the connection p...

Page 193: ...NJECT button Make sure that fuel comes out of the nozzle as a spray 3 2 Results 1 For the correct operation and to use an injection valve again read the data below D The pressure to operate the injection valve is between 200 bar and 300 bar refer to the test above D For used injection valves a pressure decrease of 30 bar is permitted D Most of the fuel will come out as a spray from the top set of ...

Page 194: ...73 through 180 5 Operate the hydraulic cylinder 94269B and the slugging wrench 94269A 46 to loosen the locknut 1 6 Remove the locknut 1 Note The needle and nozzle body are machined together so that their sealing surfaces have the same contours You must keep these items together If it is necessary to replace the needle or the nozzle body you must replace the two items Do not replace only one item 2...

Page 195: ...e new nozzle tip is the correct type for the engine 1 Clean the parts with clean diesel oil or kerosine 2 Use a low pressure air supply to dry the parts 3 Put the new nozzle tip 1 in position on the nozzle body 2 Make sure that the dowel pin 5 engages with the hole in the nozzle tip 4 If necessary put the nozzle tip 1 in a vice 5 Attach the snap ring 3 to the recess in the nozzle body 2 Note After...

Page 196: ...fully remove the T handle 94289 and the pilot valve 3 8 Remove the bush 94289B 9 Examine all parts for damage and corrosion Replace parts that have damage or corrosion 3 7 Pilot Valve Installation 1 Put the bush 94289A Fig 5 into the coupling nut 2 2 Engage the pilot valve 3 with the T handle 94289 3 Put the T handle 94289 and pilot valve 3 through the bush 94289A 4 Turn the T handle 94289 to inst...

Page 197: ...nut 1 to the injection valve 2 with your hand 4 Refer to the formulas shown where D TS the applicable torque setting for the torque spanner D TT the specified torque setting for the coupling nut D D1 the distance from the center of the square drive to the center of the hand grip D D2 the distance from the center of the square drive to the center of the adapter 5 Use the torque spanner 94012 and th...

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Page 199: ...rt procedure D The starting air pipe becomes hotter than on adjacent cylinders during operation Read the data in 0380 1 Starting air valve for the applicable intervals to do checks on the starting air valve 2 Preparation 1 Stop the engine 2 Release the pressure in the starting air system as follows a Close the shut off valves on the starting air bottles b Turn the handwheel 2 10 of the starting ai...

Page 200: ...al connection from the 3 2 way solenoid valve 1 3 Remove the four screws 6 4 Carefully remove the starting air valve from the cylinder cover 4 5 Remove and discard the gasket 3 6 Put applicable protection over the opening in the cylinder cover 4 2016 Starting Air Valve Removal Disassemble Grinding Assemble Installation 1 3 I 5 WCH03192 4 2 I 5 6 1 Fig 1 ...

Page 201: ...ts 1 6 Remove the self locking nut 2 7 Carefully loosen the two nuts 1 until there is no spring pressure 8 Remove the tool 94281 9 Remove the piston 7 Fig 4 from the valve spindle 5 10 Remove the compression spring 6 from the housing 2 11 Remove the valve spindle 5 from the housing 2 12 Remove and discard the piston rings 1 4 13 Remove and discard the O rings 3 8 2016 Starting Air Valve Removal Di...

Page 202: ... faces of the housing 1 and the valve spindle 2 to get a good finish c Make sure that you keep the radius to the values given 6 Assemble 1 Clean all the parts of the starting air valve 2 Put a small quantity of oil on all the parts 3 Put a small quantity of oil on the new O rings 3 and 8 Fig 6 and the piston rings 1 4 4 Put the two new O rings 3 8 in the housing 2 5 Put the new piston rings 1 4 on...

Page 203: ...torque the self locking nut at this step 13 Fully tighten equally the two nuts 1 of the assembly tool 94412A 14 Torque the self locking nut to 140 Nm 15 Remove the tool 94281 16 Tap the top of the valve spindle 7 with a hammer The valve spindle must spring back to its initial position 17 Attach the cover 1 Fig 8 together with the solenoid valve 4 to the housing 3 with the two screws 2 18 Torque th...

Page 204: ...inder cover 4 Make sure that the control air pipe 5 goes into the bore of the cylinder cover correctly 6 Apply Never Seez NSBT 8 to the threads of the four screws 2 7 Put the four screws 2 in position in the cover 1 8 Symmetrically torque the four screws 2 to 80 Nm 9 Symmetrically tighten the screws 2 to an angle of 90 10 Tighten the connections of the control air pipe 5 11 Connect the electrical ...

Page 205: ...ust Valve Install 4 3 2 Round Nuts Install 5 4 Completion 6 5 Elastic Studs Replace 7 6 Other Materials 8 1 Preparation 1 Drain the cylinder cooling water from the applicable cylinder refer to the Operation Manual 8017 1 2 Close the air inlet to the air spring at the control air supply 3 Remove the applicable hydraulic pipe refer to 8460 1 4 Disconnect the cooling water pipe 5 Disconnect the oil d...

Page 206: ...ct the pre tensioning jacks to the hydraulic unit 94942 as shown 4 Use the round bar 4 to turn the round nuts 2 back one turn Make sure that there is a clearance 3 5 Do the procedure given in 9403 4 paragraph 1 and paragraph 2 to apply tension to the elastic studs 1 6 Remove the round nuts 2 009 701 02 1 2 94252 94934G 94252 94934G 94935 94935 94935 94934 013 622 05 94934A 94942 WCH03193 Fig 2 3 4...

Page 207: ...om crane to remove the exhaust valve 1 from the cylinder cover 5 Remove and discard the O rings 1 and 4 Fig 4 6 Attach the valve protector 94262 to the valve seat 3 7 Tighten the three screws 2 8 Move the exhaust valve to an applicable area 9 If necessary lower the exhaust valve on to a wooden underlay 2 3 Elastic Studs Examine 1 Examine the elastic studs for damage If it is necessary to replace t...

Page 208: ...ngine room crane to lift the exhaust valve 7 Remove the valve protector 94262 8 Put a small quantity of oil on the new O rings 1 and 2 Fig 6 9 Attach the new O rings 1 2 Note When you do step 10 make sure that you do not damage the threads of the elastic studs 10 Carefully lower the exhaust valve into the cylinder cover 3 Fig 8 Make sure that the dowel pin 2 in the cylinder cover engages with the ...

Page 209: ...d nuts 2 and related marks on the valve cage This shows their initial position 6 Put the two pre tensioning jacks 94252 Fig 9 in position on the elastic studs 1 7 Connect the pre tensioning jacks to the hydraulic unit 94942 as shown 8 Do the procedure given in 9403 4 to apply tension to the elastic studs 1 and tighten the round nuts 2 9 Look at the marks made before to make sure that the round nut...

Page 210: ...2 is in the correct position nearest to the valve cage 4 Install all pipes that you removed in paragraph 1 5 Install the hydraulic pipe refer to 8460 1 6 Connect the electrical connections 2 Fig 11 to the terminal box 4 and the valve stroke sensor 1 7 Attach the electrical cable of the valve stroke sensor 1 to the valve cage and the holder 3 8 Open the air inlet to the air spring at the control ai...

Page 211: ...tic stud 1 5 Put the elastic stud 1 into the applicable position 6 Tighten the elastic stud 1 refer to the instructions given in 0352 2 paragraph 2 Note Read the data in the documentation of the manufacturer to mix and apply the jointing compounds Table 1 Jointing Compounds and Hardeners Jointing Compound Hardener Adhesive Primer Manufacturer Elastosil RT 622 A RT 622 B G 790 Wacker Chemie Gmbh Ge...

Page 212: ...er at a permanent temperature of approximately 100_C D Have a short age curing time i e a minimum of 24 hours in accordance with ISO standard reference conditions D Flow easily to fill annular spaces and prevent voids D Have good adhesion on adhesive primed metallic surface D Are easy to prepare and mix D Have none or minimum surface shrinkage D The jointing compound must stay in an elastic condit...

Page 213: ...7 Non return Valve 8 4 Exhaust Valve Lock 8 1 General The International Association of Classification Societies recommends a minimum of two exhaust valves in storage on board These on board exhaust valves must be used to replace unserviceable items Only approved personnel or a Wärtsilä Services Switzerland Ltd or Winterthur Gas Diesel Ltd authorized repair workshop can repair or recondition defect...

Page 214: ...Maintenance 2751 2 A1 Winterthur Gas Diesel Ltd 2 8 Fig 1 Fig 2 Fig 4 Fig 8 Fig 9 Fig 10 Fig 3 Fig 9 I Fig 5 Fig 6 Fig 7 Fig 8 Fig 11 II Fig 5 Fig 11 2016 Exhaust Valve Disassemble and Assemble ...

Page 215: ...ve Drive Disassemble 1 Make sure that the exhaust valve is in a vertical position on wooden underlay 2 Remove the six nuts 2 Fig 2 3 Attach the applicable equipment to the eye bolt 1 4 Remove the valve drive 5 Remove the two screws 3 Fig 3 6 Remove the transmitter housing 2 7 Remove the valve stroke sensor 1 8 Remove the two screws 2 Fig 4 9 Remove the housing 1 2016 2 Fig 2 1 Exhaust Valve Disass...

Page 216: ...e Bush Remove 1 Remove the four screws 2 Fig 6 2 Remove the spacer 1 3 Remove and discard the rod seal ring 7 4 Use two jack screws or M10 threaded rods to remove the guide bush 5 5 Measure the inner diameter of the guide bush 6 Compare the value with that given in 0330 1 Clearance Table Exhaust Valve 3 Assemble 3 1 Guide Bush Install 1 Clean the bores 6 in the valve cage 4 2 Clean the valve bush ...

Page 217: ... valve cage 4 Note When you do step 8 below make sure that you do not damage the guide bush 8 Hold the valve spindle 7 in position then carefully lower the valve cage 4 over the valve spindle 9 Put oil on the new rod seal ring 7 Fig 6 10 Put the new rod seal ring 7 in position in the valve bush 5 11 Before you install a new piston seal ring 9 Fig 7 do as follows a Put the piston seal ring into ver...

Page 218: ...e hole in the valve cage 4 5 Put oil on the six nuts 1 6 Put the six nuts 1 on the elastic bolts 7 Torque symmetrically the six nuts 1 to 125 Nm 3 4 Valve Stroke Sensor Install 1 Clean the items that follow D Valve stroke sensor 10 D Transmitter housing 11 D The bore and collar in the housing 9 2 Put the valve stroke sensor 10 and the transmitter housing 11 into the bore 3 Attach the transmitter h...

Page 219: ...ce between the valve plate and the valve seat 5 Use the depth gauge 94126 Fig 9 to measure the height H from the edge of the top housing 2 to the bottom of the damper bore 6 Make sure that the distance H is 101 0 5 mm Note For example if the measured distance H is 100 mm you must install one shim Each shim has a thickness of 1 0 mm 7 Install the correct quantity of shims to get the correct distanc...

Page 220: ...housing 3 f Tighten the screw plug 2 3 7 Non return Valve 1 Do a check of the non return valve 1 Fig 11 as follows 2 Remove the non return valve 1 from the top housing 2 3 Make sure that the non return valve 1 operates correctly 4 Install the non return valve correctly in to the top housing 2 4 Exhaust Valve Lock If it becomes necessary to lock the exhaust valve refer to the procedure given in the...

Page 221: ...eat Installation 5 1 General You must replace the valve seat when D The seating surface has too much damage or D Frequent grinding has worn the valve seat to more than the specified limit 2 Preparation 1 Disassemble the valve and remove the valve spindle refer to 2751 2 3 Valve Seat Removal If a valve seat is removed e g to replace an unserviceable O ring you must D Grind the valve seat before ins...

Page 222: ...e top of the valve cage points up do the procedure that follows 1 Use the crane and an applicable lifting tool to hold the valve cage 2 Fig 2 immediately above an applicable wooden underlay 3 2 Use applicable wooden chocks to keep the valve cage 2 in position and prevent movement 3 Install the top two halves of the tool 94261 into the groove of the valve cage 2 4 Install the bottom two halves of t...

Page 223: ...itted limits for the valve seat 1 4 Use the feeler gauge 94122 to measure the values If the measured values are more than the limits shown you must replace the valve seat 1 5 If the measured values are less than the values given do the procedure that follows a Use the tool 94991 to grind the sealing face of the valve seat 1 Make sure that you get a smooth flat surface b Keep the valve seat angle t...

Page 224: ...n the valve spindle 4 because this can cause the sealing faces to seize 4 Tap the wooden block 2 with the hammer 1 three of four times 5 Use the feeler gauge 94122 to do a check of the clearance between the sealing faces of the valve spindle 4 and valve seat 3 Note The clearance must be as shown S 0 029 mm to 0 048 mm 6 Remove the valve spindle 4 from the guide bush 7 Do a check of the engineer s ...

Page 225: ...ing do the step below a Align the marks on the valve seat 2 with the marks on the valve cage 3 5 Push the valve seat 2 into the bore of the valve cage 3 6 Install the top two halves of the tool 94261 into the groove of the valve seat 2 7 Install the bottom two halves of the tool 94261 into the groove of the valve seat 2 8 Turn equally the three jack screws 1 to fully push the valve seat 2 into the...

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Page 227: ...grinding procedure 3 Put the valve spindle in position in the tool 94291 4 Put the template 94292 Fig 2 on the valve head 1 Note The data shown on the gauge 94292 shows the maximum limits for the valve head 5 Use the feeler gauge 94122 to measure the values 6 If the values are less than the limits given do the procedure that follows a Use the tool 94291 to grind the surface of the valve head 1 Rem...

Page 228: ...paragraph 2 3 Corrosion Corrosion can occur at the bottom of the valve plate when engines operate for long periods e g in rough weather conditions If the corrosion is less than or equal to 6 0 mm see Fig 2 the valve spindle can be repaired Note The repair procedure can only be done in a Wärtsilä Services Switzerland Ltd or Winterthur Gas Diesel Ltd authorized repair workshop Valve spindles cannot ...

Page 229: ...t injection valve refer to 0380 1 Pilot injection valve You must use the test bench 94272 and calibration fluid for the tasks that follow D To do the checks D To disassemble D To assemble You must read the instructions of the test bench manufacturer before you use it At random intervals do a check of the pressure gauges of the test bench with a master pressure gauge Adjust the the pressure as nece...

Page 230: ...outlet pipe 6 D Lubricating cooling oil inlet pipe 5 D Lubricating oil and fuel leakage pipe 4 D Control fuel pipe 3 8 Make sure that the fuel supply and the lubricating oil supply are closed 9 Make sure that the drain from the pilot injection valve 2 to the sludge tank is open 10 Set to off the power supply to the solenoid valve 3 Removal 1 Remove the applicable HP pilot fuel pipe 1 or 8 refer to...

Page 231: ...valve b Put the pilot injection valve in a clean dry area that has no contamination 12 If it is not necessary to put the pilot injection valve into storage continue from step 12 13 Do a check of a pilot injection valve 2 refer to paragraph 5 4 Coupling Nut Remove 1 Make sure that the test bench 94272 Fig 3 has no pressure 2 Attach the pilot injection valve to the valve holder 94272F as shown 3 Use...

Page 232: ...s from the external areas of the nozzle 4 Attach the pilot injection valve 2 to the valve holder 94273 with the spring cages and their Allen screws Make sure that the pilot injection valve points down 5 Attach the HP hose 94275 to the connecting piece 94272F 6 Connect the electrical connection to the test bench 7 Start the test bench in accordance with the manufacturer s instructions 8 Set the pre...

Page 233: ... operate a new pilot injection valve is approximately 350 bar D Most of the fuel will come out as a spray from the holes in the nozzle tip at the specified opening pressure D At the end of an injection no fuel must come out of the nozzle 7 Holder 1 Remove the six Allen screws 1 Fig 5 from the holder 2 2 Remove the holder 2 together with the prechamber 4 3 Make sure that the seals 5 6 are serviceab...

Page 234: ...or the torque spanner D TT the specified torque setting for the coupling nut 2 D D1 the distance from the center of the square drive to the center of the hand grip D D2 the distance from the center of the square drive to the center of the adapter 5 Use the torque wrench 94012 and the wrench extension 94269C 55 to torque the coupling nut 2 to 800 30 Nm 6 Do a test of the pilot injection valve refer...

Page 235: ...njection valve 1 into the valve holder 8 4 Put the stud bolts 94270F into the valve holder 8 as shown 5 Turn down equally the two nuts 6 until you get a distance of 47 mm between the flange 7 and the valve holder 8 6 Remove the stud bolts 94270F 7 Apply Never Seez NSBT to the threads and surfaces that touch on the two Allen screws 3 8 Attach the two distance pieces 4 to the pilot injection valve w...

Page 236: ...ting Rod Studs 3303 1 A1 Bottom End Bearing Removal Inspection and Installation 3303 2 A2 Top End Bearing Removal and Installation 3303 3 A2 Removal and Installation 3303 4 A2 Top End Bearing Bearing Cover Removal and Installation 3303 5 A2 Crosshead Clearances 3326 1 A1 Crosshead Pin Removal and Installation 3326 2 A2 Piston Removal and Installation 3403 1 A1 Changing the Compression Shims 3403 2...

Page 237: ...nded that you speak to Wärtsilä for support 2 Preparation Make sure that D The indicator valves are open D The ship floats freely in the water as horizontal as possible D The crankshaft is in position on all the main bearings The data that follow have an effect when you measure the crank web D The engine is cold or has service temperature D The temperature difference between the lubricating oil su...

Page 238: ... have a difference of more than 0 01 mm 6 Use the turning gear to move the crank to each position shown At each position record the indications on the dial gauge Note You can read from the dial gauge the change in the distance between the crank webs The smaller the difference the better the crankshaft is aligned 7 If the difference between the two BDC positions is more than 0 04 mm you must do the...

Page 239: ... for all conditions of ship operation after delivery i e D The draught and trim of the ship are in the limits for usual operation D The engine is hot or cold Usual Ship Operation Crank web Deflection Limits mm Vertical Horizontal Cylinder No 1 Driving end Cylinder No 2 to Last but One Cylinder Last cylinder Free end All Cylinders Note 1 Note 2 0 42 0 42 0 30 0 30 0 30 0 30 0 30 0 42 0 14 0 14 1 Fo...

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Page 241: ...e service life of a vibration damper is related to the speed range in which the engine operates Sea water and other types of water in the lubricating oil can cause the internal parts to become worn and decrease the effect of the vibration damper For View I I see Fig 2 I I 4 1 3 2 WCH02925 Fig 1 Vibration Damper front view 1 Vibration damper monitor 3 Damper casing 2 Monitor pipe 4 Oil supply pipe ...

