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WinGD X62DF, Maintenance Manual

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WinGD X62DF Maintenance Manual Download Page 164

7.7.5

Starting air valve - assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

282

7.7.6

Starting air valve - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

284

7.7.7

Starting air valve - install the solenoid valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

286

7.8

Relief valve combustion chamber

7.8.1

Relief valve combustion chamber - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

288

7.8.2

Relief valve combustion chamber - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

290

7.9

Exhaust valve

7.9.1

Exhaust valve - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

292

7.9.2

Exhaust valve - disassemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

296

7.9.3

Exhaust valve - remove the seat (with new tool). . . . . . . . . . . . . . . . . . . . . . . . .

300

7.9.4

Exhaust valve - do a check of the seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

304

7.9.5

Exhaust valve - grind the seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

308

7.9.6

Exhaust valve - install the seat (with new tool). . . . . . . . . . . . . . . . . . . . . . . . . . .

310

7.9.7

Exhaust valve - assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

314

7.9.8

Exhaust valve - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

322

7.10

Pilot injection valve

7.10.1

Pilot injection valve - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

326

7.10.2

Pilot injection valve - remove the injection module. . . . . . . . . . . . . . . . . . . . . . .

330

7.10.3

Pilot injection valve - install the injection module. . . . . . . . . . . . . . . . . . . . . . . . .

332

7.10.4

Pilot injection valve - do a functional test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

336

7.10.5

Pilot injection valve - remove the pre-chamber. . . . . . . . . . . . . . . . . . . . . . . . . . .

340

7.10.6

Pilot injection valve - install the pre-chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . .

342

7.10.7

Pilot injection valve - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

344

X72DF

Maintenance Manual

Winterthur Gas & Diesel Ltd.

- 164 -

Issue 002 2020-10

Summary of Contents for X62DF

Page 1: ...l X72DF Issue 002 2020 10 Winterthur Gas Diesel Ltd Sch tzenstrasse 3 Tel 41 0 52 264 8844 Winterthur Gas Diesel AG P O Box 414 8401 Fax 41 0 52 264 8866 Winterthur Gas Diesel S A Winterthur Switzerla...

Page 2: ...ght holder Winterthur Gas Diesel Ltd makes no representation warranty express or implied in this publication and assumes no responsibility for the correctness errors or omissions of information contai...

Page 3: ...Jointing compounds 60 3 3 Clearances general 62 3 4 Clearances 64 3 5 Torque values standard screws 82 4 General mainteance procedures 4 1 Do maintenance work general procedure 86 4 2 Tighten a round...

Page 4: ...linder liner preserve 178 7 1 4 Cylinder liner grind 182 7 1 5 Cylinder liner grind the lubricating groove 184 7 1 6 Cylinder liner grind the scavenge ports 186 7 1 7 Cylinder liner install 188 7 2 Lu...

Page 5: ...ove 288 7 8 2 Relief valve combustion chamber install 290 7 9 Exhaust valve 7 9 1 Exhaust valve remove 292 7 9 2 Exhaust valve disassemble 296 7 9 3 Exhaust valve remove the seat with new tool 300 7 9...

Page 6: ...ver 426 8 5 10 Connecting rod install 432 8 6 Crosshead 8 6 1 Crosshead remove 444 8 6 2 Crosshead do a check of the clearances 458 8 6 3 Crosshead install 462 8 7 Piston 8 7 1 Piston installed do che...

Page 7: ...trol valve 586 10 5 3 Fuel rail install the pressure control valve 590 10 6 Fuel overpressure safety valve 10 6 1 Fuel rail remove the overpressure safety valve 592 10 6 2 Fuel rail do a check of the...

Page 8: ...rated electric balancer do a check of the bearing clearance 698 12 2 5 Integrated electric balancer adjust the bearings 702 12 2 6 Electric balancer sensor unit remove the proximity sensor 706 12 2 7...

Page 9: ...ity sensor 782 14 1 3 Crank angle sensor unit flywheel remove the proximity sensor 786 14 1 4 Crank angle sensor unit flywheel install the proximity sensor 790 14 2 Selective catalytic reduction syste...

Page 10: ...X72DF Maintenance Manual Page left intentionally blank Winterthur Gas Diesel Ltd 10 Issue 002 2020 10...

Page 11: ...Piston and piston rings 72 3 11 Supply unit drive wheels 75 3 12 Fuel and servo pump units 77 3 13 Fuel pump 79 3 14 Integrated electric balancer 81 3 15 Torque value applicable decrease 82 3 16 Torq...

Page 12: ...2 Distance X for hydraulic pipe exhaust valve 741 13 3 Distances X and Y for HP fuel pipe 753 13 4 Distance X for HP fuel pipe 765 13 5 Distance X for pilot fuel pipe 773 X72DF Maintenance Manual Win...

Page 13: ...earances fuel and servo pump units 76 3 13 Fuel pump 78 3 14 Clearances ELBA 80 4 General mainteance procedures 4 1 Tighten a round nut examples 89 4 2 Loosen a round nut examples 93 4 3 Do a check of...

Page 14: ...age 189 7 11 Cylinder liner example 190 7 12 Water guide jacket example 191 7 13 Lubricating quill example 195 7 14 Lubricating quill 197 7 15 Sealing surface 199 7 16 Lubricating quill example 200 7...

Page 15: ...7 55 Relief valve combustion chamber 289 7 56 Relief valve combustion chamber 291 7 57 Exhaust valve preparation 293 7 58 Exhaust valve removal 294 7 59 Exhaust valve disassemble 298 7 60 Guide bush r...

Page 16: ...rod move 385 8 20 Connecting rod remove 387 8 21 Connecting rod move 2 389 8 22 Preparation 394 8 23 Equipment install 395 8 24 Top bearing cover removal 396 8 25 Top end bearing remove 399 8 26 Bott...

Page 17: ...70 Piston remove example 483 8 71 Piston Preparation before disassembly 487 8 72 Piston disassemble example 488 8 73 Top surface dimensions check 491 8 74 Piston groove clearance calliper gauge 491 8...

Page 18: ...tall 591 10 26 Fuel overpressure safety valve 593 10 27 Fuel overpressure safety valve pressure check 596 10 28 Fuel overpressure safety valve installation 599 10 29 Flow limiting valve inspection 601...

Page 19: ...r separator view 9 668 12 Group 7 Cylinder lubrication and balancer 12 1 Cylinder lubrication system example do a functional test 671 12 2 Cylinder lubrication system bleed 674 12 3 Cylinder lubricati...

Page 20: ...djust 766 13 16 HP fuel pipes remove and install 767 13 17 Pilot fuel pipe remove 770 13 18 Pilot fuel pipe prepare 774 13 19 Pilot fuel pipe install 775 14 Group 9 Monitoring instruments 14 1 Proximi...

Page 21: ...ation set 26 1 4 Data module codes procedural data 28 1 5 Data module codes descriptive data 30 1 6 Data module codes illustrated parts data 32 1 7 About this book 34 1 8 About the engine 36 1 9 List...

Page 22: ...ferent data modules n a Different changes and improvements New issue 001 2020 05 All data modules n a Initial issue of the fully new structured Maintenance Manual The existing Maintenance Manual publi...

Page 23: ...X72DF AA00 0000 00AAA 003B A Maintenance Manual Maintenance Manual change record Page left intentionally blank Winterthur Gas Diesel Ltd 23 Issue 002 2020 10...

Page 24: ...manual are related to drawings from WinGD These data relate to the date of issue of the manual the year of the issue is shown on the title page and on the footer All instructions graphics and illustr...

Page 25: ...X72DF AA00 0000 00AAA 018A A Maintenance Manual Preface Page left intentionally blank Winterthur Gas Diesel Ltd 25 Issue 002 2020 10...

Page 26: ...e standard engine with all cylinder numbers alternative designs and special equipment In this manual the engine connections refer to the pipe connection plan are the interface of the description For a...

Page 27: ...setting tables shop trial documents schematic diagrams and survey certificates of the related engine are given with the first supply of the documentation 1 3 6 Marine Installation Manual The Marine I...

Page 28: ...linders 2 numeric char acters 0 9 arbitrary 00 2 WinGD design group number 4 numeric char acters 0 9 arbitrary 5556 2 Used for sequential numbering for the physical breakdown of components 00 complete...

Page 29: ...has been re moved from the product D informa tion related to all three locations A B and C No other combinations are al lowed 1 alphabetic character A D Shipdex specif ic A 1 Placeholder symbol for a...

Page 30: ...numeric char acters 0 9 arbitrary 5551 2 Used for sequential numbering of data modules 2 numeric char acters 0 9 sequential starts with 00 00 1 Used for alternative items differing in design but not e...

Page 31: ...X72DF AA00 0000 00AAA 018D A Maintenance Manual Data module codes descriptive data Page left intentionally blank Winterthur Gas Diesel Ltd 31 Issue 002 2020 10...

Page 32: ...rbitrary 05 2 WinGD design group number 4 numeric char acters 0 9 arbitrary 5562 2 Used for sequential numbering of data modules 2 numeric char acters 0 9 sequential starts with 01 01 1 Used for alter...

Page 33: ...X72DF AA00 0000 00AAA 018F A Maintenance Manual Data module codes illustrated parts data Page left intentionally blank Winterthur Gas Diesel Ltd 33 Issue 002 2020 10...

Page 34: ...tle of the section for example refer to section 1 2 Preface In the electronic version a mouse click on the blue text shows the related section NOTE The text section not applicable for this engine show...

Page 35: ...tion The signal words have the different hazard levels that follow WARNING The signal word WARNING gives a dangerous situation at which death or large injury are possible Do the related procedure to p...

Page 36: ...of the number into 9 groups Group 1 Engine frame and bearings Group 2 Cylinder Group 3 Crankshaft connecting rod and piston Group 4 Supply unit drive and control components Group 5 Supply unit pumps a...

Page 37: ...d other operating media FE Free End end that is closed with a cover ES Exhaust Side side that has the equipment for the discard of the exhaust gas and for the supply of scavenge air Fig 1 1 Side view...

Page 38: ...ES 001 002 003 005 004 Legend ES Exhaust side FS Fuel side 001 Turbocharger 004 Supply unit 002 Auxiliary blower 005 Rail unit 003 Flywheel X72DF AA00 0000 00AAA 018L A Maintenance Manual About the e...

Page 39: ...1 3 Standard and LEFT engine generic seen from the driving end 001 002 003 ES FS FS Legend 001 Standard engine ES Exhaust side 002 LEFT engine FS Fuel side 003 Exhaust gas manifold NOTE In the Spare...

Page 40: ...radial direction the numbering starts from the center of the flywheel Fig 1 4 Engine numbering generic FE DE n n 004 003 001 002 n 1 n 1 4 3 2 1 2 1 Legend FE Free end DE Driving end 001 Cylinder numb...

Page 41: ...X72DF AA00 0000 00AAA 018L A Maintenance Manual About the engine Page left intentionally blank Winterthur Gas Diesel Ltd 41 Issue 002 2020 10...

Page 42: ...Brake Specific Gas Consumption BSPC Brake Specific Pilot fuel Consumption CAN Controller Area Network CCAI Calculated Carbon Aromaticity Index CCM Cylinder Control Module CCU Cylinder Control Unit CC...

Page 43: ...ve FPP Fixed Pitch Propeller FQS Fuel Quality Setting FS Fuel Side FZG Forschungsstelle f r Zahnr der und Getriebebau gear research center GAV Gas Admission Valve GSS Gas Safety System GTD General Tec...

Page 44: ...Heating Value LLT Low Load Tuning LNG Liquefied Natural Gas LP Low Pressure LT Low Temperature MARPOL International Convention for the Prevention of Pollution from Ships MARine POLlution MCM Main Cont...

Page 45: ...cavenge Air Cooler SAE Society of Automotive Engineers SCR Selective Catalytic Reduction SCS Speed Control System SHD shutdown SLD slowdown SOI Start Of Injection SPC Spare Parts Catalogue SPC Steam P...

Page 46: ...Waste Heat Recovery WiCE WinGD Integrated Control Electronics WinGD Winterthur Gas Diesel Ltd WLL Work Load Limit X72DF AA00 0000 00AAA 005A A Maintenance Manual List of abbreviations Winterthur Gas...

Page 47: ...2 Safety 2 1 Safety precautions and safety rules 48 2 2 Safety precautions and safety rules for natural gas 52 X72DF Maintenance Manual Winterthur Gas Diesel Ltd 47 Issue 002 2020 10...

Page 48: ...hand tools in locations where you can easily get access to them Put special tools and devices in positions in the engine room near the area where you use them Make sure that all tools have protection...

Page 49: ...ep unauthorized persons away from the engine Clean walk ways and stays regularly Open valves and shut off devices carefully to prevent injury from released media Do not use water or cleaning fluid to...

Page 50: ...e Make sure that there are no explosive fluids or gases in the work area Apply protection to electronic parts to prevent damage from sparks and heat Place the connection to earth as near as possible t...

Page 51: ...X72DF AA00 0000 00AAA 012A A Maintenance Manual Safety precautions and safety rules Page left intentionally blank Winterthur Gas Diesel Ltd 51 Issue 002 2020 10...

Page 52: ...his is an area in which an explosive gas atmosphere is continuously present or is present for long periods Examples Combustion chamber gas pipes Zone Z1 This is an area in which an explosive gas atmos...

Page 53: ...ire Put on antistatic clothes Make sure that your safety shoes are in good condition Steel toe caps can cause sparks Use only approved tools that do not cause sparks and test equipment that will not c...

Page 54: ...X72DF AA00 0000 00AAA 012H A Maintenance Manual Safety precautions and safety rules for natural gas Page left intentionally blank Winterthur Gas Diesel Ltd 54 Issue 002 2020 10...

Page 55: ...for maintenance 3 1 Lifting tools 56 3 2 Jointing compounds 60 3 3 Clearances general 62 3 4 Clearances 64 3 5 Torque values standard screws 82 X72DF Maintenance Manual Winterthur Gas Diesel Ltd 55 Is...

Page 56: ...ing and disconnecting CAUTION If tools are combined for example beams with shackles RUD eye bolts or RUD swivel lugs and ropes etc it is always the weakest element which determines the maximum lifting...

Page 57: ...ave checked it for visible damages for example corrosion deformation before you use it Also obey the data that follows If there are through holes a washer should be placed from the opposite side under...

Page 58: ...suitable to be turned under load Lateral loading is permitted in no circumstances see Figure 3 1 Fig 3 1 RUD eye bolts 00284 Force Direction 001 Force Direction 002 003 Force Direction Legend 001 Ring...

Page 59: ...h fulfil or exceed these values including the safety factor All calculations for components and tools where shackles are used are laid out accordingly and based on the mentioned standards Normally the...

Page 60: ...rials must not contain acid The materials must be resistant to oil marine diesel oil heavy fuel oil and water at a temperature of 100 C A short age hardening time is necessary that is not more than 24...

Page 61: ...X72DF AA00 0000 00AAA 701A A Maintenance Manual Jointing compounds Page left intentionally blank Winterthur Gas Diesel Ltd 61 Issue 002 2020 10...

Page 62: ...able changed thickness of shims discs spacers etc the values must be those given in column Nominal dimension If this is not possible you must replace worn parts with standard new parts or reconditione...

Page 63: ...X72DF AA00 0000 00AAA 034C A Maintenance Manual Clearances general Page left intentionally blank Winterthur Gas Diesel Ltd 63 Issue 002 2020 10...

Page 64: ...d direction Nominal dimension usual new mm Maximum dimension be cause of wear mm 1203 Thrust bearing 1224 Thrust bearing pad Thickness 115 0 5 0 6 001 Thrust bearing clearance Axial total 0 8 to 1 3 2...

Page 65: ...nd main bearings Fig 3 4 Crankshaft and main bearings 001 002 1 2 3 MAIN BEARING No 1 MAIN BEARING No 2 No 3 ETC X72DF AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 65...

Page 66: ...se of wear mm 1132 Main bearing No 1 001 Bearing clearance Vertical 0 4 to 0 7 0 9 1132 Main bearing No 2 to n 002 Bearing clearance Vertical 0 3 to 0 6 0 8 NOTE All main bearing clearances are only a...

Page 67: ...teral clearance Total 0 6 to 2 0 2 5 006 Guide shoe lateral clearance Total 0 1 to 0 6 0 9 007 Crosshead pin Outer diameter 720 0 0 08 008 Bearing clearance Radial 0 08 to 0 25 0 30 NOTE For the instr...

Page 68: ...linder cov er 001 Clearance top part Total 0 40 to 0 80 002 Clearance top part Total 1 40 to 1 80 003 Clearance bottom part Total 0 50 to 0 90 004 Clearance bottom part Total 0 50 to 0 90 2124 Cylinde...

Page 69: ...g width Radial 16 Minimum 12 003 Ring width Radial 5 Minimum 3 20 004 Ring clearance Axial 0 05 to 0 19 0 40 005 Ring clearance Axial 0 05 to 0 13 0 40 006 Ring clearance Axial 0 10 to 0 17 0 40 NOTE...

Page 70: ...m clearance di mension be cause of wear mm 2754 Valve spindle 001 Spindle Outer diameter 70 0 26 0 29 69 50 2751 Guide bush 002 Bore Inner diameter 70 0 03 0 0 70 40 003 Bore Inner diameter 70 0 03 0...

