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RT-flex58T-E

Maintenance

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Table of Contents

Winterthur Gas & Diesel Ltd.

2015-08

Crankshaft, Connecting Rod and Piston

Crankshaft: Measuring Crank Deflection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibration Damper

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Taking a Silicone Fluid Sample

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Inspection (GEISLINGER Vibration Damper)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axial Damper: Dismantling and Assembling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turning Gear: Checking the Toothing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase: Utilization of Working Platform

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod

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Loosening and Tensioning the Connecting Rod Studs

. . . . . . . . . . . . . . . . . . . .

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Inspection, Removal and Fitting of Bottom End Bearing

. . . . . . . . . . . . . . . . . . .

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Inspection, Removal and Fitting of Top End Bearing

. . . . . . . . . . . . . . . . . . . . . .

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Removal and Fitting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Removal of Bearing Cover to Top End Bearing

. . . . . . . . . . . . . . . . . . . . . . . . . .

Crosshead

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Checking the Clearances and Fitting the Guide Shoes

. . . . . . . . . . . . . . . . . . . .

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Removal and Fitting of a Crosshead Pin

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston

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Removal and Fitting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Changing the Compression Shims

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Dismantling and Assembling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Checking Piston Top Surface

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Rings

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Checking Wear of Piston Rings and Ring Grooves

(Piston with four Piston Rings)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Checking Wear of Piston Rings and Ring Grooves

(Piston with three Piston Rings)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving Wheels and Shut-off Valve for Starting Air

Driving Wheels

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Checking the Running and Backlash Clearances and Condition of Teeth

. . . .

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Replacing the Gear Wheel on Crankshaft

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shut-off Valve for Starting Air: Cleaning and Function Check

. . . . . . . . . . . . . . . . .

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Summary of Contents for WARTSILA RT-flex58T-E

Page 1: ...ine No Document ID DBAC540648 Winterthur Gas Diesel Ltd 24hrs Support Sch tzenstrasse 1 3 W rtsil Services Switzerland Ltd CH 8400 Winterthur Z rcherstrasse 12 Switzerland CH 8400 Winterthur Switzerla...

Page 2: ...e copyright holder W rtsil Services Switzerland Ltd makes no representation warranty express or implied in this publication and assumes no responsibility for the correctness errors or omissions for in...

Page 3: ...ine No Document ID DBAC540648 Winterthur Gas Diesel Ltd 24hrs Support Sch tzenstrasse 1 3 W rtsil Services Switzerland Ltd CH 8400 Winterthur Z rcherstrasse 12 Switzerland CH 8400 Winterthur Switzerla...

Page 4: ...e copyright holder W rtsil Services Switzerland Ltd makes no representation warranty express or implied in this publication and assumes no responsibility for the correctness errors or omissions for in...

Page 5: ...on Crankshaft Stud side thread to be applied with MOLYKOTE and LOCTITE 262 corrected x 5801 1 A2 1 Regulating Linkage with Woodward ProAct II Analog Actuator 2nd sentence about configuration and setti...

Page 6: ...U Mk3 x 9403 3 A1 1 5 2015 08 EAAD086016 Pre Tesnioning jacks New jack for Cyl Cover studs x 9403 5 A1 30 2015 08 EAAD085234 Tool List Tool numbers 94871 and 94871A added new cyl Cover press CF94215 9...

Page 7: ...r 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...

Page 8: ...Intentionally blank...

Page 9: ...uide 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 Lubricating Link 16 17 Piston and Piston Rings 1...

Page 10: ...Intentionally blank...

Page 11: ...sidered therein It must be recognized that such data instructions and graphical illustrations may be subject to changes due to further development widened experience or any other reason This manual is...

Page 12: ...Intentionally blank...

Page 13: ...he following main chapters General guidelines for maintenance Clearance tables tightening values of screwed connections masses weights seal rings Maintenance schedule Design groups Tool lists A few ex...

Page 14: ...Intentionally blank...

Page 15: ...Crankshaft and Main Bearing 4 5 Crosshead 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 Lubri...

Page 16: ...the Wear Ridge Re dressing Lubricating Grooves and Scavenge Ports 2124 3 A1 Lubricating Quill with Pulse Jet Lubrication Removal and Fitting 2138 1 A2 Piston Rod Gland Dismantling and Assembling Measu...

Page 17: ...3303 3 A1 Removal and Fitting 3303 4 A1 Removal of Bearing Cover to Top End Bearing 3303 5 A1 Crosshead Checking the Clearances and Fitting the Guide Shoes 3326 1 A1 Removal and Fitting of a Crosshead...

Page 18: ...djusting with Heinzmann StG 10 01 Actuator 5801 1 A1 Adjusting with Woodward ProAct II Analog Actuator 5801 1 A2 Scavenge Air Receiver and Auxiliary Blower Group 6 Scavenge Air Receiver Checking the A...

Page 19: ...mbling and Adjusting 9223 1 A1 Tools Explanation 9403 1 A1 Hydraulic Jacks and Pumps Arrangement and Application 9403 2 A1 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance 9403 3 A1 Ge...

Page 20: ...Intentionally blank...

Page 21: ...bocharger DRIVING END Cylinder Number FREE END Main Bearing Number Thrust Bearing Pads Rail Unit EXHAUST SIDE FUEL SIDE Supply Unit Counterclockwise Rotation Exhaust Waste Gate Option 6 5 4 3 2 1 7 1...

Page 22: ...Pump Actuator 2 Fuel Pump Actuator 3 Fuel Pump 1 Fuel Pump 2 Fuel Pump 3 Servo Oil Pump 2 Servo Oil Pump 1 013 149 05 013 150 05 Supply Unit FUEL SIDE DRIVING END FREE END Crank Angle Sensors Sensor 2...

Page 23: ...inate a person responsible for assigning work tasks to every person who is participating in maintenance work D Make sure that fluids or gases draining or escaping cannot cause accidents fires or explo...

Page 24: ...ed with all the clamps when ever the engine is running even if this is only for a short time in order to make temperature checks e g after changing bearings during an overhaul etc D In the case of a f...

Page 25: ...by wood en pieces leather or special edge guards which are placed between the part and the rope or chain D Always use gloves a face shield and wear safety goggles when working with hydraulic tools D F...

Page 26: ...ot to damage their thread They must be screwed in by hand until metal to metal contact is achieved Always use the specified lubricants on the threads D Adhere to tightening values wherever they are in...

Page 27: ...reasons D Determination of the weight of load D Determination of the suspension centres and weight distribution D Choice of attachment elements D Attaching and disconnecting 2 Attachment elements 2 1...

Page 28: ...ad is only permissible in the direction of the ring therefore the eye bolts or eye nuts must be brought to the right position if necessary by us ing distance rings D If there are through holes a washe...

Page 29: ...ghtening the ring of the RUD eye bolt is freely rotatable the star profile wrench must be removed from the inner hexagon of the screw as shown in Fig A D Prior to loading the RUD eye bolt adjust it in...

Page 30: ...ose shackles may be used which are in accordance with American Stan dard RR C 271A or which fulfil or exceed these values including the safety factor All calculations for components and tools where sh...

Page 31: ...mooth surfaces e g tubes shafts D Protect the ropes against damages by providing a wooden pallet or a rag Sharp edges may even cut steel cables D If possible always tie down the load danger of fall D...

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Page 33: ...lumn Maximum clearance dimension are such values as may be reached after a lengthy operating period which however may not be allowed to be exceeded or fall below On components where the clearance is a...

Page 34: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 2 25 1 3 2 WCH00997 003 319 00 Clearance Table Crankshaft and Thrust Bearing 2013...

Page 35: ...normal new mm Maximum clearance dimension due to wear mm 1132 Main bearing Bearing shell width 242 1 Lateral clearance per side 12 1203 1224 Thrust bearing Thrust bearing pad thickness 66 5 0 5 0 6 2...

Page 36: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 4 25 1 2 003 318 00 003 318 00 MAIN BEARING No 1 MAIN BEARING No 2 AND FOLLOWING 1 2 Clearance Table Crankshaft and Main Bearing 2013...

Page 37: ...to wear mm 1132 Main bearing No 1 Crankshaft outer 706 0 0 08 Main bearing inner 706 1 Bearing clearance vertical 0 3 0 7 0 9 1132 Main bearing No 2 and following Crankshaft outer 706 0 0 08 Main bea...

Page 38: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 6 25 EXHAUST SIDE 6 1 2 4 5 3 7 8 003 317 00 Clearance Table Crosshead Guide 2013...

Page 39: ...ansverse 990 0 20 0 31 3 Guide shoe clearance 0 20 0 90 1 1 4 Guide rail longitudinal 559 30 560 30 5 Guide rail lateral clearance total 0 60 1 80 2 2 6 Guide shoe lateral clearance longitudinal 0 20...

Page 40: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 8 25 WCH01000 1 2 3 4 5 Approx 96 150 mm Clearance Table Cylinder Liner 2013 V2...

Page 41: ...on cylinder cover Water guide jacket 880 0 60 0 40 1 Clearance total 0 70 1 10 Water guide jacket 810 0 80 0 60 2 Clearance total 0 90 1 30 2124 Water guide jacket on cylinder liner Water guide jacke...

Page 42: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 10 25 4 1 1 4 5 6 3 1 2 006 097 99 6 6 012 153 04 Clearance Table Piston Rod Gland 2013...

Page 43: ...ar mm 2303 Piston rod gland 1 Ring width radial 31 min 25 2 Ring width radial 24 min 22 20 3 Ring width radial 5 min 3 20 4 Ring clearance axial 0 05 0 16 0 50 5 Ring clearance axial 0 05 0 13 0 40 6...

Page 44: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 12 25 L LENGTH VALVE SPINDLE GUIDE BUSH 1 3 L 2 3 L 3 2 1 003 316 00 003 316 00 Clearance Table Exhaust Valve 2013...

Page 45: ...g direction method of measuring Nominal dimension normal new mm Maximum clearance dimension due to wear mm 2751 Valve spindle 1 Spindle outer 56 0 19 0 23 55 4 2751 Guide bush 2 Bore inner 56 0 03 0 5...

Page 46: ...ntenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 14 25 10 mm 10 mm 10 mm 10 mm 6 7 6 7 2 3 2 3 4 4 8 5 1 003 315 00 003 315 00 Clearance Table Top and Bottom End Bearings to Connecting Rod 20...

Page 47: ...ner 580 1 Bearing clearance vertical 0 31 0 55 0 75 2 Lateral clearance total 0 41 0 57 3 Lateral clearance total 0 31 0 48 4 Axial clearance per side 0 2 0 4 1 2 3303 Bottom end bearing Crankshaft ou...

Page 48: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 16 25 4 1 1 3 1 3 3 2 3 2 2 003 314 00 4 003 314 00 Clearance Table Piston Cooling and Crosshead Lubricating Link 2013...

Page 49: ...Nominal dimension normal new mm Maximum clearance dimension due to wear mm 3603 Piston cooling and crosshead lu bricating link Pin outer 55 1 Bearing clearance radial 0 03 0 09 0 20 2 Bearing width 14...

Page 50: ...RT flex58T E Winterthur Gas Diesel Ltd 18 25 8 8 1 10 2 9 5 3 4 8 8 1 10 2 9 5 3 4 EXECUTION WITH THREE PISTON RINGS EXECUTION WITH FOUR PISTON RINGS 6 7 7 6 B A B A B A B A Clearance Table Piston and...

Page 51: ...ertical 16 0 35 0 30 5 Groove depth radial 19 50 3425 Piston rings Ring height vertical 16 0 0 03 Point A Point B 6 Ring clearance vertical 0 35 0 43 0 60 0 75 7 Ring clearance vertical 0 30 0 38 0 55...

Page 52: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 20 25 WCH01002 1 2 1 3 4 2 WCH01003 Clearance Table Driving Wheels for Supply Unit 2013 V2...

Page 53: ...dimension due to wear mm 4103 Intermediate wheel Shaft outer 160 1 Bearing clearance vertical 0 08 0 15 0 25 2 Axial clearance total 0 6 1 1 1 5 3 Tooth backlash 0 28 0 45 0 65 4 Tooth backlash 0 20...

Page 54: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 22 25 8 5 4 6 1 3 2 7 WCH00992 Clearance Table Supply Unit 2013 V2...

Page 55: ...ly unit 1 Pinion outer 80 0 0 019 Bearing fitted inner 80 0 10 0 058 2 Bearing clearance radial 0 058 0 119 3 Axial clearance total 0 25 0 54 0 7 5552 Camshaft unit 4 Cam shaft outer 120 0 0 022 5 Bea...