Page 242: ...ibration damper if you think there is damage or the parts have become worn to more than the specified limits You must speak to the manufacturer for instructions Note Only specialists can make adjustments of the vibration damper The torsional vibrations and these adjustments must be done at the same time To do a check of the inner spring tips and groove flanks do the procedure that follows 1 Stop t...

Page 243: ...00 940 93 WCH02925 FREE END OIL SUPPLY Note Some parts can look different I I 2 4 2 6 3 Fig 2 Vibration Damper section view 1 Damper casing 4 Oil supply pipe 2 Vibration damper 5 Coupling bolt 3 Cover 6 Vent nozzle Inspection GEISLINGER Vibration Damper 2016 ...

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Page 245: ...revent injury to personnel Note For data about the axial damper monitor refer to the Operation Manual 3140 1 1 Read the data in 0012 1 General Guidelines for Lifting Tools 1 Set to off the bearing oil pump 2 Remove the two pipes 6 Fig 1 from the axial damper monitor 6 and the screw in unions 5 3 Remove the screws that hold the top cover 4 to the column and the bottom cover 4 Use applicable lifting...

Page 246: ...assemble 1 Remove the four screws 1 Fig 2 2 Remove the eight screws 3 from top cylinder half 2 On engines that have a vibration damper loosen fully the eight screws and pull them out as far as possible 1 2 3 Fig 2 3 2016 Axial Detuner Disassemble and Assemble ...

Page 247: ...s 4 Attach the manual ratchet 94016 002 to the lifting tool 94335 5 Attach the eye bolts 94040 M20 to the top cylinder half 1 6 Attach the manual ratchets 94016 001 to the eye bolts 94040 M20 as shown I I I 94016 001 94016 001 94040 M20 1 016 608 08a 94335 Fig 3 94016 002 I Axial Detuner Disassemble and Assemble 2016 ...

Page 248: ... cylinder half 1 8 Operate the manual ratchets 94016 001 and 94016 002 to move the top cylinder half 1 to the side as shown 9 Lower the top cylinder half 1 on to an applicable surface 016 609 08a 94016 002 1 1 94335 Fig 4 I I 2 3 2 3 5 4 94016 001 10 Do a check of the gaskets 2 5 If the gaskets have damage or contamination do step a and step b below a Turn the gaskets 2 5 until you can remove the ...

Page 249: ...der half into position above the bottom cylinder half 6 Carefully lower the top cylinder half on to the bottom half of the cylinder Make sure that you do not cause damage to the and the tension springs Note Use the two taper pins 3 Fig 5 to help you to get the top cylinder in the correct position 7 Install the four M24 screws 1 to the top cylinder half 4 Refer to 0352 2 paragraph 1 for the applica...

Page 250: ...esel Ltd 6 6 4 Completion 1 Attach the two pipes 2 Fig 6 to the top cylinder half 4 2 Attach the top housing 1 3 Connect the two pipes 3 to the screw in unions 2 I I I I 1 4 5 6 WCH03505 2 3 Fig 6 Axial Detuner Disassemble and Assemble 2016 ...

Page 251: ... turning gear 1 Fig 1 you must do a check of the condition of the tooth flanks on the pinion 2 and the flywheel 3 Also you must make sure that lubricant is applied to these components For maintenance of the turning gear refer to the instructions given in the supplier documentation 2 013 051 05 3 1 Fig 1 2016 Turning Gear ...

Page 252: ...ut an applicable quantity of Klüberfluid into a container Put the container into warm water until the Klüberfluid is at approximately 35_C Apply the Klüberfluid as shown in the photograph 2 2 Lubrication Intervals 1 Look at the tooth flanks If the highest loaded areas of the tooth flanks do not have much lubricant apply the lubricant as given in Table 1 and Table 2 2 Apply the lubricant each 2000 ...

Page 253: ...ent You use the platform 94142 Fig 1 and support 94143 when you do work in the crank area and between the columns The platform and support help to prevent accidents in these areas You install the platform 942142 with the nuts 94142A to the longitudinal beam 2 and the crank 1 You install the support 94143 between the columns at the applicable height on the steps 4 You put the straps 3 around the st...

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Page 255: ...r the removal and installation of heavy engine components the lifting tool 94335 is attached between double I girders 1 The lifting tool is attached with spring dowel pins and tightened with the screws 94335C Note The permitted Work Load Limit WLL is 1740 kg The strand angle must not be more than 30 I I I I 94017 II I II I 94335B 2 94335C 94335 94335 3 1 018 385 09 WCH00684 Fig 1 Top Platform 2016...

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Page 257: ...tud of bottom end bearing 2 3 Tensioning the stud of bottom end bearing 3 4 Loosening the stud of top end bearing 4 5 Tensioning the stud of top end bearing 5 1 General Note Read the instructions 9403 4 referring to the application of hydraulic pre tensioning jacks to screwed connections Check if the nuts 2 or 5 turn freely on the threads CAUTION Never turn the crankshaft with the turning gear as ...

Page 258: ... shown in Fig 2 6 Actuate the hydraulic unit until bubble free oil flows out through the vent screws Close the vent screws 7 7 Actuate the hydraulic unit up to about 1530 bar and keep pressure constant Pistons 8 of the pre tensioning jacks must never exceed the red limiting grooves BN Fig 3 8 Use the round bar RS and screw back the nuts 5 by one turn 9 Release the pressure to 0 at the hydraulic un...

Page 259: ...nd check with the feeler gauge through slot KO Fig 3 that no clearance remains between nut and supporting surface Check with the feeler gauge that no clearance remains between bearing cover and connecting rod Should clearance remain loosen the fastening and compare the bearing protrusion with the nominal value as indicated in 3303 2 9 After tensioning to the 1st step mark the position of the nuts ...

Page 260: ...g 4 5 Actuate the hydraulic unit until bubble free oil flows out through the vent screws Close vent screws 6 Actuate the hydraulic unit up to about 1530 bar and keep pressure constant Pistons 8 of the pre tensioning jacks must never exceed the red limiting grooves BN Fig 5 7 Use the round bar RS and screw back the nuts 2 by one turn 8 Release the pressure to 0 at the hydraulic unit and then remove...

Page 261: ... round bar RS and check with the feeler gauge through slot KO Fig 5 that no clearance remains between nut and supporting surface Check with the feeler gauge that no clearance remains between bearing cover and connecting rod Should clearance remain loosen the fastening and compare the bearing protrusion with the nominal value as indicated in 3303 3 9 Do the same procedure for the second pair of the...

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Page 263: ... are near the flywheel or in the engine 2 Preparation 1 Operate the turning gear to turn the crankshaft until the applicable crank is at TDC 2 Lock the turning gear 3 Attach the swivel lugs 94048 M30 Fig 1 to the bearing cover 3 4 Attach the manual ratchets H1 H2 to the column and the eye bolts 94040 M8 on the bearing cover 3 5 Attach the lifting tool 94335 between double I girders 6 Attach the ch...

Page 264: ...e the manual ratchet H2 from the bearing cover 1 10 Unlock the turning gear 11 Operate the turning gear to move the crank approximately 70 to the exhaust side 12 Lock the turning gear 13 Remove part of the bottom plate from the middle platform 14 Operate the chain block H3 to move the bearing cover 1 through the column door 15 Lower the bearing cover 1 on to the floor plate 16 Remove the chain blo...

Page 265: ...to carefully turn the crankshaft to the fuel side until the guide shoes touch the retaining pins 94323 Make sure that the guide shoes touch equally the retaining pins If necessary adjust the retaining pins 5 Attach the manual ratchet H1 to the column and the connecting rod 6 Operate the manual ratchet H1 to hold the connecting rod in the position shown 7 Operate the turning gear to move the cranks...

Page 266: ...rod is the same 4 Attach the bearing shell to the connecting rod with the Allen screws 2 5 Make sure that the crank pin 1 is in a satisfactory condition 6 Put oil on the crank 1 7 Put oil on the surface of the bearing shell 8 Remove the work platform 94142 9 Operate the turning gear to move the crank to TDC Make sure that distances at X between the crankshaft and the bottom end bearing are equal 1...

Page 267: ...bearing shell and the connecting rod is the same 7 Remove the chain 94333I 8 Remove the two eye bolts 94040 M6 9 Attach the bottom bearing shell 1 to the bearing cover 2 with the two screws 3 9 Bearing Cover Installation 1 Attach the chain block H3 to the eye bolt on bearing cover 1 Fig 8 2 Attach the manual ratchet H1 to the top attachment point in the column and the eye bolt on the bearing cover...

Page 268: ...d for some days use a mixture of high viscosity oil steam engine cylinder oil ISO VG 1000 1500 and bearing oil The ratio is two thirds ISO VG 1000 1500 to one third bearing oil Note A list of suppliers for ISO VG 1000 1500 high viscosity oils is given in Table 1 11 Put the round nuts 1 Fig 10 on the elastic studs 12 Tighten the round nuts 1 equally with a round bar 13 Measure the distances X1 X2 b...

Page 269: ... 49 0 0 913 BP ENERGOL DCW 1000 920 40 0 0 913 CHEVRON CYLINDER OIL 1000 1000 43 1 0 937 EXXON ESSO CYLESSO 1000 950 44 0 EXXON ESSO CYLESSO TK 1000 925 46 7 MOBIL EXTRA HECLA SUPER Cylinder Oil 680 39 0 0 905 SHEEL FIONA Oil 1500 1500 37 0 0 958 SHEEL VALVATA OIL 1000 1000 45 4 0 924 TEXACO 650T MINERAL Cylinder Oil 985 44 0 0 919 2016 Bottom End Bearing Removal Inspection and Installation ...

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Page 271: ... Bearing Shell Installation 6 5 1 Installation with Piston Installed 6 5 2 Installation with Piston Removed 8 1 General WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine 2 Bearing Shell Removal Note You can examine the bearing shell with piston installed or removed 1 Read and obey the data in 0012 1 General Guidelines for L...

Page 272: ...94370H to the bearing cover 4 and guide shoe 6 3 Attach the two eye bolts 94040 M8 to the guide shoe 6 4 Attach the two lifting rings 94332 to the cylinder block 1 with the four screws 2 5 Torque the four screws 2 to 200 Nm 6 Attach the manual ratchets H3 H4 to the lifting rings 94332 and the eye bolts 94040 M8 2016 Top End Bearing Removal Inspection and Installation 013 021 05 H4 94332 H3 FREE EN...

Page 273: ...Put the four retaining pins 94323 in the holes in the guideways 1 9 Operate carefully the manual ratchets H3 H4 to lower the guide shoes on to the retaining pins 94323 10 Make sure that the guide shoes touch equally the retaining pins If necessary adjust the retaining pins 2016 Top End Bearing Removal Inspection and Installation 2 H4 H3 I I 013 627 05 Fig 3 1 94323 ...

Page 274: ... 5 Operate the engine room crane to lift the crosshead pin 6 above the bottom bores in the guideways 5 6 Put the four retaining pins 94323 in the holes in the guideways 5 as shown 7 Operate the engine room crane to carefully lower the guide shoes 3 on to the four retaining pins 94323 8 Make sure that the guide shoes 3 touch equally the retaining pins 94323 If necessary adjust the retaining pins 9 ...

Page 275: ...ell 7 Attach the chain 94666I to the eye bolts 94040 M6 and the manual ratchet H1 8 Apply protection to the threads of the elastic studs on the connecting rod This prevents damage to the bearing shell 9 Operate the manual ratchet H1 to carefully lift the bearing shell a small distance 10 Attach the chain block H5 to the chain 94666I 11 Remove the manual ratchet H1 from the sling 94666I 12 Carefull...

Page 276: ...h the chain 94666I to the manual ratchet H5 and the eye bolts 94040 M6 7 Operate the chain block H5 to lift the bearing shell 1 to the height of the column door 8 Attach the manual ratchet H1 to the chain 94666I 9 Operate the chain block H5 and the manual ratchet H1 to carefully lower the bearing shell 1 into the connecting rod 10 Install the two screw screws 2 Fig 5 Note Make sure that the distan...

Page 277: ...llow D Manual ratchets H3 H4 D Retaining pins 94323 D Stop plate 94370H D Eye bolts D Two lifting rings 94332 22 Put the round nuts 3 Fig 9 on the elastic studs 2 23 Tighten the round nuts 3 equally with a round bar 24 Measure the distance X1 X2 between the edges of the bearing shells 1 and the connecting rod 4 25 Refer to 0330 1 Group 3303 to get the clearance values X1 X2 for new bearing shells ...

Page 278: ...6I to the manual ratchet H5 and the eye bolts 94040 M6 7 Operate the chain block H5 to lift the bearing shell 1 to the height of the column door 8 Attach the manual ratchet H1 to the chain 94666I 9 Operate the chain block H5 and the manual ratchet H1 to carefully lower the bearing shell 1 into the connecting rod 10 Install the two screw screws 2 Fig 5 Note Make sure that the distance between each ...

Page 279: ...he engine room crane D Retaining pins 94323 D Stop plate 94370H D Eye bolts D Lifting plate 94324 22 Put the round nuts 3 Fig 12 on the elastic studs 2 23 Tighten the round nuts 3 equally with a round bar 24 Measure the distance X1 X2 between the edges of the bearing shells 1 and the connecting rod 4 25 Refer to 0330 1 Group 0303 to get the clearance values X1 X2 for new bearing shells 26 Install ...

Page 280: ...80 49 0 0 913 BP ENERGOL DCW 1000 920 40 0 0 913 CHEVRON CYLINDER OIL 1000 1000 43 1 0 937 EXXON ESSO CYLESSO 1000 950 44 0 EXXON ESSO CYLESSO TK 1000 925 46 7 MOBIL EXTRA HECLA SUPER Cylinder Oil 680 39 0 0 905 SHEEL FIONA Oil 1500 1500 37 0 0 958 SHEEL VALVATA OIL 1000 1000 45 4 0 924 TEXACO 650T MINERAL Cylinder Oil 985 44 0 0 919 2016 Top End Bearing Removal Inspection and Installation ...

Page 281: ... careful when you move the connecting rod 2 Preparation 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Remove the bottom end bearing cover refer to 3303 2 Note If the piston is installed refer to 3303 2 paragraph 2 1 to lift the crosshead 1 Fig 1 Note If the piston is removed refer to 3303 3 paragraph 2 2 to lift the crosshead 1 3 Attach the holder 94331 to the connecting rod 2 w...

Page 282: ...point in the column and the eye bolt EB2 7 Remove the manual ratchet H2 8 Remove the eye bolt EB1 9 Operate the turning gear to move the crank counterclockwise approximately 45 At the same time operate the manual ratchet H1 Fig 3 to get the connecting rod through the column door 10 Remove the applicable bottom plates from the middle platform 11 Attach the chain block H5 to the eye bolt EB2 12 Remo...

Page 283: ...H2 to the eye bolt EB3 Apply a light tension to the chain 17 Remove the holder 94331 18 Operate carefully the manual ratchets H1 H2 and the chain block H5 to remove the connecting rod from the crank pin 19 Remove the manual ratchet H1 20 Operate the chain block H5 Fig 5 and the manual ratchet H2 to remove the connecting rod from the engine 2016 Connecting Rod Removal and Installation H2 94331 EB3 ...

Page 284: ...lt EB2 4 Attach the manual ratchet H2 to the eye bolt EB3 Note When you do step 5 make sure that you do not cause damage to the bearing shell or the crank pin 5 Operate carefully the chain block H5 Fig 7 and the manual ratchet H2 to move the connecting rod 3 to the crank pin 1 6 Attach the manual ratchet H1 to the eye bolt EB3 7 Attach the holder 94331 to the connecting rod 2016 Fig 6 H2 H5 Fig 7 ...

Page 285: ...he manual ratchet from the eye bolt EB3 11 Remove the chain block H5 from the eye bolt EB2 12 Operate the turning gear to move the crank clockwise 13 Attach the manual ratchet H2 Fig 9 to the eye bolt EB2 14 Remove the manual ratchet H1 from the eye bolt EB2 15 Remove the manual ratchet H1 from the the top attachment point in the column 2016 Connecting Rod Removal and Installation Fig 8 013 036 05...

Page 286: ...Remove the holder 94331 5 Completion Note If the piston is installed refer to 3303 2 paragraph 5 1 step 18 to step 26 to lower the crosshead 1 Note If the piston is removed refer to 3303 3 paragraph 5 2 step 18 to step 26 to lower the crosshead 1 1 Install the bottom end bearing cover refer to 3303 2 2 Measure the clearances refer to 0330 1 3 Remove all tools and equipment from the work area 2016 ...

Page 287: ...e the crank of the applicable cylinder to BDC 3 Attach the work platform 94142 Fig 1 refer to 3301 1 4 Remove the nuts of the elastic studs on the piston rod foot refer to 9403 4 5 Attach the bosses 94333A to the piston rod foot 3 with the Allen four screws 5 6 Attach two eye bolts EB to the piston rod gland support 1 7 Attach the chains 94333B to the eye bolts EB 8 Remove the work platform 94142 ...

Page 288: ...g rings 94332 to cylinder block 1 with screws 2 4 Torque the screws 2 to 200 Nm 5 Attach the manual ratchets H1 H2 to the lifting rings 94332 and the eye bolts EB1 EB2 6 Operate equally the manual ratchets H1 H2 to lift the bearing cover 3 7 Attach protection to the crosshead pin 4 to prevent damage and contamination Top End Bearing Bearing Cover Removal and Installation 2016 EB2 H2 H1 94332 013 0...

Page 289: ...e middle platform 13 Operate equally the manual ratchets H1 H2 and H3 Fig 5 to lower the bearing cover 1 until the chains of the manual ratchet H3 is vertical 14 Remove the manual ratchets H1 H2 from the eye bolts EB1 EB2 15 Attach the chain block H5 to the chain 94666I 16 Operate the chain block H4 and the manual ratchets H3 to move the bearing cover out of the column 17 Lower the bearing cover o...

Page 290: ... the chain 94666I 7 Operate the manual ratchet H3 to move the bearing cover above the crosshead pin 8 Attach the manual ratchets H1 H2 Fig 6 to the eye bolts EB1 EB2 9 Remove the manual ratchet H3 from the chain 94666I 10 Remove the chain 94666I from the eye bolts EB1 EB2 Note During step 11 make sure that the bearing cover 3 is level and vertically aligned with the center of the crosshead pin 4 T...

Page 291: ...r to move the crosshead pin up sufficiently to loosen the chains 94333B Make sure that the dowel pins 2 engage correctly 3 Remove the chains 94333B 4 Operate the turning gear to lower the crosshead pin and the piston to BDC 5 Remove the bosses 94333A the chains 94333B and the eye bolts EB 6 Attach the round nuts to the elastic studs 1 7 Tighten the round nuts refer to 9403 4 8 Remove all tools and...