Page 71: ...3303 3326 Top end bearing 001 Bearing clearance Vertical 0 50 to 0 70 0 9 002 Lateral clearance Total 0 45 to 0 65 003 Lateral clearance Total 0 35 to 0 60 3303 Bottom end bearing 004 Bearing clearanc...

Page 72: ...ing grooves 007 Top groove height Vertical 22 0 55 0 50 011 Middle groove height Vertical 13 0 50 0 45 015 Bottom groove height Vertical 13 0 50 0 45 005 Top groove depth Radial 24 0 2 0 009 Middle gr...

Page 73: ...Point B 1 00 010 Middle ring clearance Vertical 0 45 to 0 53 Point A 0 75 Point B 0 95 010 Bottom ring clearance Vertical 0 45 to 0 53 Point A 0 75 Point B 0 95 008 Top ring width Radial 23 0 25 012...

Page 74: ...3 4 9 Supply unit drive wheels Fig 3 11 Supply unit drive wheels X72DF AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 74 Issue 002 2020 10...

Page 75: ...003 Axial clearance Total 0 60 to 1 10 1 50 004 Tooth backlash 0 24 to 0 40 0 43 005 Tooth backlash 0 33 to 0 53 0 56 006 Tooth backlash 0 16 to 0 30 0 34 NOTE The backlash must be measured longitudi...

Page 76: ...3 4 10 Fuel and servo pump units Fig 3 12 Clearances fuel and servo pump units X72DF AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 76 Issue 002 2020 10...

Page 77: ...e cause of wear mm 5552 Fuel pump unit 002 Bearing clearance Radial 0 153 to 0 237 0 33 003 Axial clearance Total 0 30 to 0 65 0 81 5552 Servo pump unit 005 Pinion Outer diameter 120 0 0 022 006 Axial...

Page 78: ...3 4 11 Fuel pump Fig 3 13 Fuel pump X72DF AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 78 Issue 002 2020 10...

Page 79: ...adial 0 15 to 0 266 0 4 005 Plunger bottom spring carrier Axial 0 10 to 0 17 0 20 006 Regulating sleeve top spring carri er Axial 0 5 to 0 7 0 8 5556 Roller guide 003 Pin Outer diameter 80 0 0 013 Gui...

Page 80: ...3 4 12 Integrated electric balancer Fig 3 14 Clearances ELBA X72DF AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 80 Issue 002 2020 10...

Page 81: ...1 5 7758 Compensating shaft 003 Tooth backlash between bottom compensating shaft and pinion 0 30 to 0 35 003 Difference over width 0 02 004 Tooth backlash between top and bottom compensating shafts 0...

Page 82: ...er Seez NSBT8 Then you have to decrease the torque values refer to Table 3 15 Torque value applicable decrease These torques values do not apply to turbocharger installations Refer to the documents of...

Page 83: ...0 M14 M14 x 1 5 94 M16 M16 x 1 5 145 M18 M18 x 1 5 200 M20 M20 x 1 5 280 M22 M22 x 1 5 380 M24 M24 x 2 490 M27 M27 x 2 720 M30 M30 x 2 980 M33 M33 x 2 1300 M36 M36 x 3 1700 M39 M39 x 3 2200 M42 M42 x...

Page 84: ...X72DF AA00 0000 00AAA 034A A Maintenance Manual Torque values standard screws Page left intentionally blank Winterthur Gas Diesel Ltd 84 Issue 002 2020 10...

Page 85: ...aintenance work general procedure 86 4 2 Tighten a round nut with a pre tensioner 88 4 3 Loosen a round nut with a pre tensioner 92 4 4 Do a check of the pre tension 96 X72DF Maintenance Manual Winter...

Page 86: ...urs Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SA...

Page 87: ...do more related work NOTE Water current for instance if the ship is tugged can cause the propeller shaft to turn 5 Make sure the all related spaces have good airflow for example if CO2 was used to ext...

Page 88: ...Part No CSN QTY HP oil pump 94931 pc 1 HP hose A R pc 1 Hydraulic unit 94942 pc 1 Round bar kit 94005 pc 1 Pre tensioner A R A R Supplies Description QTY None Spare Parts Description Part No CSN QTY...

Page 89: ...stic stud 008 version 2 do the steps that follow 5 2 1 Put the pre tensioner on the elastic stud 008 until the cylinder 003 touches the plate 007 5 2 2 Turn the nut 010 on the elastic stud 008 down to...

Page 90: ...nut 004 and the plate 007 11 5 If there is a clearance turn the round nut 004 more down 11 6 Remove the round bar 012 12 Release the pressure on the HP oil pump or on the hydraulic unit to zero 13 Dis...

Page 91: ...X72DF AA00 0000 00AAA 711A A Maintenance Manual Tighten a round nut with a pre tensioner Page left intentionally blank Winterthur Gas Diesel Ltd 91 Issue 002 2020 10...

Page 92: ...Part No CSN QTY HP oil pump 94931 pc 1 HP hose A R pc 1 Hydraulic unit 94942 pc 1 Round bar kit 94005 pc 1 Pre tensioner A R A R Supplies Description QTY None Spare Parts Description Part No CSN QTY...

Page 93: ...t X 2 2 4 Turn back the nut 010 with the related number of turns refer to the name plate on the pre tensioner to get a clearance at Y NOTE This prevents problems when you remove the pre tensioner Fig...

Page 94: ...ound nut 004 back the related number of turns 8 4 Remove the round bar 012 9 Release the pressure on the HP oil pump or on the hydraulic unit to zero 10 Disconnect the pre tensioner from the HP oil pu...

Page 95: ...X72DF AA00 0000 00AAA 510A A Maintenance Manual Loosen a round nut with a pre tensioner Page left intentionally blank Winterthur Gas Diesel Ltd 95 Issue 002 2020 10...

Page 96: ...Part No CSN QTY HP oil pump 94931 pc 1 HP hose A R pc 1 Hydraulic unit 94942 pc 1 Round bar kit 94005 pc 1 Pre tensioner A R A R Supplies Description QTY None Spare Parts Description Part No CSN QTY...

Page 97: ...re is no clearance at X 2 2 4 Turn back the nut 010 with the related number of turns refer to the name plate on the pre tensioner to get a clearance at Y NOTE This prevents problems when you remove th...

Page 98: ...r 012 from the round bar kit 8 2 2 Put the round bar 012 through the slot 005 into a hole of the round nut 004 8 2 3 Turn the round nut 004 down to the plate 007 8 2 4 Remove the round bar 012 9 Relea...

Page 99: ...5 Maintenance schedule 5 1 Maintenance schedule 100 X72DF Maintenance Manual Winterthur Gas Diesel Ltd 99 Issue 002 2020 10...

Page 100: ...ease these maintenance intervals Reasons for a change of the intervals can be the items that follow Environmental and operation conditions Heavy fuel oil and lubricating oil qualities Engine load Cool...

Page 101: ...ousing 132 6 4 2 Thrust bearing do a check of the axial clearance with a dial gauge 134 6 4 3 Thrust bearing do a check of the axial clearance with a inside micrometer 136 6 4 4 Thrust bearing remove...

Page 102: ...QTY Feeler gauge 94122 1 Pre tensioner 94145 1 HP oil pump 94931 1 Hydraulic distributors 94934A 2 HP hose 94935 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PR...

Page 103: ...the foundation must be attached with the foundation bolts 002 and the long bushes 001 The remaining area is attached with the foundation bolts 002 and the short bushes 004 Fig 6 1 Foundation bolts 00...

Page 104: ...110 1 Lug 94116C 1 Shackle 6500 kg 94019K 1 Shackle 2000 kg 94019G 1 HP oil pump 94931 1 Supplies Description QTY Copper paste A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None...

Page 105: ...hat the thrust device 004 is clean 7 Install the lifting plate 005 to the transport position 8 Use the lifting plate 005 to move and install the thrust device 004 in position on the bearing cover 002...

Page 106: ...relief valve on the HP oil pump to release the pressure to zero 20 Remove the HP hose from the thrust device 004 Fig 6 3 Thrust device 00613 001 002 004 003 002 008 006 006 005 Copper paste 007 21 Att...

Page 107: ...rate the engine room crane to put a light tension on the chain 27 Remove the chain block 002 from the lug 94116C 003 28 Operate the engine room crane to move the bearing cover on to an applicable surf...

Page 108: ...00614 001 002 003 002 004 30 For bearing no 02 to nn do this procedure in a similar way CLOSE UP None X72DF AA00 1132 00AAA 520A A Maintenance Manual Main bearing remove the cover Winterthur Gas Diese...

Page 109: ...X72DF AA00 1132 00AAA 520A A Maintenance Manual Main bearing remove the cover Page left intentionally blank Winterthur Gas Diesel Ltd 109 Issue 002 2020 10...

Page 110: ...Spur geared chain block 2500 kg 94017 028 1 Thrust device 94110 1 Lug 94116C 1 Shackle 6500 kg 94019K 1 Shackle 2000 kg 94019G 1 HP oil pump 94931 1 Supplies Description QTY None Spare Parts Descripti...

Page 111: ...ge position as shown 6 Open the vent screw 007 and make sure that the piston 006 is fully engaged 7 Make sure that the tappet 008 and the piston 006 fully engage with the cutouts in the bearing cover...

Page 112: ...pins 001 engage correctly Make sure that you do not cause damage to the elastic studs 004 NOTE The top bearing shell is attached to the bearing cover 003 Figure 6 7 with two Allen screws 002 The sprin...

Page 113: ...the clearance is in the limits given the bearing can be removed and installed again 32 After each installation of a new bearing shell measure the crank deflection refer to section 8 1 1 Crankshaft do...

Page 114: ...9 Bearing cover oil pipe 00617 003 004 001 005 002 006 005 006 CLOSE UP None X72DF AA00 1132 00AAA 720A A Maintenance Manual Main bearing install the cover Winterthur Gas Diesel Ltd 114 Issue 002 202...

Page 115: ...X72DF AA00 1132 00AAA 720A A Maintenance Manual Main bearing install the cover Page left intentionally blank Winterthur Gas Diesel Ltd 115 Issue 002 2020 10...

Page 116: ...d chain block 94017 x x 2 Shackle WLL 2000 kg 94019G 1 Lifting plate 94119 1 Turning out device 94118B 1 Lifting tool bearing shell 94116A 1 Dial gauge N A 1 Hydraulic ram 94936 3 HP oil pump 94931 1...

Page 117: ...ATIONS The bearing cover must be removed refer to section 6 2 1 Main bearing remove the cover X72DF AA00 1134 00AAA 520A A Maintenance Manual Main bearing shell remove Winterthur Gas Diesel Ltd 117 Is...

Page 118: ...teral clearances y1 and y2 between the crankshaft 007 and the main bearing shell 008 at approximately 50 mm below the bearing 3 2 Set to zero the dial gauge 006 3 3 Operate the HP oil pump to lift the...

Page 119: ...rankshaft and flywheel lift Y1 Y2 007 008 006 50 mm 50 mm 0 3 mm 001 003 001 005 002 004 X72DF AA00 1134 00AAA 520A A Maintenance Manual Main bearing shell remove Winterthur Gas Diesel Ltd 119 Issue 0...

Page 120: ...h the wire ropes to the lifting plate 008 4 7 Attach the chain block 003 to the middle hole in the lifting plate 008 4 8 Operate the chain block 003 to turn the bearing shell 002 a sufficient distance...

Page 121: ...small distance 5 5 Attach the engine room crane to the lifting tool 002 5 6 Operate the engine room crane and the chain block 001 to lift and move the bearing shell 003 out of the engine 5 7 Remove th...

Page 122: ...an hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Scotchbrite A R Spare Parts Description Part No CSN Q...

Page 123: ...ll occur 3 Use Scotchbrite to remove small scratches and running marks 4 If the running marks are not symmetrical axial or radial speak to or send a message to WinGD 5 If necessary replace the bearing...

Page 124: ...ifting plate 94119 1 Turning out device 94118B 1 Lifting tool bearing shell 94116A 1 Dial gauge N A 1 Hydraulic ram 94936 3 HP oil pump 94931 1 Pressure gauge 94934A 1 Steel beam N A 1 Steel plate N A...

Page 125: ...PRELIMINARY OPERATIONS None X72DF AA00 1134 00AAA 720A A Maintenance Manual Main bearing shell install Winterthur Gas Diesel Ltd 125 Issue 002 2020 10...

Page 126: ...ng surface of the bearing shell 003 are clean and fully lubricated with clean engine oil 1 4 Attach the lifting tool 002 to the bearing shell 003 1 5 Attach the engine room crane to the lifting tool 0...

Page 127: ...Fig 6 13 Bearing shell lift 003 00608 002 001 002 003 X72DF AA00 1134 00AAA 720A A Maintenance Manual Main bearing shell install Winterthur Gas Diesel Ltd 127 Issue 002 2020 10...

Page 128: ...nder the crankshaft 2 5 Attach the wire ropes of the device 009 to the lifting plate 008 2 6 Attach the chain block 004 to the lifting plate 008 2 7 Operate carefully the chain block 001 to move the b...

Page 129: ...g shell install WCH03015 WCH03486 001 00607 I 002 003 004 006 007 005 006 009 006 002 I 008 X72DF AA00 1134 00AAA 720A A Maintenance Manual Main bearing shell install Winterthur Gas Diesel Ltd 129 Iss...

Page 130: ...e the hydraulic rams 001 Figure 6 15 and the HP oil pump 3 3 Remove the bracket 003 and the steel plate 002 Fig 6 15 Crankshaft and flywheel lift 001 003 001 005 002 004 CLOSE UP None X72DF AA00 1134...

Page 131: ...X72DF AA00 1134 00AAA 720A A Maintenance Manual Main bearing shell install Page left intentionally blank Winterthur Gas Diesel Ltd 131 Issue 002 2020 10...

Page 132: ...escription Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None...

Page 133: ...essary remove particles from the area 001 4 Make sure th the channel 002 is clear 5 Install the cover 003 Fig 6 16 Visual examination 00624 002 003 001 CLOSE UP None X72DF AA00 1203 00AAA 310A A Maint...

Page 134: ...Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Dial gauge N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PR...

Page 135: ...the dial gauge 001 in position on the oil baffle 003 and record the value 8 Remove the dial gauge 001 9 Compare all recorded values with those given in the engine documents on the Check Dimensions pa...

Page 136: ...Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Micrometer 94101 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY P...

Page 137: ...the engine 9 Make sure that the crankshaft does not move 10 Use the micrometer 005 to measure the distance between the crankshaft flange 006 and the oil baffle 004 11 Record the value 12 Remove the mi...

Page 138: ...CLOSE UP None X72DF AA00 1203 00AAA 360B A Maintenance Manual Thrust bearing do a check of the axial clearance with a inside micrometer Winterthur Gas Diesel Ltd 138 Issue 002 2020 10...

Page 139: ...X72DF AA00 1203 00AAA 360B A Maintenance Manual Thrust bearing do a check of the axial clearance with a inside micrometer Page left intentionally blank Winterthur Gas Diesel Ltd 139 Issue 002 2020 10...

Page 140: ...ent Description Part No CSN QTY Manual ratchet 94016 012 1 Spur geared chain block WLL 2500 kg 94017 028 2 Eye bolt 94045 M56 1 Shackle 94334A 2 Carrier 94155A 1 Link 94321 1 Supplies Description QTY...

Page 141: ...ur geared chain block 005 to the shackle 013 and the M12 eye bolt 009 9 Use the chain block 005 to remove the four arbor supports 002 10 Attach the manual ratchet 010 to the other shackle 009 11 Attac...

Page 142: ...a light tension on the manual ratchet 011 and the chain block 005 while the thrust pad 007 moves up 18 Remove the thrust pad 007 19 Remove carefully the manual ratchet 010 20 Use the chain block 005...

Page 143: ...the crankshaft in position If all thrust pads from the same side are removed for example all the astern pads the crankshaft can move 23 To prevent crankshaft movement do as follows X72DF AA00 1203 00A...

Page 144: ...e same dimensions as a thrust pad 23 2 Put the hardwood in the position of the removed thrust pads CLOSE UP None X72DF AA00 1203 00AAA 520A A Maintenance Manual Thrust bearing remove the pads Winterth...

Page 145: ...X72DF AA00 1203 00AAA 520A A Maintenance Manual Thrust bearing remove the pads Page left intentionally blank Winterthur Gas Diesel Ltd 145 Issue 002 2020 10...

Page 146: ...ption Part No CSN QTY Manual ratchet 94016 012 1 Spur geared chain block WLL 2500 kg 94017 028 2 Eye bolt 94045 M56 1 Shackle 94334A 2 Carrier 94155A 1 Link 94321 1 Supplies Description QTY Engine oil...

Page 147: ...e applicable direction 9 Put the subsequent thrust bearing pad in position 10 Do Step 3 to Step 9 for each thrust pad 11 When all thrust pads are in position make sure that the top outer thrust pads a...

Page 148: ...ck of the clearances between the arbor supports and the thrust pads refer to section 6 4 2 Thrust bearing do a check of the axial clearance with a dial gauge or X72DF AA00 1203 00AAA 720A A Maintenanc...

Page 149: ...ances to the original values refer to section 3 3 Clearances general 18 Do a visual examination of the thrust bearing housing refer to 6 4 1 Thrust bearing examine the housing 19 For the configuration...

Page 150: ...Fig 6 23 Cover install 00020 001 CLOSE UP None X72DF AA00 1203 00AAA 720A A Maintenance Manual Thrust bearing install the pads Winterthur Gas Diesel Ltd 150 Issue 002 2020 10...