Page 56: ...Maintenance 0330 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 24 25 012 098 04 3 8 7 6 1 2 4 5 171 mm A B C 013 032 05 PLUNGER CYLINDER 30 mm 30 35 mm 38 mm 36 mm Clearance Table Fuel Pump 2013...

Page 57: ...0 027 Guide piston outer 130 Lower housing inner 130 2 Clearance radial 0 070 0 125 0 15 3 Thrust piece lower spring carrier axial 0 02 0 06 0 08 5556 Roller guide Bush outer 60 Roller inner 60 4 Clea...

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Page 59: ...n only When using other hydraulic jacks the required pressure in bar must be calculated in relation to the effective jack piston surface Conversion factor 1 Nm 0 102 mkp 1 bar kp cm2 D The relevant lu...

Page 60: ...Maintenance 0352 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 2 7 WCH00985 2013 V2 Tightening Values of Important Screwed Connections...

Page 61: ...Maintenance 0352 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 3 7 Starting Air Valve Exhaust Valve WCH00985 Injection Valve ER 3 2013 08 Tightening Values of Important Screwed Connections...

Page 62: ...Maintenance 0352 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 4 7 Supply Unit I Servo Oil Rail WCH00989 WCH00985 Fuel Pump I I I I WCH00992 I 2013 V2 Tightening Values of Important Screwed Connections...

Page 63: ...ntenance 0352 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 5 7 Injection Control Unit WCH00987 WCH00988 Fuel Rail Free End Fuel Rail Driving End Tightening Values of Important Screwed Connections V2 20...

Page 64: ...Maintenance 0352 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 6 7 High Pressure Fuel Pipe High Pressure Servo Oil Pipe WCH00990 WCH00991 Tightening Values of Important Screwed Connections 2013 V2...

Page 65: ...Maintenance 0352 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 7 7 Rail Unit Transport Crank Angle Sensor Unit WCH00985 WCH00985 Tightening Values of Important Screwed Connections V2 2013...

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Page 67: ...n These tightening instructions are valid only if screws are made of the 8 8 material threads have been lubricated with oil Standard thread Fine thread Tightening torque Nm M8 M8 x 1 20 M10 M10 x 1 25...

Page 68: ...o the bottom of the tap hole and tighten Always utilize a bolt driver or two nuts Tools like a pipe wrench etc which would damage the bolt shank must never be used D For the protection of the elastic...

Page 69: ...inder liner 3390 2130 Water guide jacket 330 2303 Piston rod gland 129 2708 Elastic stud for valve cage Cylinder cover without accessories 20 1336 2722 Injection valve complete 12 2728 Starting air va...

Page 70: ...uide shoes Middle part with guide shoes complete complete 1213 1807 297 3403 Piston with piston rod Piston crown Piston skirt Piston rod complete 1437 350 62 909 3603 Toggle lever to piston cooling an...

Page 71: ...MET60MA MB MET66MA MB TPL73 B TPL77 B 2000 3000 4900 7000 3550 2000 4260 4500 6250 6500 2600 4070 6545 Auxiliary blower with electric motor Electric motor complete 700 915 250 420 6606 Scavenge air co...

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Page 73: ...with friction shims Check pre tension of waisted studs first time after sea trial 6000 8000 Op h 1903 1 Tie rod Check pre tension if necessary re tension first time after one year 24 000 30 000 Op h 2...

Page 74: ...ve General inspection of valve housing valve spindle and valve seat without dismantling of exhaust valve at every piston removal 2751 4 Check condition and wear of valve spindle if necessary regrind s...

Page 75: ...ishing ring and chrome ceramic piston rings 18 000 36 000 Op H condition based Check tightness on piston in situ and with running oil pump visual check through scavenge ports after refitting 3403 3 Di...

Page 76: ...000 Op h Camshaft check thrust bearing clearances 36 000 Op h 5556 1 Fuel pump Replace O rings in valve block 18 000 Op h Random visual check of plunger cylinder roller and roller guide 18 000 Op h 55...

Page 77: ...ing Manual Air filter Check filter half yearly Cleaning of filter at a p increase of 50 compared to the shop test value at same engine load see Operating Manual 6510 1 as required 6545 1 Auxiliary blo...

Page 78: ...ds every three months 8 8135 1 Exhaust Waste Gate LLT During a longer operation period at low engine load manually open butterfly valve at least once per week see Operating Manual 8135 1 General inspe...

Page 79: ...cracks and wear of tooted belt visually Visual lubricating oil check 3000 Op h Replace toothed belt 24 000 Op h Overhaul drive ball bearing sealing ring etc and check shaft eccentricity of CAS drive...

Page 80: ...are see Operating Manual 0720 1 and 0760 1 Overhaul according to Maintenance Manual Genuine spare parts used Engine monitoring Engines according to specifications of W rtsil Switzerland Ltd On the eng...

Page 81: ...Winterthur Gas Diesel Ltd 1 2 Cross Section 3326 1 3326 2 6545 1 5556 1 5562 1 2728 1 8460 1 8733 1 3301 1 4325 1 1112 1 6420 1 8447 1 6708 1 6606 1 6606 2 1903 1 5801 1 WCH00993 Engine Cross Section...

Page 82: ...nal Section 2303 1 1132 1 1132 2 1203 1 2138 1 2722 1 2751 1 to 2751 4 3140 1 9223 1 3303 1 to 3303 4 3403 1 to 3403 4 2124 1 to 2124 3 3103 1 3130 1 3130 2 2708 1 to 2708 3 3425 1 1224 1 8752 1 4103...

Page 83: ...s 1132 1 A1 Removal and Fitting of a Main Bearing 1132 2 A1 Thrust Bearing Checking the Axial Clearance 1203 1 A1 Removal and Fitting the Thrust Bearing Pads 1224 1 A1 Engine Stays with Friction Shims...

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Page 85: ...O Slot 9 Chock RS Round bar 10 Ship s foundation plate SA Gap 1 General The pre tension of the foundation bolts holding down studs must be checked at longer intervals e g during overhauls see 0380 1 I...

Page 86: ...piston the maximum stroke of the piston is reached Therefore do not continue to operate the pre tensioning jack Check with feeler gauge through slot KO if there is any clearance between nut 6 and its...

Page 87: ...stroke of the piston is reached Therefore do not continue to operate the pre tensioning jack Turn back nut 6 by one turn and release the pressure to zero Remove the pre tensioning jack E 002 853 99 1...

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Page 89: ...emark Pay attention to General Application Instructions 9403 4 for hydraulic pre tensioning jacks 2 Loosening the elastic studs Hook assembly tool 94114A into suspension holes 9 of double pre tensioni...

Page 90: ...c unit adjust the pressure to 1500 bar and keep it constant Mark the position of nuts 3 against bearing cover 1st step Fig A Tighten all nuts 3 with round bar RS until firmly seated TIGHTENING ANGLE 1...

Page 91: ...1132 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 3 3 B C I I I I L 1 4 5 4 6 RS KO 011 310 03 9 3 7 GAP 0 mm 94942 8 94935 94934 94932 94114 98 7663 2 Main Bearing Loosening and Tensioning of Elastic...

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Page 93: ...tool 94130 1 Support 94141 hereafter called bearing cover 2 Ground plates 94141A bearing shell 2 Working platforms 94142 1 HP oil pump 94931 1 Hydr distributor 94932 1 Hydr distributor 94934A 1 HP hos...

Page 94: ...e 94111 must always be used for removal and fitting of the bearing covers and handled carefully and not be changed as its arm lengths correspond to a spe cified dimension Eyelet 94120 must be used for...

Page 95: ...ing cover over the elastic bolts using rope 94120B and manual ratchet H1 Remark Oil bore 7 in bearing girder 6 must be closed off immediately after lifting the bearing cover to prevent any dirt from e...

Page 96: ...120F to the column wall and lift the bearing cover 2 via roller support 94117 over the elastic studs Remark Oil bore 7 in bearing girder 6 must be closed off immediately after lifting the bearing cov...

Page 97: ...Lift bearing cover 2 out of crankcase by means of manual ratchet H2 with rope 94120G and manual ratchet H4 Carefully put the bearing cover in horizontal position on wooden underlay WU Make sure the pr...

Page 98: ...toothing put a copper or aluminium plate between the ram and the flywheel Fig K 4 1 Placing of hydraulic jacks Turn corresponding crank to exhaust side approx 90_ after T D C Put support 94141 on two...

Page 99: ...the point where the neighboring main bear ings show no vertical clearance between upper bearing shells and crankshaft Keep pressure in the hydraulic jacks constant Measure again lateral bearing cleara...

Page 100: ...of the bearing shell 3 to the other side and connect them with lifting yoke 94119 Remark By means of a wire attached to the ropes they can be pulled below the bearing journal to the other side Slowly...

Page 101: ...ll 3 Attach manual ratchet H2 and connect it to lifting device 94116 Lift bearing shell 3 as high as possible and move it to exhaust side Disconnect manual ratchet H1 with rope 94120B and reposition i...

Page 102: ...e 94119 are mounted in the same way as described in paragraph 4 4 With manual ratchet H1 pull bearing shell slowly out from the bearing girder until both ends of the bearing shell are free no meshing...

Page 103: ...t bearing shell up to roller support 94117 Connect rope 94120G to lifting tool 94116 and manual ratchet H2 Connect rope 94120E to lifting tool 94116 and manual ratchet H4 Take over bearing shell to ma...

Page 104: ...4130 to clean the bearing bore For this purpose the round bar of the cleaning tool is to be wrapped in clean cloths then stuck between the bearing bore and the bearing journal of crankshaft 1 and by m...

Page 105: ...de 94115 P 94115 9 4 6 002 779 98 010 438 02 I I TURNING IN DIRECTION OF BEARING SHELL Fasten turning out device 94118 94118A to the front face of lower bearing shell 3 The two recesses in the turning...

Page 106: ...the crankcase The bearing clearances and the crank deflection must be measured after a new lower bearing shell has been fitted and the bearing cover has been tightened see 3103 1 7 Fitting of main bea...

Page 107: ...2 Measuring method 2 Displace the crankshaft axially until it rests on the engine side thrust bearing pads AHEAD and then fix it in this position Measure the distance between the coupling flange and...

Page 108: ...1 A1 RT flex58T E Winterthur Gas Diesel Ltd 2 2 THRUST 0 8 1 3 mm 2 5 8 4a 7a 6 4 3 7 B 003 311 00 CHECK HOLE FOR FREE PASSAGE EVERY 6000 8000 OP HOURS 1 WCH01018 Thrust Bearing Checking the Axial Cl...

Page 109: ...thrust bearing pads must all be replaced in their original position Note the numbering of the individual pads Also refer to the follow ing pages for the arrangement of thrust bearing pads on engines w...

Page 110: ...RT flex58T E Winterthur Gas Diesel Ltd 2 4 FUEL SIDE EXHAUST SIDE I I II II I I 4 2 2a 1 6 2 2a 5 3 1 2 2a 94155 A B 7 94155A 94155 94155A 003 309 00 003 309 00 003 309 00 Removal and Fitting the Thr...

Page 111: ...PADS ON ENGINE SIDE VIEW FROM DRIVING END PADS AT DRIVING END AHEAD ASTERN CLOCKWISE ROTATING ENGINE ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH FIXED PITCH PROPELLER COUNTER CLOCKWISE ROTATIN...

Page 112: ...G END PADS ON ENGINE SIDE VIEW FROM DRIVING END PADS AT DRIVING END ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH CONTROLLABLE PITCH PROPELLER SUPPORT SURFACE AHEAD ASTERN AHEAD ASTERN COUNTER C...

Page 113: ...1 each are installed on the fuel side and at the free end of the engine Fig A The pre tension of screws 3 must be checked at specified intervals see 0380 1 Remark Pay attention to General Application...

Page 114: ...auge through slot KO if there is any clearance between nut 4 and its seating If there is no clearance this means that the tensioning condition of the screw has remained unchanged since the last check...

Page 115: ...r such checks it is not required to loosen the elastic studs of the main bearings nor the clamp screws 10 Fig D Remark Pay attention to General Application Instructions 9403 4 for hydraulic pre tensio...

Page 116: ...ny clearance does exist tighten the nut with rod 94005F until it rests firmly on the intermediate ring Subsequently release the pressure to zero at the hy draulic unit If no clearance exists the press...