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Page 293: ...3 Note The clearance C is applicable for the full length of the guide way 3 and measured at the position shown in Fig 2 2 2 Crosshead 1 Measure the lateral clearance D at each position of the crosshead as follows a Use an applicable hardwood wedge or an item that is almost the same to push the crosshead axially to one side Make sure that you apply the pressure only to the guide shoe 2 3 Guide Shoe...

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Page 295: ...4 Guide Shoes Installation 7 5 Crosshead Pin Installation 7 6 Clearance Checks 10 7 Completion 10 1 Preparation WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Operate the turning gear to move the applicable crank to BDC 3 Lock the turning gear to prevent an...

Page 296: ...6 to the manual ratchet H1 and to one of the shackles on the lifting plate 94324 4 Attach the eye bolts EB Fig 2 to the connecting rod 2 as shown 5 Attach the manual ratchets H2 H3 to the attachment points in the column and the eye bolts EB Apply a light tension to the manual ratchets 6 Operate the manual ratchets H2 H3 to lift the crosshead pin 1 as far as possible 2016 Crosshead Pin Removal and ...

Page 297: ...onnecting rod cannot move back to the fuel side 9 Remove the manual ratchet H3 and the related eye bolt EB 10 Operate the manual ratchet to move the connecting rod until on to the wooden chock 1 11 Remove the manual ratchet H2 12 Operate the manual ratchet H1 Fig 4 to lower the crosshead pin 1 to the same height as the column door frame 2016 Crosshead Pin Removal and Installation 013 239 05 94666 ...

Page 298: ... 1 4 16 Connect the manual ratchets H4 H5 to the lifting rings 94332 and the eye bolts EB 17 Operate the manual ratchets H4 H5 to hold the weight of the guide shoes 1 4 from the crosshead pin 18 Remove the bolts 2 Fig 6 tab washers 5 and holding plates 3 from the guide shoe 1 Fig 6 1 2 3 5 WCH03529 Crosshead Pin Removal and Installation 2016 I I 013 241 05 013 242 05 I I 6 94332 5 3 94324 2 Fig 5 ...

Page 299: ...the driving end as shown 20 Operate the manual ratchet H4 to lift the guide shoe 2 21 Move the crosshead pin 1 to the free end 22 Operate the manual ratchet H5 to lift the guide shoe 3 Crosshead Pin Removal and Installation 2016 DRIVING END H4 013 243 05 H5 3 1 FREE END 013 244 05 Fig 7 2 1 ...

Page 300: ...n 3 Guide Shoes Removal 1 Record the positions of the guide shoes The shims of the guide shoes can have different dimensions This will help you during the installation procedure 2 Attach the manual ratchet H1 Fig 9 to the eye bolt EB at the free end 3 Lower the guide shoe to the door frame 4 Remove the manual ratchet H4 5 Turn the guide shoe 1 in the center of the cylinder H5 H4 H5 H4 H1 H1 94666 ...

Page 301: ...frame 4 Attach the manual ratchet H5 Fig 9 to the eye bolt on the guide shoe Apply tension to the chain 5 Remove carefully the chain block H6 6 Operate the manual ratchets H5 H1 to lift the guide shoe 7 Remove the manual ratchet H1 8 Do step 1 to step 7 for the other guide shoe use the manual ratchet H4 5 Crosshead Pin Installation 1 Clean the crosshead pin 1 Fig 11 and the guide and bearing surfa...

Page 302: ... 11 Lower and align the guide shoe 3 with the crosshead pin 1 12 Align the crosshead pin 1 with the two guide shoes 2 3 13 Attach the two holding plates 5 to the to the guide shoe 2 3 with new tab washers 6 and bolts 4 14 Make sure that there is no clearance between the holding plates 5 and the crosshead pin 1 15 Crosshead Pin Removal and Installation 2016 Fig 12 DRIVING END H4 013 243 05 H5 3 1 F...

Page 303: ...dually tighten the manual ratchet H2 At the same time keep tension on the chain of the manual ratchet H3 22 Continue with the step above until the connecting rod 1 aligns with the crosshead pin 3 Note During the step below make sure that the elastic bolts in the connecting rod align with the holes in the crosshead pin 23 Carefully lower the crosshead pin 3 on to the connecting rod 1 24 Remove the ...

Page 304: ...ing rod refer to 9403 4 2 Install the top bearing cover refer to 3303 5 paragraph 3 3 Attach the piston to the crosshead refer to 3303 5 paragraph 4 4 Set to on the lubricating oil pump 5 Make sure that the crosshead and the bottom end bearings of the connecting rod have sufficient lubrication 6 Remove all tools and equipment from the work area Crosshead Pin Removal and Installation 2016 ...

Page 305: ...op the engine refer to the procedure in the Operation Manual 4002 2 3 Let the engine temperature decrease before you start the removal procedure 4 Make sure that all tools and equipment are clean 5 Remove the cylinder cover refer to 2708 1 6 Look at the area of the piston ring stroke If there is unwanted material refer to the procedure in 2124 3 7 Clean the top part of the cylinder liner 8 Install...

Page 306: ...e support 6 Do not remove the support 6 5 Attach the two eye bolts EB to the support 6 6 Attach the lifting bosses 94333A to the piston rod foot 4 with the Allen screws 3 7 Attach the two suspension chains 94344B to the eye bolts EB and the lifting bosses 94333A Note When you do step 8 make sure that the bolts of the piston rod foot do not catch 8 Operate the turning gear to move the crank to BDC ...

Page 307: ...e the turning gear to move the crosshead up sufficiently so there is no tension on the chains 94344B Fig 6 12 Remove the chains 94344B the eye bolts EB and the lifting bosses 94333A 13 Attach the two distance holders 94345 Fig 7 to the piston rod foot 1 with the four screws Piston Removal and Installation 2016 94344A Fig 5 94344B Fig 6 WCH03082 WCH03082 1 94345 Fig 7 ...

Page 308: ... six bolts 1 and the three brackets 2 19 Apply Molykote paste G n to the threads of the six bolts 1 20 Attach the crane hook 4 Fig 11 to the lifting tool 94341 21 Carefully lower the tool 94341 on to the piston crown Make sure that the grooves for the brackets 2 align with the holes in the piston crown 3 Note To help you align the brackets 2 first attach one bracket to the tool 94341 22 Attach the...

Page 309: ...n rod foot is below the plates 2 31 Close the plates 2 32 Push fully in the two supports 1 33 Tighten the four screws 3 34 Lower the piston on to the supports 1 35 Remove the crane hook from the tool 94341 36 Remove the distance holders 94230 from the piston rod foot 37 Remove the tool 94341 38 To disassemble the piston refer to 3403 3 39 Do a check of the top surface of the piston refer to 3403 4...

Page 310: ...the sling 94209 to the engine room crane 10 Operate the crane to put the tool 94342 in position on the cylinder liner 3 Lock the tool in position with the three bolts 2 11 Make sure the distance holders 94345 Fig 7 are installed on the piston rod foot 1 12 Make sure that the spacer 94344A Fig 15 is in position on the crosshead 13 Attach the tool 94341 to the piston crown refer to step 17 to step 2...

Page 311: ...e four eye bolts EB 29 Operate the turning gear to move the piston to BDC until the two chains 94333B have tension 30 Continue to operate the turning gear to move the crank to BDC until you can remove the spacer 94344A 31 Remove the spacer 94344A Note When you do step 32 make sure that the bolts on the crosshead 1 align with the holes in the piston rod foot 32 Operate the turning gear to move the ...

Page 312: ...emove the tool 94209 from the cylinder liner 3 44 Make sure that the cylinder liner and the anti polishing ring 1 Fig 19 are clean and in a satisfactory condition 45 Put oil on the surfaces of anti polishing ring 1 46 Connect the crane to the lifting tool 94209 47 Attach the tool 94208 to the tool 94208 48 Operate the crane to lower the anti polishing ring 1 into the cylinder liner 49 Remove the l...

Page 313: ...e ports on the fuel side Make sure that the running surface of the cylinder liner stays dry Note A defective O ring in the piston rod gland can cause an increase of the dirty oil level in the scavenge air space 4 Do a function check of the cylinder lubrication refer to 7218 1 paragraph 1 2 5 Remove all tool and equipment from the work area Piston Removal and Installation 2016 ...

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Page 315: ...re that no personnel are near the flywheel 1 Turn crank of the cylinder concerned to B D C 2 Install working platform 94142 refer to the instruction in 3301 1 3 Loosen the nuts of the waisted studs for the screwing of piston rod foot 3 and crosshead pin 4 as described in 3403 1 4 Attach the lifting bosses 94333a with their Allen screws 5 on the piston rod foot 5 Screw two RUD eye bolts RC into pis...

Page 316: ... and remove the screws fastening compression shim 6 9 Use the two eye bolts to remove the compression shims 6 For installation a new compression shim note that there are two different compression shims see below Use an applicable one for installation Do the installation in a reverse sequence to the removal Note Please note the correlation between setting screw ST on measuring gauge 94225 see 2124 ...

Page 317: ...Winterthur Gas Diesel Ltd 3 3 013 693 05 013 694 05 RC 7 94333B 94333A 3 8 6 I II ONLY FOR ENGINES WITHOUT ADDITION HP CROSSHEAD LUBRICATION PUMP ONLY FOR ENGINES WITH ADDITION HP CROSSHEAD LUBRICATION PUMP COMPRESSION SHIMS ...

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Page 319: ...2 3 Assemble 4 1 General 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Remove the piston refer to 3403 1 Note You disassemble a piston to clean the chamber in the piston head do an overhaul of the ring grooves etc Note When you do step 3 apply tension to the elastic bolts in the sequence given in Fig 1 3 Apply tension to the elastic bolts 1 to loosen the eight round nuts refer t...

Page 320: ... bolts 1 6 Attach the engine room crane to the lifting tool 94341 Fig 3 7 Attach the crane hook to the lifting tool 94341 8 Carefully lower the tool 94341 on to the piston crown Make sure that the grooves for the brackets 2 align with the holes in the piston crown 3 Note To help you align the brackets 2 first attach one bracket to the tool 94341 9 Attach the three brackets 2 to the tool 94341 with...

Page 321: ...cking screws 94364C to remove the piston skirt 5 from the piston rod 6 Note When you lift the piston skirt 5 make sure that the spring dowel pin 1 does not catch c Lift the piston skirt 5 away from the piston rod 6 15 Remove the 12 bolts 8 16 Use the two jacking screws 94364B to remove the spray plate 4 from the piston rod 6 17 If necessary remove the pipes 3 and nozzles 2 18 Do a check of the top...

Page 322: ...te 5 Fig 6 to the piston rod 6 with the 12 screws 8 9 Torque the 12 screws 8 as follows a Symmetrically torque the 12 screws to 12 Nm b Symmetrically torque the eight screws to an angle of 30 This is equal to to a torque value of 22 Nm Note When you do step 10 make sure that the dowel pin 3 engages in the related hole in the piston skirt 5 10 Attach the piston skirt 5 to the piston rod 6 with the ...

Page 323: ... to Fig 1 for the sequence to apply tension to the elastic studs 13 Apply tension to the 12 elastic studs 1 Fig 7 14 Tighten the round nuts 1 on the elastic bolts 2 15 Install the piston refer to 3403 1 paragraph 3 2016 Piston Disassemble and Assemble 2 1 Fig 7 ...

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Page 325: ...e 94366B around the axis of the piston head 3 Use the feeler gauge 94122 to measure the depth of the burn scar s 4 Remove the template 94366B Note You can also use a depth gauge to measure the depth of the burn scar s 5 If the burn scars are less than 10 mm do step a and step b a Use an applicable tool to grind the burn scars b Use emery paper to make sharp edges smooth 6 If the burn scars are mor...

Page 326: ...the template 94366A 6 If there are more burn scars put the template 94366A through the related scavenge port 1 and do step 2 to step 4 again 7 If the burn scars are less than 10 mm do step a and step b a Use an applicable tool to grind the burn scars b Use emery paper to make sharp edges smooth 8 If the burn scars are more than 10 mm do step a to step d a Remove the piston refer to 3403 1 paragrap...

Page 327: ...ston Rings Installation 8 3 5 New Piston Rings Installation 9 4 Piston Rings Storage 9 1 General Use the data in paragraph 2 1 and paragraph 2 3 to make an analysis of the of the condition of the cylinder liner piston and piston rings The rates of wear are related to the type of fuel used the engine load profile ambient conditions etc during engine operation Visual inspections show very important ...

Page 328: ...ve the piston almost to BDC so that you can see the piston rings 4 Clean the surface of the piston ring 1 Fig 1 at the locations P1 to P9 5 Put the sensor of the Permascope MP0 94356 against the middle of the piston ring 1 6 Record the value on the digital display of the Permascope MP0 94356 7 Compare the measured data with the limits given in 0330 1 Clearance Table Piston and Piston Rings If the ...

Page 329: ...yer is Worn Fig 2 With regular procedures to measure the chrome ceramic layer you can calculate the rate of wear for each piston ring You can continue to use the piston rings if the remaining chrome ceramic layer is more than the limits that follow D Top piston ring more than 0 05 mm D Middle and bottom piston rings more than 0 02 mm If the thickness of the chrome ceramic layer is less than the li...

Page 330: ... Table 1 Rate of Wear Examples D1 D2 T1 T2 WR 0 382 0 367 0 new 1500 0 01 0 351 0 340 3500 5000 0 0073 Use the formula below to calculate the remaining piston ring service life LT D2 Dmin x 1000 WR Where D LT Remaining in service time hrs D D2 second recorded thickness of chrome ceramic layer mm D Dmin Minimum thickness of the chrome ceramic layer mm see paragraph 2 2 D WR Calculated rate of wear ...

Page 331: ...e feeler gauge will touch the inner diameter of the groove 2 Measure the clearance X1 at Point A If there is unwanted material on the chrome ceramic layer you can push the feeler gauge only to that point 3 Measure the clearance at X2 4 Do step 2 and step 3 above at between two and four different locations around the piston 2 The sum of each value from X1and X2 will give the total piston ring clear...

Page 332: ...piece of piston ring paragraph 3 3 2 to measure the grooves in the piston head 3 3 1 Procedure with Calliper Gauge or Inside Micrometer Set 1 Use the calliper gauge 1 Fig 5 or inside micrometer set 94101 to measure the height of the groove at point A and point B Measure the height of the groove at a minimum of four locations around the circumference of the piston head 2 Record the value from the c...

Page 333: ... circumference of the piston head 2 4 Use the data that follow to calculate the piston ring clearance C GH RT Where D C Clearance mm D GH the measured height of the piston ring groove mm D RT the nominal piston ring thickness mm Note If the clearance at X1 is more than the permitted value you must repair the piston head For the maximum values refer to 0330 1 Piston and Piston Rings For the repair ...

Page 334: ...en the piston rings too far This will cause damage to the piston rings Note Only install piston rings that are in a satisfactory condition Make sure that the mark TOP on the piston ring points up Note The piston rings must be installed in the same position as before Use your recorded notes Note Make sure that you use tool 94338 Fig 7 to install the piston rings 1 Install the bottom piston ring 4 t...

Page 335: ...g operation 2 Install the bottom piston ring 4 to the piston head 3 Install the middle piston ring 3 to the piston head 4 Install the top piston ring 1 to the piston head Make sure that the ring clearance 5 is opposite the ring clearance 2 of the middle piston ring 3 5 Refer to the Operation Manual 0410 1 for the running in procedure for new piston rings 1 4 3 5 2 WCH02682 WCH02956 Fig 8 4 Piston ...

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Page 337: ...hat no personnel are near the flywheel or in the engine 1 Operate the turning gear to move the applicable crank approximately 30_ after TDC 2 Remove the oil inlet pipe 1 Fig 1 from the piston cooling and crosshead lubrication 3 Attach the lifting tool 94337 to the inner pipe 2 and the engine room crane 3 013 398 05 013 399 05 013 400 05 94337 2 3 1 I I II Fig 1 Note For View II see Fig 2 2016 Pist...

Page 338: ... the inner pipe 4 together with the sleeve 1 and the ring holder 3 2 Oil Inlet Pipe If the engine must operate with the connecting rod removed do as follows 1 Install the flange 94337B Fig 3 to the inlet pipe 11 013 417 05 5 94337B Fig 3 11 2016 Piston Cooling and Crosshead Lubrication Removal and Installation of Inside Pipe 013 414 05 9 II III 013 415 05 III 1 3 2 4 5 6 7 8 10 9 6 4 7 8 013 416 0...

Page 339: ...er TDC 7 Push the ring holder 6 and the sleeve 7 into the bore of the cylinder block 1 Hold the ring holder and the sleeve with the screws 5 Do not tighten the screws at this step 8 Lightly tighten the screws 2 5 Make sure that you can move the inner pipe 8 and the ring holder 6 9 Use the centering piece 94337A to align the ring holder 6 and the inner pipe 8 until you get the clearance A is 0 30 m...

Page 340: ... 3 Driving Wheels and Shut off Valve for Starting Air Group 4 Driving Wheels Running and Backlash Clearances and Tooth Condition 4103 1 A1 Starting Air Shut off Valve Clean and Function Check 4325 1 A1 Winterthur Gas Diesel Ltd RT flex50DF MM 2016 ...

Page 341: ...r inside the engine 1 Operate the turning gear to move the crankshaft while you do an inspection of all teeth 2 Set to on the service pump 3 Make sure that oil flows freely from all nozzles 4 Set to off the service pump 5 Make sure that all screws are correctly locked 6 After the running in period do a check of the drive wheels each three months as given above If faults show during this period rep...

Page 342: ...e gear wheel moves between the profiles of two gear wheel teeth 3 3 Lead Wire Note Use a new lead wire of 1 5 mm diameter Pb 9 99 fine each time you measure the backlash 1 Attach three lengths of lead wire approximately 200 mm in the positions shown with Scotch tape 2 Put marks 0 to 9 on the tooth profiles as shown 3 Operate the turning gear to move the gear wheel Make sure that the lead wire goes...

Page 343: ...nd 0 2 across the width of the tooth 4 Performance After commissioning do a check of the performance of the gear train as follows 1 Apply a thin layer of oil resistant engineer s blue ink to three of the teeth on each of the gear wheels 2 Operate the turning gear 3 Do a check of the marks on the gear wheel teeth and driving wheel teeth This is to make sure that the teeth engage correctly and are p...