Page 151: ...X72DF AA00 1203 00AAA 720A A Maintenance Manual Thrust bearing install the pads Page left intentionally blank Winterthur Gas Diesel Ltd 151 Issue 002 2020 10...

Page 152: ...equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Hydraulic tools can cause injury to pers...

Page 153: ...instructions 2 Do a check of the pre tension of the engine stays refer to section 4 4 Do a check of the pre tension CLOSE UP None X72DF AA00 1715 00AAA 360A A Maintenance Manual Engine stays friction...

Page 154: ...cription Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Hydraulic tools can cause injury to personnel Always p...

Page 155: ...l pressure 2 3 Fill the accumulator with nitrogen to a pressure of 40 bar 2 4 Make sure that the pressure stays constant If not there is a leak in the gas system 2 5 Increase the oil pressure to 80 ba...

Page 156: ...alization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Pre tensioning jacks 94180 2 Feeler gauge 94122 1 Supplies Description QTY Molykote paste G A R Spare Parts Description...

Page 157: ...pre tension NOTE Start with the tie rods in the middle of the engine a a then b b etc 4 Do Step 3 again for the other tie rods 5 Apply a layer of Molykote paste G to the threads of the tie rods 002 t...

Page 158: ...rt equipment Description Part No CSN QTY Pre tensioning jacks 94180 2 Eye bolt applicable A R Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Use...

Page 159: ...tensioner 5 Loosen the two set screws 006 6 Use two round nuts to remove the tie rod 004 from the nut 007 7 Attach an eye bolt to the tie rod 004 8 Attach the engine room crane to the eye bolt 9 Opera...

Page 160: ...ption Part No CSN QTY Pre tensioning jacks 94180 2 Eye bolt applicable A R Supplies Description QTY Molykote paste G A R Loctite 577 A R Spare Parts Description Part No CSN QTY Tie rod A R SAFETY PREC...

Page 161: ...the tie rod 003 until the bottom is flush with the bottom of the nut 007 11 Attach the intermediate ring 002 to the tie rod 003 12 Apply Molykote paste G to the top thread of the tie rod 003 and to t...

Page 162: ...limit refer to section 16 1 Tightening instructions 23 Tighten the round nut 003 and remove the pre tensioner 001 refer to section 4 2 Tighten a round nut with a pre tensioner 24 Apply Loctite 577 to...

Page 163: ...7 4 1 Piston rod gland remove 224 7 4 2 Piston rod gland do a check of the wear 228 7 4 3 Piston rod gland install 230 7 5 Cylinder cover 7 5 1 Cylinder cover remove 234 7 5 2 Cylinder cover grind the...

Page 164: ...e seat 304 7 9 5 Exhaust valve grind the seat 308 7 9 6 Exhaust valve install the seat with new tool 310 7 9 7 Exhaust valve assemble 314 7 9 8 Exhaust valve install 322 7 10 Pilot injection valve 7 1...

Page 165: ...X72DF Maintenance Manual Page left intentionally blank Winterthur Gas Diesel Ltd 165 Issue 002 2020 10...

Page 166: ...adder 94224 1 Gauge 94225 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Gas Hazard Poisonous gas can stay in the cylinder liner There is a ris...

Page 167: ...do work in areas where there are hot parts PRELIMINARY OPERATIONS The cylinder cover must be removed refer to section 7 5 1 Cylinder cover remove X72DF AA00 2124 00AAA 360A A Maintenance Manual Cylin...

Page 168: ...ck the lever of the cooling water valve in the closed position 3 Put the ladder 007 Figure 7 1 in position in the cylinder liner 004 X72DF AA00 2124 00AAA 360A A Maintenance Manual Cylinder liner do a...

Page 169: ...4 Clean the area 001 above the running surface 002 5 Remove the bottom part of the measuring gauge 005 X72DF AA00 2124 00AAA 360A A Maintenance Manual Cylinder liner do a check of the bore Winterthur...

Page 170: ...12 Read the values from when the bore was measured before Compare these values with the new values 13 Use the formula shown below to calculate the wear rate with the values as follows WR Wear rate mm...

Page 171: ...X72DF AA00 2124 00AAA 360A A Maintenance Manual Cylinder liner do a check of the bore Page left intentionally blank Winterthur Gas Diesel Ltd 171 Issue 002 2020 10...

Page 172: ...Supplies Description QTY Molyslip Copaslip A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped and made safe for maintenance ref...

Page 173: ...move the holder 008 1 8 Remove the four bolts 012 1 9 Remove the pipe connections 013 1 10 Remove the tubes 014 NOTE The tubes are a push fit in the pipe connections 013 1 11 Attach the engine room cr...

Page 174: ...the pipes to the lubricating quills as follows 2 1 Remove the applicable pipe holders 2 2 Disconnect the related pipes X72DF AA00 2124 00AAA 520A A Maintenance Manual Cylinder liner remove Winterthur...

Page 175: ...03 refer to section 16 1 Tightening instructions 4 Operate the engine room crane 001 to move the lifting tool 002 and plates 004 into position on the cylinder liner 006 NOTE The connection between the...

Page 176: ...Fig 7 4 Cylinder liner example move CLOSE UP None X72DF AA00 2124 00AAA 520A A Maintenance Manual Cylinder liner remove Winterthur Gas Diesel Ltd 176 Issue 002 2020 10...

Page 177: ...X72DF AA00 2124 00AAA 520A A Maintenance Manual Cylinder liner remove Page left intentionally blank Winterthur Gas Diesel Ltd 177 Issue 002 2020 10...

Page 178: ...Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Chain 94202A 1 Lifting tool 94201 1 Wooden chocks N A A R Wooden underlay N A A R Supplies Description QTY None S...

Page 179: ...small distance to tilt the cylinder liner 4 Operate the engine room crane to lower the cylinder liner 004 on to the wooden underlays 005 007 5 Fully lower the cylinder liner 6 Turn the cylinder liner...

Page 180: ...Fig 7 6 Cylinder liner storage 2 CLOSE UP None X72DF AA00 2124 00AAA 810A A Maintenance Manual Cylinder liner preserve Winterthur Gas Diesel Ltd 180 Issue 002 2020 10...

Page 181: ...X72DF AA00 2124 00AAA 810A A Maintenance Manual Cylinder liner preserve Page left intentionally blank Winterthur Gas Diesel Ltd 181 Issue 002 2020 10...

Page 182: ...n hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Grinding device 94299 1 Supplies Description QTY None Spare Parts Description Part N...

Page 183: ...e Manufacturer s Instruction Manual and Figure 7 7 3 Attach an applicable air supply to the grinding tool 001 4 Use the grinding tool to carefully remove the unwanted edge 003 from the cylinder liner...

Page 184: ...e crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Oil stone 1 Emery cloth A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Before yo...

Page 185: ...s 2 1 Use an oil stone or an emery cloth to get the lubricating grooves back to their initial depth 3 Fully clean the lubricating grooves and the bore of the cylinder liner 4 Remove unwanted particles...

Page 186: ...nel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Emery cloth A R Spare Parts Description Part No CSN QTY None SAFETY...

Page 187: ...perate the turning gear to move the piston to get access to the scavenge ports 2 Use emery cloth to polish the surfaces of the scavenge ports Figure 7 9 Make sure that you keep the shape of the scaven...

Page 188: ...cription Part No CSN QTY Shackle 94019L 3 Shackle 94019H 3 Lifting tool 94201 1 Assembly tool 94233 1 Lever chain hoist 94016 003 3 Eye bolt 94045 Mxx 3 Chain 94202A 1 Supplies Description QTY Oil A R...

Page 189: ...part of the lifting tool 006 to the cylinder liner 001 with the screws 002 7 Operate the engine room crane 007 to lower the lifting tool 006 on to the cylinder liner 001 8 Apply copper paste to the t...

Page 190: ...7 11 15 Attach the lever chain hoists 004 Figure 7 12 to the shackle 003 and the shackle 005 as shown 16 Operate the lever chain hoists 004 to lift the water guide jacket 007 17 Attach the water guid...

Page 191: ...iner with the special screws 005 20 Attach the holder and pin 003 to the cylinder block with the bolts 21 Clean the seating surface on the cylinder liner and cylinder block X72DF AA00 2124 00AAA 720A...

Page 192: ...nder liner into the cylinder block Make sure that the pin 003 engages with the hole in the holder 25 Remove the lifting tool 006 26 Install the pipes to the lubricating quills as follows 26 1 Remove t...

Page 193: ...X72DF AA00 2124 00AAA 720A A Maintenance Manual Cylinder liner install Page left intentionally blank Winterthur Gas Diesel Ltd 193 Issue 002 2020 10...

Page 194: ...n 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY N...

Page 195: ...prevent contamination 4 Remove two the bolts 004 5 Remove the lubricating quill 003 6 If necessary do a function check of the lubricating quills refer to 7 2 2 Lubricating quill do a functional test F...

Page 196: ...35 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Hydraulic tools can cause injury to personnel Always put on gloves a face shiel...

Page 197: ...pressure to 2 0 bar 8 Close the relief valve 005 9 Hold the lubricating quill 002 in a horizontal position so that it points away from your body 10 Operate the HP oil pump 006 to increase the pressure...

Page 198: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Oil A R Spar...

Page 199: ...the lubricating quill is defective you must replace all components of the lubricating quill Fig 7 15 Sealing surface 2 Apply oil to the threads of the screws 004 Figure 7 16 3 Attach the lubricating...

Page 200: ...example CLOSE UP Bleed the cylinder lubrication system refer to 12 1 2 Cylinder lubrication system bleed X72DF AA00 2138 00AAA 720A A Maintenance Manual Lubricating quill install Winterthur Gas Diesel...

Page 201: ...X72DF AA00 2138 00AAA 720A A Maintenance Manual Lubricating quill install Page left intentionally blank Winterthur Gas Diesel Ltd 201 Issue 002 2020 10...

Page 202: ...alization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Measuring tool N A 1 Pressure reducing valve 94214B 1 Supplies Description QTY Lubricating oil SAE 30 A R Spare Parts D...

Page 203: ...ng valve 94214B Fig 7 17 GAV do a check of the oil leakage flow 001 002 003 005 004 2 Do a check of the oil leakage flow as follows 2 1 Read the oil level on the scale of the measuring tool 003 2 2 St...

Page 204: ...r unwanted material or for damage 6 2 If necessary clean or replace the O rings 6 3 Check the spindle of the GAV for damage 6 4 If necessary replace the GAV 7 If the oil leakage flow is less than the...

Page 205: ...X72DF AA00 2140 00AAA 363A A Maintenance Manual Gas admission valve do a check of the oil leakage flow Page left intentionally blank Winterthur Gas Diesel Ltd 205 Issue 002 2020 10...

Page 206: ...TY None SAFETY PRECAUTIONS WARNING Danger If a gas detector alarm is activated keep away from the engine The natural gas is flammable There is a risk of fire or explosion WARNING Injury Hazard When yo...

Page 207: ...tool 006 together with the compensator 001 9 Make sure that the six O rings 008 on the flange couplings are serviceable If necessary replace the O rings 10 Remove the tool 006 from the compensator 00...

Page 208: ...AV 005 in the position shown 20 Attach an applicable lifting tool to the eye bolt 004 21 Remove the Allen screws 006 22 Move the GAV carefully to a clean dry area 23 Attach a flange or plug to the ope...

Page 209: ...X72DF AA00 2140 00AAA 520A A Maintenance Manual Gas admission valve remove Page left intentionally blank Winterthur Gas Diesel Ltd 209 Issue 002 2020 10...

Page 210: ...ment Description Part No CSN QTY Handle 94214A 1 Pressure reducing valve 94214B 1 Dismantling and assembling tool 94214C 1 Bracket 94214D 1 Bush 94214E 1 Supplies Description QTY Lubricating oil A R W...

Page 211: ...s from the valve seat No bubbles come from the gasket 010 9 If the test results are different than those given do the procedure given in Step 13 10 Stop the pressurized air supply 11 Remove the pressu...

Page 212: ...valve seat 13 6 Turn the handle clockwise and counterclockwise some times 13 7 Remove the handle 001 from the valve spindle 004 13 8 Remove the lapping paste from the valve seat Fig 7 21 Valve seat la...

Page 213: ...the dismantling and assembling tool and the bracket from the bush 007 15 Do the test procedure given in Step 3 to Step 11 again 16 If the leakage is unsatisfactory replace the valve spindle and valve...

Page 214: ...Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Disassembly assembly tool 94214 1 Pusher 94214D 1 Bush 94214E 1 Supplies Description QTY Molykote G Rapid Plus A...

Page 215: ...cotter 003 out of the spring carrier 014 11 Remove the valve cotter 003 12 Remove the pusher 010 13 Turn the valve spindle 004 14 To release the tension in the spring 005 turn back the rod 001 15 Rem...

Page 216: ...Fig 7 22 Valve spindle remove CLOSE UP None X72DF AA00 2140 00AAA 530A A Maintenance Manual Gas admission valve disassemble Winterthur Gas Diesel Ltd 216 Issue 002 2020 10...

Page 217: ...X72DF AA00 2140 00AAA 530A A Maintenance Manual Gas admission valve disassemble Page left intentionally blank Winterthur Gas Diesel Ltd 217 Issue 002 2020 10...

Page 218: ...the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spar...

Page 219: ...emove the GAV from the vice 3 Remove the pusher 003 Figure 7 23 4 Remove the plate 002 5 Remove the disassembly assembly tool 001 Fig 7 23 GAV assemble CLOSE UP None X72DF AA00 2140 00AAA 710A A Maint...

Page 220: ...man hours Support equipment Description Part No CSN QTY Disassembly assembly tool 94890 1 Eye bolt 94040 M8 1 Connection tool 94023A 1 Supplies Description QTY Never Seez High Temperature Stainless l...

Page 221: ...e grind the sealing faces 9 Adjust the claw 011 with an open ended wrench until there is a distance of 5 5 mm between the claw and the end of the pipe 001 10 Apply oil to the threads and surfaces that...

Page 222: ...sator 001 is sufficiently compressed for installation 21 Make sure that the O rings 008 are in their correct positions 22 Put the compensator 001 and tool 006 in position between the connecting block...

Page 223: ...Do a leakage check of the pipe 001 Figure 7 24 30 Do a pressure test of the opening pressure CLOSE UP None X72DF AA00 2140 00AAA 720A A Maintenance Manual Gas admission valve install Winterthur Gas D...

Page 224: ...er job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY Assembly tool 94233 1 Supplies Description QTY None S...

Page 225: ...he two parts of the housing 001 005 away from the piston rod 5 Remove the two parts of the housing 001 005 Fig 7 27 Piston rod gland remove and install 6 Remove the parts that follow Tension springs 0...

Page 226: ...Fig 7 28 Piston rod gland disassemble CLOSE UP None X72DF AA00 2303 00AAA 520A A Maintenance Manual Piston rod gland remove Winterthur Gas Diesel Ltd 226 Issue 002 2020 10...

Page 227: ...X72DF AA00 2303 00AAA 520A A Maintenance Manual Piston rod gland remove Page left intentionally blank Winterthur Gas Diesel Ltd 227 Issue 002 2020 10...

Page 228: ...l Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS No...

Page 229: ...d the O rings 008 are serviceable 3 If necessary replace the worn or the unserviceable parts Fig 7 29 Piston rod gland example Legend 001 4 part scraper ring 005 Spring 002 4 part gaskets 006 Ring sup...

Page 230: ...ription Part No CSN QTY Assembly tool 94233 1 2 part clamp ring 94231A 1 Distance piece 12 mm 94231B 1 Distance piece 11 mm 94231C 1 Distance piece 9 mm 94231D 1 Template 94231E 1 Supplies Description...

Page 231: ...PRELIMINARY OPERATIONS None X72DF AA00 2303 00AAA 720A A Maintenance Manual Piston rod gland install Winterthur Gas Diesel Ltd 231 Issue 002 2020 10...

Page 232: ...the four ring supports 010 are attached to the piston rod 9 Put the two parts of the distance piece 013 on the top ring support 010 10 Put the gasket 4 part and the gasket 4 part 007 on the distance...

Page 233: ...the two parts of the housing 001 and 005 Figure 7 31 over the assembled rings Make sure that the dowel pins 004 are correctly installed 24 Attach the bolts and nuts 003 006 to the housing 001 005 25 T...

Page 234: ...ool 94215 1 Pre tensioning jacks 94215A 10 Cylinder cover support 94266 1 Hydraulic unit 94942 1 Pressure gauge 94934A 1 HP hose 94935 1 Flexible hose 94935A 10 Lifting tool 94265 1 Supplies Descripti...

Page 235: ...ngine must be stopped and made safe for maintenance refer to section 4 1 Do maintenance work general procedure X72DF AA00 2708 00AAA 520A A Maintenance Manual Cylinder cover remove Winterthur Gas Dies...

Page 236: ...cover 9 Disconnect all other connections to the cylinder cover and to the exhaust valve 10 Operate the engine room crane to put the lifting tool 006 Figure 7 33 and the pre tensioners in position abov...

Page 237: ...oden support 004 21 Remove the screws 008 of the water guide jacket 22 Operate the engine room crane to lift the cylinder cover 003 23 Put the cylinder cover together with the exhaust valve on to a wo...