Page 117: ...inary works D Clamp screws 10 must not be tightened up D Lower tie rod nut 14 is screwed on Clean the seating surface for intermediate ring 2 and upper tie nut 3 and smear them with MOLYKOTE G paste S...

Page 118: ...the two upper tie rod nuts 3 with rod 94005F Never move pistons 5 of the pre tensioning jacks further up than to the red limiting grooves BN Measure again distance L and record it as L1 The tie rods a...

Page 119: ...A2 RT flex58T E Winterthur Gas Diesel Ltd 5 5 III I III II I I I I 11 7 15 D 7 8 1 3 2 WCH00667 1 15 12 10 FLUSH AN 13 14 9 II I 16 Checking the Pre tension and Tensioning the Tie Rods with M80x6 Thre...

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Page 121: ...1 Loosening and Tensioning of Cylinder Cover Elastic Studs 2708 2 A1 Machining of Sealing Face for Injection Valve 2708 3 A1 Injection Valve with FAST Checking Dismantling Assembling and Adjusting 272...

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Page 123: ...ng wear ridge and the antipolishing ring The unrun position must be thoroughly cleaned from any deposits or lacquer before measurement Hook the measuring gauge over the top face of the cylinder liner...

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Page 125: ...Centring pin DP Depository for GF 94207 10 Cylinder cover WU Wooden underlay Overview 1 Preparatory works 1 7 2 Removal and fitting of cylinder liner 2 7 3 Removal and fitting of antipolishing ring 4...

Page 126: ...pieces press fit I 5 5 10 I A 3 2 17 6 18 8 7 19 3 WCH01000 2 1 Placing device GF 94201 Place the device GF 94201 with its lifting tool GF 94202 and all parts diagon ally onto cylinder liner 2 as show...

Page 127: ...cylinder block 1 Apply a non hardening sealing compound Turn the cylinder liner 2 and align the centring hole in holder 14 with the cent ring pin 9 of the cylinder block 1 Lower the cylinder liner Fit...

Page 128: ...nd then it can be removed 3 2 Fitting Clean the seating surfaces on the antipolishing ring and cylinder liner Fit four suspension straps 94208 D Pay attention that one of the holes for fastening the s...

Page 129: ...ets with the RUD eye bolts Loosen three screws 15 If necessary use them to separate the water guide jacket from the cylinder liner Lay down water guide jacket on the bottom plates by means of manual r...

Page 130: ...4 Loosen all tension springs 13 with assembly tool 94345E Remove the plate 12 for insulation bandage Remove the insulation bandage 11 5 2 Fitting Fitting of the insulation bandage is carried out analo...

Page 131: ...r liner following the sequence drawn below and secure it against rolling away by means of wooden underlays and wedges D Raising the cylinder liner is carried out in reversed sequence Risk of accident...

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Page 133: ...have passed into the scavenge space through the ports D Actuate the cylinder lubrication until oil flows from all the lubricating points thereby flushing away any metal dust 2 Removing wear ridge When...

Page 134: ...124 3 A1 RT flex58T E Winterthur Gas Diesel Ltd 2 3 II II II SN II II II A SHARP EDGES REMOVED FUEL SIDE I I 018 944 09 SI WCH01000 I I Cylinder Liner Re dressing Lubricating Grooves and Scavenge Port...

Page 135: ...Maintenance 2124 3 A1 RT flex58T E Winterthur Gas Diesel Ltd 3 3 94299 5 3 7 4 8 9 11 1 2 6 10 T D C 1 mm 2 3 mm 11 12 B 009 641 02 009 642 02 Cylinder Liner Removing Wear Ridge 2013...

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Page 137: ...19 Pipe bracket 1 HP hose 94935 8 Non return valve 20 Stop valve 9 Screw 10 Screw in union 11 Angle union 12 Lubricating oil pipe DF Sealing surface 1 General If the lubricating quill items 6 to 8 mus...

Page 138: ...fit de sign The lubricating quill must be replaced as a whole unit i e nozzle tip 6 with non return valve 8 inserted and holder 7 D When refitting the lubricating quill the sealing surface DF must be...

Page 139: ...Test procedure D Instead of screw in union fit connection nipple 94934I into lubricating quill Connect lubricating quill 5 to oil pump 94931 as shown below Vent the lubricating quill Apply a pressure...

Page 140: ...bubble free out of the loosened connection Remark As described above the lubricating module can also be operated with the operator interface of the control system Further information and adjustments a...

Page 141: ...ng variant 1 2 7 2 1 Removing a gland 2 7 2 2 Dismantling a gland 2 7 2 3 Assembling a gland 4 7 3 Removing dismantling and assembling variant 2 6 7 1 General The removal of the piston rod gland herea...

Page 142: ...sing 1 of the gland must rest on the two hinged covers 18 of the device Loosen screws 10 and remove 2 part ring 15 Fig B Loosen and remove screws 12 and fitted bolts 12a to 2 part housing 1 Push both...

Page 143: ...ntenance 2303 1 A1 RT flex58T E Winterthur Gas Diesel Ltd 3 7 I I FUEL SIDE B 1 012 170 04 17 12 19 16 19 12a 15 14 10 I I 10 14 12a 13 2013 Piston Rod Gland Dismantling and Assembling Measuring the W...

Page 144: ...stribute the distances evenly Use assembly tool 94345E see 9403 5 for fitting tension spring 9 Place two distance pieces 94345F 11 mm on ring support 5 and fit another ring support with scraper ring 6...

Page 145: ...ch Place distance pieces 94345F 19 mm on the assembled sealing ring 3 and fit again sealing rings 3 4 and scraper ring 2 with tension springs 8 for groove b D Proceed in the same way as mentioned abov...

Page 146: ...of the O rings D When fitting the gland into the cylinder block dis tance holders 94345 must be mounted on the foot of the piston rod D For fitting the gland in the cylinder block see also 3403 1 E CH...

Page 147: ...n clamping ring 94345B goes over the heads of screws 20 Fig G This makes sure of correct contact between the clamping ring and dismantling device 94344 This will let you use gauge 94345C correctly Att...

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Page 149: ...be lifted or transported with tool GF 94265 and eye bolt RC which is part of the exhaust valve as shown in Fig A and B Attention Wooden underlays WU placed on the upper platform are pro vided for cyli...

Page 150: ...den underlays WU Fig B 3 Removal of water guide jacket Loosen all Allen screws 7 Screw them into the three threaded holes TH until they stop at the cylinder cover Lift the cylinder cover slightly with...

Page 151: ...cylinder liner must be clean and undamaged D A new soft iron joint ring 4 of 2 mm thickness must be placed on the cylinder liner in such a way that it lies flat all over D Fit new O rings 12 in pipes...

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Page 153: ...cylinder cover elastic studs have to be replaced please observe the indi cation in 2751 1 2 Loosening and tensioning of cylinder cover elastic studs Please refer to General Application Instructions 94...

Page 154: ...and O rings defective Piston of pre tensioning jack jams Junctions of HP hoses leaky D To remedy the cause loosen all studs and then repeat the tensioning proce dure according to 9403 4 Release press...

Page 155: ...r injection valve with Fuel Actuated Sacless Technology FAST Carefully insert profile cutter 5 into the hole in cylinder cover 1 Fasten guide flange 3 with screws 4 When the device is being used the c...

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Page 157: ...ment of cup spring packet 11 12 9 Fitting an injection valve in cylinder cover 11 12 10 Protecting a nozzle tip 12 12 11 Storage and handling of injection valve 12 12 1 General For checking dismantlin...

Page 158: ...with a brass wire brush Place injection valve 1 with nozzle tip pointing downwards into valve holder 94273 and fasten it with Allen screws 2 and spring cages 19 Tighten HP hose 94275 to connecting pi...

Page 159: ...essure D In order to test tightness between the nozzle needle and needle seat keep the pressure in the test bench constant at approx 20 bar below the opening pressure During a time period of 30 second...

Page 160: ...by means of slugging wrench 94269A 55 and hydraulic cylinder 94269B Unscrew the clamping nut and coupling nut Remove the nozzle body 14 with nozzle needle 13 and nozzle tip 8 tappet 10 and compression...

Page 161: ...1 ST Nm TT Nm D1 mm D2 mm Coupling nut 11 AF55 89 100 530 65 Clamping nut 15 AF41 172 190 530 55 ST Set Torque to be set on the scale of torque spanner TT Tightening torque specified for coupling nut...

Page 162: ...does not lie flat on nozzle holder 5 during assembly Apply a layer of Never Seez NSBT 8 to the thread and the seating surface SS of coupling nut 11 First tighten the coupling nut to 89 Nm see paragra...

Page 163: ...2 11 13 9 12 10 17 I II II D LF I 7 6 3 22 5 x 1 18 13 DESIGNATION OF NOZZLE BODY MANUFACTRER x DRG NO x EXECUTION x NEEDLE LIFT 14 14 SF SF 16 SS 15 SS 8 10 WITH ICU Mk3 WCH02530 2015 08 Injection Va...

Page 164: ...n spring 12 must first be completely released by means of spring tensioner 7 Then operate the valve test bench and tighten the spring tensioner simulta neously until the required opening pressure is r...

Page 165: ...Disassemble the injection valve see paragraph 4 Make sure that the needle 5 is removed from the nozzle body 4 see Fig D Attach the nozzle body 4 with coupling nut 6 to the injection valve 1 on the in...

Page 166: ...sh A2 Turn the mounting cylinder A1 until the recess of the nozzle tip aligns with the dowel pin 13 The mounting cylinder lowers a little bit and can not be turned anymore Use copper or rubber hammer...

Page 167: ...see 2708 3 The sealing must be metal to metal i e no joint must be put in between Place the injection valve carefully in the cylinder cover Dowel pin 18 assures the correct position 2 4 015 744 07 I 1...

Page 168: ...in a place contaminated with exhaust gases or any other corrosive atmosphere Keep the injection valve in its original packing Handle with care when preparing for use and avoid any hard contact agains...

Page 169: ...ntioned in the Operating Manual 0320 1 In addition regular checks must be carried out to make sure that nut 18 on solenoid 17 is tight see also Maintenance Schedule 0380 1 2 Removal from the cylinder...

Page 170: ...in the groove in the valve casing and connecting pipe 14 respectively and oil lightly After completing the assembly without cover 2 check the easy movement of the spindle by moderately tapping the up...

Page 171: ...Winterthur Gas Diesel Ltd 3 3 I I II III III IV IV II I I 7 10 2 1 3 4 16 8 16 9 11 12 2 4 2 4 15 15 14 x IV III IV III CA 13 003 305 00 5 6 18 17 RC Starting Air Valve Removal Fitting and Dismantlin...

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Page 173: ...connected by relief bore RB to the compression chamber An inadmissible high pressure peak in the compression chamber opens the valve and the over pressure is immediately reduced A relief valve which...

Page 174: ...e Firing pressure bar Blow off pressure bar 156 160 225 166 169 235 174 175 245 176 180 250 B 013 484 05 013 486 05 94935 94934A 94272 94931 EV 017 670 08 10 94272C 2 3 Fitting the relief valve Apply...

Page 175: ...valve drain first the cylinder cooling water from the respective cylinder see 2708 1 and close the air inlet to the air spring at the control air supply see 0520 1 in the Operating Manual The exhaust...

Page 176: ...ifting lugs 94811 and the wire rope sling GF 94333D Therefore two screws of each suspension strap have to be screwed into the expansion piece flange After removing the con necting screws from the expa...

Page 177: ...pin set in the cylinder cover Lightly oil the threads of the elastic studs Fit nuts 2 and tighten them firmly with round bar RS until fully seated before mounting the pre tensioning jacks check seati...

Page 178: ...adhesive primer and any lubricant to the thread Screw in the stud right to the bottom and until it rests on its seating surface and tighten it according to instructions 0352 2 using always a stud driv...

Page 179: ...manufacturer Products of other manufacturers are also allowed when fulfilling the below specifi cation Containing no acid e g no acetic acid Resistant to oil marine diesel oil heavy fuel oil and water...

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Page 181: ...ring 18 Disc spring BO Bore 19 Distance ring OB Oil bore 20 Head screw RC Eye bolt Overview 1 General 1 9 2 Dismantling of exhaust valve 3 9 3 Assembling of exhaust valve 5 9 4 Blocking of exhaust va...

Page 182: ...nance 2751 2 A1 RT flex58T E Winterthur Gas Diesel Ltd 2 9 B BO 32 RC 32 33 7 8 34 11 22 17 36 6 3 37 2 38 1 21 15 16 19 18 20 39 25 24 5 9 10 WCH00736 40 23 2013 V2 Exhaust Valve Dismantling and Asse...