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Page 345: ...r Systems 2 Preparation 1 Engage the turning gear 2 On the starting air bottles 9 01 close the stop valves 3 Open the vent valves 2 21 and 2 27 to release the air in the system 4 Disconnect the electrical connections from the pressure switch 7 and the solenoid valves 1 5 Remove the pipe 3 Fig 1 6 Remove the pipe 4 7 Remove the pipe 5 8 Remove the eight screws 6 from the flange of the inlet pipe no...

Page 346: ...pring 20 valve 21 and piston 22 11 Remove the control valve 2 from the cover 4 Servicing 1 If necessary clean the items of the control valve 2 that follow D Valve 21 D Piston 22 D Spring 20 2 If necessary clean the items from the shut off valve that follow D Springs 8 and 14 D Stopper 11 D Valve body 15 D Valve guide 10 D Valve 21 D Spindle 5 3 If you find corrosion on the springs 8 14 and or 20 y...

Page 347: ...Maintenance 4325 1 A1 Winterthur Gas Diesel Ltd 3 6 Fig 2 13 15 18 1 3 WCH03534 7 4 5 9 8 2 10 11 I 14 4 I 23 22 19 20 21 16 12 17 6 1 0 mm 2 2016 Starting Air Shut off Valve Clean and Function Check ...

Page 348: ... paste to the inner cylinder of the cover 6 12 Put the spring 8 on to the spindle 5 in the cover 6 13 Attach the cover 6 spring 8 and spindle 5 to the housing with the six M24x70 screws 7 14 Torque the six M24x70 7 to the value given in 0352 2 paragraph 1 15 Install the handwheel 7 16 Attach the control valve 2 to the cover 6 with the two M24x90 bolts 4 17 Torque the two M24x90 bolts 4 to the valu...

Page 349: ...mbled engine that is ready to start 1 Make sure that the stop valves on the starting air bottles 9 01 are closed 2 Operate the handwheel to move the shut off valve to the position CLOSED 3 Close the vent valve 2 21 4 Disengage the turning gear 6 2 Test Procedure 1 Close vent valve 2 27 in the main starting air pipe 2 Slowly open the stop valve on the starting air bottles 9 01 3 Slowly open the scr...

Page 350: ...hut off valve operates automatically 3 Make sure that air flows from the bore of the screw plug 5 4 Close the test valve 2 06 5 Make sure that no air flows from the bore of the screw plug 5 6 Operate slowly the handwheel to move the shut off valve to the position OPENED Make sure that you can feel the spindle 8 touch the spindle guide 9 7 Turn back the handwheel sufficiently to get a clearance of ...

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Page 352: ...pply Unit Lubrication 5555 1 A1 Pilot Fuel Pump Removal and Installation 5555 2 A1 Fuel Pump Removal Disassemble Assemble Installation 5556 1 A1 Fuel Pressure Control Valve Removal Check Installation 5562 1 A1 Fuel Pressure Control Valve Manual Release Valve Clean 5562 1 A2 Fuel Overpressure Safety Valve Checks and Setting 5562 2 A1 Flow Limiting Valve Replacement 5562 3 A1 Fuel Pump Actuator Conn...

Page 353: ...d documentation of the servo oil pump manufacturer Do the related maintenance in 0380 1 Maintenance Schedule Supply Unit For more data refer to the Operation Manual 5551 1 Servo Oil Pump 2 Preparation 1 Stop the engine 2 Close the stop valve downstream from the automatic filter refer to the Operating Manual 5551 1 3 Disconnect the electrical connections from the applicable servo oil pump 2 Fig 1 4...

Page 354: ...room crane to put sufficient tension on the sling 94657 to hold the weight of the servo oil pump 4 Remove the four nuts 2 and washers 3 5 Remove the servo oil pump 1 and the O ring not shown 6 Move the servo oil pump 1 to an applicable area 7 Lower the servo oil pump 1 to the floor 8 Remove the sling 94657 from the servo oil pump 9 Do step 1 to step 8 to remove the other servo oil pump 10 If neces...

Page 355: ...on on the pinion 6 2 Put the pinion 6 and shaft 3 in a vice 3 Use a hammer and copper rod 9 to hit the shaft until the shaft and snap ring 8 are removed from the pinion 6 3 3 Shaft Installation 1 Attach the shaft 3 in position in the pinion 6 with the snap ring 8 2 Remove the pinion 6 and shaft 3 from the vice 3 4 Pinion Installation 1 Put the shaft 3 and pinion 6 in position in the housing 5 2 At...

Page 356: ...is serviceable Replace the gasket if necessary 6 Remove the nozzle 4 7 Remove and discard the two O rings 3 4 2 Installation 1 Clean the nozzles 9 4 2 Put the nozzle 9 in position 3 Apply Loctite No 243 to the threads of the two Allen screws 10 4 Attach the cover 11 with the two Allen screws 10 5 Put two new O rings 3 on the nozzle 4 6 Put the nozzle 4 in position Make sure that the pin 7 engages ...

Page 357: ...ne to put the servo oil pump 4 in position 6 Attach the servo oil pump 4 to the casing with the four washers 2 and nuts 3 7 Do step 1 to step 6 to install the servo oil pump 1 6 Completion 1 Attach the oil inlet pipes to the servo oil pumps 1 4 2 Attach the drain pipes to the servo oil pumps 1 4 3 Install the HP servo oil pipes refer to 8447 1 paragraph 4 and paragraph 5 4 Install the HP fuel pipe...

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Page 359: ... Bearing Covers Removal 3 3 Bearing Shells Removal 4 4 Camshaft Removal 4 5 Camshaft and Bearing Shells Installation 6 6 Bearing Covers Installation 7 7 Completion 8 1 Preparation 1 Stop the engine and main lubricating pump 2 Remove the screws 2 Fig 1 3 Remove the cover 1 4 There are two alternatives as follows a Remove the fuel pumps refer to 5556 1 paragraph 1 and paragraph 2 or b Lift the rolle...

Page 360: ...sure that the bearing covers at positions No 2 No 3 and No 4 Fig 3 and the housing 1 have marks to identify them as a set Note The bearing at position No 2 has the two thrust bearing ring halves 3 2016 Supply Unit Removal and Fitting of Camshaft and Bearing Shells 012 980 05 Fig 2 1 2 I I 012 981 05 1 1 2 3 4 5 4 3 2 1 Fig 3 I I ...

Page 361: ...pump No 1 2 Put the screwdriver bit 2 on to the screw 1 3 Attach the torque amplifier 4 and the applicable extension 5 to the screwdriver bit 2 in the position shown 4 Operate the torque wrench 3 to remove the screw 1 5 Do step 2 to step 4 for the bottom screw 6 Remove the bearing cover 7 Do step 2 to step 6 for the remaining screws 1 of the bearing covers Supply Unit Removal and Fitting of Camsha...

Page 362: ...e 4 Move the template 94567 and the top bearing shell down 5 Remove the template 94567 6 Put a mark on the top bearing shell to identify its position 7 Remove the related bearing shell 4 Camshaft Removal 1 On the supports 94566 and 94566A Fig 6 remove the screws 3 2 Remove covers 2 4 from the supports 94566 94566A 3 Loosen the screws 1 5 2016 Supply Unit Removal and Fitting of Camshaft and Bearing...

Page 363: ...7 Remove the remaining bearing covers refer to the procedure given in paragraph 2 step 3 to step 9 8 Make sure that the camshaft 3 and the gear wheel 2 do not move 9 Carefully move the camshaft and the gear wheel on to the two supports 94566 945666A 10 Put the chock 4 in position to hold the camshaft and gear wheel 2 3 Note When you do step 11 make a mark on the bearing shells to identify their po...

Page 364: ... 5 Carefully move the camshaft gear wheel 1 into the housing 3 Make sure that the bearing shells 2 stay in position and do not fall 6 Put the bearing shells 4 in position Make sure that the holes in the bearing shells align with the dowel pins 6 in the bearing covers 7 7 To align the bearing shell 4 put the centering tool 94566B in position in the related hole for the elastic screw 8 Apply oil to ...

Page 365: ...e The ratio between the torque wrench 3 and the torque amplifier 4 is 1 5 4 Torque the screw 1 as follows a Adjust the torque wrench 3 to 290 Nm The torque value for the screws 1 is 1450 Nm b Put the torque wrench 3 on the torque amplifier 4 c Torque the screw 1 to the value of 290 Nm on the torque amplifier 4 5 Make sure that there is no clearance at X Fig 10 6 Do step 7 to step 13 for the bottom...

Page 366: ...vo oil pump 1 refer to 5552 1 paragraph 4 2 and paragraph 5 6 Apply sealing compound to the sealing surfaces of the cover 1 Fig 12 7 Attach the cover 1 to the casing with the screws 2 8 Cut in the fuel pumps and remove tools 94430 refer to the procedure given in the Operation Manual 5556 2 9 Set to on the oil pump WARNING Injury Hazard Before you operate the turning gear make sure that no personne...

Page 367: ...all parts are clean and in a satisfactory condition 2 Apply oil to the surfaces of the gear wheel 2 and the shaft 1 3 Push carefully the gear wheel 2 on to the shaft 1 4 Attach the gear wheel 2 to the shaft 1 with the screw 5 5 Apply oil to the surfaces of the camshaft 4 and the gear wheel 2 6 Carefully attach the camshaft 4 to the gear wheel 2 with the screws 3 7 Torque symmetrically the screws 3...

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Page 369: ...hets 94016 013 related to number of cylinders 2 Chain 94202L 1 Preparation 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Remove the HP fuel pipes refer to 8752 1 3 Remove the HP servo oil pipes refer to 8447 1 4 Remove screws 1 Fig 1 and the cover 2 5 Cut out the fuel pumps refer to the Operation Manual 5556 2 2016 Supply Unit Fig 1 2 1 ...

Page 370: ... lifting tool above the eye bolts EB 7 Attach the lifting tool 94557 to the two eye bolts EB 8 Operate the manual ratchets H1 H2 to apply a light tension on the chains 9 Remove the screws 8 together with the distance sleeves 10 Remove the screws 2 4 and 6 11 Operate carefully the engine room crane to lift the supply unit from the engine 12 Move carefully the supply unit away from the engine 13 Low...

Page 371: ...screws at this step 6 Install the dowel pins 3 7 Tighten the screws 2 4 6 and 7 8 Do a check of the backlash refer to 0330 1 Driving Wheels for the Supply Unit 4 Completion 1 Install the HP fuel pipes refer to 8752 1 2 Install the HP servo oil pipes refer to 8447 1 3 Attach the cover 1 Fig 1 to the supply unit with the screws 4 Cut in the fuel pumps refer to the Operation Manual 5556 2 5 Start the...

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Page 373: ... nipple 4 10 Attach the lubricating tool 94844 to an applicable position approximately 2 0 m above the supply unit as shown 11 Attach the flexible hose 2 to the adaptor 3 with the hose clip 6 12 Remove the inspection covers from the supply unit 5 13 Fill the lubricating tool 94844 with system oil 14 Open the ball valve 10 15 Make sure that the system oil flows on to the bearings and camshaft 9 WAR...

Page 374: ...Maintenance 5552 5 A1 Winterthur Gas Diesel Ltd 2 2 Fig 1 I I II II 1 II II I I 2 3 2 4 94844 10 2 5 9 6 7 8 WCH03859 Lubrication of Supply Unit during Maintenance 2018 02 ...

Page 375: ...e the grease nipple 3 Lubricate the flexible coupling 4 Install the service cover 4 CAUTION Injury Hazard The weight of the pilot fuel supply unit is approximately 367 kg Use the correct equipment to lift and move the pilot fuel supply unit This will prevent injury to personnel Note To get access to duplex filter 2 you must remove the cover on the pilot fuel pump 3 After the period given in the Ma...

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Page 377: ...5 1 Removal 1 Stop the engine 2 Make sure that the pilot fuel pump 5 Fig 1 has stopped 3 Disconnect the electrical connection from the electric motor 1 4 Close the stop valve 3 5 Remove the pilot fuel pressure pipe 4 6 Remove the pilot fuel return pipe 2 7 Remove the fuel inlet pipe 9 8 Hold the weight of the pilot fuel pump 7 9 Remove the four Allen screws 6 10 Remove the pilot fuel pump 5 from t...

Page 378: ...3 Do not tighten the special nut 16 Connect the HP oil pump and hose to the assembly tool 94573 17 Operate the HP oil pump tp increase the pressure to between 1600 bar and 1800 bar Make sure that the coupling half floats on the oil film 18 Operate the HP oil pump to keep the pressure constant 19 Turn back 5 0 mm the special nut 2 Make sure that the hydraulic force pushes the coupling half against ...

Page 379: ...ce is approximately 107 5 mm 3 On the assembly tool 94573 turn fully back the special nut 2 4 Apply Molykote G Rapid Plus to the surfaces 3 5 Attach the adapter piece 4 to the shaft of the pilot fuel pump 1 6 Torque the adapter piece 4 to 45 Nm 7 Turn the special nut 2 until it touches the spherical disc 7 8 Attach the HP hose 9 to the HP oil pump 8 9 Attach the hose 9 to the closing valve 5 10 Op...

Page 380: ...7 4 5 1 16 Attach the pilot fuel pump to the electric motor temporarily with the four bolts and nuts 8 Fig 1 17 Measure the distance X through the opening in the connection piece 1 Fig 4 18 Remove the electric motor 6 from the connection piece 1 19 Push the flange on the motor shaft until you get a distance of X 3 0 mm 20 Lock the hubs with an M8 screw 5 21 Fill the coupling with grease 22 Attach ...

Page 381: ... to 36 Nm 26 Make sure that the sleeves 1 turn freely an axial distance of 1 5 mm 3 Completion 1 Apply NeverSeez NSBT8 to the threads and surfaces that touch of the pilot fuel pressure pipe 4 Fig 5 2 Attach the pilot fuel pressure pipe 4 as shown 3 Torque the two coupling nuts 5 to 30 Nm 4 Install the pilot fuel return pipe 2 5 Install the fuel inlet pipe 10 6 Connect the electrical connection to ...

Page 382: ...Maintenance 5555 2 A1 Winterthur Gas Diesel Ltd 6 6 Fig 5 8 1 3 WCH03857 I I 2 9 7 6 2 4 10 I II 5 5 4 2018 Pilot Fuel Pump Removal and Installation ...

Page 383: ... 3 Disassemble 4 3 1 Guide Pin Removal 4 3 2 Guide Piston and Roller Removal 4 3 3 Toothed Rack Removal 5 3 4 Pump Cylinder Removal 6 3 5 Non return Valve Removal 7 4 Fuel Pump Assemble 7 4 1 Preparation 7 4 2 Pump Cylinder Installation 7 4 3 Pump Cover Installation 8 4 4 Toothed Rack Installation 8 4 5 Regulating Sleeve Installation 8 4 6 Pump Plunger and Bottom Housing Installation 9 4 7 Plunger...

Page 384: ...ta in 0012 1 General Guidelines for Lifting Tools 1 Stop the engine refer to the Operation Manual 0310 1 2 Set to off the fuel supply 3 Set to off the main oil supply 4 Make sure that the fuel return valve is open refer to the Operation Manual Control Diagram 4003 2 and Pipe Diagram 4003 11 5 Close the fuel inlet valve refer to the Operation Manual Control Diagram 4003 2 and the Pipe Diagram 4003 ...

Page 385: ...crews to lift the fuel pump until the pin disengages 5 Attach the cover 94552 Fig 2 to the pump cover 5 6 Use the applicable lifting equipment to lift and move the fuel pump 7 Move the fuel pump to an applicable work bench 8 Put the fuel pump on its side on the wooden surface Make sure that you do not cause damage to the toothed rack 7 or and the roller 6 9 Remove the lifting equipment from the fu...

Page 386: ...guide pin 2 4 Turn the screw 1 to remove the guide pin 2 5 Remove the tool 94551 3 2 Guide Piston and Roller Removal 1 Attach the two eye bolts EB to the guide piston 4 Fig 4 2 Remove the guide piston 4 from the housing 3 Remove the circlip 1 4 Push out the pin 2 5 Remove the roller 3 together with the pressure discs 8 and the bush 7 6 Remove and discard the O ring 6 7 Remove the snap ring 5 Fuel ...

Page 387: ... thread of the bush c Torque the new bush to 200 Nm 3 3 Toothed Rack Removal 1 Disassemble the bottom spring carrier 1 Fig 6 together with the pump plunger 3 2 Put the pump plunger 3 in a dry clean area to prevent damage 3 Remove the compression spring 2 4 Remove regulating sleeve 4 together with the top spring carrier 5 Fuel Pump Removal Disassemble Assemble Installation 2016 013 673 05 Fig 5 1 2...

Page 388: ... 2 Use applicable equipment to hold the pump cover 2 to the work bench 3 Remove the screws 1 4 Remove the pump cover 2 valve block 4 valve body 8 and compression spring 9 5 Remove the circlip 5 6 Remove the intermediate disc 10 7 Remove the screw 6 8 Remove the pump cylinder 7 Note The pump cylinder 7 and pump plunger 3 Fig 6 must stay together as a set Fuel Pump Removal Disassemble Assemble Insta...

Page 389: ...s 2 Do a check the condition of all parts If necessary replace damaged parts 3 Use a low pressure air supply to make sure that all bores in the housings and pump cylinder 1 Fig 11 are clear 4 Replace all O rings and rod seal rings 4 2 Pump Cylinder Installation 1 Attach the top housing 3 vertically to the work bench 2 Align the groove in the pump cylinder with the bore for the screw 2 in the top h...

Page 390: ...stallation 1 Make sure that the pump cover 4 Fig 13 points down 2 Attach the top housing 5 to the work bench 3 Put a new rod sealing ring on the flange 9 4 Make sure the toothed rack 3 moves freely 5 Put the rod sealing rings 6 in each flange 9 6 Attach the two flanges 9 to the housing 2 with the two screws 5 7 Attach the stop ring 8 and the circlip 7 4 5 Regulating Sleeve Installation 1 Move the ...

Page 391: ...carrier 6 in position in the top housing 7 Make sure that the two drivers of the pump plunger 3 engage with the regulating sleeve 4 5 Apply oil to the new O ring 8 6 Put the O ring 8 on the top housing 7 7 Put the bottom housing 1 Fig 15 on to the top housing 4 8 Tighten equally the Allen screws 5 This compresses the compression spring 6 9 Make sure that the toothed rack 3 moves freely Fuel Pump R...

Page 392: ...he screw plug to the check bore 2 10 Lubricate the new O ring 6 Fig 16 11 Put the new O ring 6 on the guide piston 4 12 Put grease on the snap ring 5 13 Attach the snap ring 5 to the guide piston 4 14 Lubricate the pump plunger 15 Install the bush 6 pressure discs 7 and the roller 3 to the guide bush 4 16 Install the pin 2 and the circlip 1 17 Put the guide piston 4 in the housing 18 Do a check of...