Page 238: ...wer the lifting tool 002 on to the elastic studs 001 31 Attach the lifting tool 002 to the elastic studs 001 with the round nuts 005 32 Operate the engine room crane to lift and move the cylinder cove...

Page 239: ...Fig 7 35 Cylinder cover and exhaust valve cage example CLOSE UP None X72DF AA00 2708 00AAA 520A A Maintenance Manual Cylinder cover remove Winterthur Gas Diesel Ltd 239 Issue 002 2020 10...

Page 240: ...scription Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Grinding device 94270 01 1 Stencil 94270 1D 1 Electric drill N A 1 Supplies Description QTY Emery cloth...

Page 241: ...y the two bolts 008 to 1 0 Nm Make sure that the grinding tool is in the center of the bore 007 10 Torque equally the two bolts 008 to 6 0 Nm 11 Attach an electric drill to the spindle 010 12 Operate...

Page 242: ...36 Fuel injection valve position grind CLOSE UP None X72DF AA00 2708 00AAA 655A A Maintenance Manual Cylinder cover grind the sealing face for injection valve Winterthur Gas Diesel Ltd 242 Issue 002 2...

Page 243: ...X72DF AA00 2708 00AAA 655A A Maintenance Manual Cylinder cover grind the sealing face for injection valve Page left intentionally blank Winterthur Gas Diesel Ltd 243 Issue 002 2020 10...

Page 244: ...iption Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Grinding device 94270 02 1 Stencil 94270 2D 1 Stud bolts 94270 F 2 Supplies Description QTY Emery cloth A R...

Page 245: ...e Allen screw 006 to 8 0 Nm 10 Attach the grinding device 002 to the cylinder cover 011 with the two stud bolts 001 11 Attach an electric drill to the spindle 010 12 Operate the electric drill at a ma...

Page 246: ...lot injection valve 011 001 002 003 004 005 006 007 008 009 010 CLOSE UP None X72DF AA00 2708 00AAA 655B A Maintenance Manual Cylinder cover grind the sealing face for pilot injection valve Winterthur...

Page 247: ...X72DF AA00 2708 00AAA 655B A Maintenance Manual Cylinder cover grind the sealing face for pilot injection valve Page left intentionally blank Winterthur Gas Diesel Ltd 247 Issue 002 2020 10...

Page 248: ...ription Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Grinding device 94270 03 1 Stencil 94270 3D 1 Supplies Description QTY Emery cloth A R Spare Parts Descrip...

Page 249: ...e two bolts 002 9 Attach an electric drill to the spindle 010 10 Operate the electric drill at a maximum speed of 500 rpm 11 Apply a light pressure and start grinding 12 Regularly remove the unwanted...

Page 250: ...CLOSE UP None X72DF AA00 2708 00AAA 655C A Maintenance Manual Cylinder cover grind the sealing face for prechamber Winterthur Gas Diesel Ltd 250 Issue 002 2020 10...

Page 251: ...X72DF AA00 2708 00AAA 655C A Maintenance Manual Cylinder cover grind the sealing face for prechamber Page left intentionally blank Winterthur Gas Diesel Ltd 251 Issue 002 2020 10...

Page 252: ...scription Part No CSN QTY Lifting tool 94215 1 Pre tensioner 94215A 10 Cylinder cover support 94266 1 Hydraulic unit 94942 1 Pressure gauge 94934A 1 HP hose 94935 1 Flexible hose 94935A 10 Lifting too...

Page 253: ...he round nuts 006 to the elastic studs 003 9 Tighten the round nuts 006 refer to section 4 2 Tighten a round nut with a pre tensioner 10 Operate the engine room crane to lift the cylinder cover 004 to...

Page 254: ...er with the exhaust valve and top water guide jacket on to the bottom water guide jacket 15 Remove the engine room crane from the eye bolt from the exhaust valve X72DF AA00 2708 00AAA 720A A Maintenan...

Page 255: ...nut with a pre tensioner 24 Remove the pre tensioners 001 25 Operate the engine room crane to remove the lifting tool 006 Fig 7 40 Lifting tool pre tensioner example 26 Attach the cooling water pipe 2...

Page 256: ...CLOSE UP None X72DF AA00 2708 00AAA 720A A Maintenance Manual Cylinder cover install Winterthur Gas Diesel Ltd 256 Issue 002 2020 10...

Page 257: ...X72DF AA00 2708 00AAA 720A A Maintenance Manual Cylinder cover install Page left intentionally blank Winterthur Gas Diesel Ltd 257 Issue 002 2020 10...

Page 258: ...2 Stud bolt 94270D 2 Brass wire brush N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Danger of injury to personnel Use applicable equipment...

Page 259: ...articles from the external parts of the nozzle 7 If necessary attach protection to the nozzle tip 8 If it is not necessary to disassemble the injection valve carefully clean it and put it in its corre...

Page 260: ...QTY Test fluid ISO 4113 A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Do not put your fingers near the holes in the nozzle tip High pressure fluid can go th...

Page 261: ...ve 004 to the valve holder 005 1 7 Attach the adapter 006 to the injection valve 004 1 8 Connect the HP hose 008 of the test bench to the adapter 006 1 9 Connect the cable 007 to the test bench 1 10 A...

Page 262: ...injection takes place 7 Do a check of the seating surface between the needle seat and the nozzle as follows 7 1 Set the pressure of the test fluid to 400 bar 7 2 Make sure that for 30 seconds there i...

Page 263: ...X72DF AA00 2722 00AAA 340A A Maintenance Manual Direct controlled injection valve do a functional test Page left intentionally blank Winterthur Gas Diesel Ltd 263 Issue 002 2020 10...

Page 264: ...Part No CSN QTY Torque spanner 94011A 1 Wrench extension 94022D 55 1 Wrench extension 94022D 70 1 Injector test bench 94272 1 Nozzle removal tool 94278A 1 Slugging wrench 94269A 70 1 Supplies Descript...

Page 265: ...ed locknut 8 2 Make sure that the needle the compression spring and the tappet are removed from the coupling nut 002 Figure 7 44 NOTE It is possible but not recommended to replace the nozzle tip with...

Page 266: ...ecessary to remove the pilot valve do as follows 12 1 Turn the valve holder 003 through 90 so that the injection valve is in the horizontal position This prevents the pin to fall out from the pilot va...

Page 267: ...X72DF AA00 2722 00AAA 530A A Maintenance Manual Direct controlled injection valve disassemble Page left intentionally blank Winterthur Gas Diesel Ltd 267 Issue 002 2020 10...

Page 268: ...escription Part No CSN QTY Torque spanner 94011A 1 Wrench extension 94022D 55 1 Wrench extension 94022D 70 1 Supplies Description QTY Never Seez NSBT A R Kerosene A R Diesel oil A R Spare Parts Descri...

Page 269: ...he nozzle tip and tighten it with your hand 3 Put the complete nozzle body in position of the injection valve 4 Apply a thin layer of Never Seez NSBT to the thread and seating face of the coupling nut...

Page 270: ...c AR Support equipment Description Part No CSN QTY Stud bolt 94270D 2 Supplies Description QTY White spirit A R Never Seez NSBT A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUT...

Page 271: ...into the valve bush 005 7 Turn the nuts of the stud bolts equally to insert the injection valve into the valve bush 005 8 Remove the stud bolts 9 If the spring cage 002 was disassembled make sure that...

Page 272: ...ents after job completion 0 0 man hours Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINAR...

Page 273: ...3 2 way solenoid valve 002 Figure 7 47 3 Remove the screws from the 3 2 way solenoid valve 002 4 Remove the 3 2 way solenoid valve 002 Fig 7 47 Starting air valve example CLOSE UP None X72DF AA00 272...

Page 274: ...job completion 0 0 man hours Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATION...

Page 275: ...e electrical connection from the 3 2 way solenoid valve 002 Figure 7 49 4 Remove the screws 003 5 Carefully remove the starting air valve from the cylinder cover 004 6 Remove and discard the gasket 00...

Page 276: ...Fig 7 49 Starting air valve remove CLOSE UP None X72DF AA00 2728 00AAA 520A A Maintenance Manual Starting air valve remove Winterthur Gas Diesel Ltd 276 Issue 002 2020 10...

Page 277: ...X72DF AA00 2728 00AAA 520A A Maintenance Manual Starting air valve remove Page left intentionally blank Winterthur Gas Diesel Ltd 277 Issue 002 2020 10...

Page 278: ...0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QT...

Page 279: ...ve 002 4 Remove the hexagon nut 011 5 Remove the piston 010 from the valve spindle 007 6 Remove the compression spring 009 from the housing 004 7 Remove the valve spindle 007 from the housing 004 8 Re...

Page 280: ...the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spar...

Page 281: ...valve spindle 002 have more than minimum damage do as follows 2 1 Use an applicable machine tool to grind the seating faces of the housing 001 and of the valve spindle 002 2 2 Use an applicable tool t...

Page 282: ...uirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Oil A R Spare Par...

Page 283: ...4 7 Put the piston 010 in position on the valve spindle 007 8 Attach the hexagon nut 011 to the valve spindle 007 9 Torque the hexagon nut 011 to the value given in section 16 1 Tightening instruction...

Page 284: ...nts after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Oil A R Spare Parts Des...

Page 285: ...he cylinder cover 004 with the bolts 003 Make sure that the pipe 005 goes into the bore of the cylinder cover correctly 4 Torque symmetrically the bolts 003 5 Connect the electrical connection to the...

Page 286: ...equirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Part...

Page 287: ...the screws of the 3 2 way solenoid valve 002 3 Connect the electrical connection to the 3 2 way solenoid valve 002 Fig 7 54 Starting air valve example CLOSE UP None X72DF AA00 2728 00AAB 720A A Maint...

Page 288: ...scription Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None...

Page 289: ...Fig 7 55 Relief valve combustion chamber 005 001 003 002 004 6 If necessary remove the sensor 004 6 1 Remove the holder 005 and the sensor 004 from the tip of the relief valve 6 2 Remove the holder 0...

Page 290: ...tion QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Never Seez NSBT A R Spare Parts Description Part No CSN QTY Relief valve combustion chamber 1...

Page 291: ...rings in the grooves of the relief valve 4 Apply a thin layer of Never Seez to the contact surface of the relief valve 5 Turn the spindle nut 001 to the upper position to get the open position 6 Put t...

Page 292: ...crew Intermediate AR Support equipment Description Part No CSN QTY Sling 94049A 2 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION To prevent injur...

Page 293: ...06 in position around the expansion piece 004 as shown 2 2 Attach the two slings 006 to the engine room crane 2 3 Operate the engine room crane to put a light tension on the slings 006 2 4 Remove the...

Page 294: ...011 from the valve cage and valve seat Fig 7 58 Exhaust valve removal 007 008 009 011 010 00718 003 004 005 001 006 002 X72DF AA00 2751 00AAA 520A A Maintenance Manual Exhaust valve remove Winterthur...

Page 295: ...CLOSE UP None X72DF AA00 2751 00AAA 520A A Maintenance Manual Exhaust valve remove Winterthur Gas Diesel Ltd 295 Issue 002 2020 10...

Page 296: ...CSN QTY Jack screws 94263 2 Depth gauge 94126 1 Eye bolts 94045 M12 2 Eye bolts 94045 M24 2 Chain 94019B 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS...

Page 297: ...chain 1 12 Operate the engine room crane to remove the bottom housing 004 2 Remove the valve spindle 2 1 Remove the circlip 013 2 2 Push the piston 011 down then remove the valve cotters 012 2 3 Remov...

Page 298: ...8 into the two threads of the guide bush flange 003 3 5 Turn equally the two jack screws 008 to push up the guide bush 007 3 6 Remove the guide bush 007 3 7 Measure the inner diameter of the guide bus...

Page 299: ...Fig 7 60 Guide bush removal CLOSE UP None X72DF AA00 2751 00AAA 530A A Maintenance Manual Exhaust valve disassemble Winterthur Gas Diesel Ltd 299 Issue 002 2020 10...

Page 300: ...rew Basic AR Support equipment Description Part No CSN QTY Assembly tool TN 94114 1 Valve seat dismantling device TN 94115 1 Wooden support N A 1 Supplies Description QTY None Spare Parts Description...

Page 301: ...ts 003 of the valve seat dismantling device 004 8 2 Put the two halves in the correct position 8 3 Tighten the two bolts 003 9 Tighten equally the four lifting screws 001 a few turns to lift the valve...

Page 302: ...CLOSE UP None X72DF AA00 2751 01AAA 520C A Maintenance Manual Exhaust valve remove the seat with new tool Winterthur Gas Diesel Ltd 302 Issue 002 2020 10...

Page 303: ...X72DF AA00 2751 01AAA 520C A Maintenance Manual Exhaust valve remove the seat with new tool Page left intentionally blank Winterthur Gas Diesel Ltd 303 Issue 002 2020 10...

Page 304: ...ion QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Eye bolt 94045 M16 1 Hammer N A 1 Feeler gauge 94122 1 Wooden block N A 1 Rope N A 1 Supplies Description QTY Engineer s blue...

Page 305: ...uge to do a check of the clearance X between the sealing faces of the valve spindle 004 and valve seat 005 refer to Table 7 2 Exhaust valve clearance X Tab 7 2 Exhaust valve clearance X Engine type Cl...

Page 306: ...clearance I 00725 Engineer s blue paste mark I X 001 004 002 004 005 003 CLOSE UP None X72DF AA00 2751 01AAA 360A A Maintenance Manual Exhaust valve do a check of the seat Winterthur Gas Diesel Ltd 30...

Page 307: ...X72DF AA00 2751 01AAA 360A A Maintenance Manual Exhaust valve do a check of the seat Page left intentionally blank Winterthur Gas Diesel Ltd 307 Issue 002 2020 10...

Page 308: ...n 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Grinding tool 94291 1 Gauge 94279 1 Feeler gauge 94122 1 Supplies Descriptio...

Page 309: ...he gauge 002 shows the maximum permitted limits for the valve seat 001 5 If the values are less than the limits given do as follows 5 1 Operate the grinding tool 003 to grind the sealing face of the v...

Page 310: ...crew Basic AR Support equipment Description Part No CSN QTY Assembly tool TN 94114 1 Hydraulic cylinder 700 bar TN 94082 1 Wooden support N A 1 Supplies Description QTY None Spare Parts Description P...

Page 311: ...ate the engine room crane to lift the valve cage 005 some millimeter above the valve seat 003 10 Install the applicable hydraulic cylinder 007 to the spindle of the assembly tool 004 11 Connect the hy...

Page 312: ...7 64 Valve seat install 003 001 002 004 005 007 CLOSE UP None X72DF AA00 2751 01AAA 720C A Maintenance Manual Exhaust valve install the seat with new tool Winterthur Gas Diesel Ltd 312 Issue 002 2020...

Page 313: ...X72DF AA00 2751 01AAA 720C A Maintenance Manual Exhaust valve install the seat with new tool Page left intentionally blank Winterthur Gas Diesel Ltd 313 Issue 002 2020 10...

Page 314: ...t equipment Description Part No CSN QTY Jack screws 94263 2 Depth gauge 94126 1 Eye bolts 94045 M12 2 Eye bolts 94045 M24 2 Chain 94019B 1 Feeler gauge 94122 1 Supplies Description QTY Oil AR System o...

Page 315: ...e 002 1 9 Put oil on the rod joint ring 007 1 10 Put the rod joint ring 007 in position Fig 7 65 Guide bush installation 2 Install the valve spindle 2 1 Measure the dimensions of the valve spindle 015...

Page 316: ...r installation as follows 3 3 1 Put sufficient water in an applicable container 3 3 2 Apply heat to get the water to 100 C 3 3 3 Put the new piston joint ring in the 100 C water for some minutes until...

Page 317: ...ores 009 in the damper 002 are clear 4 3 Make sure that the exhaust valve is closed 4 4 Use the feeler gauge to make sure there is no clearance between the valve plate and valve seat 4 5 Use the depth...

Page 318: ...X40 B X40DF 90 4 X52 X52DF 140 0 X62 X62 B X62DF 143 7 X72 X72 B X72DF 165 2 X82 X82 B X82DF 175 0 X92 X92 B X92DF 228 7 5 Install the valve stroke sensor 5 1 Clean the parts that follow X72DF AA00 2...

Page 319: ...ug 009 6 2 Remove the throttle 008 6 3 Make sure that the throttle 008 is clean 6 4 Put oil on the threads of the throttle 008 6 5 Put the throttle 008 in the housing 6 6 Torque the throttle 008 to 20...

Page 320: ...CLOSE UP Install the exhaust valve refer to section 7 9 8 Exhaust valve install X72DF AA00 2751 00AAA 710A A Maintenance Manual Exhaust valve assemble Winterthur Gas Diesel Ltd 320 Issue 002 2020 10...

Page 321: ...X72DF AA00 2751 00AAA 710A A Maintenance Manual Exhaust valve assemble Page left intentionally blank Winterthur Gas Diesel Ltd 321 Issue 002 2020 10...

Page 322: ...letion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Slings 94049A 2 Supplies Description QTY Oil A R Heat resistant lubrica...

Page 323: ...of oil to the new O rings 002 003 10 Attach the engine room crane 005 Figure 7 70 to the eye bolt 006 11 Operate the engine room crane to lift and move the exhaust valve 007 12 Put the exhaust valve 0...

Page 324: ...the expansion piece 004 to the valve cage 006 and the exhaust pipe 002 with the screws 001 005 and the nuts 003 21 Remove the two slings 007 Fig 7 70 Expansion piece installation 22 Complete the insta...