Page 183: ...t the upper valve drive and remove it using eye bolt RC Loosen screws 30 and remove transmitter housing 31 and valve stroke sen sor 29 See Fig H Loosen and remove all screws 4 Fig A Lift lower housing...

Page 184: ...k and measure the inner diameter of the guide bush according to Clearance Table 0330 1 Exhaust Valve D 1 21 94263 99 7543 2 4 Fitting of guide bush Clean the bore in valve cage 1 concerned and guide b...

Page 185: ...er before fitting them When fitting proceed with care to avoid their damage do not use any sharp edged utensils for assis tance Check all O rings of the dismantled parts for damage and replace them if...

Page 186: ...r part of valve drive paying attention to position of spring dowel pin 12 Fig G Oil nuts 3 fit and tighten them equally up to a torque of 125 Nm 3 3 Fitting of valve stroke sensor Clean valve stroke s...

Page 187: ...nce between the valve plate and valve seat Use a depth gauge 94124 to measure the height H between the top and bot tom of the bore in the top housing Make sure that the distance H is 122 0 5 mm Remark...

Page 188: ...th its orifice and check them for fouling 3 7 Checking non return valve Loosen and remove adapter 26 Check non return valve 27 for cleanliness on every overhaul Remark When fitting the non return valv...

Page 189: ...of an emergency i e with water leakages into the combustion chamber damper 32 Fig B can be removed and the exhaust valve blocked in open posi tion by means of pressure element GF 94259 The latter mus...

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Page 191: ...erted upside down position it must be suspended on the engine room crane slightly above a wooden underlay Device 94261 can then be attached from below and the valve seat carefully withdrawn until it d...

Page 192: ...ng 3 of original specification with the same lubricant Push valve seat as far as possible into the bore then mount valve seat fitting and dismantling device 94261 and by equal tightening of the jack s...

Page 193: ...ust be avoided as a matter of principle Therefore always use the valve grinding device 94291 for grinding in the valve seats in the following cases When new or reconditioned valve spindles are fitted...

Page 194: ...nding allowance on the valve seat is maximum 3 mm The wear condition can be checked efficiently with gauge 94279 in combination with feeler gauge 94122 Possible burn scars at the inside of the valve s...

Page 195: ...e valves makes contact by 50 100 from the outer edge Fig F The blue ing check should show that the cold valve makes contact only from inside around the whole circumference The angle difference can be...

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Page 197: ...down The devices from the makers HUNGER and CHRIS MARINE are well proven for valve grinding and can also be ordered directly from W rtsil Switzerland Ltd Winterthur 2 Grinding the seating surface D O...

Page 198: ...seating surface Valve plates where the seat surface has been ground back by more than 3 mm can be reconditioned by build up welding D On engines with arduous operating conditions corrosion may form at...

Page 199: ...Inspection Removal and Fitting of Top End Bearing 3303 3 A1 Removal and Fitting 3303 4 A1 Removal of Bearing Cover to Top End Bearing 3303 5 A1 Crosshead Checking the Clearances and Fitting the Guide...

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Page 201: ...crank webs can be read from the dial gauge as it indicates any open ing or closing up The smaller the variation the better the alignment of the crank shaft Thereby however the function of the checking...

Page 202: ...iate more than 0 01 mm Set subsequently dial gauge to zero Turn crankshaft by means of turning gear reading the dial gauge in the shown crank positions at B D C FUEL SIDE T D C EXHAUST SIDE B D C and...

Page 203: ...within the limits for normal operation The engine is stopped and hot or cold In case of measurements at cold engine condition any tank heating which is arranged close or below the main engine as well...

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Page 205: ...parts as well as changes in the silicone oil properties can reduce the effectiveness of the damper By periodic examination of the silicone oil the makers of the vibration damper can draw conclusions o...

Page 206: ...reads are used for the sample bores of the Simpson In ternational and STE vibration dampers Therefore the ends of the sample con tainer are provided with different threads Remove the previously loosen...

Page 207: ...connections and air hose must be clean free from any fouling As soon as fluid reaches open end of sample container shut off compressed air supply and then fit one of the two cap nuts 8 to the sampling...

Page 208: ...ent to Hasse Wrede Metaldyne International UK Ltd 131 Parkinson Lane GB Halifax HX1 3RD United Kingdom Tel 44 1422 357 234 Fax 44 1422 354 432 Geislinger GmbH Hallwanger Landesstrasse 3 A 5300 Hallwan...

Page 209: ...opped immediately otherwise the damper may be seriously damaged The oil supply has to be reestablished before restarting the engine D Should damage be noticed on the engine bearings which is due to wa...

Page 210: ...intenance 3130 2 A1 RT flex58T E Winterthur Gas Diesel Ltd 2 2 FREE END OIL SUPPLY A 8 2 000 940 93 3 1 6 7 4 5 8 9 B 002 493 96 DRAWN FOR STEEL SPRING DAMPER 2013 Inspection GEISLINGER Vibration Damp...

Page 211: ...bearing shell 6 2 part gasket 17 Oil drain pipe 7 2 part gasket 18 Upper casing 8 Tension spring 19 Screw M16x160 9 Tension spring 20 Piping for damper 10 Housing monitoring 11 Taper pin 1 Dismantlin...

Page 212: ...e upper and lower part of cylinder 1 and 2 Remove all screws 5 and 3 Fig B Remove all screws 4 to the upper part of cylinder 1 On engines provided with vibration damper loosen the screws and pull them...

Page 213: ...art as shown in figures below using the manual ratchet Attention When lifting make sure that the cylinder upper part slides out of 2 part gaskets 6 and 7 without jamming as otherwise the gaskets risk...

Page 214: ...nt when fitted D The assembling of the axial damper is done analogously to dismantling but in reverse sequence Pay the utmost attention when lowering upper part of cylin der 1 into place to prevent 2...

Page 215: ...ng the turning gear into operation the condition of the tooth flanks i e the lubricant of pinion 2 and toothing of flywheel 3 must always be checked See also 0750 1 in the Operating Manual For mainten...

Page 216: ...ny layer of lubri cant it is recommended to warm up Kl berfluid to approx 35 _C in a small tin which is put into warm water 2 2 Re lubrication intervals According to visual inspection results when har...

Page 217: ...he crankcase The grids must always be fitted in such a way that their U profiles come to lie between engine lon gitudinal beam 1 and that the opposite end rests on crank web 2 Working support 94143 ca...

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Page 219: ...bearing 1 HP hose 94935 5 Stud of top end bearing 2 HP hoses 94935A 6 Nut 1 Hydraulic unit 94942 7 Nut 1 General Attention Never turn the crankshaft with the turning gear as long as the pre ten sioni...

Page 220: ...e about 60_ for compari son 2 2 Top end bearing D Tighten the nuts with a round bar and equally distribute clearance y between the bearing halves bearing protrusion as shown in Fig A D Tensioning of t...

Page 221: ...ng to 3303 1 Attention Never turn the crankshaft as long as the pre tensioning jacks are mounted on the connecting rod studs Remark Pay attention to General Guidelines for Lifting Tools 0012 1 Utiliza...

Page 222: ...ecure the connecting rod with manual ratchet H1 Carefully turn down the crank to fuel side following with the connecting rod bottom by pulling it with the lifting tackle H1 just as far as to keep alwa...

Page 223: ...ver until the connecting rod studs 1 are out of the connecting rod Turn crankshaft about 30 in exhaust side direction Slacken manual ratchet H2 until the bearing cover is moved in position as shown in...

Page 224: ...e at both ends of the separating face This protrusion is a must and under no circumstances may the separating face of the bearing shell be filed to reduce it x2 x1 G 013 540 05 Protrusion of new botto...

Page 225: ...op plate GF 94335 9 Guide way 1 Connecting flange 94336 10 Guide shoe DL Pressure pipe 2 Shackles 94572C 11 Dowel pin OP Lubricating pump 1 Inspection of bearing shell Risk of accident Ensure that the...

Page 226: ...5 Nm Fit RUD eye bolts RC into guide shoe 10 and tighten them with 60 Nm Connect manual ratchets H2 with RUD eye bolts RC Lift crosshead pin 4 beyond the lower bores in guide ways 9 Make sure dowel pi...

Page 227: ...in the figure below Remove Allen screw 8 for positioning bearing shell 7 Remove bearing shell by means of handle screws 94009 M8 which are screwed into the front faces of the bearing shell Lift the be...

Page 228: ...st be carried out according to 3303 1 D When fitting the bearing shell as well as the crosshead pin pay attention not to damage the two guide segments 12 The two white metal lined guide seg ments are...

Page 229: ...1 Fitting a new top end bearing shell Proceed as described in section 3 however protru sion x1 x2 must be measured prior to tension elas tic studs 1 4 1 2 Measuring the protrusion Hand tighten nuts 2...

Page 230: ...as to be con nected via an oil pressure hose to a lubricating pump OP The pump has to be filled with the mentioned oil mixture steam engine cylinder oil or special oil The lubricating pump has to be o...

Page 231: ...ached from connecting rod 2 tilted upward and secured with a rope Turn crank of the respective cylinder to B D C Install working platform 94142 Loosen nuts of elastic studs to piston rod foot fasten i...

Page 232: ...er block WCH01031 GF 94333B 94040 M20 RC1 GF 94333A 10 4 94040 M20 RC1 VIEW II Stop plate mounted and top end bearing cover locked against tilting WCH00390 94040 M30 RC2 94040 M20 RC1 GF 94335 7 8 VIE...

Page 233: ...d and suspension centers a and b on the column and lock the connecting rod into position Using manual ratchets H1 hoist crosshead 6 until retaining pins 94323 can be inserted into guide ways 9 Careful...

Page 234: ...nual ratchet H2a Detach manual ratchet H2 from RUD eye bolt RC2 in connecting rod Turn crankshaft 15_ in counter clockwise direction Tilt the connecting rod towards fuel side by slackening manual ratc...

Page 235: ...45_ before T D C tighten manual ratchet H2 until the connecting rod is pro truding from the engine Hook spur geared chain block H3 in lifting tool GF 94337 in order to take over the connecting rod th...

Page 236: ...onnecting rod from the crankpin by means of spur geared chain block H3 and manual ratchet H2a Completely remove the connecting rod by loosening manual ratchet H2a If more space between the crankpin an...

Page 237: ...earings and bearing pins must be in perfect condition They must be smeared lavishly with fresh bearing oil Measure the clearances according to Clearance Table 0330 1 Top and bottom end bearings to con...

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Page 239: ...1 Deviation pipe GF 94117A 1 Working platform 94142 2 Lifting tools GF 94333A 2 Chains with hook and shackle GF 94333B 1 Wire rope sling GF 94333D 2 Shackles 94572I 1 Removal Remark Pay attention to...

Page 240: ...connect it with manual ratchet H1 Screw eye bolts RC into bearing cover 5 Fasten bearing cover by means of two round slings 94049 to manual ratchet H1 Lift the bearing cover Protect crosshead pin 6 a...

Page 241: ...of the bearing cover is carried out analogously to the removal but in reverse sequence D The running surfaces have to be lavishly smeared with clean bearing oil D Tensioning of the elastic studs must...

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Page 243: ...Top end bearing 10 Retaining cover 1 General On the occasion of an overhaul or when a crosshead has been removed the op portunity should be taken to measure the various running clearances and to compa...

Page 244: ...th suitable hardwood wedges or similar aids The pressure must be exerted onto the guide shoe or the middle part 7 and not onto the crosshead pin 1 Clearance Lateral clearance between middle part and c...

Page 245: ...t be paid when mounting a guide shoe onto middle part 7 so that the middle part bears the guide shoe with no clearance whatsoever For this purpose screws 9 are first to be tightened slightly Then scre...

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Page 247: ...orking platform 94142 10 Guide way 2 Cover and lifting plate 94324 2 Holders 94325 1 Wire rope sling GF 94333D 3 Shackles WLL 4750 kg 94572C 2 Shackles WLL 2000 kg 94572I WU Wooden underlay 1 General...

Page 248: ...o either side of connecting rod 2 with 330 Nm D Wire rope sling GF 94333D attached by means of shackles 94572I to the middle lifting lugs in the column D Manual ratchet H4 attached to the eyelet of wi...

Page 249: ...e connecting rod reaches the column door and lower the upper part onto wooden underlay WU Install working platform 94142 Lower the crosshead as far as possible Install holders 94325 in the bores of gu...