Page 393: ... guide pin 2 22 Remove the eye bolts EB 23 Attach the tool 94551 Fig 19 as shown 24 Turn the handle 3 to push down the guide piston 2 until you can install the guide pin 1 If the guide pin touches the guide groove turn the pressure piece 4 to align the guide pin 25 Remove the tool 94551 Fuel Pump Removal Disassemble Assemble Installation 2016 013 671 05 94551 2 1 Fig 18 1 013 671 05 3 2 Fig 19 4 3...

Page 394: ... fuel pump into the supply unit WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine 32 Operate the turning gear until the cam base touches the roller 3 33 Lubricate the threads and seating surfaces of the four screws 1 Fig 21 34 Put the four screws 1 in position 35 Torque symmetrically in equal steps the four screws 1 to 600 ...

Page 395: ...tion Manual Control Diagram 4003 2 and Pipe Diagram 4003 11 7 Set to on the main oil supply 8 Set to on the fuel supply 9 Operate the turning gear to move the cam Make sure that there are no leaks or an unusual temperature increase 7 Storage 1 Make sure that the storage area is clean and dry 2 Put the fuel pump in a vertical position 3 Apply clean oil to the fuel pump 4 Put Vaselinet in the open i...

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Page 397: ...heck and adjust the PCV D Replace the PCV For the maintenance intervals of the PCV refer to the Maintenance Schedule 0380 1 Group 5 For faults in the high pressure fuel system and defective pressure control valve refer to the Operation Manual 0515 1 paragraph 5 2 Preparation WARNING Injury hazard Put on gloves and eye protection Hot fuel can come out as a spray and cause injury WARNING Fire hazard...

Page 398: ...rical connection from the solenoid valve 2 3 Remove the fuel return pipe 5 from the PCV 1 4 Remove the four screws 8 5 Remove the PCV 1 from the valve block 3 6 Do a check of the lip seal 9 Replace the lip seal if necessary 2016 Fuel Pressure Control Valve Removal Check Installation WCH02900 DRIVING END WCH02366 Fig 1 5 8 7 6 4 2 1 3 9 3 4 ...

Page 399: ... hand b Torque the screws to 80 Nm c Torque the screws to 190 Nm 8 Attach the flexible tube 94556C part of the test block 94556 to the PCV outlet 2 Put the other end of the flexible tube into an applicable container 3 9 Connect the HP oil pump 94931 hydraulic distributor pressure gauge 94934A and HP hose 94935 to the test block 94556 CAUTION Damage Hazard Do not adjust the safety valve Damage to t...

Page 400: ...Check 1 On the HP oil pump 94931 close the relief valve 2 Operate the HP oil pump 94931 3 Make sure that the PCV opens at 1050 30 bar 4 If the PCV opens at less than 1020 bar or more than 1080 bar do the procedure in paragraph 4 2 again Note If the PCV does not open at less than 1300 bar or opens at less than 1020 bar when the SAV 6 is fully closed the PCV has a malfunction You must find and repai...

Page 401: ...c Torque the screws to 190 Nm 6 Install the fuel return pipe 5 to the PCV 1 7 Connect the electrical connection to the solenoid valve 2 6 Storage on Board The spare parts must be carefully protected against corrosion as follows 1 Make sure that the PCV has no dirt oil and grease 2 Apply liquids e g Tectil 506 ISOTEC 337 or equivalent liquids to the applicable surfaces 3 Plug all blind holes and ta...

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Page 403: ... the fuel rail 2 to do this procedure Note For the full PCV overhaul instructions speak to or send a message to WinGD 1 Stop the engine 2 Make sure that the PCV 1 is open Note If HFO is used the drain port will be hot when the PCV is open 3 Operate the pressure release button more than two times to release pressure WCH02900 DRIVING END 6 1 2 Solenoid Tube Lever Plunger Spring O ring Pusher Rubber ...

Page 404: ...e valve closes and you can get rail pressure it is not necessary to continue the procedure Refer to paragraph 2 3 step 5 to step 9 to assemble the PCV CAUTION Injury Hazard Make sure that there is no pressure in the fuel rail or the drain side of the system High pressure fuel can cause injury to personnel 9 Remove the four Allen screws from the block 10 Remove the block Fuel Pressure Control Valve...

Page 405: ...unger and spring into the pusher assembly 2 Put the O ring and pusher in position in the block 3 Attach the valve block to the PCV with the four M6 Allen screws 4 Torque the for M6 Allen screws to 15 Nm 5 Attach the solenoid tube to the valve block 6 Put the solenoid in position on the valve block 7 Put the thick part of the collar against the solenoid 8 Attach the nut to the solenoid Tighten the ...

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Page 407: ...silä Switzerland Ltd authorized repair workshop for inspection and repair The International Association of Classification Societies IACS approval is given for D The type of test D The type of certificate D The frequency of the test The results of the test must be recorded in the Inspection Report Note The two bores 2 identify the relief valve as a new item Fig 1 Applicable pressure that opens the ...

Page 408: ...est bench 1 Put the relief valve 1 Fig 2 in the valve holder 94272A 2 Tighten the relief valve 1 3 Connect the valve holder 94272A to the HP oil pump 94931 or the hydraulic unit 94942 3 3 Sealing Pressure Check 1 Operate the HP oil pump 94931 to increase the pressure to 1150 bar 2 Keep the pressure constant for one minute 3 Make sure that there are no leaks 3 4 Operation Pressure Check 1 Operate t...

Page 409: ... 8 to the thread of valve housing 4 Fig 3 2 Attach new O rings 3 to the relief valve 1 3 Put the relief valve into the intermediate piece of the fuel pressure control valve 3 06 4 Torque the relief valve 1 to 300 Nm Applicable pressure that opens the relief valve is stamped here 015 499 07 3 1 AF80 2 4 Fig 3 2016 Fuel Overpressure Safety Valve Checks and Setting ...

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Page 411: ...you do work on hot components Fuel and oil can come out as a spray and cause injury WARNING Injury Hazard Do not operate the turning gear Fuel can come out of the opening in the fuel rail and cause injury 1 Stop the engine refer to the Operation Manual 0310 1 2 Cut out the injection refer to the Operation Manual 0510 1 3 Let the engine temperature decrease 4 Let the pressure in the fuel rail decre...

Page 412: ...ve the lip seal 3 Make sure that you do not cause damage to the lip seal 5 Put the lip seal 3 in a safe area 6 Make sure that the dowel pins stay in the fuel rail 7 Lower the FLV on to an applicable clean surface 8 Clean all seating surfaces of the blind flange 94585B Fig 3 9 Make sure that the lip seal is installed in the blind flange 94585B 10 Attach the blind flange 98585B to the fuel rail with...

Page 413: ...Remove the FLV from the surface plate 94585A 4 2 Installation CAUTION Injury Hazard The weight of the FLV is approximately 35 kg Use the correct equipment to lift and move the FLV This will prevent injury to personnel 1 Remove the blind flange 94585B Fig 3 from the fuel rail 2 Clean the inlet bores of the FLV 2 Fig 5 3 Attach the M10 eye bolts 94045 M10 to the FLV 2 4 Lift the FLV 2 5 Carefully pu...

Page 414: ... Gas Diesel Ltd 4 4 10 Connect the leakage pipes 2 and 3 Fig 6 to the FLV 1 11 Install the HP injection pipes refer to 8733 1 12 After you start the engine do a check for leaks 2016 Flow Limiting Valve Replacement 2 3 1 WCH03116 Fig 6 ...

Page 415: ...rder Number RT flex50DF CW PWM 504 00 100 13 RT flex68 D CCW mA 504 00 100 16 W X62 DF CCW PWM 504 00 100 14 W X72 DF CCW PMW 504 00 100 14 W X82 DF CCW mA 504 00 100 16 W X92 DF CW mA 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...

Page 416: ...sition Loosen the screws 4 from the shaft 3 5 Remove the six screws 9 then remove the cover 10 6 Move the toothed rack 6 to get a distance of 48 mm at each end The distance between both rack ends must be equal 7 Attach the lever 2 to the connecting element 1 with the screw 8 and the self locking nut 7 Make sure that the toothed rack 6 stays in position and the indicator 5 position shows 50 8 Tight...

Page 417: ...I I 7 48 mm 48 mm 8 9 10 I 6 11 1 2 3 4 5 6 48 mm Fig 1 Maintenance 5583 1 A1 Winterthur Gas Diesel Ltd 3 4 Fuel Pump Actuator Connection to Fuel Pump 2020 ...

Page 418: ...ing wire between terminals 5 and 43 red wire 2 5 In E85 turn ON the related power supply 6 Use an applicable tool to gently push the switch 3 The actuator automatically moves to the maximum and minimum position self adjustment 7 When movement of the fuel pump actuator stops continue to the next step 8 In E85 turn OFF the related power supply 9 Remove the two bridging wires attached in step 3 and 4...

Page 419: ... 4 Completion 2 1 General The pilot valve for each VCU for cylinder can be replaced individually 2 Preparation 1 Stop the engine refer to 0310 1 2 Release the pressure in the servo oil rail refer the Operation Manual 0520 1 paragraph 2 3 3 Remove the applicable hydraulic pipe refer to 8460 1 paragraph 1 and paragraph 2 Exhaust Valve Control Unit Pilot valve Removal and Installation 2020 ...

Page 420: ... ring are in the correct position 4 Tighten the pilot valve screws 2 at 9 Nm 5 Connect the electrical connection from the pilot valve 1 4 Completion 1 Install the hydraulic pipe refer to 8460 1 paragraph 4 2 Put the replaced VCU in its original package 3 Close any drain for servo oil rail 4 Start the service pump 5 Check for any leakages from the pilot valve 6 Stop the service pump 2020 Exhaust Va...

Page 421: ...l After the installation of a new fuel pump 1 Fig 1 or actuator 2 do a check of the regulating linkage If necessary adjust the regulating linkage refer to paragraph 2 Maintenance of the connection between the fuel pump and the actuator is not necessary 1 2 WCH02905 Fig 1 2016 Regulating Linkage ...

Page 422: ...moves freely 6 Apply grease to the linkage joints 7 Put the two spacers 94555A in position on each side of the toothed rack 1 8 Move the output shaft 3 to move the pointer 5 to the mark 50 9 Put the lever 9 on the sleeve 8 10 Tighten the screw 6 11 Attach the connecting element 10 to the lever 9 with the screw 2 and the self locking nut 12 Remove the spacers 94555A 94555A 36 mm 36 mm WCH02905 I 3 ...

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Page 424: ...Blower Maintenance 6545 1 A1 Auxiliary Blower TC at Exhaust Side Maintenance 6545 2 A1 Scavenge Air Cooler Removal and Installation 6606 1 A1 Scavenge Air Cooler Cleaning Instructions 6606 1 A2 Scavenge Air Cooler TC at Exhaust Side Removal and Installation 6606 2 A1 Water Separator Removal and Installation 6708 1 A1 Water Separator Removal and Installation TC at Exhaust Side 6708 2 A1 Winterthur ...

Page 425: ...al For the intervals to clean the scavenge air receiver 1 Fig 1 refer to 0380 1 Scavenge air receiver You must also clean and do a check of the scavenge air receiver after each piston overhaul I I 1 3 I FREE END II I I WCH03010 For View II II see Fig 3 and Fig 4 II I 2 Fig 1 2016 Scavenge Air Receiver ...

Page 426: ...cturer of the relief valve or Wärtsilä Switzerland Ltd 1 Do a check of the relief valve during each engine overhaul as follows a Do a visual check for damage and corrosion If necessary replace the relief valve 1 Fig 2 b Do a check of the seal wire 3 and the lead seal 2 If the seal wire and lead seal are broken you must replace the relief valve I 1 I 3 2 1 2 1 II II II II WCH03554 Fig 2 2016 Scaven...

Page 427: ...ut a flat bar 10 stop plate 7 the other flat bar 10 new tab washers 9 and screws 8 in position Do not tighten the screws at this step 3 Put the screw 5 and new tab washers 6 in position Do not tighten the screws at this step 4 Make sure that the axle 3 and the flap 4 can move freely 5 Tighten the screws 8 5 6 Bend the tab washers 6 9 to lock the screws 8 5 II II III III IV IV IV IV Access to air f...

Page 428: ...or more data refer to the Operation Manual 4003 4 Pipe Diagram Water Systems a At regular intervals look at the sight glasses 3 of the condensate collector 6 to make sure that water flows b If necessary clean the filters 7 and the drain pipes 4 5 For more data refer to the Operation Manual 8345 1 c Do a check of the flaps 8 for damage free movement and dirt If necessary clean or replace the flaps ...

Page 429: ...eral For the intervals to clean the scavenge air receiver 1 Fig 1 refer to 0380 1 Scavenge air receiver You must also clean and do a check of the scavenge air receiver after each piston overhaul 1 II WCH03363 Fig 1 I II I For View II II see Fig 3 4 3 2 5 2016 Scavenge Air Receiver TC at Exhaust Side ...

Page 430: ...urer of the relief valve or Wärtsilä Services Switzerland Ltd 1 Do a check of the relief valve during each engine overhaul as follows a Do a visual check for damage and corrosion If necessary replace the relief valve 1 Fig 2 b Do a check of the seal wire 3 and the lead seal 2 If the seal wire and lead seal are broken you must replace the relief valve 1 I 3 2 1 2 1 II II II II WCH03554 Fig 2 2016 S...

Page 431: ...he axle 2 spacer 10 guide 1 and flap 3 in position 2 Put a flat bar 9 stop plate 6 the other flat bar 9 new tab washers 8 and screws 7 in position Do not tighten the screws at this step 3 Put the screw 4 and new tab washers 5 in position Do not tighten the screws at this step 4 Make sure that the axle 2 and the flap 3 can move freely 5 Tighten the screws 4 7 6 Bend the tab washers 5 8 to lock the ...

Page 432: ...ctors 6 For more data refer to the Operation Manual 4003 4 Pipe Diagram Water Systems a At regular intervals look at the sight glasses 3 of the condensate collector 6 to make sure that the water flows b If necessary clean the filters 7 and the drain pipes 4 5 For more data refer to the Operation Manual 8345 1 c Do a check of the flaps 8 for damage free movement and dirt If necessary clean or repla...

Page 433: ...ore data about the auxiliary blower refer to the Operation Manual 6545 1 Auxiliary Blower and Switch Box Auxiliary blowers that do not operate for long periods must be started for a short time two times each month If this is not possible turn the impeller with your hand This is necessary to prevent corrosion to the bearings For the Inspection and Overhaul intervals refer to 0380 1 Group Auxiliary ...

Page 434: ...h of the two electric motors 1 Attach the two slings 94657 to the pipe of the support 94658 2 Operate the engine room crane to put the support 94658 on the beam 1 as shown 3 Attach the support 94658 to the beam 1 with the bolts 4 and nuts 5 4 Attach two slings 94657 to the electric motor 2 5 Attach the two manual ratchets 94016 007 to the two slings 94657 on the support 94658 6 Attach the two manu...

Page 435: ...xiliary blower manufacturer 3 Installation 1 Attach the two slings 94657 to the electric motor 2 and the engine room crane 2 Operate the engine room crane to lift the electric motor 2 until you can attach the manual ratchets 94016 007 to the two slings 94567 3 Attach the manual ratchets 94016 007 to the two slings 94567 Note When you do step 4 hold the mass of the electric motor 2 4 Carefully remo...

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Page 437: ...ger period must be started for a short time two times each month If this is not possible turn the impeller with your hand This is necessary to prevent damage or corrosion to the bearings For the Inspection and Overhaul refer to 0380 1 Group 6545 If the auxiliary blowers do not operate install the two covers to the flange connection at the inlet pipe of the auxiliary blower one for each auxiliary b...

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Page 439: ... Support LEFT 94663A 1 Preparation 1 2 Removal 2 3 Installation 5 4 Completion 7 1 Preparation 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Stop the engine refer to the Operation Manual 0310 1 3 Stop the cooling water pump 4 Close the butterfly valves 1 Fig 1 of the scavenge air cooler SAC 3 5 Drain the water from the SAC 3 6 Remove the drain and vent pipes 5 6 7 Remove the inl...

Page 440: ...ld the mass of the SAC Note During step 10 operate the manual ratchet H1 to keep tension on the chain 10 Operate the manual ratchet H3 to pull the SAC approximately 750 mm from the receiver 11 Attach the two lugs 94663C Fig 3 to the SAC 12 Attach the two safety chains 94663D to the lugs 13 Operate the manual ratchet H3 to carefully move the SAC from the platform area to below the engine room crane...

Page 441: ... approximately 1142 kg To prevent injury be careful when you move the SAC 23 Operate the manual ratchet H2 and the engine room crane until the rear of the SAC is fully on the supports 94663A 94663B view II i e the SAC is moved 70 mm in front of guide end of the left and right supports 94663A 94663B 24 Operate the engine room crane and the manual ratchet H2 to hold the full weight of the cooler 25 ...

Page 442: ...l ratchet H2 to lower the rear of the SAC 28 Continue with step 27 until the SAC is in a vertical position 29 Remove the manual ratchet H2 30 Operate the engine room crane to lower the SAC through the platform on to an applicable surface 31 Remove the engine room crane from the chains 94666I 32 Remove the chains 94666I and the four swivel lugs 94048 M16 from the SAC Scavenge Air Cooler Removal and...

Page 443: ... position shown 10 Operate the manual ratchet H2 and the engine room crane to get the SAC into the horizontal position shown 11 Attach the manual ratchet H3 to the rear chain 94666I 12 Attach the two supports 94663A and 94663B Fig 7 to the left and the right side of the receiver 13 Attach the two lugs 94663C and the two safety chains 94663D as shown 14 Apply a high temperature and non hardening jo...

Page 444: ...te During step 23 operate the manual ratchet H2 to control the height of the SAC 24 Operate the manual ratchet H3 to pull the SAC fully into the scavenge air receiver At the same time operate the manual ratchet H1 to keep a light tension on the chain 25 Install the bottom plates and rails that you removed before 26 Remove the manual ratchets H1 H2 H3 27 Remove the left and right supports 94663A B ...

Page 445: ...nstall the vent pipe 6 5 Open the butterfly valves 1 of the SAC 3 6 Release the air from the SAC 7 Start the cooling water pump 8 Make sure that there are no leaks 9 Make sure that no scavenge air flows between the SAC 3 and the SAC housing 10 Stop the cooling water pump Scavenge Air Cooler Removal and Installation 2016 WCH00708 FUEL SIDE 2 3 4 1 6 5 7 Fig 10 ...