Page 325: ...71 Exhaust valve complete the installation 001 003 004 005 006 00719 002 CLOSE UP None X72DF AA00 2751 00AAA 720A A Maintenance Manual Exhaust valve install Winterthur Gas Diesel Ltd 325 Issue 002 20...

Page 326: ...ion Part No CSN QTY Plate 94270E 1 Stud bolt 94270F 2 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Danger Do not weld or grind materials in the...

Page 327: ...ve the flange 007 Fig 7 72 Pilot injection valve 7 Put the plate 002 Figure 7 73 on the pilot injection valve 004 as shown 8 Put the stud bolts 001 in the plate 002 9 Turn equally the stud bolts 001 u...

Page 328: ...Fig 7 73 Pilot injection valve remove CLOSE UP None X72DF AA00 2790 00AAA 520A A Maintenance Manual Pilot injection valve remove Winterthur Gas Diesel Ltd 328 Issue 002 2020 10...

Page 329: ...X72DF AA00 2790 00AAA 520A A Maintenance Manual Pilot injection valve remove Page left intentionally blank Winterthur Gas Diesel Ltd 329 Issue 002 2020 10...

Page 330: ...rs Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Test bench N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY No...

Page 331: ...on valve 6 Carefully remove the nozzle nut NOTE If necessary you can use an applicable tool to remove the nozzle nut 7 Remove and discard the two O rings from the inner side of the nozzle nut 8 Carefu...

Page 332: ...e crew Basic AR Support equipment Description Part No CSN QTY Test bench N A 1 Injection module N A 1 O ring N A 2 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRE...

Page 333: ...le onto the distributor piece NOTE Make sure that you not cause damage to the cables 7 Apply a thin layer of oil to the new O rings 8 Put the new O rings in the related grooves of the nozzle nut 9 Cle...

Page 334: ...76 Pilot fuel valve install the nozzle nut CLOSE UP None X72DF AA00 2790 00AAC 720A A Maintenance Manual Pilot injection valve install the injection module Winterthur Gas Diesel Ltd 334 Issue 002 202...

Page 335: ...X72DF AA00 2790 00AAC 720A A Maintenance Manual Pilot injection valve install the injection module Page left intentionally blank Winterthur Gas Diesel Ltd 335 Issue 002 2020 10...

Page 336: ...not put your fingers near the nozzle tip Fuel can go through your skin and cause injury or kill You WARNING Injury Hazard Test fluid is dangerous Always read the manufacturer s safety instructions bef...

Page 337: ...ed refer to section 7 10 1 Pilot injection valve remove You must read the instructions of the test bench manufacturer X72DF AA00 2790 00AAA 362A A Maintenance Manual Pilot injection valve do a functio...

Page 338: ...ates correctly 11 Do a check of the seating surface between the needle seat and the nozzle as follows 11 1 Keep the pressure of the test bench constant at approximately 350 bar 11 2 Monitor the pilot...

Page 339: ...Fig 7 77 Pilot injection valve checks CLOSE UP None X72DF AA00 2790 00AAA 362A A Maintenance Manual Pilot injection valve do a functional test Winterthur Gas Diesel Ltd 339 Issue 002 2020 10...

Page 340: ...rs Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Eye bolts N A 2 Supplies Description QTY None Spare Parts Description Part No CSN QTY Non...

Page 341: ...ber 007 from the cylinder cover 005 7 Remove the two screws 002 and the pre chamber 007 8 Remove and discard the O ring 006 and the seal 008 9 Do a check of the sealing surfaces of the pre chamber and...

Page 342: ...ion Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Eye bolts N A 2 Pre chamber A R 1 Seal N A 1 O ring N A 1 Supplies Description QTY None Spare Parts Descriptio...

Page 343: ...crews 003 7 Torque the two screws 003 8 Carefully put the holder 004 together with the pre chamber into the cylinder cover 005 9 Apply Never Seez NSBT to the screws 001 10 Torque crosswise the screws...

Page 344: ...Y Assembly tool 94289E 1 Stud bolts 94270F 2 Supplies Description QTY White spirit A R Never Seez NSBT A R Spare Parts Description Part No CSN QTY Pilot injection valve 1 Seal 1 O rings 4 SAFETY PRECA...

Page 345: ...UTION Injury Hazard Always put on gloves and safety goggles that have a closed side frame when you do work with white spirit White spirit can cause damage to your skin and eyes 6 Clean the pilot injec...

Page 346: ...he two Allen screws 007 14 Torque the two Allen screws 007 to the correct value refer to section 16 1 Tightening instructions Fig 7 81 Pilot injection valve install 15 Install the applicable HP pilot...

Page 347: ...Fig 7 82 Pilot injection valve CLOSE UP None X72DF AA00 2790 00AAA 720A A Maintenance Manual Pilot injection valve install Winterthur Gas Diesel Ltd 347 Issue 002 2020 10...

Page 348: ...X72DF AA00 2790 00AAA 720A A Maintenance Manual Pilot injection valve install Page left intentionally blank Winterthur Gas Diesel Ltd 348 Issue 002 2020 10...

Page 349: ...rod remove the top end bearing 398 8 5 5 Connecting rod remove the bottom end bearing 400 8 5 6 Connecting rod examine the bearing shells 408 8 5 7 Connecting rod install the bottom end bearing 410 8...

Page 350: ...upport equipment Description Part No CSN QTY Dial gauge 94305 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Before you operate t...

Page 351: ...a that follow Load of the engine Temperature of the engine Temperature of the seawater Temperature of the HT water Temperature of the system oil Draught of the vessel fore side and aft side 4 Measure...

Page 352: ...time to release pressure between pinion and flywheel 4 8 At each position record the indication on the dial gauge For the last position make sure that the connecting rod 003 does not touch the dial ga...

Page 353: ...nk and the bedplate for unwanted material Visually do a check of the edge for unusual colors 5 Do Step 4 again for the other cranks 6 For each crank calculate the vertical deviation dvert as follows 6...

Page 354: ...0 0 56 0 18 X72 X72 B X72DF 0 82 0 58 0 58 0 58 0 27 0 82 0 58 0 58 0 82 0 27 X82 X82 B X82DF 0 90 0 64 0 64 0 64 0 29 0 90 0 64 0 64 0 90 0 29 X92 X92 B X92DF 1 08 0 76 0 76 0 76 0 35 1 08 0 76 0 76...

Page 355: ...ese 9 If a minimum of one calculated value is more than the given limits speak to WinGD for the related procedures CLOSE UP None X72DF AA00 3103 00AAA 360A A Maintenance Manual Crankshaft do a check o...

Page 356: ...No CSN QTY Platform 94143 1 Adjustable platform 94142 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Do not operate the engine or the turning g...

Page 357: ...the adjustable platform 001 to the applicable position between the columns 005 3 Obey the maximum load of the platforms on the related nameplate Fig 8 5 Platforms CLOSE UP None X72DF AA00 3103 00AAA...

Page 358: ...ialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Platform 94143 1 Adjustable platform 94142 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY Non...

Page 359: ...columns 005 2 Remove the platform 004 from the crankshaft 002 and the longitudinal beam 003 Fig 8 6 Platforms CLOSE UP None X72DF AA00 3103 00AAA 520A A Maintenance Manual Crankshaft remove the work p...

Page 360: ...ation QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Related to manufacturer N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS...

Page 361: ...the torsional vibration damper related to the manufacturer s instructions CLOSE UP None X72DF AA00 3130 00AAA 310A A Maintenance Manual Torsional vibration damper examine Winterthur Gas Diesel Ltd 36...

Page 362: ...CSN QTY Spur geared chain block 94016 2 5 5 5 1 Eye bolts 94045 M30 2 Chain 94325 1 Shackles 94019P 2 Sling 94038 011 2 Link 94321P 1 Supplies Description QTY None Spare Parts Description Part No CSN...

Page 363: ...ousing 004 Fig 8 7 Axial vibration damper housing and pipes 2 Remove the four bolts 001 Figure 8 8 and the six bolts 002 from the top cylinder half 3 Examine the 2 part gaskets 003 004 for damage and...

Page 364: ...and the link 003 9 Operate the chain block 004 to carefully lift the top cylinder half 007 10 Attach the engine room crane 008 to the chain 005 11 Operate the engine room crane 008 to hold the weight...

Page 365: ...Fig 8 9 Axial vibration damper move CLOSE UP None X72DF AA00 3140 00AAA 530A A Maintenance Manual Axial vibration damper disassemble Winterthur Gas Diesel Ltd 365 Issue 002 2020 10...

Page 366: ...chain block 94016 2 5 5 5 1 Eye bolt 94045 M30 2 Chain 94325 1 Shackle 94019P 2 Sling 94038 011 2 Link 94321P 1 Supplies Description QTY Oil A R Molykote paste G A R Spare Parts Description Part No CS...

Page 367: ...ch the engine room crane 010 to the chain 007 10 Operate the engine room crane 007 to lift and move the top cylinder half 009 into position above the bottom cylinder half 11 Attach the chain block 006...

Page 368: ...Molykote paste G n to the threads of the bolts 002 Figure 8 11 16 Put the bolts 002 in position in the top cylinder half X72DF AA00 3140 00AAA 710A A Maintenance Manual Axial vibration damper assemble...

Page 369: ...the top cylinder half 19 Torque the bolts 001 Fig 8 11 Axial vibration damper bolts 20 Install the pipes 002 Figure 8 12 21 Install the oil supply pipe 003 22 Connect the two cables 001 23 Install the...

Page 370: ...Fig 8 12 Axial vibration damper housing and pipes CLOSE UP None X72DF AA00 3140 00AAA 710A A Maintenance Manual Axial vibration damper assemble Winterthur Gas Diesel Ltd 370 Issue 002 2020 10...

Page 371: ...X72DF AA00 3140 00AAA 710A A Maintenance Manual Axial vibration damper assemble Page left intentionally blank Winterthur Gas Diesel Ltd 371 Issue 002 2020 10...

Page 372: ...completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Oil A R Spare Parts Description Part...

Page 373: ...002 3 Apply oil to the threads of the bolts 002 4 Tighten the round nuts 001 related to the data given in Figure 8 13 refer to section 4 2 Tighten a round nut with a pre tensioner Fig 8 13 Turning gea...

Page 374: ...ption Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Pyroshield A R Kl berfluid A R Spare Parts Description Part No CSN QTY None SAF...

Page 375: ...inimum of lubricant remaining or are dry continue the procedure 4 If you use Kl berfluid as lubricant prepare the lubricant as follows 4 1 Put an applicable quantity of Kl berfluid into a container 4...

Page 376: ...ecommended suppliers Lubrication Engineers Inc Kl ber Lubrication M nchen KG 300 Bailey Avenue Geisenhausenerstrasse 7 Forth Worth 81379 M nchen Texas 76107 Germany USA http www klueber com http www l...

Page 377: ...X72DF AA00 3206 00AAA 240A A Maintenance Manual Turning gear lubricate the teeth Page left intentionally blank Winterthur Gas Diesel Ltd 377 Issue 002 2020 10...

Page 378: ...CSN QTY Shackles 94018A 4 Lever chain hoists 94016 1 2 5 2 Connecting rod tool 94334 1 Stop plate 94335 1 Eye bolt 94045 M30 1 Supplies Description QTY Molyslip copaslip A R Spare Parts Description Pa...

Page 379: ...ual ratchets 004 to lift the tool 009 into position on the rods 006 7 Tighten the nuts and bolts 008 8 Torque the rods 006 to the correct value refer to section 16 1 Tightening instructions Fig 8 17 C...

Page 380: ...ool 009 14 Remove the toggle lever 001 from the crosshead 15 Put protection on the toggle lever 001 and the crosshead to prevent contamination and damage CLOSE UP None X72DF AA00 3303 00AAA 523A A Mai...

Page 381: ...X72DF AA00 3303 00AAA 523A A Maintenance Manual Connecting rod prepare before removal Page left intentionally blank Winterthur Gas Diesel Ltd 381 Issue 002 2020 10...

Page 382: ...hackle 94018C 1 Spur geared chain block 94017 2 4 3 4 Shackles 94018E 4 Chain symmetrical 94019A 1 Tool connecting rod assembly 94334A 1 Chain asymmetrical 94019B 1 Supplies Description QTY Copper pas...

Page 383: ...e connecting rod must be prepared for removal refer to section 8 5 1 Connecting rod prepare before removal X72DF AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winterthur Gas Diesel L...

Page 384: ...chain hoists 001 003 8 Operate the turning gear and the chain block 004 to move the connecting rod 002 counterclockwise to the position shown in view B 9 Continue to operate the turning gear and the...

Page 385: ...d move 15 NOTE During this step operate the chain block 002 Figure 8 20 to get the connecting rod to 45 X72DF AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winterthur Gas Diesel Ltd...

Page 386: ...18 Attach the chain block 007 to the lifting tool 004 and tighten lightly the chain view B 19 Remove the connecting rod tool 006 20 Remove the lever chain hoist 003 21 Operate the chain blocks 002 007...

Page 387: ...cessary to move the connecting rod away from the area do Step 23 1 to Step 23 14 23 1 Read the applicable safety precautions X72DF AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winte...

Page 388: ...B 23 9 Operate carefully the chain blocks 002 006 007 008 to move the connecting rod 23 10 Attach and remove the chain blocks 002 006 007 008 and shackles 005 009 as given in Step 23 9 to continue to...

Page 389: ...Fig 8 21 Connecting rod move 2 X72DF AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winterthur Gas Diesel Ltd 389 Issue 002 2020 10...

Page 390: ...CLOSE UP None X72DF AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winterthur Gas Diesel Ltd 390 Issue 002 2020 10...

Page 391: ...X72DF AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Page left intentionally blank Winterthur Gas Diesel Ltd 391 Issue 002 2020 10...

Page 392: ...Y Platform 94143 1 Deviation pipe 94117B 1 Holder 94333 2 Eye bolt 94045 M36 2 Chain 94325 1 Shackle 94019P 2 Spur geared chain block 94017 6 5 2 Spur geared chain block 94017 1 5 4 2 Shackle 94019L 1...

Page 393: ...stopped and made safe for maintenance refer to section 4 1 Do maintenance work general procedure X72DF AA00 3303 01AAA 520A A Maintenance Manual Connecting rod remove the top end bearing cover Winter...

Page 394: ...he piston rod foot 005 with the four bolts 004 1 6 Torque the four bolts 004 to the correct value refer to section 16 1 Tightening instructions 1 7 Tighten the two bolts 002 1 8 Operate the turning ge...

Page 395: ...he beam 11 Attach spur geard chain block 011 to the sling 010 12 Operate the chain blocks 007 009 to move the bearing cover 003 to a position near the column door Make sure that the chain of the chain...

Page 396: ...emoval 001 002 003 004 005 006 007 008 001 003 009 006 010 009 003 001 011 012 00740 X72DF AA00 3303 01AAA 520A A Maintenance Manual Connecting rod remove the top end bearing cover Winterthur Gas Dies...

Page 397: ...CLOSE UP None X72DF AA00 3303 01AAA 520A A Maintenance Manual Connecting rod remove the top end bearing cover Winterthur Gas Diesel Ltd 397 Issue 002 2020 10...

Page 398: ...pment Description Part No CSN QTY Spur geared chain block 94017 2 5 5 4 1 Lever chain hoist 94016 3 2 5 5 2 Chain 94325 1 Brackets 94326A 2 Deviation pipe 94117B 1 Sling 94039 015 1 Supplies Descripti...

Page 399: ...ach the sling 006 to the gallery 9 Attach the spur geared chain block 005 to the sling 006 and to the chain 010 10 Remove the screws 009 11 Operate the lever chain hoist 007 and the chain block 005 to...

Page 400: ...6 5 1 Lever chain hoist 94016 3 2 5 5 1 Lever chain hoists 94016 2 5 5 5 2 Eye bolt 94045 M24 4 Eye bolt 94045 M10 1 Shackles 94019K 2 Shackles 94019L 4 Shackles 94019P 2 Sling 94038 015 1 Deviation p...

Page 401: ...nd bearing must be removed refer to section 8 5 4 Connecting rod remove the top end bearing X72DF AA00 3303 03AAA 520A A Maintenance Manual Connecting rod remove the bottom end bearing Winterthur Gas...

Page 402: ...a round nut with a pre tensioner 1 9 Operate the lever chain hoists 002 008 to lower the bearing cover 004 1 10 Do an inspection of the bearing shell 005 1 11 If the bearing shell 005 is in good cond...

Page 403: ...005 to the chain 010 2 5 Operate the chain block to lift the bearing shell 009 out of the bearing cover 004 2 6 Lower the bearing cover on to an applicable surface Fig 8 27 Bottom end bearing shell r...

Page 404: ...ng gear to move the crank 002 to the fuel side At the same time operate the lever chain hoist 004 to keep tension on the chain NOTE Make sure that there is no load on the corners X of bearing shell 00...

Page 405: ...o screws 007 3 18 Operate the lever chain hoists 002 to lower the console frame 004 together with the bearing shell 008 3 19 Attach the chain block 010 to the eyelet on the console frame 004 3 20 Oper...

Page 406: ...ll remove 005 001 002 003 003 004 004 006 009 004 008 010 011 002 005 007 008 00768 X72DF AA00 3303 03AAA 520A A Maintenance Manual Connecting rod remove the bottom end bearing Winterthur Gas Diesel L...