Page 250: ...atchets H2 and H3 con nected to RUD eye bolts RC1 Remove end covers 9 9a Retract guide shoe middle parts form crosshead pin 4 and lift them beyond the crosshead pin Remove working platform 94142 E II...

Page 251: ...olumn Turn crosshead pin by 90_ and remove it from column using manual ratchets H4 and spur geared chain block H6 Lower guide shoe middle parts 6 6a and remove it from column using manual ratchets H1...

Page 252: ...l direction with manual ratchet H2 Fig B so that it can not tilt to fuel side Attention Always fit the toggle lever to crosshead lubrication and piston cooling in such a way that its curvature stands...

Page 253: ...element SP Stop plate 1 Hydr distributor 94934A 1 HP hose 94935 2 HP hoses 94935A Overview 1 General 1 7 2 Loosening and tensioning the elastic studs of piston rod foot fastening 2 7 3 Removal of pist...

Page 254: ...nsion all elastic studs first with 600 bar 1st step then finish ten sioning with 1000 bar 2nd step Based on the markings applied check by how much the nuts were turned after pre tightening 1st step to...

Page 255: ...nt details see also Fig G Screw fasten both distance holders 94345 to the piston rod foot 3 Turn crank to T D C whereby piston rod gland 8 is pushed out of its seating in the cylinder block by distanc...

Page 256: ...ce until the piston rod foot pro trudes below the supporting device Turn the two hinged covers 18 down and lower the piston until piston rod gland 8 rests on the two hinged covers Push supports 15 tog...

Page 257: ...ower the piston until access is obtained to securing screws 13 In place of straps 16 which are fixed to the piston as shown in Fig F loosen and remove securing screws 13 together with their locking pl...

Page 258: ...see 2124 1 and carry out any needed recondition ing to lubricating grooves and scavenge ports see 2124 3 Actuate the cylinder lubrication until oil flows from all the lubricating points D Piston rod...

Page 259: ...ngine interior and how it must be turned to guide the piston rod foot without jam ming into centring pins 5 Fig A in the crosshead pin 4 Slacken the crane rope a bit and remove the sus pension device...

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Page 261: ...al Guidelines for Lifting Tools 0012 1 Utilization of Working Platform 3301 1 Turn crank of the cylinder concerned to Approx 160_ before B D C Install working platform 94142 according to the instructi...

Page 262: ...l pins 8 in cross head pin 4 do not jam in the piston rod foot Loosen and remove the screws fastening compression shim 6 Remove the compression shim with the aid of two eye bolts For fitting the new c...

Page 263: ...praying nozzles are not damaged 2 Dismantling of a piston Remove locking elements 3 with screw and locking plate 4 from all elastic screws 5 Fig A Loosen and remove all elastic screws 5 Insert both ja...

Page 264: ...be paid to locating pin 10 when assembling piston skirt 7 with piston rod 6 Insert and tighten both screws 9 D For the assembly of piston crown 1 to piston rod 6 make sure that two center ing pins 8 F...

Page 265: ...E Winterthur Gas Diesel Ltd 3 4 FUEL SIDE IV IV II II I I III III II II I 1 1 13 8 1 9 2a 12 2 10 7 6 5 3 4 14 15 5 IV IV V V 4 A 4 4 003 708 95 003 708 95 003 708 95 003 708 95 003 708 95 V V Piston...

Page 266: ...lex58T E Winterthur Gas Diesel Ltd 4 4 SEPARATING THE PISTON CROWN SEPARATING THE PISTON SKIRT 1 94341 2 11 1 2a 7 5 6 94350 2 8 6 7 94363 94364 7 6 B C D 003 513 00 003 513 00 003 513 00 Piston Disma...

Page 267: ...ed x 10 mm the original material thickness must be restored by surface welding This entails the removal of the piston crown Before re starting the engine the reason for such heavy burns should be esta...

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Page 269: ...erational factors such as fuel in use engine load profile ambient conditions etc By visual inspections critical conditions of cylinder liners and piston rings can be detected at an early stage Further...

Page 270: ...ENDED MEASURING POINTS ON PISTON RING P3 P5 P7 P1 P9 P5 P1 P9 2 2 Wear rate The chrome ceramic coating is a lifetime coating However the actual wear de pends on operating conditions When during a pist...

Page 271: ...xample for wear rate calculation 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 lifetime according to the latest c...

Page 272: ...its in the piston ring groove and or on the piston ring top face Move piston 3 down C1 by means of the turning gear Make sure that the total clearance is measured First measure the clearance x1 at poi...

Page 273: ...sure the thickness of piece of a piston ring 1 Place piece of piston ring into the piston ring groove Measure gap x2 between the face of piston ring and groove with feeler gauge 94122 Evaluate the pis...

Page 274: ...the coating from being chipped off at the ring ends To prevent deformation it is of the utmost importance not to open the rings more than absolutely necessary i e allowing removal over the piston crow...

Page 275: ...arrangement Ring type Coating material Application Uppermost piston ring a 1 x SCP1CC16_Straight Cut chrome ceramic coated for new and fully honed cylinder liners as well as for used cylinder liners i...

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Page 277: ...trongly depend on operational factors such as fuel in use engine load profile ambient conditions etc By visual inspections critical conditions of cylinder liners and piston rings can be detected at an...

Page 278: ...NDED MEASURING POINTS ON PISTON RING P3 P5 P7 P1 P9 P5 P1 P9 2 2 Wear rate The chrome ceramic coating is a lifetime coating However the actual wear de pends on operating conditions When during a pisto...

Page 279: ...ample for wear rate calculation 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 lifetime according to the latest co...

Page 280: ...its in the piston ring groove and or on the piston ring top face Move piston 3 down C1 by means of the turning gear Make sure that the total clearance is measured First measure the clearance x1 at poi...

Page 281: ...ure the thickness of piece of a piston ring 1 Place piece of piston ring into the piston ring groove Measure gap x2 between the face of piston ring and groove with feeler gauge 94122 Evaluate the pist...

Page 282: ...ust be fitted onto piston ring tensioning device for the 1st gastight piston ring a see also Tool List 9403 5 To prevent deformation it is of the utmost importance not to open the rings more than abso...

Page 283: ...piston ring arrangement Ring type Coating material Application Uppermost piston ring a 1 x GTP1CC16_Gas Tight chrome ceramic coated for new and fully honed cylinder liners as well as for used cylinde...

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Page 285: ...Running and Backlash Clearances and Condition of Teeth 4103 1 A1 Replacing the Gear Wheel on Crankshaft 4103 3 A1 Shut off Valve for Starting Air Cleaning and Function Check 4325 1 A1 Driving Wheels a...

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Page 287: ...els as soon as ever possible to prevent damage to the mating gear wheels D When the gear wheels have run well for an initial running period of 6000 8000 hours the above mentioned inspection may be car...

Page 288: ...1 and f2 thickness of lead wire f f1 f2 D Obliquity Df is calculated from the difference in thickness of the squashed lead wires along driving flanks TF Fig A Df a1 b1 or a3 b3 etc D The admissible de...

Page 289: ...w 1 Feeler gauge 94122 2 Crankshaft flange 7 Distance sleeve 1 Fork wrench 94412E 3 Elastic studs 8 Self locking nut 4 Castle nut 9 Dowel pin 5 Base Overview 1 General 2 5 2 Preparing assembly of 2 pa...

Page 290: ...re wheel is manufactured according to these di mensions 2 Preparing the assembly of gear wheel The undersize of center hole d Fig A on 2 part gear wheel 1 with regard to the corresponding centring dia...

Page 291: ...ply LOCTITE 262 to it In addition secure the castle nut with a split pin to prevent it from slipping when tightening the elastic studs afterwards D Wait one or two days before tightening the elastic s...

Page 292: ...f and tighten it temporarily Fig G Remove flange screws 6 from each end of the lower gear wheel half so that there are now only two flange screws 6 each of them tightened temporarily in the centres of...

Page 293: ...en temporarily fitted beforehand Fig H Degrease the threads of all flange screws 6 and their self locking nuts 8 and then apply LOCTITE 262 to them do not use MOLYKOTE Fit all flange screws 6 with dis...

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Page 295: ...Risk of accident Before starting work on the shut off valve for starting air it is es sential to manually close the stop valves on the starting air receivers The turning gear must be engaged Venting v...

Page 296: ...valve 4 and spindle guide 6 are to be thoroughly degreased and then smeared with LOCTITE Insert the spindle and fully tighten the spindle guide For the assembly smear all the parts lightly with MOLYK...

Page 297: ...Check whether the automatic shut off valve is airtight i e verify that no air escapes from the bore of screw plug 15 3 3 Manual opening Open the shut off valve slowly with the help of handwheel 16 unt...

Page 298: ...ob tained as when actuating control valve 11 D Upon opening test valve 2 06 the shut off valve opens automatically The air now escaping at the bore for screw plug 15 indicates that valve 4 of the shu...

Page 299: ...1 A1 Fuel Pressure Control Valve Removal Fitting Dismantling and Assembling 5562 1 A1 Fuel Overpressure Safety Valve Checking and Setting 5562 2 A1 Injection Control Unit Removal and Fitting 5564 1 A...

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Page 301: ...the servo oil pump observe the instructions from the manufacturer The servo oil pump drive must be checked in accordance with the Maintenance Schedule 0380 1 Supply Unit In order to prevent damages i...

Page 302: ...on 6 and shaft 5 into a vice Using a hammer and copper rod 10 strike onto the shaft until the latter with snap ring 8 comes off the pinion PROTECTION 2 1 Removal of pinion Loosen screws 3 and remove p...

Page 303: ...4 Fitting Fitting is carried out analogously to the removal but in reverse sequence whereby attention must be paid to the following D Screws 16 for fastening spray nozzles 11 view II II must be secur...

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Page 305: ...st bearing cover 22 Torque wrench 9 Bearing cover 23 Short backing rod 10 Housing 24 Long backing rod 11 Thrust bearing ring half 12 Camshaft 13 Screw HK Wooden wedge 14 Cover HU Wooden underlay Overv...

Page 306: ...ng of bearings Bearing No 2 is designed as thrust bearing the other ones as normal bearing Remark All bearing covers 8 and 9 are machined together with housing 10 therefore never inter change them The...

Page 307: ...D Press camshaft 12 accordingly by means of wooden underlay HU so that the upper bearing shell can be turned downwards with the assembly template at the same time Fig E Remove the assembly template th...

Page 308: ...4566A Loosen screws 15 a bit Fasten supports 94566 and 94566A to housing 10 as follows using elastic screws 7 belonging to the bearing cover as shown in Fig G and screws 16 to cover 3 in Fig A and the...

Page 309: ...g shells as described in sec tion 3 Roll out the camshaft with the gear wheels onto the supports and secure it at the stop with wooden wedges HK for safety reason as shown in Fig K Remove all bearing...

Page 310: ...so that their bores provided for dowel pins 17 in the bearing covers point to the same side Fig C and D D in order to align the bearing shell centring device 94566B provided for this purpose is inser...

Page 311: ...ers 3 4 5 and fit the latter Fit servo oil pump 2 see 5552 1 Install all pipings Cut in the fuel pumps and remove tools 94430 see 5556 2 in the Operating Manual After assembly turn the engine by means...

Page 312: ...h backing rod 23 or 24 together with screw driver bit 21 onto elastic screw 7 to be tightened Remark Place the torque amplifier in such a manner that the corresponding back ing rod 23 or 24 lies on li...

Page 313: ...er application for every single elastic screw 7 Backing rod 23 or 24 is drawn in the required position with continuous lines for tightening and with broken lines for loosening procedure O P Q R 22 22...

Page 314: ...552 2 A1 RT flex58T E Winterthur Gas Diesel Ltd 10 11 T U V S 20 23 22 20 23 22 013 072 05 BEARING COVER NO 3 BEARING COVER NO 4 94566C 94566C 2013 V2 Supply Unit Removal and Fitting of Camshaft and B...

Page 315: ...552 2 A1 RT flex58T E Winterthur Gas Diesel Ltd 11 11 X Y Z W 94566C 24 22 20 20 22 24 013 073 05 BEARING COVER NO 5 BEARING COVER NO 6 94566C V2 2013 Supply Unit Removal and Fitting of Camshaft and B...

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Page 317: ...ews M10 2 Fitting All parts must be clean and in perfect condition Oil the mating surfaces of gear wheel 2 and shaft 3 Push gear wheel 2 carefully onto shaft 3 and fasten it with head screws 6 Oil the...