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Page 447: ... the cooler If the measurements indicate fouling of the water side of the air cooler element the element must be overhauled cleaned If the measurements indicate fouling of the air side of the air cooler element it is necessary to inspect the air cooler element If the air side of the element is fouled clean the element using the spray pipe arrangement fitted above the air cooler element D SAC air s...

Page 448: ...ir supply pipe 19 Shut off valve vent 5 Shut off valve 20 Shut off valve 6 Container 21 Funnel 7 Ball valve 22 Shut off valve 8 SAC drain 9 Condensate collector 10 Throttle disc AV Vent 11 Condensate and wash water drain BT Drain to bilge water tank 12 3 way ball valve CA Compressed air from board system 7 0 bar to 8 0 bar 13 Vent unit FW Fresh water 2 5 bar 14 Cleaning fluid and wash water drain ...

Page 449: ...ge too much of the cleaning agent to evaporated 1 Make sure that compressed air and fresh water are available at the shut off valves 1 and 12 Fig 2 2 Open the ball valves 2 and 10 Fig 2 3 Fill the mixture tank with recommended chemical doses at the funnel 11 4 Open the freshwater valve 12 fill the tank up to desire level 5 Close the ball valves for air vent and freshwater 2 and 10 6 Open the ball ...

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Page 451: ...paration WARNING Injury Hazard The mass of the SAC is approximately 2760 kg To prevent injury use only the applicable equipment to move the SAC 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Stop the engine refer to the Operation Manual 0310 1 3 Stop the cooling water pump 4 Close the butterfly valves 4 Fig 1 of the scavenge air cooler SAC 5 Drain the water from the SAC 6 Remove ...

Page 452: ...he gallery beam with its screws 11 At the driving end a Attach the two swivel lugs 94048 M30 to the front of the SAC b Attach the wire rope sling 94666 to the two outer swivel lugs 94048 M30 12 Attach the manual ratchet H1 to the hole in the support 94661 IL 13 Attach the wire rope sling 94666 to the manual ratchet H1 14 Operate the manual ratchet H1 to get sufficient tension to hold the mass of t...

Page 453: ...IL 94663B IL to 145 Nm 20 Attach the two plates 94664 IL to the SAC with its screws 21 Make sure that the length of the safety chains 94663F IL is 1998 mm for a SAC A44 SD WARNING Injury Hazard The mass of the SAC is approximately 2760 kg To prevent injury keep the the two safety chains attached to the plates 22 Attach the safety chains 94663F IL to the plates 94664 IL Scavenge Air Cooler Removal ...

Page 454: ...94048 M30 25 Attach the lifting plate 94663 IL to the chain block H2 26 Operate the two chain blocks H2 H3 to hold the weight of the SAC 27 Remove the plates 94664 IL safety chains 94663F IL manual ratchet H1 and the support 94661 IL 28 Move the SAC until the chain block H3 touches the end stop 2 in the rail 1 Scavenge Air Cooler Removal and Installation 7 Cyl 2016 H2 WCH03309 II H1 I I 94663 IL H...

Page 455: ...t 94040 M30 33 Operate the engine room to pull out the SAC until the chain block H2 Fig 7 is adjacent to the platform lug 1 34 Attach the manual ratchet H1 Fig 8 to the platform lug 1 and the lifting plate 94663 IL 35 Remove the chain block H2 from the lifting plate 94663 IL 36 Operate the manual ratchet H1 to lower the SAC to the vertical position Scavenge Air Cooler Removal and Installation 7 Cy...

Page 456: ... the SAC and the related surfaces in the receiver housing 3 Attach the swivel lugs 94048 M30 Fig 10 and the eye bolts 94040 M30 to the SAC 4 Make sure that the supports 94663A IL 94663B IL are installed to the left and right side of receiver frame 5 Attach the wire rope sling 94666 to the swivel lugs 94048 M30 6 Attach the hook 1 Fig 11 of the engine room crane to the wire rope sling 94666 7 Opera...

Page 457: ... block H2 to move the SAC to the horizontal position 14 Operate the engine room crane and the chain block H2 Fig 13 to move the SAC adjacent to the opening 15 Attach the chain block H3 to the eye bolt 94040 M30 16 Operate the chain block H3 to hold the weight of the SAC 17 Remove the hook 1 of the engine room crane 18 Operate the chain blocks H2 H3 to lift the SAC to the applicable height Scavenge...

Page 458: ...Note During step 25 operate the chain block H3 to lift the end of the SAC a small distance This keeps most of the SAC weight off the supports 94663A B 25 Operate the manual ratchet H1 Fig 15 to move the SAC into the receiver until the rear of the SAC is 750 mm from the opening 26 Remove the chain blocks H2 H3 from the platform rail 27 Operate the manual ratchet H1 to pull the SAC fully in 28 Remov...

Page 459: ...to the value given in 0352 2 4 Completion 1 If necessary install the bottom plates rails and platform elements 2 Install the drain pipe 3 Fig 17 3 Install the vent pipe 1 4 Install the inlet pipe 5 5 Install the outlet pipe 6 6 Install the auxiliary blower 7 Open the butterfly valves 4 8 Release the air in the SAC 9 Start the cooling water pump 10 Make sure that there are no leaks 11 Make sure tha...

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Page 461: ...nstallation 5 4 Completion 10 5 Condensate Drain 10 1 Preparation CAUTION Injury Hazard The cover of the water separator weighs approximately 53 kg Use applicable equipment to install the cover 1 Read and obey the data in 0012 1 General Guidelines for Lifting Tools 2 Remove the applicable supports and bottom plates for access 3 Remove the cover 1 Fig 1 4 Open the inspection cover 3 to get access t...

Page 462: ...Winterthur Gas Diesel Ltd 2 10 2 Removal 1 Remove the 18 screws 2 Fig 2 2 Remove the 18 intermediate rings 1 Fig 2 I I II II III III I II II III III I 5 5 4 WCH00709 I 6 I 3 1 2 2016 Water Separator Removal and Installation ...

Page 463: ...ng plate 94667A 7 Attach the shackle S2 to the lifting plate 94667A 8 Attach the manual ratchet H2 to the shackle S2 9 Operate the manual ratchet H3 to pull out the water separator until you can attach the plate 94667 Fig 4 as shown 10 Attach the shackle S1 to the eyelet of the plate 94667 in the position shown 11 Remove manual ratchet H2 the support 94667B and the lug 94667C 2016 Water Separator ...

Page 464: ...al ratchet H2 to pull out the water separator At the same time operate the manual ratchet H1 to release the tension 14 Remove the manual ratchet H1 15 Attach the manual ratchet H1 to the end attachment point 1 16 Attach the shackle S1 to the middle eyelet of the plate 94667 2016 Water Separator Removal and Installation H1 H2 H1 H2 Fig 5 H2 H1 1 94667 S1 ...

Page 465: ...ne room crane to move the water separator to an applicable area 23 Remove and discard the rubber cords 3 and 5 Fig 2 3 Installation 1 Make sure that the seating surfaces on the water separator and the frame are clean and in good condition 2 Make sure that the guide bars 1 Fig 7 and the areas where the rubber cords go are clean and in good condition 3 Put a new rubber cord 2 around the rod 3 Bond t...

Page 466: ...frame 9 Attach the two manual ratchets H1 H2 to the attachment points and the shackle S1 10 Operate the manual ratchets H1 H2 to hold the weight of the water separator 11 Remove the engine room crane from the water separator 12 Operate the manual ratchets H1 and H2 Fig 9 to move the water separator to the frame 13 Make sure that the manual ratchet H2 has the weight of the water separator 2016 Wate...

Page 467: ...Fig 11 to move the water separator into the frame as shown 17 Attach the plate 94667A Fig 12 to the water separator 18 Attach the shackle S2 to the plate 94667A 19 Attach the support 94667D to the side of the water separator 20 Make sure that the manual ratchet H1 has the weight of the water separator 2016 Water Separator Removal and Installation H1 H2 H1 H2 2 Fig 10 Fig 11 Fig 12 94667 94667A S2 ...

Page 468: ...H2 to keep tension on the manual ratchets H1 H2 23 Use the tool 94667D Fig 14 to push the water separator to the position shown 24 Remove the manual ratchets H1 H2 25 Remove the shackle S1 and the plate 94667 26 Use the tool 94667D Fig 15 to push fully in the water separator 27 Remove the support 94667D 2016 Water Separator Removal and Installation Fig 13 Fig 14 WCH00709 H1 H2 94667 S1 H1 H2 94667...

Page 469: ... on the threads of the 18 M16x55 screws 2 31 Put the 18 intermediate rings 1 and the 18 M16x55 2 screws in position 32 Torque the 18 M16x55 screws 2 to the value given in 0352 2 CAUTION Injury Hazard The cover weighs approximately 53 kg Use applicable equipment to install the cover 33 Attach the cover 1 Fig 17 to the scavenge air receiver 2016 Water Separator Removal and Installation Fig 16 I Fig ...

Page 470: ...pin 1 in the stowage position 5 Condensate Drain Make sure that the drains are not blocked refer to the Operation Manual 8345 1 You must make sure that water flows correctly Refer to 0380 1 for the intervals to do regular checks Make sure that the orifices 1 2 and 3 Fig 19 in the drain pipes are kept in a clean condition 2 3 EXHAUST SIDE DRIVING END 1 WCH00702 Fig 19 Water Separator Removal and In...

Page 471: ...f the front cover is approximately 61 kg Use the applicable equipment to remove the cover 1 Read and obey the General Guidelines for Lifting Tools 0012 1 2 Use an applicable chain block to remove the front cover 1 Fig 1 from the scavenge air receiver 3 3 Remove the cover 4 from the driving end of the scavenge air receiver 3 4 Remove the platform 2 and the applicable bottom plates 5 Open the inspec...

Page 472: ...o parts To remove the front or rear water separator remove the screws 7 Fig 2 and the plate 1 Remove the 32 screws 9 2 Remove the 32 intermediate rings 8 I I III II II III IV IV I I I II II III III IV IV I WCH03360 8 9 1 2 4 5 3 10 7 6 Fig 2 2016 2 Water Separator Removal and Installation 7 Cyl ...

Page 473: ...t H3 to pull out the water separator 2 a approximately 660 mm 10 Attach the lifting tool 94667G to the water separator 2 11 Attach the limiter 94667H to the receiver housing and the lifting tool 94667G 12 Operate the manual ratchet H3 Fig 4 to pull out the water separator approximately 1030 mm At the same time operate the chain block H2 to keep the height of the water separator constant 13 Remove ...

Page 474: ...k H1 to move the water separator to an applicable area 22 Operate the chain block H1 to lower the water separator on to the platform 23 Remove the chain block H1 and the lifting tool 94667G 24 If it is necessary to divide the water separator do step a and step b a Remove the two screws 1 b Divide the water separator into its two parts 3 Installation 1 If the water separator was divided do step a a...

Page 475: ...ords 3 around the rods 4 Bond together the ends of the rubber cords 5 Lubricate the the guide bars 2 and the rubber cords 3 6 Attach the lifting tool 94667G Fig 8 to the water separator 2 7 Attach the chain block H1 to the lifting tool 94667G 8 Operate the chain block H1 to lift the water separator to the applicable height 2016 Water Separator Removal and Installation 7 Cyl I WCH03360 II I WCH0336...

Page 476: ...older 94667I 15 Operate the manual ratchet H3 Fig 10 to pull the water separator into the frame to the position shown Make sure that the water separator level stays level 16 Continue to operate the manual ratchet H3 Fig 11 until the lifting tool 94667G is adjacent to the frame 17 Remove the chain block H1 from the lifting tool 94667G 18 Remove the lifting tool 94667G from the middle of the water s...

Page 477: ...e ends of the rubber cord 22 Make sure that the rubber cords 1 4 are seated correctly 23 Put oil on the threads of the 18 M16x55 screws 3 24 Put the 32 intermediate rings 2 and the 32 M16x55 3 screws in position 25 Torque the 18 M16x55 screws 3 to the value given in 0352 2 2016 Water Separator Removal and Installation 7 Cyl H1 H2 Fig 12 I WCH03360 I WCH03360 2 3 4 Fig 13 1 ...

Page 478: ...er 1 Fig 14 and the rear cover 4 to the scavenge air receiver 4 Completion 1 Install the platform 2 and the applicable bottom plates that you removed before 2 Remove the pin 6 to unlock the inspection cover 5 3 Close the inspection cover 5 4 Install the pin 6 in the stowage position 2016 Water Separator Removal and Installation 7 Cyl FREE END DRIVING END 4 WCH03354 WCH03355 1 2 3 Fig 14 5 6 ...

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Page 480: ...Maintenance Group7 Winterthur Gas Diesel Ltd 1 6 Cylinder Lubrication Group 7 Cylinder Lubricating System 7218 1 A1 Winterthur Gas Diesel Ltd RT flex50DF MM 2016 ...

Page 481: ...er Lubrication System For more data about the cylinder lubrication system refer to the Operation Manual 7218 1 1 1 Cylinder Lubrication System Operate For more data refer to the Operation Manual 4002 2 paragraph 3 2 and paragraph 3 21 1 In the LDU 20 get the MAIN page 2 In the navigation menu select Cylinder Lubrication 3 In the CYL LUBRICATION page field Manual lub Cyl select the applicable cylin...

Page 482: ...Maintenance 7218 1 A1 Winterthur Gas Diesel Ltd 2 6 DRIVING END I WCH02910 I Fig 1 2 1 4 5 3 7 6 9 10 8 Note Some parts can look different 2 2 2016 Cylinder Lubricating System ...

Page 483: ...ubrication 4 Manually release a lube pulse as follows a Use a pin or a screwdriver 6 Fig 1 to push the plunger 7 of the 4 2 way valve 8 5 Look through the scavenge air ports in the cylinder liner 1 while the lubricating system operates 6 Make sure that the lubricating oil flows on to the cylinder liner wall refer to the Operation Manual 7218 1 paragraph 8 2 and 8 3 7 Make sure that the oil that fl...

Page 484: ...n the vent screw 9 5 Clean the external surface of the cylinder lubricating pump 10 6 If necessary bleed the oil pipes 2 to the lubricating quills refer to paragraph 3 2 7 Do a function check of the cylinder lubrication system refer to paragraph 1 2 3 2 Oil Pipes To bleed the oil pipes 2 do step 1 to step 8 below 1 Set to on the cylinder lubricating system refer to paragraph 1 1 2 Use an open ende...

Page 485: ...licable filter chamber 4 then remove the cover 2 5 Replace the clogged filter element Note As an alternative you can clean the clogged filter element refer to paragraph 4 2 6 Attach the cover 2 to the filter chamber 4 with the three nuts 3 7 Clean the external surface of the duplex filter 1 8 Install the cover you removed before to the rail unit 9 Open the ball valve 6 4 2 Filter Element Clean For...

Page 486: ...Maintenance 7218 1 A1 Winterthur Gas Diesel Ltd 6 6 FREE END WCH03018 1 I I FREE END WCH03020 Fig 2 Note Some parts can look different 4 5 2 3 2 4 6 2016 Cylinder Lubricating System ...

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Page 488: ...emoval Grind Installation 8447 1 A1 Hydraulic Pipe for Exhaust Valve Drive Removal Grind Installation 8460 1 A1 HP Injection Pipe Removal Grind Installation 8733 1 A1 HP Fuel Pipe Removal Grind Installation TC at Aft End 8752 1 A1 HP Pipe Pilot Fuel Removal and Installation 8790 1 A1 Winterthur Gas Diesel Ltd RT flex50DF MM 2016 ...

Page 489: ... actuator 3 Fig 1 closed A pressure of 5 5 bar opens the control actuator 2 Maintenance Special maintenance of the butterfly valve 7 is not necessary For a general inspection refer to the instructions in the documentation of the manufacturer 1 To do a function check refer to the Operation Manual 8135 1 and the Maintenance Schedule 0380 1 Exhaust Waste Gate LLT WCH02971 1 2 3 4 5 3 7 5 6 Fig 1 Key ...

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Page 491: ...eration Manual 0310 01 2 Make sure that the servo oil service pump is set to off 3 Put an oil tray under the applicable intermediate piece 3 Fig 1 4 Put an oil tray under the connecting blocks of the applicable HP servo oil pump 2 5 Remove the stirrup bolts 1 from the applicable HP servo oil pipe III WCH02974 2 1 I I II II IV V For views I I to V see Fig 2 and Fig 5 WCH02974 1 3 Fig 1 HP Servo Oil...

Page 492: ...drain the HP servo oil pipe 12 2 Removal 2 1 HP Servo Oil Pipes 11 12 1 Remove the screws 21 from the flange 20 2 Move the flange 20 away from the servo oil pump 3 Remove the screws 10 from the flange 9 4 Push down the flange 9 5 Carefully remove the HP servo oil pipe 11 6 Remove the non return valve 22 7 Apply protection to the sealing faces SF to prevent damage 2 2 HP Servo Oil Pipes 3 4 1 Remov...

Page 493: ...faces of the four screws T2 8 Remove the cover T1 9 Put the emery cloth you cut out into the grinding tool 94841 10 Put the grinding tool 94841 emery cloth and the cover T1 in position on the hydraulic pipe 1 11 Torque symmetrically the the four screws T2 to 2 0 Nm 12 Put the hydraulic pipe 1 in a vice as vertically as possible 13 Adjust the speed of the hand drill to between 200 rpm and 500 rpm 1...

Page 494: ... you get a smooth finish 23 Replace the emery cloth with a polishing cloth as a last step to polish the HP servo oil pipe 24 Clean the HP servo oil pipe 1 25 If necessary do step 3 to step 24 for the other servo oil pipes 4 Adjustment 1 Make sure that the claw 4 Fig 4 is correctly attached to the HP servo oil pipe 1 2 Do a check of the O ring 3 If the O ring is unserviceable remove and discard it ...

Page 495: ...the non return valve 23 is in the correct position 7 Torque symmetrically the eight screws 21 four screws for each HP servo oil pipe to 40 Nm 8 Torque symmetrically the four screws 10 and the four screws 13 to 40 Nm 5 2 HP Servo Oil Pipes 3 4 1 Remove the protection from the sealing faces SF of the HP servo oil pipes 3 4 2 Carefully put the HP servo oil pipes 3 4 in position in the intermediate pi...