Page 407: ...CLOSE UP None X72DF AA00 3303 03AAA 520A A Maintenance Manual Connecting rod remove the bottom end bearing Winterthur Gas Diesel Ltd 407 Issue 002 2020 10...

Page 408: ...0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY Non...

Page 409: ...2 If you find damage remove the bearing shell 001 refer to section 8 5 2 Connecting rod remove Fig 8 31 Visual examination CLOSE UP None X72DF AA00 3303 05AAA 310A A Maintenance Manual Connecting rod...

Page 410: ...block 94017 2 5 6 5 1 Lever chain hoist 94016 3 2 5 5 1 Lever chain hoists 94016 2 5 5 5 2 Eye bolt 94045 M24 4 Eye bolt 94045 M10 1 Shackle 94019K 1 Shackle 94019L 4 Shackle 94019P 2 Sling 94038 015...

Page 411: ...you operate the turning gear make sure that no personnel are near the flywheel PRELIMINARY OPERATIONS None X72DF AA00 3303 03AAA 720A A Maintenance Manual Connecting rod install the bottom end bearing...

Page 412: ...ole frame 004 7 Remove the chain block 010 8 Put oil on the surface of the bearing shell 008 9 Operate the lever chain hoists 002 move the console frame 004 and bearing shell 008 into position NOTE Ma...

Page 413: ...he turning gear to move the crank 002 Figure 8 33 to the position shown 15 Make sure that there is no load on the points X between the connecting rod 003 and the crank pin 002 X72DF AA00 3303 03AAA 72...

Page 414: ...7 Loosen the screws 003 Figure 8 34 18 Remove the four bolts 004 19 Remove the two supports 002 and or 005 20 Remove the lever chain hoist from the connecting rod X72DF AA00 3303 03AAA 720A A Maintena...

Page 415: ...four eye bolts 003 30 Attach the chain block 008 to eye bolt on the bearing cover 004 31 Operate the chain block 005 to lift the bearing cover 004 32 Attach the lever chain hoist 007 to the bearing c...

Page 416: ...e the distance X1 X2 between the edges of the bearing shells 002 003 and the bearing cover 004 41 For new bearing shells the dimensions X1 plus X2 must be between 1 18 mm and 1 34mm 42 Tighten the rou...

Page 417: ...bearing install 006 007 004 008 009 001 002 003 004 005 002 X X 2 1 010 00773 X72DF AA00 3303 03AAA 720A A Maintenance Manual Connecting rod install the bottom end bearing Winterthur Gas Diesel Ltd 41...

Page 418: ...0 1000 43 1 0 937 Exxon Esso Cylesso 1000 950 44 0 Exxon Esso Cylesso TK1000 925 46 7 Mobil Extra Hecla super cylin der oil 680 39 0 0 905 Shell Fiona oil 1500 1500 37 0 0 958 Shell Valvata oil 1000 1...

Page 419: ...X72DF AA00 3303 03AAA 720A A Maintenance Manual Connecting rod install the bottom end bearing Page left intentionally blank Winterthur Gas Diesel Ltd 419 Issue 002 2020 10...

Page 420: ...5 4 1 Lever chain hoist 94016 3 2 5 5 2 Chain 94325 1 Bracket 94326A 2 Deviation pipe 94117B 1 Sling 94039 015 1 Platform 94143 1 Flange 94336 1 Lever chain hoist 94016 3 2 5 5 2 Supplies Description...

Page 421: ...eating surface of the connecting rod and make sure that there is no damage 4 Make sure that the surface of crosshead pin is in a satisfactory condition 5 Install the brackets 008 on the bearing shell...

Page 422: ...06 is installed 20 Operate the chain blocks 008 009 to lift the crosshead 002 a small distance 21 Remove the two supports 004 22 Operate the chain blocks 008 009 to lower the crosshead into position o...

Page 423: ...3 to the support 001 32 Attach the hose 004 to the flange 003 33 Fill the lubricating pump 005 with steam engine cylinder oil see Table 8 5 ISO VG 1000 1500 suppliers 34 Operate the lubricating pump 0...

Page 424: ...Fig 8 38 Bearing lubrication CLOSE UP None X72DF AA00 3303 02AAA 720A A Maintenance Manual Connecting rod install the top end bearing Winterthur Gas Diesel Ltd 424 Issue 002 2020 10...

Page 425: ...X72DF AA00 3303 02AAA 720A A Maintenance Manual Connecting rod install the top end bearing Page left intentionally blank Winterthur Gas Diesel Ltd 425 Issue 002 2020 10...

Page 426: ...pur geared chain blocks 94017 1 5 4 2 Shackle 94019L 1 Sling 94039 015 1 Spur geared trolley 94015 008 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY Bearing cover 1 SAFETY PR...

Page 427: ...ur geared chain blocks 008 to the shackle 001 9 Operate the chain blocks 008 006 to move the bearing cover 003 into the engine 10 Remove the chain block 006 11 Attach the chain block 004 to the shackl...

Page 428: ...002 006 chain 004 shackles 001 003 and eye bolts 17 Install the four round nuts 008 to the elastic bolts 007 refer to section 4 2 Tighten a round nut with a pre tensioner X72DF AA00 3303 01AAA 720A A...

Page 429: ...ing cover install 001 002 003 004 005 006 001 005 007 008 007 009 00742 X72DF AA00 3303 01AAA 720A A Maintenance Manual Connecting rod install the top end bearing cover Winterthur Gas Diesel Ltd 429 I...

Page 430: ...CLOSE UP None X72DF AA00 3303 01AAA 720A A Maintenance Manual Connecting rod install the top end bearing cover Winterthur Gas Diesel Ltd 430 Issue 002 2020 10...

Page 431: ...X72DF AA00 3303 01AAA 720A A Maintenance Manual Connecting rod install the top end bearing cover Page left intentionally blank Winterthur Gas Diesel Ltd 431 Issue 002 2020 10...

Page 432: ...1 Spur geared chain block 94017 2 4 3 4 Shackles 94018E 4 Chain symmetrical 94019A 1 Tool connecting rod assembly 94334A 1 Chain asymmetrical 94019B 1 Supplies Description QTY None Spare Parts Descri...

Page 433: ...002 006 1 8 Attach the two chain blocks 002 and 006 to the top platform and the shackles 005 1 9 Lift the connecting rod 003 a small distance 1 10 Attach two more shackles 009 to the top platform 1 11...

Page 434: ...e platform at the applicable installation position 3 Clean the bearing shell and the crank pin 4 Put oil on the bearing shell and the crank pin X72DF AA00 3303 00AAA 720A A Maintenance Manual Connecti...

Page 435: ...move the connecting rod 001 into the position shown in view C 10 Attach the lever chain hoist 004 to the lug 005 11 Attach the chain block 008 to the plate 006 12 Operate the chain block 880 to lift...

Page 436: ...ck 002 Figure 8 43 to move the connecting rod clockwise to the position shown in view A 17 Attach the chain block 001 to the bottom shackle on the lifting tool X72DF AA00 3303 00AAA 720A A Maintenance...

Page 437: ...Attach the lever chain hoists 005 007 to the lifting tool on the connecting rod 006 as shown in view C 21 Remove the chain block 001 22 Operate the turning gear and the lever chain hoists 005 007 to...

Page 438: ...23 Operate the chain block 006 Figure 8 44 to lift the crosshead a small distance 24 Remove the two supports 001 X72DF AA00 3303 00AAA 720A A Maintenance Manual Connecting rod install Winterthur Gas...

Page 439: ...rod align with the holes in the crosshead Operate the chain block 006 to lower carefully the crosshead on to the connecting rod 26 Remove the chain block 006 X72DF AA00 3303 00AAA 720A A Maintenance M...

Page 440: ...l lever chain hoists chain blocks eye bolts shackles and other equipment 28 Remove the protection from the crosshead pin X72DF AA00 3303 00AAA 720A A Maintenance Manual Connecting rod install Winterth...

Page 441: ...s in the position shown Fig 8 45 Toggle lever attach 30 Remove the platform refer to section 8 1 3 Crankshaft remove the work platform 31 Do the a check of the clearances refer to section 8 6 2 Crossh...

Page 442: ...e that the crosshead touches the piston rod foot 36 Loosen the two nuts 007 37 Remove the two bolts 011 from the cylinder jacket 38 Remove the four bolts 008 then remove the holders 010 from the plate...

Page 443: ...X72DF AA00 3303 00AAA 720A A Maintenance Manual Connecting rod install Page left intentionally blank Winterthur Gas Diesel Ltd 443 Issue 002 2020 10...

Page 444: ...k 94017 10 4 3 1 Spur geared chain block 94017 5 5 4 2 Spur geared chain block 94017 0 5 5 4 1 Spur geared chain block 94017 7 5 6 5 1 Lever chain hoist 94016 3 2 5 5 2 Lifting tool 94324 1 Eye bolt 9...

Page 445: ...ury Hazard Before you operate the turning gear make sure that no personnel are on the platform or near the flywheel PRELIMINARY OPERATIONS The piston must be removed refer to section 8 7 3 Piston remo...

Page 446: ...astic studs on the connecting rod refer to section 4 3 Loosen a round nut with a pre tensioner 1 3 Make sure that the platforms is installed 1 4 Put protection on the oil inlets of the crosshead pin t...

Page 447: ...he screws 005 on the lifting tools 002 8 Attach a lifting tool 002 to each side of the connecting rod with the screws 005 9 Torque the screws 005 to the correct value refer to section 16 1 Tightening...

Page 448: ...gear to move the platform and tools up to a sufficient height 17 Attach four of the eye bolts 008 to the cylinder block 007 18 Attach two of the spur geared chain block 012 to the eye bolts 008 and th...

Page 449: ...1 to the guide shoes 002 28 Attach the shackles 004 to the column as shown 29 Attach the lever chain hoists 005 010 to the shackles 004 30 Attach the lever chain hoists 005 010 to the two top shackles...

Page 450: ...the chain block 001 Figure 8 52 to lift the crosshead pin to approximately 300 mm above the center of the pin holes in the column walls 34 Attach the two chain blocks 002 007 to the eye bolts on the g...

Page 451: ...Continue until the connecting rod touches the wooden chock 010 42 Remove the two lever chain hoists 008 011 43 Remove the supports 003 as follows 43 1 Remove the special screw 005 43 2 Loosen the bolt...

Page 452: ...the shackle 011 to an applicable position on the column 46 11 Attach the lever chain hoist 010 to the shackle 011 and the chain 008 46 12 Do Step 46 1 to Step 46 8 for the other guide shoe 47 When th...

Page 453: ...make sure that you keep tension on the chain block 002 57 Attach the chain block 008 to the shackle on the lifting tool on the crosshead pin 003 58 Apply tension to the chain of the chain block 008 59...

Page 454: ...icable area 63 6 Lower the crosshead pin on an applicable surface 63 7 Remove the chain block 008 from the lifting tool 007 on the crosshead 003 X72DF AA00 3326 00AAA 520A A Maintenance Manual Crosshe...

Page 455: ...003 Figure 8 56 The shims of the guide shoes can have different dimensions 0 3 mm 0 5 and 1 mm thickness This will help you during the installation procedure 65 Operate the chain blocks 002 to lower t...

Page 456: ...hoe 73 If necessary move the guide shoe 00X as follows 73 1 Attach the sling and the chain block 004 to the trolley 005 73 2 Attach the chain block 004 to the eye bolt on the guide shoe 003 73 3 Opera...

Page 457: ...X72DF AA00 3326 00AAA 520A A Maintenance Manual Crosshead remove Page left intentionally blank Winterthur Gas Diesel Ltd 457 Issue 002 2020 10...

Page 458: ...ipment Description Part No CSN QTY Feeler gauge 94122 1 Tool TBD 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury hazard Before you operat...

Page 459: ...004 and measured at position 008 1 4 Operate the turning gear to move the crank to the position 90 before after TDC 1 5 Do Step 1 3 again 1 6 Operate the turning gear to move the crank to the top pos...

Page 460: ...he clearances P1 P2 4 5 Loosen the two screws 003 4 6 Operate the turning gear to move the crankshaft in the astern direction to a position of between 30 and 35 4 7 Tighten equally the two screws 003...

Page 461: ...X72DF AA00 3326 00AAA 360A A Maintenance Manual Crosshead do a check of the clearances Page left intentionally blank Winterthur Gas Diesel Ltd 461 Issue 002 2020 10...

Page 462: ...block 94017 5 5 4 2 Spur geared chain block 94017 0 5 5 4 1 Spur geared chain block 94017 7 5 6 5 1 Lever chain hoist 94016 3 2 5 5 2 Lifting tool 94324 1 Eye bolt 94045 M56 6 Eye bolt 94045 M20 2 Sha...

Page 463: ...ECAUTIONS WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are on the platform or near the flywheel PRELIMINARY OPERATIONS None X72DF AA00 3326 00AAA 720A A Mainte...

Page 464: ...de shoe move 001 002 003 004 00753 8 Clean the 003 Figure 8 60 and all surfaces that touch 9 Make sure that the surfaces of the crosshead pin 003 are clean and have no damage 10 Apply to all surfaces...

Page 465: ...he chain 008 to the eye bolts 007 23 Attach the eye bolt 011 to an applicable position on the column 24 Attach the lever chain hoist 010 to the eye bolt 011 and the chain 008 25 Operate the lever chai...

Page 466: ...to the supports 006 35 Attach the lever chain hoist 010 to the shackle 011 on the column and to the shackle on the lifting tool 007 on the connecting rod 008 36 Operate the lever chain hoist 010 to m...

Page 467: ...s in the crosshead pin 44 Remove the two lever chain hoists 011 45 Use an applicable tool and sufficient personnel to remove the two lifting tools 007 014 from the connecting rod 008 X72DF AA00 3326 0...

Page 468: ...012 013 002 014 015 016 006 017 00756 FUEL SIDE 46 Install the platform to top of the crosshead 47 Attach the lever chain hoist 012 Figure 8 63 to the shackle 008 and the platform X72DF AA00 3326 00AA...

Page 469: ...ove all remaining eye bolts chain blocks lever chain hoists and shackles etc 57 Remove the protection from the crosshead pin Fig 8 63 Tools remove 001 002 003 004 005 006 007 008 009 010 008 010 011 0...

Page 470: ...to the thread of the temperature sensor 002 Figure 8 65 61 Attach the temperature sensor 002 to the crosshead 001 62 Connect the electrical connection to the temperature sensor 002 X72DF AA00 3326 00A...

Page 471: ...he top bearing cover refer to section 6 2 2 Main bearing install the cover 65 Set to on the lubricating oil pump 66 Make sure that the crosshead and the bottom end bearings of the connecting rod have...

Page 472: ...Description Part No CSN QTY Template 94366A 1 Feeler gauge 94122 1 Supplies Description QTY Emery cloth A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Befor...

Page 473: ...applicable tool to grind the burn scars 7 2 Use an emery cloth to make sharp edges smooth 8 If the burn scars are 10 mm or more do as follows 8 1 Remove the piston refer to section 8 7 3 Piston remove...

Page 474: ...ove 11 2 Record the total clearance X X1 X2 12 If possible do Step 11 again on different positions of the first piston ring 13 Do Step 11 and Step 12 again for the other piston rings 14 Compare the re...

Page 475: ...X72DF AA00 3403 00AAA 360A A Maintenance Manual Piston installed do checks of the surface and clearances Page left intentionally blank Winterthur Gas Diesel Ltd 475 Issue 002 2020 10...

Page 476: ...der 94230 2 Piston suspension device 94341 1 Plate 94341A 2 Supplies Description QTY Oil A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Before you operate th...

Page 477: ...piston rod foot 006 with the screws 008 10 Remove the knee lever from the crosshead connection 11 Attach the knee lever in a save position Fig 8 68 Piston Preparation 001 002 003 004 005 006 007 008 0...

Page 478: ...tach the three brackets to the lifting tool with the six bolts Make sure that the brackets fully engage in the holes in the piston crown 22 Torque the four screws to the related value refer to section...

Page 479: ...ation before removal example 001 002 003 002 001 004 005 006 007 008 009 007 009 010 I X I 00780 X72DF AA00 3403 00AAA 523A A Maintenance Manual Piston prepare before removal Winterthur Gas Diesel Ltd...

Page 480: ...CLOSE UP None X72DF AA00 3403 00AAA 523A A Maintenance Manual Piston prepare before removal Winterthur Gas Diesel Ltd 480 Issue 002 2020 10...

Page 481: ...X72DF AA00 3403 00AAA 523A A Maintenance Manual Piston prepare before removal Page left intentionally blank Winterthur Gas Diesel Ltd 481 Issue 002 2020 10...

Page 482: ...Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY Lifting tool 94341 1 Piston support 94350 1 Cover 94345 1 Supplies Description QTY None Spare Parts Descri...

Page 483: ...ars 004 7 Lower the piston 001 and the gland box 008 until the piston rod foot is below the plates 006 8 Close the plates 006 9 Push in the supports 002 10 Tighten the screws 003 11 Lower the piston o...

Page 484: ...CLOSE UP None X72DF AA00 3403 00AAA 520A A Maintenance Manual Piston remove Winterthur Gas Diesel Ltd 484 Issue 002 2020 10...

Page 485: ...X72DF AA00 3403 00AAA 520A A Maintenance Manual Piston remove Page left intentionally blank Winterthur Gas Diesel Ltd 485 Issue 002 2020 10...