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Page 319: ...11 Screw with distance sleeve for transporting SU_7 8 Cyl 5 Screw 12 Holder 2 Roller lifting tools 94430 6 Screw 7 Screw MR Manual ratchet 1 Removal D Cut out of fuel pump 3 by means of device 94430 s...

Page 320: ...manual ratchets MR WLL 2000 kg each and connect these with RUD eye bolts Tauten manual ratchets MR Loosen screws 11 and remove them together with the distance sleeves Loosen screws 5 6 7 and cap screw...

Page 321: ...pply unit rests on the housing however can still be freely moved Insert dowel pins 4 Fig C and tighten screws 5 6 7 Check and compare the backlash with 0330 1 Driving wheels for Supply Unit Remove all...

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Page 323: ...le 4 Attach the lubricating tool 94844 to an applicable position approximately 2 0 m above the supply unit as shown Attach the flexible hose 2 to the adaptor 3 with the hose clip 6 Remove the inspecti...

Page 324: ...Maintenance 5552 5 A1 RT flex58T E Winterthur Gas Diesel Ltd 2 2 I I II II 1 II II I I 2 3 2 4 94844 10 2 5 9 6 7 8 WCH03859 A Supply Unit Lubrication of Supply Unit During Maintenance 2018 02...

Page 325: ...36 Screw 15 Pin 37 Bush 16 Allen screw 38 Rod seal ring 17 Lower spring carrier 39 41 O rings 18 Pump plunger 19 Compression spring 20 Guide pin 21 Regulating sleeve DS Pressure piece 22 Upper spring...

Page 326: ...se circle Fig A Remove all screws 3 Using a jacking screw M12 lift the fuel pump until the locating pin is no longer meshing Fit cover 94552 onto pump cover 4 B C 013 661 05 013 662 05 I I I I 28 9455...

Page 327: ...umps in a clean room which should be as dust free as possible grinding dust etc 3 1 Removal of guide pin With the head of the pump turned towards the bot tom fasten the fuel pump onto a work bench Mou...

Page 328: ...unger in a manner not to damage it Remove compression spring 19 Remove regulating sleeve 21 together with upper spring carrier 22 Remove Allen screws 16 Separate lower housing 6 from upper housing Rem...

Page 329: ...gulating rack 25 3 5 Removal of pump cylinder With pump cover 4 turned upwards clamp the fuel pump into the work bench Unscrew Allen screws 28 Remove pump cover 4 valve block 29 valve body 30 and comp...

Page 330: ...four screws M10x60 valve block 29 can be withdrawn from pump cover 4 Remove circlip 35 with a snap ring tong Remark The non return valve must be replaced as a unit only i e valve block 29 valve body 3...

Page 331: ...w in and tighten the holding screw together with the Cu ring Remark There must be a clearance between holding screw 32 and the groove base 33 32 5 008 654 00 4 3 Fitting the pump cover Remark Thorough...

Page 332: ...the upper housing the toothed rim turned to the bottom and the groove of 12 mm width being flush with guide pin 20 5 40 4 6 Fitting the pump plunger and lower housing Fit upper spring carrier 22 and...

Page 333: ...the checking bore and in sert checking gauge 94556 in its place until the stop Remove spacer 94555 again and check whether the regulating rack is blocked With blocked regulating rack the plunger is co...

Page 334: ...the grooves at lower housing 6 Fig B 5 Fitting of a fuel pump Turn the engine until the cam belonging to the fuel pump concerned is on the base circle Check whether the seating surfaces as well as the...

Page 335: ...to the fuel pressure control valve PCV W rtsil recommends only performing the below mentioned maintenance PCV maintenance onboard is limited to Replacement of the complete PCV Replacement of the 3 2 w...

Page 336: ...3 Fitting the fuel pressure control valve Bring the PCV in fitting position at the fuel rail by means of a manual ratchet Apply Never Seez NSBT 8 to the screw threads 17 Place new O rings 24 and 25 i...

Page 337: ...Storage on board The spare parts must be carefully protected against corrosion D The PCV has to be free from any dirt oil and grease D Apply coating liquids e g Tectil 506 ISOTEC 337 or similar on th...

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Page 339: ...rized repair workshop for inspection and repair The opening pressure of the relief valve must be approved by IACS International Association of Classification Societies and recorded on the Inspection R...

Page 340: ...constant during one minute D No leakage is allowed 2 3 Checking the opening pressure Increase the pressure by means of HP oil pump and observe at what value the relief valve opens Correct opening pre...

Page 341: ...enance on board On request at W rtsil Switzerland you can get several ouverhaul kits for the ICU including the work instruction Repair kit for fuel valve assembly repair kit for pre control device Rep...

Page 342: ...can come out as a spray and cause injury Attention Fire hazard Do not weld or grind materials in the area Clean the work area you see in Fig B Remove HP fuel pipe refer to 8733 1 Remove the hoses 2 a...

Page 343: ...D Lift the injection control unit 1 and mount it on the transport plate 94585A with two hex head screws 9 Make sure the dowel pins fit cor rectly Clean the area on the fuel rail 10 around the injectio...

Page 344: ...t surfaces of the four bolts 7 and tighten them with 35 Nm Remove all plugs from unions and from injec tion control unit see also Fig C Connect pipes 3 4 and 5 to Injection control unit 1 and fuel rai...

Page 345: ...three months If there is still no change in pressure an annual check might be sufficient however it is recom mended to continue carrying out checks every three months Attention Ensure that servo oil...

Page 346: ...ort hose 4 to the left side A of control unit Open valve A and read pressure from gauge 7 Slowly open valve C and refill accumulator to the required pressure of 35 bar Close valves A and C and drain r...

Page 347: ...iesel Ltd 3 4 Case with measurement set 94720C for CLU4 C and PRV 8 11 1 4 4a A C B 3 5 2 1 7 Case 94720C 4 A Arrangement of equipment B 8 WCH00703 15 1 13 2 4 5 A B C 4a 3 7 PI2041L 12 2013 Pressure...

Page 348: ...OIL PIPE TO LUBRICATING PUMPS 14 4 30 5 1 2 10 11 9 13 WCH00852 PRESSURE RE DUCING UNIT Details of servo oil rail 4 11 pressure reducing valve 8 11 1 lubricating pump 8 06 D E DRAWN FROM CONTROL DIAG...

Page 349: ...s to be stopped Attention HP Servo oil pipes must be pressureless Follow the instruction in 0520 1 of the Operating Manual without fail The respective work station must be clean welding and grinding s...

Page 350: ...ntling of exhaust valve control unit Loosen screws 9 and remove cover 10 Withdraw piston 11 using a jacking screw M10 Loosen screws 12 and remove cover 13 Remove compression spring 14 and slide rod 15...

Page 351: ...ews piston 11 and slide rod 15 Fig C must be oiled prior to their fitting Equally tighten screws 9 with a torque of 170 Nm and screws 12 of 70 Nm Fit rail valve 3 with screws 5 and tighten them with a...

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Page 353: ...e 7 Screw MA Mark 1 General After overhauling the linkage or the fuel pumps as well as after fitting a new fuel pump or a new actuator the adjustment of the linkage must be checked and if nec essary a...

Page 354: ...h inserted sleeve 6 and adjusting pin 94575A on actuator shaft 4 so that the pinpoint points at 0_ line as exactly as possible Slightly tighten screw 7 Rotate lever 5 to 75_ mark maxi mum stop so that...

Page 355: ...ment Join connecting element 8 with lever 5 and toothed rack 9 of fuel pump 1 using set screws 10 Remark The connecting element must be fitted in such a way that its spot face 11 points to lever 5 C 9...

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Page 357: ...crew 3 Shaft 10 Self locking nut 4 Lever 11 Mark 5 Clamping sleeve 6 Screw 7 Connecting element 1 General Make sure that the connecting element 1 Fig A is lubricated with Molykote paste G Make sure th...

Page 358: ...ide of the toothed rack Put the lever 4 in position on the shaft 3 Make sure that the center line of the lever aligns with the 50 fuel indication on the actuator Use a center punch to make the marks 1...

Page 359: ...1 A2 RT flex58T E Winterthur Gas Diesel Ltd 3 3 B I I WCH03870 016 366 07 GF 94555A 36 mm 36 mm 10 2 9 7 8 7 9 4 6 3 WCH03870 WCH03870 11 4 Regulating Linkage Adjusting with Woodward ProAct II Digital...

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Page 361: ...tenance 6545 1 A1 Scavenge Air Cooler Cleaning Water Side on Engine at Standstill 6606 1 A1 Removal and Fitting of Tube Stack 6606 2 A1 Water Separator Maintenance of Water Separator 1 part Water Sepa...

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Page 363: ...avenge air receiver and in fixed support 5 must be checked for damage movability as well as fouling in the course of the periodic cleaning of the scavenge air receiver see 0380 1 The air flaps in the...

Page 364: ...in the piston underside In particular check whether water drain piping 10 from the scavenge air receiver is not clogged so that a permanent drainage is assured during operation During a major overhau...

Page 365: ...T flex58T E Winterthur Gas Diesel Ltd 3 3 B x 133 mm RELIEF VALVE WITH COMPRESSION SPRING RELIEF VALVE WITH DISC SPRINGS WCH00970 GAP GAP WCH00969 I II I II 2013 Checking the Air Flaps and Cleaning th...

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Page 367: ...1 General 1 3 2 Removal 2 3 3 Dismantling 3 3 4 Fitting 3 3 1 General The auxiliary blowers are fastened with screws 8 8a to fixed support 6 and ma chined receiver surfaces 5 without any shims Auxilia...

Page 368: ...orresponding ropes Unscrew two screws 7 Fig A facing each other then screw in two centring studs 94652 instead Unscrew the remaining screws of motor plate 2 Separate the motor plate from the spiral ca...

Page 369: ...suffer damage The impeller must be rebalanced in case of any damaged or re placed parts turning together with the motor shaft 4 Fitting Fit both centring studs 94652 With the aid of trolley 94651C an...

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Page 371: ...ess of the utilized cooling water a cleaning of the cooler tubes is required after a shorter or longer operating period The necessity to clean becomes evident by measuring the temperature difference b...

Page 372: ...ed from the cooler manufacturers 2 3 Cleaning by chemical solvents in removed condition removal see 6606 2 Should the above mentioned methods not be successful then chemical means must be utilized By...

Page 373: ...eaking tubes will be revealed by soap bubbles Defective tubes are sealed up by hammering in slightly tapered plugs of hard wood copper etc Stop the engine Remove cover 1 and return chamber 2 Seal the...

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Page 375: ...eiver 16 Support 1 Dismantling and 94663A B 5 Screw assembling device 6 Vent 1 Pulley support 94664 7 Drain 1 Pin 94665 8 Cooling water inlet AH Stop lever 1 Roller 94665A 9 Cooling water outlet DF Se...

Page 376: ...flex58T E Winterthur Gas Diesel Ltd 2 6 2 Removal Loosen screws 13 in cover 1 Remove screws 13a from tube stack 12 B I 12 13 I 010 938 03 010 939 03 1 2 12 1 14 13a 2013 Scavenge Air Cooler Removal a...

Page 377: ...d cooling water outlet pipe 9 between connection chamber 3 and butterfly valve 10 Loosen screws 5 of the screw connection to tube stack 12 for scavenge air receiver 4 Fig A Fix roller plate 94662 A at...

Page 378: ...ropes Raise stop lever AH see Fig C of roller plate and pull tube stack out of the scavenge air receiver until stop b Draw with the engine room crane at the same time thereby the wire ropes should alw...

Page 379: ...k into the cooler casing until arrester stop a Fig E Remove wire ropes to transport straps TR Raise stop lever AH Fig C of the roller plate and pull tube stack completely into the casing Take care tha...

Page 380: ...s 5 Subsequently tighten all screws Remove assembling device pulley support Connect piping close drains 7 open vents 6 and butterfly valves 10 Start cooling water pump and check tube stack for possibl...

Page 381: ...nterval for future servicing should be established on the basis of the degree of contamination found If the air suction filter of the exhaust gas turbochar ger is well maintained the degree of contami...

Page 382: ...5 and put both covers 14 with their air flaps 2 fitted approx 47 kg each on the bottom of receiver 1 Loosen screws 8 and remove them together with plates 7 Loosen and remove spring packs 9 Loosen scre...

Page 383: ...GUN to all seating faces AF thus avoiding an air bypass between frame and wall Carefully lift water separator 3 by means of manual ratchets H1 until cover 4 rests on the receiver Insert screws 6 Fit s...