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Page 497: ...ill 1 Preparation 2 2 Removal 3 3 Sealing Faces Grind 4 4 Adjustment 5 5 Installation 5 5 I III III I II II 7 WCH02976 1 2 6 Fig 1 For View II II see Fig 2 Fig 4 and Fig 7 For View III III see Fig 3 and Fig 7 1 Flange 5 Exhaust valve control unit VCU 2 Top housing 6 Flange 3 Screw plug 7 Hydraulic pipe 4 Drain screw Hydraulic Pipe for Exhaust Valve Drive 2016 ...

Page 498: ...f the main bearing oil supply 4 Make sure that there is no pressure in the servo oil system refer to the data given in the Operation Manual 0520 1 paragraph 2 3 5 Put an oil tray under the drain screw 5 Fig 2 6 Carefully loosen the screw plug 4 7 Carefully loosen the drain screw 5 to drain the oil from the servo oil system 8 Put an oil tray under the applicable hydraulic pipe 1 9 Loosen the screws...

Page 499: ... screws 4 Fig 4 from the flange 2 4 Carefully move the flange 2 away from the VCU 3 CAUTION Injury Hazard The weight of the hydraulic pipe is approximately 21 kg Use approved equipment or sufficient personnel to lift and move the hydraulic pipe 5 Carefully remove the hydraulic pipe 4 6 Apply protection to the sealing faces SF to prevent damage and contamination Hydraulic Pipe Removal Grind Install...

Page 500: ...etrically the the four screws T2 to 2 0 Nm 11 Put the hydraulic pipe 1 in a vice as vertically as possible 12 Adjust the speed of the hand drill to between 200 rpm and 500 rpm 13 Align the hand drill and the grinding tool 94841 accurately with the hydraulic pipe 1 as shown 14 Use light pressure and start grinding 15 Regularly remove the unwanted material from the grinding tool 94841 16 Make sure t...

Page 501: ...y lateral force to the hydraulic pipe and the flanges 1 Remove all of the protection from the sealing faces SF Fig 7 in the top housing 3 and the VCU 6 2 Apply oil to the threads of the screws 2 5 3 Carefully put the hydraulic pipe 1 in position in the top housing 3 and the VCU 6 4 Torque symmetrically the four screws 2 to 20 Nm 5 Make sure that there is a distance of 5 0 mm between the flange 4 a...

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Page 503: ...nsulation from the applicable HP injection pipe 8 Put an oil tray under the applicable HP injection pipe 1 9 Carefully loosen the screws 5 10 Lift the applicable flange 7 to drain the fuel from the HP injection pipe 1 2 Removal CAUTION Damage Hazard Make sure that you do not damage the sealing faces or the HP injection pipes 1 On the injection valve 4 remove the four screws 3 2 On the flange 7 rem...

Page 504: ...ipe 1 Turn the locknut until it is fully attached to the HP injection pipe 10 Attach the screw on sleeve 94870A to the locknut 94870C 11 Lock the screw on sleeve in position with the locknut 94870C 12 Attach the grinding tool 94870B to the hand drill 13 Put the grinding tool 94870B into the screw on sleeve 94870A Make sure that emery cloth touches the HP injection pipe 1 14 Adjust the speed of the...

Page 505: ...d the flow limiting valve 9 6 Make sure that there is a distance of 5 7 mm between the ends of the HP injection pipe 1 and the claws 7 11 7 Apply Never Seez NSBT8 to the threads of the screws 2 13 8 Carefully put the HP injection pipe 1 in position in the injection valve 3 and the flow limiting valve 9 9 Torque symmetrically the four screws 2 to 40 Nm 10 Make sure that there is a distance of 10 5 ...

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Page 507: ...870G 1 Screw on sleeve 94870E 1 Template 94870H 1 Grinding tool countersunk screw M8 94870F 1 Hand drill 1 Preparation 2 2 Removal 3 3 Sealing Faces Grind 4 4 Installation 5 II I III I V IV IV III V Note The different views are shown in Fig 2 Fig 3 Fig 8 and Fig 9 II VI VI VII 1 2 WCH02982 WCH02982 Fig 1 HP Fuel Pipe 2016 ...

Page 508: ...damage the sealing faces or the HP fuel pipes Do not apply lateral force to the HP fuel pipes and the flanges 1 Stop the engine refer to the Operation Manual 0310 1 2 Set to off the fuel supply pump 3 Set to off the trace heating 4 If necessary remove the insulation from the applicable HP fuel pipe 5 Put an oil tray under the applicable fuel pump 6 Loosen the screws 4 Fig 2 a maximum of three turn...

Page 509: ...Use approved equipment or sufficient personnel to lift and move the HP fuel pipe 7 Carefully remove the HP fuel pipe 3 8 Apply protection to the sealing faces SF to prevent damage and contamination 9 Remove the four screws 8 from the flange 7 10 Carefully move the flange 7 down 11 Remove the four screws 10 from the flange 11 12 Carefully move the flange 11 up 13 Carefully remove the HP fuel pipe 9...

Page 510: ...crew 1 7 Put the HP fuel pipe 3 in a vice 8 Remove the claw 2 from the HP fuel pipe 3 9 Attach the locknut 94870G to the threads on the end of the HP fuel pipe 3 Turn the locknut until it is fully attached to the HP fuel pipe 10 Attach the screw on sleeve 94870E to the locknut 94870G 11 Lock the screw on sleeve in position with the locknut 94870G 12 Attach the grinding tool 94870F to the hand dril...

Page 511: ...nd the sealing face SF on the HP fuel pipe 21 Remove the screw on sleeve 94870E Fig 4 22 Attach the claw 2 to the HP fuel pipe 3 4 Installation 1 Do a check for damage of the O rings 1 and 3 Fig 6 If necessary replace the O rings 2 Remove all the protection from the sealing faces SF 3 Make sure that the claw 4 is correctly attached to the HP fuel pipe 2 Note You can adjust the claw 4 with an open ...

Page 512: ... HP fuel pipe 3 in the intermediate piece 7 and the valve housing 4 8 Torque symmetrically the four screws 1 6 to 30 Nm 9 Make sure that the flanges 2 5 are not tilted and in the correct position 10 Torque symmetrically the four screws 1 6 to 55 Nm 11 Make sure that there is a distance of 43 mm between the shoulder of the flange 5 and the intermediate piece 7 12 Make sure that there is a distance ...

Page 513: ...come out and cause injury CAUTION Damage Hazard Make sure that you do not cause damage to the sealing faces or the pilot fuel pipes Do not apply lateral force to the HP pilot fuel pipes and the flanges 1 Stop the engine refer to the Operation Manual 0310 1 2 Set to off the fuel supply pump 3 Make sure that the pilot fuel supply unit 2 Fig 1 is set to off 4 Make sure that the pressure in the Pilot ...

Page 514: ...an dry area 2 2 Pilot Fuel Pipe 4 5 1 Put an oil tray under the applicable pilot fuel pipe 4 or 5 2 On the applicable distributor blocks 11 loosen the applicable coupling nuts 12 or 13 a maximum of two turns 3 Loosen the applicable coupling nuts 12 or 13 a maximum of three turns Note Make sure that the fuel drains into the oil tray 4 Fully loosen the the applicable coupling nuts 12 or 13 5 Careful...

Page 515: ...ipe 1 9 1 Remove all protection from the openings and sealing faces 2 Apply oil to the applicable coupling nuts 2 or 8 and 10 or 14 Fig 2 3 Make sure that the sealing faces SF Fig 3 have no damage 4 Put new O rings on the applicable pilot fuel pipe 1 or 9 5 Attach the applicable pilot fuel pipe 1 or 9 to the pilot injection valve 3 or 7 Fig 2 and the distributor block 11 6 Make sure that the coupl...

Page 516: ...or Removal and Installation 9258 1 A1 Tools Description 9403 1 A1 Hydraulic Jacks and Pumps Configuration 9403 2 A1 Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 9403 3 A1 General Application Instructions 9403 4 A1 Tool List 9403 5 A1 Standard Tools Pages 1 to 39 Recommended Special Tools Pages 40 to 41 Winterthur Gas Diesel Ltd RT flex50DF MM 2016 ...

Page 517: ...e electrical connection from the proximity sensor 5 4 Loosen the locknut 4 5 Remove the proximity sensor 5 from the holder 6 Attach a new proximity sensor 5 to the holder 7 Make sure that the proximity sensor 5 touches the tooth 3 8 Loosen the proximity sensor 5 to get a clearance of 4 0 mm between the tooth 3 and the bottom of the proximity sensor 9 Carefully tighten the locknut 4 with your finge...

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Page 519: ... pressure in cylinder cover 2 Fig 1 2 Disconnect the electrical connection from the pressure sensor 1 PT3601 3 Attach the tool 94022H to the casing of the sensor 1 4 Carefully remove the sensor 1 5 Put the sensor 1 in a clean dry area 3 Installation 1 Apply oil to the thread of the sensor 1 2 Attach the tool 94022H to the sensor 1 3 Fully install the sensor 1 4 Torque the sensor 1 to 25 5 Nm 5 Con...

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Page 521: ...ve special screws and devices These tools have stowage positions for the special screws and devices When the tool is not used the special screws and devices must stay in their stowage positions When oil must be added to the hydraulic pumps the related oil quality specification from the pump manufacturers must be obeyed Use lubricating oils that have the viscosities SAE 30 to SAE 40 In unusual cond...

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Page 523: ...nt 94934G 14 Adapter piece 94934F 7 Connection piece 94215B 15 Hydraulic distributor 94934H 8 Pre tensioning jack 94215A with pressure gauge 0 to 25 bar 16 Connection nipple 94934I 3 9 3 1 3 4 5 3 6 3 5 2 14 016 623 08 8 7 16 15 3 WCH00724 A B C H Fig 1 A Apply tensioning loosen tie rods elastic studs to exhaust valve cages top and bottom end bearings to connecting rod piston rod screwing and elas...

Page 524: ...cting rod piston rod screws and elastic studs to piston crown Apply tensioning loosen the elastic studs to the main bearing G Set up of pre tensioning jacks 94215a i e collection the hydraulic oil E Removal and installation of main bearing shells H Checks of non return valve in the lubricating quill for pulse lubrication F Setting and checks of the fuel overpressure safety valve Hydraulic Jacks an...

Page 525: ... use tools with sharp edges Table 1 Tool Number Position of Pre tensioning Jack Part Back up Ring not cut O ring Dimension mm o x i x t i x s 94114B Elastic studs main bearing Piston Cylinder 95 4 x 86 x 1 7 66 2 x 60 x 1 4 88 27 x 5 33 59 92 x 3 53 94145 Foundation bolts and engine stays Piston Cylinder 92 x 82 6 x 1 7 79 2 x 73 x 1 4 81 92 x 5 33 72 62 x 3 53 94180A Tie rods with M80x6 thread di...

Page 526: ...s 94340 Elastic studs for the piston rod screw connection piston cylinder 58 x 51 8 x 1 4 47 2 x 41 x 1 4 50 39 x 3 53 40 87 x 3 53 94346 Elastic studs for the piston head piston cylinder 50 5 x 44 3 x 1 4 46 2 x 40 x 1 4 44 04 x 3 53 40 87 x 3 53 O ring t i o i o 002 696 98 Back up ring s 011 032 03 Fig 1 2016 Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance ...

Page 527: ... Elastic Studs 1 Piston 7 O ring 2 Double cylinder 8 Back up ring 3 Round nut 9 O ring 4 Holder 10 Adapter 5 Vent screw 11 Closing valve 6 Back up ring 94114B KJ Kit with back up and O rings for double pre tensioning Jack 3 1 2 018 674 09 6 7 9 8 4 5 5 4 1110 Fig 2 94114B KJ 2018 02 Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance ...

Page 528: ...lt and Engine Stay 1 Piston 6 Back up ring 2 Cylinder 7 O ring 3 Vent screw 8 Back up ring 4 Adapter 9 O ring 5 Connection piece 94145 KJ Kit with back up and O rings for pre tensioning Jack 3 1 2 5 013 471 05 6 7 9 8 4 Fig 3 94145 KJ 2018 02 Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance ...

Page 529: ...1 Piston 6 Back up ring 2 Cylinder 7 O ring 3 Vent screw 8 Back up ring 4 Adapter 9 O ring 5 Connection piece 10 Eyelet 94180A KJ Kit with back up and O rings for double pre tensioning Jack 3 WCH03123 6 7 9 8 5 4 1 2 10 Fig 4 94180A KJ Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 2018 02 ...

Page 530: ...der Cover 1 Piston 6 Back up ring 2 Cylinder 7 O ring 3 Vent screw 8 Back up ring 4 Adapter 9 O ring 5 Connection piece 10 Holder 94215A KJ Kit with back up and O rings for pre tensioning Jack 013 472 05 3 1 2 5 4 10 6 7 9 8 Fig 5 94215A KJ Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 2018 02 ...

Page 531: ... Valve Cage 1 Piston 6 Back up ring 2 Cylinder 7 O ring 3 Vent screw 8 Back up ring 4 Adapter 9 O ring 5 Connection piece 10 Holder 94252 KJ Kit with back up and O rings for pre tensioning Jack 013 475 05 3 10 1 5 4 2 6 7 9 8 Fig 6 94252 KJ Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 2018 02 ...

Page 532: ... Bearing 1 Piston 6 Back up ring 2 Cylinder 7 O ring 3 Vent screw 8 Back up ring 4 Adapter 9 O ring 5 Connection piece 10 Distance bush 94314 KJ Kit with back up and O rings for pre tensioning Jack 3 1 2 5 4 10 013 474 05 6 7 9 8 Fig 7 94314 KJ Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 2018 02 ...

Page 533: ...nd Bearing 1 Piston 6 Back up ring 2 Cylinder 7 O ring 3 Vent screw 8 Back up ring 4 Adapter 9 O ring 5 Connection piece 10 Holder 94315 KJ Kit with back up and O rings for pre tensioning Jack 010 039 02 2 1 3 4 10 5 6 7 9 8 Fig 8 94315 KJ Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 2018 02 ...

Page 534: ...d Piston Rod Foot 1 Piston 6 Back up ring 2 Cylinder 7 O ring 3 Vent screw 8 Back up ring 4 Adapter 9 O ring 5 Connection piece 94340 KJ Kit with back up and O rings for pre tensioning Jack 3 1 5 4 2 013 476 05 6 7 9 8 Fig 9 94340 KJ Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 2018 02 ...

Page 535: ...ud Piston Crown 1 Piston 6 Back up ring 3 Cylinder 7 O ring 4 Vent screw 8 Back up ring 5 Adapter 9 O ring 6 Connection piece 94346 KJ Kit with back up and O rings for pre tensioning Jack 016 651 08 6 7 9 8 3 5 1 2 4 Fig 10 94346 KJ Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 2018 02 ...

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Page 537: ...must make sure that the threads of elastic bolts and hydraulic jacks are smooth and clean 2 You must make sure that you add lubricant to the elastic bolts and hydraulic jacks refer to 0352 1 3 Connect the hydraulic components to the hydraulic jacks refer to 9403 2 4 Fully tighten the high pressure HP hoses to make sure that the built in non return valves can operate WARNING Injury Hazard Always pu...

Page 538: ... to the HP oil pump or the hydraulic unit 4 Put a hose on the vent screw 1 5 Put a container below the hose to drain the oil 6 Operate the HP oil pump 7 Close the vent screw 1 when oil that has no air flows out Note Do not move the piston 2 above the limit of the red groove 3 8 Operate the HP oil pump to slowly increase the pressure to between approximately 20 bar to 30 bar more than the value giv...

Page 539: ...ut 7 3 3 Procedure 1 On the HP oil pump close the relief valve 2 Connect the hydraulic jack to the HP oil pump or the hydraulic unit 3 Operate the HP oil pump 4 Close the vent screw 1 when oil that has no air flows out 5 Slowly increase the pressure to the nominal value then keep the pressure constant refer to Table 1 for the pressure values 6 Make sure that there are no leaks Note Do not move the...

Page 540: ...0 to 14 5 mm 3 Molykote paste G Elastic studs cylinder cover 2708 2 94215A 1500 530_ 1 Oil Exhaust valve cage 2751 1 94252 1500 155_ 1 Oil Elastic stud top end bearing 3303 1 94315 1st step 1000 then 1500 1st to 2nd step 15_ Oil Bottom connect ing rod 3303 1 94252 1st step 950 then 1500 1st to 2nd step 30_ 1 Oil Crosshead and guide shoe 3326 1 94340 1st step 1000 then 1500 1st to 2nd step 80_ Oil ...

Page 541: ...110 Ring slugging wrenches set compl consisting of 12 wrenches AF27 to AF110 for ordering single wrenches state AF Example 94000 27 94000 110 000 382 93 94003 94003 5 94003 27 Allen keys set compl consisting of 11 Allen keys AF5 to AF27 for ordering single wrenches state AF Example 94000 5 94000 27 000 381 93 94004 94004 10 94004 12 94004 25 Angle screwdrivers 1 Piece b 10 mm 1 Piece b 12 mm 1 Pie...

Page 542: ...0 375 93 94008 94008 M4 94008 M5 94008 M6 94008 M8 94008 M10 94008 M12 94008 M20 94008A M56 Withdrawing gears for taper cylindrical dowels and pins 1 Piece M4 1 Piece M5 1 Piece M6 1 Piece M8 1 Piece M10 1 Piece M12 1 Piece M20 for removal of Cyl cover elastic stud 1 Piece M56 X 146 mm X WCH00836 94010 94010A 1 Torque spanner 3 8 Range of adjustment 2 5 11 Nm Adapter piece 3 8 010 229 02 94011 1 T...

Page 543: ...2 2 2 Manual ratchets WLL 800 kg 2 5m stroke Manual ratchets WLL 1600 kg 2 5m stroke Manual ratchets WLL 3200 kg 2 5m stroke Manual ratchets WLL 6300 kg 3 5m stroke Manual ratchets WLL 250 kg 2 5m stroke 012 233 04 94017 021 94017 022 1 1 Spur geared chain block WLL 2000 kg 4m stroke Spur geared chain block WLL 2000 kg 5m stroke 016 621 08 94018 003 94018 006 2 2 Spur geared chain blocks WLL 1500 ...

Page 544: ...lifier with transmission factor 1 4 WCH02642 94021 1 Pipe to power amplifier X 563 mm WCH02643 X 94022 94022A 1 1 Adapter piece 3 8 Socket wrench insert AF 3 010 233 02 94022H 1 Dismantling and assembling tool for sensor cylinder pressure AF30 X 313 X WCH033226 94023 94023A 94024 1 1 1 Hex head driver 1 AF 22 Assembly tool AF 13 X 225 mm Hex head driver AF 19 013 556 05 X WCH03326 94023 94024 9402...