Page 486: ...port equipment Description Part No CSN QTY Hydraulic unit 94942 1 Pressure gauge 94934A 1 Distributing piece 94934 1 Flexible hose 94935 5 Jacking screws 94364A 3 Jacking screws 94364B 2 Jacking screw...

Page 487: ...ructions 6 Attach the engine room crane to the lifting tool 004 7 Operate the engine room crane to lift the piston head 001 8 Move the piston head 001 to an applicable area 9 Remove the three jacking...

Page 488: ...iston disassemble example 001 002 003 002 002 004 001 005 006 007 008 009 003 010 011 012 00781 X72DF AA00 3403 00AAA 530A A Maintenance Manual Piston disassemble Winterthur Gas Diesel Ltd 488 Issue 0...

Page 489: ...CLOSE UP None X72DF AA00 3403 00AAA 530A A Maintenance Manual Piston disassemble Winterthur Gas Diesel Ltd 489 Issue 002 2020 10...

Page 490: ...Support equipment Description Part No CSN QTY Template 94366 1 Feeler gauge 94122 1 Calliper gauge N A 1 Inside micrometer set 94101 1 Supplies Description QTY Emery cloth A R Spare Parts Description...

Page 491: ...n head to its original thickness 6 3 Assemble the piston refer to section 8 7 6 Piston assemble Fig 8 73 Top surface dimensions check 001 002 10 mm 00776 7 Find the cause of the burn scars and repair...

Page 492: ...2 related to the defective item 14 1 Replace the piston rings 14 2 Repair the piston head NOTE For the repair of piston heads speak to the nearest WinGD Service Center 15 Measure the diameter of the...

Page 493: ...X72DF AA00 3403 00AAA 360B A Maintenance Manual Piston removed do checks of the surface and clearances Page left intentionally blank Winterthur Gas Diesel Ltd 493 Issue 002 2020 10...

Page 494: ...cialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Lifting tool 94341 1 Hydraulic unit 94942 1 Pressure gauge 94934A 1 Distributing piece 94934 1 Flexible hose 94935 5...

Page 495: ...to the piston rod 010 with the bolts 012 6 Symmetrically torque the bolts 012 related to Table 8 6 Torque values Tab 8 6 Torque values Engine type 1 step 2 step X52 X52DF 15 Nm 40 X62 B X62DF 20 Nm 4...

Page 496: ...pressure gauge the distributing piece and the flexible hoses 11 Install the round nuts to the elastic studs in the sequence given refer to section 4 2 Tighten a round nut with a pre tensioner CLOSE UP...

Page 497: ...X72DF AA00 3403 00AAA 710A A Maintenance Manual Piston assemble Page left intentionally blank Winterthur Gas Diesel Ltd 497 Issue 002 2020 10...

Page 498: ...quipment Description Part No CSN QTY Installation tool 94342 1 Lifting tool 94209 1 Piston suspension device 94341 1 Distance holder 94230 2 Lifting plate 94342A 4 Supplies Description QTY Oil A R Spa...

Page 499: ...gs of the piston rod gland 9 Attach the piston suspension device 004 to the top of the piston 005 10 Torque the bolts to the correct value refer to section 16 1 Tightening instructions 11 Attach the d...

Page 500: ...n 004 to align with the crosshead Fig 8 77 Piston install example I I I I 001 002 004 003 00785 23 Put oil on the four bolts 002 Figure 8 78 24 Attach the piston rod gland 001 to the cylinder block wi...

Page 501: ...and the antipolishing ring 006 are clean and in a satisfactory condition 31 Put oil on the surfaces of the antipolishing ring 006 32 Attach the four lifting plates 005 to the antipolishing ring 006 w...

Page 502: ...Fig 8 79 Piston attach example 001 002 003 002 004 005 006 007 00786 CLOSE UP None X72DF AA00 3403 00AAA 720A A Maintenance Manual Piston install Winterthur Gas Diesel Ltd 502 Issue 002 2020 10...

Page 503: ...X72DF AA00 3403 00AAA 720A A Maintenance Manual Piston install Page left intentionally blank Winterthur Gas Diesel Ltd 503 Issue 002 2020 10...

Page 504: ...pletion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Piston ring tool 94338 1 Supplies Description QTY None Spare Par...

Page 505: ...iston rings 001 will be installed again clean the piston rings 001 6 Measure and record the thickness of the chrome ceramic layer of each piston ring 001 This will help you monitor the rate of wear du...

Page 506: ...mpletion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Piston ring tool 94338 1 Supplies Description QTY None Spare Pa...

Page 507: ...r liner in good condition 2 Use the piston ring tool to install the applicable bottom piston ring 003 to the related groove of the piston head 3 Use the piston ring tool to install the other applicabl...

Page 508: ...X72DF AA00 3425 00AAA 720B A Maintenance Manual Piston ring install Page left intentionally blank Winterthur Gas Diesel Ltd 508 Issue 002 2020 10...

Page 509: ...el crankshaft do a check of the teeth backlash 512 9 2 Shut off valve for starting air 9 2 1 Shut off valve for starting air disassemble 516 9 2 2 Shut off valve for starting air assemble 522 9 2 3 Sh...

Page 510: ...mediate AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Before you operate the...

Page 511: ...bearings 2 Set to on the service pump 3 Make sure that oil flows freely from all nozzles 4 Set to off the service pump 5 Make sure that all screws are correctly locked 6 After the running in period do...

Page 512: ...QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY Feeler gauge 94122 1 Micrometer N A 1 Dial gauge N A 1 Supplies Description QTY Wire 1 5 mm A R Spare Parts Description Pa...

Page 513: ...tooth backlash with a wire as follows NOTE Use a new wire of 1 5 mm diameter Pb 9 99 fine for each measurement NOTE The wire c shows the full backlash f The wires a and b show the parallelity of the t...

Page 514: ...002 004 0 1 2 3 4 5 6 7 8 9 003 004 f2 f1 a1 a3 15 mm 15 mm b1 b3 Equal Distances a b c 00795 X72DF AA00 4106 00AAA 360A A Maintenance Manual Gear wheel crankshaft do a check of the teeth backlash Wi...

Page 515: ...CLOSE UP None X72DF AA00 4106 00AAA 360A A Maintenance Manual Gear wheel crankshaft do a check of the teeth backlash Winterthur Gas Diesel Ltd 515 Issue 002 2020 10...

Page 516: ...equirements after job completion 0 0 man hours Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRE...

Page 517: ...ne 1 6 Make sure that the two gaskets on the flanges 003 006 are serviceable If the gaskets have damage replace them Fig 9 2 Shut off valve for starting air prepare for disassembly 008 009 001 007 006...

Page 518: ...016 Valve guide 013 Valve 010 Spindle 006 15 If you find corrosion on the springs 007 022 and or 002 you must replace them 16 Do a check of all gaskets and O rings that you removed for damage If you...

Page 519: ...015 016 017 018 019 001 002 003 004 005 006 007 008 009 010 011 012 013 020 023 013 021 004 I I 00800 022 024 025 X72DF AA00 4325 00AAA 530A A Maintenance Manual Shut off valve for starting air disas...

Page 520: ...CLOSE UP None X72DF AA00 4325 00AAA 530A A Maintenance Manual Shut off valve for starting air disassemble Winterthur Gas Diesel Ltd 520 Issue 002 2020 10...

Page 521: ...X72DF AA00 4325 00AAA 530A A Maintenance Manual Shut off valve for starting air disassemble Page left intentionally blank Winterthur Gas Diesel Ltd 521 Issue 002 2020 10...

Page 522: ...for performing the requirements after job completion 0 0 man hours Support equipment Description Part No CSN QTY None Supplies Description QTY Molykote paste A R Loctite 0243 A R Spare Parts Descripti...

Page 523: ...e eight screws 012 16 Torque the screws 012 to the value given in section 3 5 Torque values standard screws 17 Attach the hand wheel 019 18 Attach the control valve 011 to the cover 018 with the bolts...

Page 524: ...6 005 011 010 024 025 026 027 023 018 028 020 019 029 022 021 031 030 I I 015 016 017 013 014 011 1 0 0 2 mm 027 032 007 008 009 00802 009 012 X72DF AA00 4325 00AAA 710A A Maintenance Manual Shut off...

Page 525: ...CLOSE UP None X72DF AA00 4325 00AAA 710A A Maintenance Manual Shut off valve for starting air assemble Winterthur Gas Diesel Ltd 525 Issue 002 2020 10...

Page 526: ...uipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard During this test do not select START Injury...

Page 527: ...UTOMAT Make sure that the lever 002 engages with the groove in the spindle 2 8 Make sure that no air flows from the bore of the screw plug 011 When no air flows the automatic function of the shut off...

Page 528: ...ration test 012 013 001 002 003 004 011 009 008 00799 005 006 007 010 014 CLOSE UP None X72DF AA00 4325 00AAA 320A A Maintenance Manual Shut off valve for starting air do a test of the operation Winte...

Page 529: ...5 Fuel pressure control valve 10 5 1 Fuel rail remove the pressure control valve 584 10 5 2 Fuel rail do a check of the pressure control valve 586 10 5 3 Fuel rail install the pressure control valve...

Page 530: ...hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFET...

Page 531: ...he value for clearance with the value given in section 3 3 Clearances general 5 If there is too much wear and or damage you must replace the pinions and the camshaft gear wheel 6 Attach the cover to t...

Page 532: ...017 0 5 5 4 2 Lifting tool 94651 1 Slings WLL 1000 kg 94039 002 2 Deviation pipe 94319 1 Sling WLL 2000 kg 94039 005 1 Lever chain hoist 94016 0 8 5 5 1 Shackle 94019P 1 Supplies Description QTY None...

Page 533: ...icable HP servo oil pipes must be removed refer to section 13 1 1 HP servo oil pipe remove X72DF AA00 5551 00AAA 520A A Maintenance Manual Servo oil pump remove Winterthur Gas Diesel Ltd 533 Issue 002...

Page 534: ...sling to the engine room crane 2 3 Operate the engine room crane and put sufficient tension on the sling to hold the weight of the servo oil pump 2 4 Remove the nuts and the washers 2 5 Remove the se...

Page 535: ...X72DF AA00 5551 00AAA 520A A Maintenance Manual Servo oil pump remove Page left intentionally blank Winterthur Gas Diesel Ltd 535 Issue 002 2020 10...

Page 536: ...017 0 5 5 4 2 Lifting tool 94651 1 Slings WLL 1000 kg 94039 002 2 Deviation pipe 94319 1 Sling WLL 2000 kg 94039 005 1 Lever chain hoist 94016 0 8 5 5 1 Shackle 94019P 1 Supplies Description QTY None...

Page 537: ...icable HP servo oil pipes must be removed refer to section 13 1 1 HP servo oil pipe remove X72DF AA00 5551 00AAA 720A A Maintenance Manual Servo oil pump install Winterthur Gas Diesel Ltd 537 Issue 00...

Page 538: ...6 Attach the servo oil pump to the casing with the nuts and the washers 1 7 Remove the sling from the servo oil pump 2 Do Step 1 again to install the other servo oil pump s 3 Finish the installation o...

Page 539: ...X72DF AA00 5551 00AAA 720A A Maintenance Manual Servo oil pump install Page left intentionally blank Winterthur Gas Diesel Ltd 539 Issue 002 2020 10...

Page 540: ...n QTY Engine crew Basic AR Support equipment Description Part No CSN QTY HP oil pump 94931 1 Pressure gauge 94934A 1 HP hose 94935 1 Assembly tool 94573 1 Supplies Description QTY Molykote G Rapid Plu...

Page 541: ...ure 10 2 turn fully back the special nut 003 12 Apply Molykote G Rapid Plus to the surfaces 005 13 Attach the adapter piece 007 to the shaft of the pilot fuel pump 001 14 Torque the adapter piece 007...

Page 542: ...isc 004 20 Make sure that the coupling half is loose 21 Release the pressure from the HP oil pump 008 22 Remove the gear coupling Fig 10 2 Supply unit for pilot fuel tool CLOSE UP None X72DF AA00 5555...

Page 543: ...X72DF AA00 5555 00AAA 520A A Maintenance Manual Supply unit for pilot fuel remove the pump Page left intentionally blank Winterthur Gas Diesel Ltd 543 Issue 002 2020 10...

Page 544: ...iption Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Grease for gear couplings A R Spare Parts Description Part No CSN QTY None SA...

Page 545: ...ease nipple 5 Lubricate the coupling with an applicable grease for gear couplings 6 Attach the service cover 002 with the two screws 004 7 Attach the cover 003 Fig 10 3 Pilot fuel supply unit CLOSE UP...

Page 546: ...t equipment Description Part No CSN QTY HP oil pump 94931 1 Pressure gauge 94934A 1 HP hose 94935 1 Assembly tool 94573 1 Supplies Description QTY Molykote G Rapid Plus A R Never Seez NSBT8 A R Spare...

Page 547: ...P hose 010 to the closing valve 005 10 Operate the HP oil pump 009 to get a pressure of between 1600 bar and 1800 bar 11 Make sure that the coupling floats on the oil film 12 Push the special nut 002...

Page 548: ...Fig 10 5 Pilot fuel supply unit clearances 001 II II 002 003 II I I I I 004 007 006 3 0 mm 008 X 3 0 mm X II II 005 1 5 0 3 0 27 Apply NeverSeez NSBT8 to the threads and surfaces that touch of the cou...

Page 549: ...Fig 10 6 Pilot fuel supply unit completion CLOSE UP None X72DF AA00 5555 00AAA 720A A Maintenance Manual Supply unit for pilot fuel install the pump Winterthur Gas Diesel Ltd 549 Issue 002 2020 10...

Page 550: ...AR Support equipment Description Part No CSN QTY Cover N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Before you operate the...

Page 551: ...es to the fuel pumps are closed 1 9 Remove the applicable HP fuel pipe s refer to 13 3 2 HP fuel pipe fuel rail to injection valve remove and 13 3 6 HP fuel pipe fuel pump to fuel rail remove Fig 10 7...

Page 552: ...fuel pump 8 Move the fuel pump to an applicable work bench 9 Put the fuel pump on its side on the wooden surface Make sure that you do not cause damage to the toothed rack 008 or and the roller 007 1...

Page 553: ...X72DF AA00 5556 00AAA 520A A Maintenance Manual Fuel pump remove Page left intentionally blank Winterthur Gas Diesel Ltd 553 Issue 002 2020 10...

Page 554: ...onnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY Spindle press 94551 pc 1 Supplies Description QTY Loctite No 648 A R Spare Parts Descript...

Page 555: ...to move in the guide piston 004 sufficiently to remove the guide pin 003 1 4 Turn the screw 002 to remove the guide pin 003 1 5 Remove the spindle press 001 Fig 10 8 Guide pin removal 003 00422 004 0...

Page 556: ...4 Remove and discard the O ring 006 2 5 Remove the snap ring 005 2 6 Remove the Allen screws 011 2 7 Remove the bottom housing 009 from top housing 2 8 If necessary replace the bush 010 as follows 2 8...

Page 557: ...unger 003 in a dry clean area to prevent damage 3 3 Remove the compression spring 002 3 4 Remove regulating sleeve 004 together with the top spring carrier 005 3 5 Remove the screws 008 3 6 Remove the...

Page 558: ...the work bench 4 3 Remove the screws 001 4 4 Remove the pump cover 002 valve block 004 valve body 008 and compression spring 009 4 5 Remove the circlip 005 4 6 Remove the intermediate disc 010 4 7 Rem...

Page 559: ...aced as a unit only this means valve block 001 valve body 002 compression spring 004 and intermediate disc 003 5 2 Use the two screwdrivers as levers to push out the valve block 001 Make sure that you...

Page 560: ...on QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY Circlip pliers 94007 A41 pc 1 Spacer 94555 pc 1 Gauge 94556 pc 1 Spindle press 94551 pc 1 Supplies Description QTY Neve...

Page 561: ...mble the pump cylinder do the steps that follow 5 1 Attach the top housing 003 vertically to the work bench 5 2 Align the groove in the pump cylinder with the bore for the screw 002 in the top housing...

Page 562: ...009 and compression spring 010 into the valve block 004 6 5 Put the valve block into the top housing 007 6 6 Attach the intermediate disc 011 to the valve block 004 with the circlip 003 6 7 Install th...

Page 563: ...o flanges 009 7 6 Attach the two flanges 009 to the top housing 002 with the two screws 005 7 7 Attach the stop ring 008 and the circlip 007 8 To assemble the regulating sleeve do the steps that follo...

Page 564: ...03 9 4 Put the pump plunger 003 and the bottom spring carrier 006 in position in the top housing 007 Make sure that the two drivers of the pump plunger 003 engage with the regulating sleeve 004 9 5 Ap...

Page 565: ...I I 002 I I 015 003 003 001 001 10 To do a check the plunger position do the steps that follow 10 1 Move the toothed rack 002 Figure 10 17 to the position shown 10 2 Put the spacer 003 in the positio...

Page 566: ...17 Put the guide piston 008 in the housing 10 18 Do a check of the axial clearances 10 19 Attach the two eye bolts to the guide piston 008 10 20 Attach the applicable lifting tools to the eye bolts 10...

Page 567: ...X72DF AA00 5556 00AAA 710A A Maintenance Manual Fuel pump assemble Page left intentionally blank Winterthur Gas Diesel Ltd 567 Issue 002 2020 10...