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Page 385: ...nterval for future servicing should be established on the basis of the degree of contamination found If the air suction filter of the exhaust gas turbochar ger is well maintained the degree of contami...

Page 386: ...nsured that intermediate flange 6 26 kg cannot fall down Remove screws 7 together with spring washer 8 and tension sleeves 9 Remove screws 10 and put both covers 11 with their air flaps fitted approx...

Page 387: ...all Lift water separator 3 by means of manual ratchets H1 and fit loose screws 12 together with sleeves 13 pressure springs 14 and discs 15 Pull water separator up until it rests on sleeves 13 paying...

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Page 389: ...ance Group7 RT flex58T E Winterthur Gas Diesel Ltd 1 4 Lubrication Pump CLU4 C Checking the Gas Pre charge Pressure 7218 1 A2 Cylinder Lubrication Group 7 Winterthur Gas Diesel Ltd RT flex58T E PULSE...

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Page 391: ...ight be sufficient however it is recom mended to continue carrying out checks every three months Attention Ensure that servo oil supply is shut off before starting accumulator pressure checking and ch...

Page 392: ...rt hose 4 to the left side of control unit Open valve A and read pressure from gauge 7 Slowly open valve C and refill accumulator to the required pressure of 35 bar Close valves A and C and drain rema...

Page 393: ...Winterthur Gas Diesel Ltd 3 4 Case with measurement set 94720C for CLU4 C 4 4a A C B 3 5 2 1 7 Case 94720C 4 A Arrangement of equipment 14 4 3 4a A C B 7 5 10 B CLU4 C 2013 Lubricating Pump CLU4 C Ch...

Page 394: ...211 09 9 SERVO OIL TO LUBRICATING QUILLS 10 12 11 8 1 2 Details of servo oil rail 4 11 lubricating pump 8 06 D E DRAWN FROM CONTROL DIAGRAM 4003 2 4 30 5 4 11 WCH00205 8 11 1 PI2041L 13 WCH00852 8 06...

Page 395: ...47 1 A1 Hydraulic Pipe for Exhaust Valve Drive Removing Fitting and Regrinding 8460 1 A1 HP Pipe to Injection Valve Removing Fitting and Regrinding 8733 1 A1 HP Pipe to Injection Valve for ICU Mk3 Rem...

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Page 397: ...match for part load operation This is done by increasing the com bustion pressure at less than 75 load through an increased scavenge air pres sure and a higher air flow waste gate closed and by blowi...

Page 398: ...nual and Mainte nance Schedule 0380 1 D The control actuator is single acting and normally closed by spring force The control actuator opens by a pneumatic pressure of 5 5bar 2 1 11 5 10 11 8 7 4 9 A2...

Page 399: ...ing 2 the relevant servo oil piping 3 must be removed first D Pay attention not to damage sealing faces DF D All connections must be closed off immediately and the sealing faces must be protected agai...

Page 400: ...3 can be removed 2 2 Removal of HP servo oil pipe 2 Loosen screws 4a and push flanges 5 back Loosen screws 6 and remove them together with intermediate piece 7 Loosen screws 4b and remove HP servo oil...

Page 401: ...grinding com pound No 200 then fine grind with grinding com pound No 500 After grinding thoroughly clean the HP servo oil pipes 013 459 05 94834 DF 2 3 C 4 Adjusting the claws Before fitting the HP s...

Page 402: ...D Apply oil to the threads of screws 4 4a 4b and tighten them crosswise with a torque of 40 Nm D If the non return valves Fig B have been removed maintain their flow direc tion and observe the follow...

Page 403: ...haust valve control unit 13 Stop valve 6 Screw 7 Screw DF Sealing face 8 8a Flange LB Leak oil bore 1 Removal Stop the motor before beginning any work on the hydraulic pipe Strictly follow the instruc...

Page 404: ...damage the sealing faces DF when removing the hydraulic pipe D Close off all openings after removing the connections 1 1 Checking claw position Prior to fitting the hydraulic pipe check if the claws 9...

Page 405: ...securely fasten screw plug 3 and follow in structions 0520 1 in the Operating Manual D Apply Never Seez NSBT 8 to the threads of screws 6 7 and tighten them crosswise with a torque of 40 Nm 3 Regrind...

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Page 407: ...rain screw HD Hand drill 1 Removal When working on a HP pipe 4 the engine has to be stopped and it is essential that instructions 0510 1 in the Operating Manual be strictly followed Remove all pipe br...

Page 408: ...protrude by x 8 mm compared to the claw Measurement x can be adjusted by turning the claw using special spanner 94874 Fit HP pipe Apply Never Seez NSBT 8 to threads of screws 8 and tighten them crossw...

Page 409: ...Nm Put the HP injection pipe 1 in a vice as vertically as possible Adjust the speed of the hand drill between 200 rpm and 500 rpm Align the hand drill and the grinding tool 94841 accurately with the...

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Page 411: ...trace heating and remove the insulation from HP injec tion pipe 2 Removal CAUTION Damage Hazard Make sure that you do not damage the sealing faces or the HP injection pipes On the applicable HP inject...

Page 412: ...the regrinding device 94871 Torque symmetrically the four screws T2 to 2 Nm Install the HP injection pipe 4 in a vice as vertically as possible Adjust the speed of the hand drill between 200 and 500 r...

Page 413: ...ended wrench to adjust the claw 5 Remove all of the protection from the sealing faces SF in the injection valve 2 and the injection control unit 3 Apply Never Seez NSBT 8 to threads of screws 8 and 9...

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Page 415: ...fuel bore A WCH01047 1 General The engine must be stopped and the fuel supply pum switched off After approx 10 minutes the pressure is reduc in the HP fuel pipe and the fuel can be drained as follows...

Page 416: ...15 and push flange 9 down and flange 14 up as much as possible Fig A Press intermediate ring 10 together with upper HP fuel pipe 1 down by approx 2mm and push the latter sideways Remove the pipe toge...

Page 417: ...d surfaces of screws 8 13 15 15a Place HP fuel pipe and slightly tighten screws 15 13 on flange 14 12 Fit intermediate ring 10 10a onto upper flange 9 14a of HP fuel pipe 1 2 Carefully align bended pi...

Page 418: ...ve been ground off use a fine or ultra fine emery cloth D E 016 738 08 016 738 08 94870H EC 94870F GRAINED FACE TIGHTENED CONDITION Place template 94870H on the back of emery cloth EC Trace inner cont...

Page 419: ...on sleeve until it slightly touches the HP fuel pipe Let the grinding tool rotate with a max speed of 1500 rpm and grind for 3 to 5 seconds Withdraw the grinding tool from the screw on sleeve and blow...

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Page 421: ...nd Pumps Arrangement and Application 9403 2 A1 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance 9403 3 A1 General Application Instructions 9403 4 A1 Tool List 9403 5 A1 Standard Tools...

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Page 423: ...c screw 56 Distance piece 21 Screw with locking plate 57 Screw with locking plate 22 Packing ring 58 Locating pin 23 Adjusting disc 59 Spring balance 24 Locking plate 60 O ring 25 Shaft nut 26 Locking...

Page 424: ...otec tive sleeve SH and withdraw sensor cable from protective pipes SR 1 2 Outer shaft encoder Loosen screws 3 and remove them together with protection plates 10 Loosen screws 11 and remove them toget...

Page 425: ...rank angle sensor 6 is fastened to the holder 7 and set by the manufacturer Attention Never loosen screw 8 008 728 00 008 728 00 7 D 6 19 8 3 Fitting the shaft encoder 3 1 Inner shaft encoder Turn cra...

Page 426: ...ing plates 17 Apply MOLYKOTE paste G to the threads and head seatings Align toothed belt exactly in running direction Attach spring balance 59 to the shaft encoder and slightly preload it according to...

Page 427: ...lates bending them once only 3 3 Outer shaft encoder Fitting the outer shaft encoder 13 is carried out analo gously to the inner one Attention When fitting shaft encoders toothed belts or crank angle...

Page 428: ...d belt proceed as follows Remove protection plate 10 and angle holder 12 Fig B Remove screws 15a with locking plates and washers Remove screws 15 replace locking plates and loosely refit the screws Pu...

Page 429: ...ening of the crankcase see Warning labels located near the crankcase doors on the engine Start the flexView programme and go to the ADJUST card With the flywheel position as described above read the c...

Page 430: ...ve nuts 4 Attention When loosening nut 4 hold up shaft 5 by means of an open end span ner AF27 Remove screws 21 and withdraw the crank angle sensor from the elastic screw 20 view II Remark Do not unsc...

Page 431: ...emove shaft encoder according to paragraphs 1 2 and 1 3 Unbend locking plate 24 loosen and remove shaft nut 25 using hook spanner 94924 Withdraw gear wheel 18 from the shaft 5 Remark If withdrawing by...

Page 432: ...th sealing ring 30 and O ring 60 Distance ring 31 Ball bearing 32 distance ring 33 distance sleeve 34 and disc springs 35 Circlip 36 Disc 37 together with ball bearing 32a Parts to be removed in the f...

Page 433: ...istance ring 31 onto the shaft 5 according to Fig O Attention Big collar SU on inner ring of the ball bearings must point outwards Screw shaft nut 27 onto shaft 5 and lightly tighten it by means of ho...

Page 434: ...earing and fit circlip 36 6 3 Completing of the bearing housing Oil all parts Fit shaft 5 Push distance sleeve 34 onto the shaft Fit disc springs 35 according to view I Fit distance ring 33 with thick...

Page 435: ...hook spanner 94925 Lock shaft nut with locking plate Fit circlip 28 008 738 01 S 5 27 26 28 6 5 Fitting gear wheel 18 Oil bore and push gear wheel 18 onto shaft 5 until the stop Apply MOLYKOTE paste G...

Page 436: ...onding bore in the shaft are in line Push crank angle sensor drive further until the locating pin fits into the corre sponding bore in shaft 5 Fasten screws 21 with their locking plates Turn crankshaf...

Page 437: ...ration Remove oil inlet OE Fig A Dismantle crank angle sensor drive according to section 4 Remove screws 47 and housing 46 Remove screws 48 and connecting unit 49 Remove screws 44 and withdraw elastic...

Page 438: ...008 750 01 008 749 01 8 2 Removing the compression spring Loosen screws 53 and remove them together with spring tensioner 52 Remove and check compression springs Remark When replacing only one compre...

Page 439: ...5 with a torque of 35 Nm and lock them 008 752 01 008 749 01 Z II II II II 42 55 43 56 x x 54 40 50 8 6 Fitting the connecting unit Fig W Fit elastic screw 20 and screw 44 with new locking plates Tigh...

Page 440: ...st be carried out according to Maintenance Schedule 0380 1 Crank angle sensor unit 9 1 Lubricating oil flow in the crank angle sensor drive Start main lubricating oil pump and adjust bearing oil press...

Page 441: ...uantity and also keeps back larger oil particles Checking the throttle is carried out as follows Stop main lubricating pump Remove oil inlet OE from the throttle Unscrew throttle and check its oil spr...

Page 442: ...f the CAS drive see Fig B Install the magnetic base with dial gauge MB MB 9 18 D1 Remark The measuring point must be horizontally adjacent of the gear wheel 18 Read the deviation on the dial gauge whi...

Page 443: ...er removing the toothed belt tighten the screws 15a and 15 again Install the magnetic base with dial gauge MB as shown below Push the gear wheel of the CAS to the left and right direction The measurem...

Page 444: ...aragraph 9 3 Maintenance schedule Work to be carried out at 48 000 operating hours Before carrying out the replacement of a CAS drive which is available as a stan dard spare part a new CAS drive must...

Page 445: ...also can be used in exceptional cases A separate set of tools is issued for certain components from sub suppliers which should also be stored separately from the engine tools 2 Standard tools are tool...

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Page 447: ...Tensioning loosening of tie rods elastic studs to exhaust valve cage top and bottom end bearings to connecting rod piston rod foot B Tensioning loosening of elastic studs to cylinder cover C Set up o...

Page 448: ...00728 I 23 18 17 18 E Tensioning loosening of elastic studs to main bearing F Removal and fitting of main bearing shell G Checking and setting of fuel overpressure safety valve H Checking of non retur...

Page 449: ...bearing 94315 9 Pre tensioning jack piston rod foot 94340 10 HP oil pump 2800 bar 94931 10A Adapter piece 94934F 11 Hydr distributor 94932 12 Connection block 94934 13 Hydr distributor 94934A 13A Reli...