Page 545: ...16 94040 M20 94040 M24 94040 M30 RUD eye bolts 6 Pieces M8 6 Pieces M10 6 Pieces M12 6 Pieces M16 6 Pieces M20 4 Pieces M24 4 Pieces M30 013 560 05 94048 94048 M16 94048 M30 Swivel lug 4 Pieces M16 6 Pieces M30 WCH00113 94050 94050A 94050B 94050C 94050D 94050E 94050F 94050G 94050H 1 Tool for pressure measurement for pneumatic elements 1 Compressed air pump 1 Pressure gauge 0 4 bar 1 Pressure gauge...

Page 546: ...cover X 590 mm 018 664 09 X 94114B 2 Double pre tensioning jacks for elastic studs to main bearing X 222 mm 018 664 09 X 94116A 1 Transportation tool with 2 head screws M6x25 for removal and fitting of main bearing shell X 210 mm WLL 50 kg 018 662 09 X 94116B 1 Lifting lug for removal and fitting of main bearing cover X 72 mm 018 662 09 X 94116C 1 Trolley for removal and fitting of main bearing co...

Page 547: ... fitting of main bearing cover shell crosshead pin X 340 mm WCH00265 X 94118A 1 Turning out device with 2 head screws M6x25 for removal and fitting of main bearing shell X 215 mm 018 662 09 X 94119B 1 Device with 3 shackles for removal and fitting of main bearing shell X 190 mm 018 662 09 X 94120A 1 Rope 6 mm for removal and fitting of main bearing shell X 1050 mm WLL 310 kg 018 X 2020 Standard To...

Page 548: ...ool for removal of bearing shell 94122 1 Feeler gauge 000 361 93 94123 1 Special feeler gauge for main bearing X 620 mm 000 395 93 X 94126 1 Depth gauge measuring range 760 mm 000 394 93 94141 1 Support for removal of main bearing shells X 735 mm X 013 565 05 2020 Standard Tools ...

Page 549: ...esel Ltd 9 45 94142 94142A 1 2 Work platform X 1088 mm Nuts M20 X 76 mm WCH03524 X X 94143 1 Working support X 450 540 mm X WCH03524 94145 1 Pre tensioning jack for foundation bolts and engine stays X 130 mm X 013 567 05 2020 Standard Tools ...

Page 550: ...rning out thrust bearing pads with 1 part gear wheel X 161 4 mm X 013 568 05 94155A 1 Turning out device with screws M20x45 for turning out thrust bearing pads with 2 part gear wheel X 161 4 mm X 013 569 05 94180 2 Pre tensioning jacks for tie rods M80x6 X 232 mm Y 243 5 mm WCH00668 X Y 2020 Standard Tools ...

Page 551: ...63 mm Mass approx 100 kg 94201B 2 Holders X 940 mm Mass approx 19 7 kg 94201C 2 Flange couplings X Ø176 mm 94201D 1 Shackle 94201A 94201B 94201C 94201D WCH03066 X 94202L 1 Chain X 707 mm WLL 5000 kg WCH02588 X 94208 1 Dismantling tool for removal of antipolishing ring X 442 mm Y 37 mm WCH02873 X Y 94209 1 Lifting hook for removal and installation of antipolishing ring X 1000 mm WLL 750 kg 012 242 ...

Page 552: ... 1 Bush 94214F 1 Angle steel 94214G 4 Hexagon head screw M6x12 94214H 6 Hexagon socket head cap screw M6x50 94214I 1 Gasket Sealing between bush and for gas admission valve 94214K 1 O Ring for gas admission valve 94214L 2 Screws for gas admission valve 94214M 2 Nuts for gas admission valve 94214F WCH03395 94214G 94214E 94214C 94214D 94214L 94214H 94214M 94214A 1 Handle X 37 5 mm X WCH03331 94214B ...

Page 553: ... 800 mm 94215E 4 Hoses X 1000 mm 701 013 574 013 574 05 94215A 94215B 94215D 94215E 94215A 1 Pre tensioning jacks X 177 mm 016 765 08 X 94225 1 Measuring gauge for measuring cylinder liner bore accessory for it inside micrometer tool 94101 X 2339 mm X 000 419 93 94238 1 Feeler gauge 10 part for checking bearing clearances Leaf length 300 mm 000 418 93 2020 Standard Tools ...

Page 554: ...t valve cage X 194 mm 009 952 02 X 94259 1 Pressure element for exhaust valve X 189 mm X 016 765 08 94261 1 Valve seat fitting and extracting device X 490 mm 000 415 93 X 94262 1 Valve protector only to be used for transporting a complete exhaust valve X 450 mm X 013 576 05 2020 Standard Tools ...

Page 555: ... 2100 kg X a a 003 971 96 013 577 05 X KF 94124 1 Support for cylinder cover and exhaust valve assembly X 990 mm Y 1719 mm X Y 94269C 46 94269C 55 1 1 Socket wrench insert for loosening and tightening of clamping nut to injection valve X 115 mm Y 70 mm Socket wrench insert for tightening of coupling nut to pilot injection valve X 126 5 mm Y 65 mm WCH01208 X Y 2020 Standard Tools ...

Page 556: ... dismantling and assembly an injection valve X 180 mm X WCH02263 94270D 2 Stud bolts for dismantling and assembly an injection valve X 186 mm X WCH02263 94270E 1 Supporting plate for dismantling and assembly a pilot injection valve with two head screws M12x90 with dog point X 130 mm X WCH02810 94270F 2 Stud bolts for dismantling and assembly a pilot injection valve with two nuts M12 X 176 mm X WCH...

Page 557: ...Hydraulic cylinder for loosening and tightening of coupling nut to injection valve and pilot injection valve and X 395 5 mm 94272A 1 Valve holder for checking the fuel overpressure safety valve X 170 mm 94272B 1 Connecting piece for adjusting the injection valve X 133 mm 94272C 1 Valve holder for checking and adjusting relief valve to cylinder cover and fuel rail X 68 mm 94272F 1 Adapter for pilot...

Page 558: ...jection valve X 568 mm Y 546 mm 94275 1 HP hose to OBEL test bench for testing loosening and tightening of coupling nut to injection valve X 1000 mm Max working pressure 1500 bar 94275A 1 Cable to OBEL test bench Electric connection between OBEL test bench and injection valve X 1200 mm X WCH03070 X Y WCH03069 WCH01208 X 94275 WCH01208 X 94275A Y X 2020 Standard Tools ...

Page 559: ...0 1D WCH00865 94270 03 94270 3D 1 1 Grinding device To grind the pilot injection valve bore X 172 mm Stencil X 94270 3D WCH00866 94279 1 Gauge for checking wear and burn scar on exhaust valve seat 002 563 98 X KF 94153 1 Cleaning tool for injection nozzle assembly X 113 mm X 94281 1 Assembly tool for installation of starting air valve X 386 mm X WCH03071 94289 1 Bush with dowel pin for dismantling...

Page 560: ...or assembling O rings of injection valve X 65 mm WCH00896 X 94292 1 Template for checking wear on disc of exhaust valve spindle X 160 mm X 013 582 05 94305 1 Crankshaft checking equipment for measuring crank deflection in wooden box X 364 mm X 94314 94314A 2 1 Pre tensioning jacks for connecting rod studs to bottom end bearing X 155 mm Distance bushes 013 583 05 X 94314 94314A 2020 Standard Tools ...

Page 561: ...o top end bearing X 132 mm X 94323 4 Retaining pins to prop up crosshead guide shoes when removing or fitting a connecting rod or a crosshead X 75 mm 1 013 584 X 013 584 05 94324 1 Cover and lifting plate to crosshead including 2 shackles 6 5 t X 257 mm WLL 3400 kg 701 013 58 5 013 585 05 X 2020 Standard Tools ...

Page 562: ...l and fitting of main bearing bearing cover of top end bearing guide shoe connecting rod X 194 mm WLL 8000 kg X 013 587 05 94333 1 Lifting device to piston for removal and fitting of top end bearing cover crosshead pin and changing compression shim consisting of 94333A 2 Lifting bosses with 4 Allen screws M16x45 X 166 mm WLL 1100 kg 94333B 2 Suspension chains X1 440 mm 94333A 94333B X 1 X 013 588 ...

Page 563: ... X 94335C 94335B 94337 1 Lifting tool for removal and fitting of inside pipe to piston cooling and crosshead lubrication X 137 mm 701 013 589 X 013 589 05 94337A 1 Centring piece for alignment of inside pipe X 58 mm 701 013 590 X 013 590 05 94337B 1 Flange for blanking off oil bore X 155 mm X 013 591 05 94338 1 Piston ring tensioning device X 296 mm Y 235 mm X Y WCH02872 2020 Standard Tools ...

Page 564: ...d 24 45 94340 2 Pre tensioning jacks for piston foot fastening and crosshead screw connection X 88 mm X 013 594 05 94341 1 Lifting tool for removal and installation of piston X 612 mm X WCH03301 94342 1 Inserting cone X 407 mm X 2020 Standard Tools ...

Page 565: ...ce For piston assembly X 141 mm Y 153 mm Z 417 mm X Y Z KF 94157 1 Dismantling and assembling tool For piston assembly X 616 mm Y 221 mm Y X 94344 2 Dismantling tool for removal and installation of piston rod gland and piston including 94344A 1 Holder X 312 mm 94344B 2 Chains X 2020 Standard Tools ...

Page 566: ... 94345 2 Distance holders for removal and installation of piston rod gland and piston X 495 mm X 701 013 596 013 596 05 94345B 1 Clamp ring X 52 mm X 000 402 93 94345C 1 Gauge for fitting scraper rings X 270 mm X 701 013 597 013 597 05 2020 Standard Tools ...

Page 567: ... for tensioning springs to piston rod gland and insulation bandage X 150 mm 004 284 98 X 94345F 9 94345F 11 94345F 13 2 2 2 Distance pieces 9 mm for fitting rings to upper gland group X 297 mm Distance pieces 11 mm X 297 mm Distance pieces 13 mm X 297 mm X 005 65 94346 2 Pre tensioning jacks for elastic studs to piston head X 66 mm 016 649 08 X 94350 1 Device for supporting piston and removal of p...

Page 568: ...557 mm Y 197 mm 009 972 02 X Y 94370H 1 Stop plate for locking top end bearing cover X 133 mm X 013 601 05 94410E 2 Head bolts M30x150 for intermediate wheel assembly 013 699 05 94410F 2 Pins for intermediate wheel assembly X 150 mm X 013 698 05 94430 Device for cutting out and cutting in of fuel pump 2 pieces for 5 6 cylinder engines 3 pieces for 7 8 cylinder engines including 94430A 1 Claw 94430...

Page 569: ...p X 116 mm X 701 013 603 013 603 05 94555 94555A Spacer for cutting out of individual fuel pumps 1 piece for 5 8 cylinder engines X 72 mm Spacers for cutting out of individual fuel pumps 2 pieces for 5 6 cylinder engines 4 pieces for 7 8 cylinder engines X1 36 mm 016 649 08 X X1 94556 1 Checking device for plunger position X 130 mm 008 765 01 KF 94216 1 Assembly tool for fuel pump assembly X 614 m...

Page 570: ... engines X 922 mm WLL 2250 kg of 7 8 cylinder engines X 1182 mm WLL 2500 kg 013 604 05 X 94566 1 Support for removal and fitting of camshaft X 510 mm X 013 605 05 94566A 1 Support for removal and fitting of camshaft X 510 mm X 013 606 05 94566B 1 Centring device for aligning bearing shells X 70 mm X 013 607 05 2020 Standard Tools ...

Page 571: ... X 013 608 05 94567 1 Assembly template for removal and fitting of bearing shells to supply unit X 68 mm 701 013 609 X 013 609 05 94575 1 Adjusting scale for Heinzmann StG 10 01 Actuator for regulating linkage X 120 mm including 94575A 1 Adjusting pin for Heinzmann StG 10 01 Actuator X 51 mm 013 610 05 X 013 611 05 X 2020 Standard Tools ...

Page 572: ...k with tube for pressure check of pressure control valve X 954 mm X WCH02283 94585A 1 Surface plate For alignment of fuel limiting valve including 2 screws M8x30 X 400 mm X WCH02590 94585B 1 Blind flange tool rail unit maintenance to seal the injection port in fuel rail including 4 screws M12x60 X 80 mm X WCH02595 94585C 3 Screw plug G 3 4 to close the servo oil unions DIN 908 KF 94239 1 Screw plu...

Page 573: ...rvo oil unions DIN 908 KF 94242 2 Lifting eye bolt to lift the servo oil unions DIN 580 94585E 4 Capping end to close the opening in exhaust valve control unit WCH0259 8 94589 2 Dismantling tools for removal lip seal from injection control unit X 310 mm and 638 mm 012 308 04 X 2020 Standard Tools ...

Page 574: ...to turbocharger inlet for ABB A165 X 600 mm 12 holes for ABB A175 X 630 mm 16 holes Cover to scavenge air receiver for ABB A165 X 460 mm 16 holes for ABB A175 X 820 mm 16 holes Cover to turbocharger outlet for ABB A165 X 430 mm 16 holes for ABB A175 X 600 mm 16 holes X 000 487 93 In case of auxiliary blower breakdown 94656A 94656B 2 2 Covers to connecting pipe auxiliary blower X 430 mm 14 holes Co...

Page 575: ... installaton of auxiliary blower X 1893 mm WLL 800 kg X WCH03036 Tools for removal and fitting of scavenge air cooler SAC A46 SD 94661 1 Support including 1 Shackle WLL 2000 kg 4 Screws M12x35 X 376 mm Y 255 mm WCH00662 Y X 94663A 94663B 1 1 Support LEFT including 1 Lug 1 Safety chain 6 Screws M16x40 X 425 mm Support RIGHT including 1 Lug 1 Safety chain 6 Screws M16x40 X 425 mm X DP 94663B 94663A ...

Page 576: ... cooler X 800 mm WLL 3000 kg at 0 45_ 012 316 04 X Ø 94666I 2 Chains double sling including 4 Shackles X 554 mm WLL 1600 kg at 45 60_ 016 468 07 X Tools for removal and installation of scavenge air cooler SAC A44 SD SAC 261 IL SAC 265 IL 94661 IL 1 Support including 6 Screws M12x45 X 1220 mm X DP WCH00113 94663 IL 1 Lifting plate including 1 Shackle WLL 6500 kg 2 Shackles WLL 4750 kg X 779 mm A44 ...

Page 577: ... chains X 1654 mm SAC265 WLL 1000 kg Safety chains X 1222 mm SAC261 WLL 1000 kg Safety chains X 1998 mm SAC A44 SD WLL 1000 kg Plates including 4 hex Head screws M20x50 X 672 5 mm X 016 822 08 X X 94663C IL 94663D IL 94663E IL 94663F IL WCH03304 94664 IL 94667 1 Tools for removal and installation of water separator TC at DE Lifting plate for removal and installation of water separator including 4 ...

Page 578: ...t for pulling out water separator X 1054 mm Y 540 mm DP X Y WCH00663 94667C 1 Lifting lug for pulling out water separator X 100 mm X DP WCH00663 94667D 1 Support for installation of water separator including 4 nuts M16 X 1000 mm Y 400 mm X Y WCH00663 2020 Standard Tools ...

Page 579: ...g 1 Shackle 4 Screws M12x25 X 330 mm WLL 400 kg and 6000 N X 016 829 08 kg N DP 94667F 1 Disassembling tool including 1 RUD eye bolt 4 Screws M12x25 X 240 mm WLL 6000 N DP X 016 829 08 94667G 1 Lifting tool including 1 RUD eye bolt 1 Shackle 2 Screws M12x65 X 330 mm WLL 400 kg X 016 829 08 94667H 1 Limiter including 1 Wire rope 10 mm 2 Shackles 2 Screws M16x50 X 1187 mm WLL 6000 N X 018 229 09 202...

Page 580: ...ff starting air pipe during emergency operation X 200 mm X 004 017 96 94841 94841A 1 1 Grinding tool for hydraulic pipe X 65 mm R100 5 Stencil Y 65 mm X WCH02756 Y 94841A 94841 94930 94930A 94930B 94930C 1 SW download package to UNIC for uni tool consisting of 1 UBS to CAN adapter 1 CAN cable ca 2 5 m 1 Ethernet adapter cable software tool ca 1000 80 WCH03349 2020 Standard Tools ...

Page 581: ...776 08 94844 1 Lubrication device for supply unit lubrication during maintenance X 600 mm Adaptors Y 28 mm Y1 45 mm Flexible hose Z 3500 mm WCH03855 X Y1 Z Y 94870 1 1 Regrinding device for sealing surfaces on HP fuel piping 8752 1 X 151 mm including 94870E 1 Screw on sleeve AF 50 94870F 1 Grinding tool with countersunk screw M8 94870G 1 Lock nut M30x2 AF 46 94870H 1 Template X 75 mm 016 741 08 X ...

Page 582: ...X 242 mm 008 771 00 Hydraulic parts and pump 94931 94934F 1 1 HP oil pump working pressure max 2800 bar Adapter piece 010 001 02 94934F 94934 1 Connection block 005 956 00 94934A 2 Hydr distributors with pressure gauges 010 242 02 94934G 2 Coupling elements 013 620 05 94934H 1 Hydr distributor with pressure gauge 0 25 bar WCH00724 2020 Standard Tools ...

Page 583: ... HP hoses 2600 bar with closing valves and coupling sockets X 2130 mm X 005 954 00 94935C 1 Hose for set up of pre tensioning jacks Length 2000 mm 701 013 621 013 621 05 94936 2 Hydraulic jacks 500 kN 50 t 005 952 00 94942 1 Hydraulic unit working pressure max 2500 bar 013 622 05 2020 Standard Tools ...

Page 584: ...asuring complete with extension and case Measuring range 150 600 mm 018 223 09 94291 94291A 1 2 Valve grinding device complete for valve spindle and valve seat Grinding discs C M No 11373 01 01 WCH03339 WCH03339 94291A 94299 1 Grinding device X 587 mm X WCH02384 94300 1 Tool cupboard X 1120 mm X 000 500 93 2020 ...

Page 585: ...005 02 X 94356 1 Equipment case with instruments for measuring thickness of chrome ceramic layer on piston rings WCH01216 94929 2 Connecting cables with plugs for emergency cylinder lubrication Connector plug C Plug B with cable lenght 0 5 m Plug C with cable lenght 2 5 m WCH01087 Recommended Special Tools 2020 ...

Page 586: ...arget is to set the industry standard for reliability efficiency and environmental friendliness WinGD provides designs licences and technical support to manufacturers shipbuilders and ship operators worldwide The engines are manufactured under licence in four shipbuilding countries WinGD has its headquarters in Winterthur Switzerland where its activities were founded in 1898 www wingd com ...

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