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Page 451: ...ing Dimension mm o x i x t i x s 94114 Elastic bolts to main bearing piston cylinder 109 x 99 6 x 1 7 79 9 x 70 5 x 1 7 97 79 x 5 33 69 22 x 5 33 94145 Foundation bolt and engine stay piston cylinder...

Page 452: ...1 Piston 7 Distance sleeve 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Double cylinder 10 Cover 5 Back up ring O ring Sealing ring 11 Round nut 6 94114 KJ Kit with back up...

Page 453: ...ston 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 10 Control pin 5 Back up ring O ring Sealing ring 6 94145 KJ Kit with back up and O rings for pre tens...

Page 454: ...screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 10 Eyelet 5 Back up ring O ring Sealing ring 6 GF 94180 KJ Kit with back up and O rings for pre tensioning Jack 1...

Page 455: ...ston 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 10 Eyelet 5 Back up ring O ring Sealing ring 6 CF 94215 KJ Kit with back up and O rings for pre tensio...

Page 456: ...cage 1 Piston 7 Adapter piece 2 Back up ring O ring Sealing ring 8 Closing valve 3 9 Control pin 4 Cylinder 5 Back up ring O ring Sealing ring 6 94252 KJ Kit with back up and O rings for pre tensionin...

Page 457: ...iston 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 10 Control pin 5 Back up ring O ring Sealing ring 6 94314 KJ Kit with back up and O rings for pre ten...

Page 458: ...ston 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 10 Control pin 5 Back up ring O ring Sealing ring 6 94315 KJ Kit with back up and O rings for pre tens...

Page 459: ...ston 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 10 Control pin 5 Back up ring O ring Sealing ring 6 94340 KJ Kit with back up and O rings for pre tens...

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Page 461: ...bolts must be carefully cleaned Moreover the threads must be undamaged and freely working Concerning utilization of lubricant for screwing on the nuts the instruc tions in 0352 1 must be followed How...

Page 462: ...t step 600 1000 1132 1 94114 1500 1715 1 94145 150 1903 1 GF 94180 1st step 100 1500 from 100 to 1500 bar 14 5 16 5 mm 3 2708 2 GF 94215 1500 380_ 1 2751 1 94252 1000 165_ 3303 1 94314 1st step 300 10...

Page 463: ...n of the bolt in one single working sequence Shut relief valve EV at the HP oil pump Connect the jack to the HP oil pump or hydraulic unit and actuate the latter Close vent screw 4 as soon as oil flow...

Page 464: ...HP oil pump Connect the jack to the HP oil pump or hydraulic unit and actuate the latter Close vent screw 4 as soon as oil flows out bubble free Slowly raise the pressure approx 20 30 bar beyond the n...

Page 465: ...relief valve EV at the HP oil pump Connect the jack to the HP oil pump or hydraulic unit and actuate the latter Close vent screw 4 as soon as oil flows out bubble free Slowly raise the pressure to th...

Page 466: ...p or hydraulic unit and actuate the latter Close vent screw 4 as soon as oil flows out bubble free Slowly raise the pressure to the nominal value and keep it constant see table Use round bar RS to tig...

Page 467: ...2 27 94002 30 94002 32 94002 36 94002 41 94002 46 94002 50 94002 55 94002 60 94002 65 94002 70 94002 75 94002 85 94002 95 94002 110 94002 135 Ring slugging wrenches 1 Piece AF27 1 Piece AF30 1 Piece A...

Page 468: ...et head keys 1 Piece AF11 1 Piece AF12 1 Piece AF14 1 Piece AF17 1 Piece AF19 1 Piece AF22 1 Piece AF27 000 377 93 94007 94007 C8 94007 C19 94007 C40 Tongs 1 Piece Type C 8 1 Piece Type C 19 1 Piece T...

Page 469: ...30 02 94012 94012A 94012B 94012C 1 Torque spanner Consisting of adapter piece shell type ratchet Torque spanner Range of adjustment 140 760 Nm with extension tube and tool box 010 231 02 94014 94014 2...

Page 470: ...ssion factor 1 5 1 Short backing rod 1 Angle 1 Case 013 554 05 A B C GF 94021 1 Large backing rod to power amplifier X 540 mm 013 555 05 X 94022 94022A 94022B 1 1 1 Adapter piece consisting of Socket...

Page 471: ...M20 94040 M30 RUD eye bolts 2 Pieces M16 6 Pieces M20 2 Pieces M30 013 560 05 94045 94045 M10 94045 M12 94045 M16 94045 M20 94045 M24 94045 M30 94045 M36 94045 M42 94045 M48 94045A M16 Eye bolts 8 Pie...

Page 472: ...94050F 94050G 94050H 1 Tool for pressure measurement for pneumatic elements 1 Compressed air pump 1 Pressure gauge 0 4 bar 1 Pressure gauge 0 6 bar 1 Pressure gauge 0 16 bar 2 HP hoses 1 Adjusting too...

Page 473: ...r X 733 4 mm X 002 669 98 94114 94114 KJ 2 1 Double pre tensioning jacks for elastic studs to main bearing including a metal box X 254 mm Kit with back up and O rings for pre tensioning Jack 002 670 9...

Page 474: ...urning out device for removal and fitting of main bearing shell X 252 mm for girder width 230 mm 010 930 03 94119 1 Lifting yoke for removal and fitting of main bearing shell X 210 mm 005 934 00 94120...

Page 475: ...ring X 625 mm 000 395 93 X 94124 1 Depth gauge measuring range 250 mm 012 237 04 94128 1 Allen wrench for Allen screw to main bearing X 680 mm X 004 220 99 94129 1 Hexagon screwdriver for screws to tu...

Page 476: ...0 399 02 X 017 848 08 X Y 94142 L 94142 R 1 1 Working platform X 1532 mm Grid left side Grid right side 009 947 02 X 94142 L 94142 R 94143 2 Working supports X 570 680 mm 009 323 01 X 94145 94145 KJ 1...

Page 477: ...or tie rods including a metal box X 246 mm Kit with back up and O rings for pre tensioning Jack X WCH01016 GF 94201 GF 94202 GF 94202L GF 94202M GF 94206 GF 94207 1 1 1 1 2 2 Device for fitting and tr...

Page 478: ...a metal box X 170 mm High pressure hoses Y 1328 mm Kit with back up and O rings for pre tensioning Jack WCH03499 X Y 94219 1 Cylinder pressure measuring tool indicator including a wooden box X 165 mm...

Page 479: ...259 1 Pressure element for exhaust valve with an O ring X 247 7 mm X 016 765 08 94261 1 Valve seat fitting and extracting device X 555 mm 000 415 93 X 94262 1 Valve protector only to be applied for tr...

Page 480: ...94269C 41 94269C 55 1 1 Socket wrench insert for loosening and tightening of clamping nut to injection valve with FAST X 106 mm Y 55 mm Socket wrench insert for pre tightening of coupling nut to injec...

Page 481: ...r for checking and adjusting Safety valve to cylinder cover X 68 mm Support device for injector test bench Y 852 mm Valve holder to injector test bench for fastening FAST injection valve 94272B X 9427...

Page 482: ...ing surface X approx 600 mm X 000 463 93 94305 1 Crankshaft checking equipment for measuring crank deflection in wooden box X 364 mm X 000 412 93 94314 94314 KJ 94315 94315 KJ 2 1 2 1 Pre tensioning j...

Page 483: ...e shoes when removing or fitting a connecting rod or a crosshead X 85 mm X 000 409 93 94324 1 Cover and lifting plate to crosshead X 255 mm X 000 408 93 94325 2 Holders for removal of a crosshead guid...

Page 484: ...0_ 012 316 04 X 94334 1 Holder for removal and fitting of connecting rod including 2 Fastening shafts 2 Threaded rods 1 Lifting lug X 1010 mm WCH00317 X 94334A 1 Connecting element with shackle X 70 m...

Page 485: ...ion including a metal box X 110 mm Kit with back up and O rings for pre tensioning Jack X 010 400 02 94341 1 Piston suspension device X 469 8 mm 7056 03 F101197 X GF 94342 GF 94343 1 2 Insertion funne...

Page 486: ...6 03 F101181 X 94345B 1 Clamping ring X 55 mm 93 7515 X 94345C 1 Gauge for fitting scraper rings X 366 mm 012 158 04 X 94345D 1 Cover plate for covering bore of piston rod gland in cylinder jacket whe...

Page 487: ...ieces each 11 mm X 305 mm X 005 655 94348 1 Tap M20 for cleaning carbon deposits in threaded holes of piston crown X 140 mm 000 398 93 X 94350 1 Device for supporting piston and removal of the piston...

Page 488: ...GF 94410D 1 1 Head bolt M30x150 for intermediate wheel assembly Head bolt M30x170 for intermediate wheel assembly WCH01007 94430 3 Roller lifting tools for cutting out and cutting in of fuel pump inc...

Page 489: ...er for cutting out of individual fuel pumps X 72 mm Spacers for cutting out of individual fuel pumps X1 36 mm 016 649 08 X X1 94556 1 Checking device for plunger position X 130 mm 008 765 01 GF 94557...

Page 490: ...ing 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 94566C 1 Limi...

Page 491: ...ng 42 52x2 62 mm X 93 mm Blank flange to valve housing at fuel rail with 4 Screws M12x80 X1 92 mm 016 650 08 X X1 94572C 94572E 94572F 94572I 3 3 3 3 Shackles WLL 4750 kg Shackles WLL 3250 kg Shackles...

Page 492: ...ews M10x25 X 88 mm max lifting capacity 180 kg 015 675 07 94587 8 Conical plugs 4 pieces per Cyl for servo and fuel oil returns in rail unit X 20 mm X 011 976 04 94589 2 Withdrawing tools for removing...

Page 493: ...ABB A180 Cover to air connection at diffuser X 470 mm TPL 73 B X 555 mm TPL 77 B X 460 mm MET 53MA MB X 520 mm MET 66S X 520 mm MET 60MA MB X 545 mm ABB A170 X 625 mm ABB A175 X 690 mm ABB A180 X 000...

Page 494: ...m X 010 696 03 94665 94665A 1 1 Pin with double spring clip for removal and fitting of tube stack including Roller 012 701 05 94665 94665A 94720C 1 Tool pulse accumulator for CLU4 C consisting of meas...

Page 495: ...ration X 200 mm X 004 017 96 94834 1 Regrinding device to hydraulic pipes for radius of 100 mm X 38 mm 015 676 07 X 94870D 1 Stencil X 48 mm X 016 740 08 94870H 1 Stencil X 75 mm X 016 741 08 94870J L...

Page 496: ...r fitting claws on HP pipe to injection valve X 24 mm X 000 699 98 94924 94925 1 1 Hook spanner for crank angle sensor X 205 mm Hook spanner for crank angle sensor X 242 mm 008 771 00 94930 1 SW downl...

Page 497: ...r Adapter piece 010 001 02 94934F 94932 2 Hydr distributor with pressure gauge 010 242 02 94934 1 Connection block 005 956 00 94934A 94934K 94934E 1 1 1 Hydr distributor with pressure gauge Relief val...

Page 498: ...2130 mm X 005 954 00 94935A 2 HP hoses 1500 bar with closing valves and coupling sockets X 1880 mm X 005 954 00 94935C 1 Hose for set up of pre tensioning jacks Length 2000 mm 701 013 621 013 621 05 9...

Page 499: ...rews for turning out thrust bearing pads For 2 part gear wheel X 57 5 mm WCH02515 X 94291 94291A 1 2 Valve grinding device complete for valve spindle and valve seat Grinding discs C M No 11373 01 01 W...

Page 500: ...2 93 X 94344 1 Dismantling device for removal of piston rod gland downwards X 812 mm 003 988 96 94349 1 Pressure testing device for piston X 252 mm X 004 134 98 94356 1 Equipment case with instruments...

Page 501: ...red chain block for removing and fitting electric motor to auxiliary blower WLL 1000 kg 000 460 93 94655 1 Cover to air inlet casing with suction pipe in case of a turbocharger breakdown X 480 mm TPL...

Page 502: ...000 459 93 X GF 94174 1 Thread protector to upper threads of tie rod with screw M24x55 X 38 mm WCH00668 X GF 94177 1 Thread protector to lower thread of tie rod with screw M20x30 X 104 mm X WCH00748...

Page 503: ...Lifting elements incl 24 screws M24x80 and nuts 016 149 07 94690A 94692 94690A 94690B 1 2 1 Transport tool for 7 Cyl rail unit modules max lifting capacity 14 000 kg X 6176 mm consisting of Lifting e...

Page 504: ...Intentionally blank...

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