Page 568: ...ription Part No CSN QTY Cover 94552 pc 1 Supplies Description QTY Oil A R Molykote paste G A R Penetrating oil for example WD 40 A R Spare Parts Description Part No CSN QTY Fuel pump A R O rings 3 SAF...

Page 569: ...Torque symmetrically in equal steps the four screws 001 to the correct value refer to section 16 1 Tightening instructions 9 Connect the regulating linkage 003 on the actuator 002 to the connecting e...

Page 570: ...ng gear to move the cam Make sure that there are no leaks or an unusual temperature increase CLOSE UP None X72DF AA00 5556 00AAA 720A A Maintenance Manual Fuel pump install Winterthur Gas Diesel Ltd 5...

Page 571: ...X72DF AA00 5556 00AAA 720A A Maintenance Manual Fuel pump install Page left intentionally blank Winterthur Gas Diesel Ltd 571 Issue 002 2020 10...

Page 572: ...A 1 Small drill bit N A 1 Nylon brush N A 1 Supplies Description QTY WD 40 A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Do not operate the engine Injury to...

Page 573: ...oil in the inlet pipe 005 does not flow freely it is possible that there are unwanted particles in the oil supply system If you find particles remove them 7 If there is incorrect oil flow or no flow t...

Page 574: ...CLOSE UP None X72DF AA00 5556 00AAA 320A A Maintenance Manual Fuel pump do a test of the operation Winterthur Gas Diesel Ltd 574 Issue 002 2020 10...

Page 575: ...X72DF AA00 5556 00AAA 320A A Maintenance Manual Fuel pump do a test of the operation Page left intentionally blank Winterthur Gas Diesel Ltd 575 Issue 002 2020 10...

Page 576: ...hours Personnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY Non...

Page 577: ...witch is pushed correctly the actuator moves to the maximum and minimum position self adjustment NOTE The switch is very fragile Make sure to use as little force as possible when pushing it 7 Wait unt...

Page 578: ...CLOSE UP None X72DF AA00 5583 00AAA 273A A Maintenance Manual Fuel pump actuator calibrate Winterthur Gas Diesel Ltd 578 Issue 002 2020 10...

Page 579: ...X72DF AA00 5583 00AAA 273A A Maintenance Manual Fuel pump actuator calibrate Page left intentionally blank Winterthur Gas Diesel Ltd 579 Issue 002 2020 10...

Page 580: ...nnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRE...

Page 581: ...move the screws 009 Figure 10 22 and the cover 008 on the fuel pump 007 6 Move the toothed rack 006 to get a distance of 48 mm at each end 7 Attach the lever 002 to the connecting element 001 with the...

Page 582: ...Fig 10 22 Actuator adjust 2 009 008 007 006 CLOSE UP None X72DF AA00 5583 00AAA 360A A Maintenance Manual Fuel pump actuator adjust Winterthur Gas Diesel Ltd 582 Issue 002 2020 10...

Page 583: ...X72DF AA00 5583 00AAA 360A A Maintenance Manual Fuel pump actuator adjust Page left intentionally blank Winterthur Gas Diesel Ltd 583 Issue 002 2020 10...

Page 584: ...TY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Put on gl...

Page 585: ...the screws 008 5 Remove the PCV 001 from the valve block 003 6 Put the PCV 001 to a clean dry area 7 Put protection on the valve block 003 to prevent contamination Fig 10 23 Pressure control valve rem...

Page 586: ...rt No CSN QTY HP oil pump 94931 1 Pressure gauge 94934A 1 HP hose 94935 1 PCV test block with tube 94556 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS...

Page 587: ...given in view I refer to section 16 1 Tightening instructions 1 9 Attach the flexible tube part of the test block 009 to the PCV outlet 002 Put the other end of the flexible tube into an applicable co...

Page 588: ...the PCV opens at 1050 30 bar 3 4 If the PCV opens at less than 1020 bar or more than 1080 bar do the procedure in step Step 2 again If the PCV does not open at less than 1300 bar or opens at less than...

Page 589: ...X72DF AA00 5562 00AAA 360A A Maintenance Manual Fuel rail do a check of the pressure control valve Page left intentionally blank Winterthur Gas Diesel Ltd 589 Issue 002 2020 10...

Page 590: ...fter job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Never Seez NSBT 8 A R Spare...

Page 591: ...5 Apply Never Seez NSBT 8 to the screw threads 008 6 Put the screws 008 in position in the PCV 001 7 Torque the screws 008 refer to section 16 1 Tightening instructions 8 Tighten the angle union 006 9...

Page 592: ...iption Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Socket wrench AF41 94022B 41 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None S...

Page 593: ...001 as a new item 2 Make sure that there is no damage to the housing 003 Fig 10 26 Fuel overpressure safety valve II II I Applicable pressure that opens the relief valve 001 001 002 003 004 005 004 12...

Page 594: ...Y Injector test bench 94272 1 Valve holder 94272A 1 HP oil pump 94931 1 Pressure gauges 94934A 2 HP hoses 94935 2 Supplies Description QTY Test fluid ISO 4113 A R Spare Parts Description Part No CSN Q...

Page 595: ...bench 008 or the HP oil pump 006 to increase the pressure until the overpressure safety valve 003 opens 3 2 Make sure that the overpressure safety valve 003 opens at between 1200 bar and 1350 bar 4 Co...

Page 596: ...ety valve pressure check 001 002 003 004 001 005 006 007 008 00827 CLOSE UP None X72DF AA00 5562 01AAA 360A A Maintenance Manual Fuel rail do a check of the overpressure safety valve Winterthur Gas Di...

Page 597: ...X72DF AA00 5562 01AAA 360A A Maintenance Manual Fuel rail do a check of the overpressure safety valve Page left intentionally blank Winterthur Gas Diesel Ltd 597 Issue 002 2020 10...

Page 598: ...n 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Socket wrench AF41 94022B 41 1 Torque spanner 94012 1 Supplies Description Q...

Page 599: ...orque spanner and the socket wrench to torque the relief valve 001 to the correct value refer to section 16 1 Tightening instructions Fig 10 28 Fuel overpressure safety valve installation 001 001 002...

Page 600: ...ecialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Scotchbrite A R WD40 or similar A R Oil A R Never Seez NSBT A R Spare Parts Desc...

Page 601: ...001 7 If you feel resistance because of contamination pull the piston rod 008 back and clean it again 8 If you again feel resistance because of contamination replace the flange 005 and the piston rod...

Page 602: ...CLOSE UP None X72DF AA00 5565 00AAA 281A A Maintenance Manual Flow limiting valve do an inspection Winterthur Gas Diesel Ltd 602 Issue 002 2020 10...

Page 603: ...X72DF AA00 5565 00AAA 281A A Maintenance Manual Flow limiting valve do an inspection Page left intentionally blank Winterthur Gas Diesel Ltd 603 Issue 002 2020 10...

Page 604: ...SN QTY None Supplies Description QTY Scotchbrite A R WD40 or similar A R Oil A R Never Seez NSBT A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury hazard To prevent in...

Page 605: ...tion to the openings on the FLV 2 5 Apply protection to the open ends of the pipes 3 Remove the bolts 002 Figure 10 30 from the FLV 4 Lift the FLV and put it on an applicable clean surface 5 Make sure...

Page 606: ...from the flange 005 7 2 Remove and discard the O ring 007 7 3 Remove the Allen screws 002 7 4 Remove carefully the flange 005 together with the piston rod 008 and the piston 006 Fig 10 31 Flow limitin...

Page 607: ...X72DF AA00 5565 00AAA 520A A Maintenance Manual Flow limiting valve remove Page left intentionally blank Winterthur Gas Diesel Ltd 607 Issue 002 2020 10...

Page 608: ...ion QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Never Seez NSBT A R Spare Parts Description Part No CSN QTY Flow limiting valve complete...

Page 609: ...ever Seez NSBT to the threads of the Allen screws 002 1 4 Tighten symmetrically with your hand the Allen screws 002 1 5 Torque symmetrically the Allen screws 002 in two steps to 60 Nm 1 6 Make sure th...

Page 610: ...llen screws 002 9 Make sure that the distance sleeves 004 are in the positions shown 10 Attach the valve block 001 to the fuel rail with the Allen screws 002 11 Torque symmetrically the Allen screws 0...

Page 611: ...parts can look different 002 00505 003 14 Install the HP fuel pipes 001 refer to section 13 3 4 HP fuel pipe fuel rail to injection valve install 15 Operate the engine for a minimum of one hour with...

Page 612: ...Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Do not operate welding or grinding equipment Sparks can cause a fire CAUTION The servo oil pipes must have no pressure Injury to pers...

Page 613: ...rn pipe 002 from the VCU 006 5 Remove the supply pipe 008 from the VCU 006 6 Remove the six screws 005 from the VCU 006 7 Carefully remove the VCU 006 8 Put protection over the bore in the holder 007...

Page 614: ...hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY...

Page 615: ...the piston 009 moves freely 5 Remove the filter holder 002 and the screw plug 003 from the valve control block 010 6 Make sure that the oil filter 001 is clean and has no damage If necessary remove a...

Page 616: ...job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Oil A R Spare Parts Description...

Page 617: ...section 16 1 Tightening instructions 6 Put a new O ring 006 and back up ring 005 on the plug 008 Fig 10 37 Exhaust valve control unit disassemble assemble 001 002 003 004 005 006 FLUSH 007 008 009 010...

Page 618: ...equipment Description Part No CSN QTY None Supplies Description QTY Oil A R Spare Parts Description Part No CSN QTY Exhaust valve control unit 1 Piston joint ring 1 SAFETY PRECAUTIONS CAUTION Injury...

Page 619: ...haust valve control unit install 001 002 003 004 005 006 007 008 A B C D E F 00402 4 Clean the seating surfaces of the VCU 005 and the holder 006 5 Make sure that the mating surfaces of the holder 006...

Page 620: ...ply oil to the threads of the screws 004 10 Tighten with your hand the crews 004 11 In the sequence given torque the screws 004 to the correct value refer to section 16 1 Tightening instructions 12 In...

Page 621: ...CLOSE UP None X72DF AA00 5612 00AAA 720A A Maintenance Manual Exhaust valve control unit VCU install Winterthur Gas Diesel Ltd 621 Issue 002 2020 10...

Page 622: ...X72DF AA00 5612 00AAA 720A A Maintenance Manual Exhaust valve control unit VCU install Page left intentionally blank Winterthur Gas Diesel Ltd 622 Issue 002 2020 10...

Page 623: ...630 11 1 4 Scavenge air receiver install the flaps 632 11 2 Auxiliary blower 11 2 1 Auxiliary blower remove 634 11 2 2 Auxiliary blower install 640 11 3 Scavenge air cooler 11 3 1 Scavenge air cooler...

Page 624: ...man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None S...

Page 625: ...003 Figure 11 1 2 Lock the covers 002 003 in position with the pins 001 004 3 Clean the scavenge air receiver X72DF AA00 6420 00AAA 310A A Maintenance Manual Scavenge air receiver examine Winterthur G...

Page 626: ...0859 4 If necessary clean the filters 007 and the drain pipes 005 006 5 Make sure that the flaps 010 have no dirt or damage and have free movement If necessary clean the flaps X72DF AA00 6420 00AAA 31...

Page 627: ...ed position 7 Close the covers 002 003 8 Put the pins 001 004 in their stowage positions Fig 11 2 Level switches and filters II II 001 002 003 004 005 006 007 008 009 010 001 00860 IV CLOSE UP None X7...

Page 628: ...one Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard If the disc springs are compressed do not disassemble the relief valve Parts can...

Page 629: ...nd the seal plate 003 thus the O ring 005 is serviceable 3 Make sure that the distance X is 133 mm thus the pressure of the disc springs 002 is sufficient Fig 11 3 Relief valve X Y 001 001 002 004 003...

Page 630: ...nel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS...

Page 631: ...he screw 008 and the tab washer 007 4 Remove the guide 006 distance ring 005 shaft 004 and the flap 001 Fig 11 4 Flaps remove I 00536 001 I II II 001 003 005 008 009 011 002 010 007 004 006 CLOSE UP N...

Page 632: ...l Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY Flap A R SAFETY PRECAUTIO...

Page 633: ...nd new tab washers 007 in position Do not tighten the screws at this step 4 Make sure that the shaft 004 and the flap 001 move freely 5 Tighten the screws 008 010 6 Bend the tab washers 007 011 to loc...

Page 634: ...ed chain block 94017 2 5 6 5 2 Spur geared chain block 94017 2 5 5 4 3 Shackle 94019L 2 Shackle 94019K 1 Shackle 94019H 3 Slings 94039 013 2 Trolley 94015F 1 Lifting tool 94651 1 Supplies Description...

Page 635: ...ht of the electric motor 006 1 8 Remove the four nuts bolts and eight washers 005 from the support 1 9 Remove the bolts from the flange 004 1 10 Operate the chain blocks 003 010 to remove the electric...

Page 636: ...emove the chain block 004 from the auxiliary motor 005 1 26 Operate the engine room crane to lower the auxiliary motor 005 on to an applicable surface Fig 11 7 Electric motor driving end remove 001 00...

Page 637: ...1 9 to the shackle 008 and the shackle on the lifting tool 002 2 15 Attach the shackle 010 to the lug in the gallery 2 16 Attach the spur geared chain block 009 to the shackle 010 and the lifting tool...

Page 638: ...crane to move the electric motor 004 to an applicable surface Fig 11 9 Auxiliary blower remove CLOSE UP None X72DF AA00 6545 00AAA 520A A Maintenance Manual Auxiliary blower remove Winterthur Gas Dies...

Page 639: ...X72DF AA00 6545 00AAA 520A A Maintenance Manual Auxiliary blower remove Page left intentionally blank Winterthur Gas Diesel Ltd 639 Issue 002 2020 10...

Page 640: ...4017 2 5 5 4 3 Shackle WLL 8500 kg 94019L 2 Shackle WLL 6500 kg 94019K 1 Shackle WLL 3250 kg 94019H 3 Slings WLL 2000 kg 94039 013 2 Trolley 94015F 1 Lifting tool 94651 1 Supplies Description QTY None...

Page 641: ...k 009 to hold the weight of the electric motor 004 1 9 Remove the engine room crane from the lifting tool 002 1 10 Attach the spur geared chain block 007 to the shackle 008 1 11 Operate the chain bloc...

Page 642: ...23 Remove the chain block 001 1 24 Operate the chain blocks 004 009 to move the electric motor into the casing 1 25 Attach the electric motor to the flange 005 with the screws 1 26 Attach the electric...

Page 643: ...8 2 7 Attach the shackle 010 to the lug 2 8 Attach the spur geared chain block 009 to the shackle 010 2 9 Operate the chain block 004 to lift the electric motor 006 2 10 Move carefully the trolley 003...

Page 644: ...te the chain blocks 002 010 to move the electric motor 006 into the casing 2 20 Attach the electric motor 006 to the flange 004 with the bolts 2 21 Attach the electric motor 006 to the support 005 wit...

Page 645: ...3 On the control panel set to ON the auxiliary blower refer to the Operation Manual 4 Make sure that the electric motor operates in the correct direction CLOSE UP None X72DF AA00 6545 00AAA 720A A Ma...

Page 646: ...Part No CSN QTY Trolley 94015F 2 Lever chain hoist 94016 x x 2 Lever chain hoist 94016 y y 1 Spur geared chain block 94017 z z 1 Shackle 94018X 2 Chain 94019A B 1 Swivel lug 94048 Mxx 6 Left support...

Page 647: ...ne must be stopped and made safe for maintenance refer to section 4 1 Do maintenance work general procedure X72DF AA00 6606 00AAA 520A A Maintenance Manual Scavenge air cooler remove Winterthur Gas Di...

Page 648: ...lose the shut off valves 007 Figure 11 14 1 2 Open the vent valve 001 1 3 Use the drain valve 004 to drain the water from the SAC 005 1 4 Remove the attached pipes 002 006 as necessary Fig 11 14 Scave...

Page 649: ...ring 005 2 4 Attach three swivel lugs 008 2 5 Attach the left and the right support 011 009 with the screws 012 Fig 11 15 Scavenge air cooler example prepare front side 001 002 003 I III 004 I 005 006...

Page 650: ...ar 010 and the flange 008 3 3 Remove and discard the O ring 011 3 4 Attach two swivel lugs on the outer positions of the SAC 004 Fig 11 16 Scavenge air cooler example prepare rear side II 004 002 008...

Page 651: ...e shackle to the trolley 012 4 7 Attach the spur geared chain block to the shackle on the trolley 012 and to the middle lug on the SAC 4 8 Operate the spur geared chain block to hold the weight of the...

Page 652: ...in the correct position 5 3 Use the engine room crane and applicable equipment to move the SAC to the stowage position 5 4 Remove the equipment Fig 11 18 Scavenge air cooler example put down 001 002 I...

Page 653: ...X72DF AA00 6606 00AAA 520A A Maintenance Manual Scavenge air cooler remove Page left intentionally blank Winterthur Gas Diesel Ltd 653 Issue 002 2020 10...

Page 654: ...QTY Trolley 94015F 2 Lever chain hoist 94016 x x 2 Lever chain hoist 94016 y y 1 Spur geared chain block 94017 z z 1 Shackle 94018X 2 Chain 94019A B 1 Swivel lug 94048 Mxx 6 Left support 94663A 1 Righ...

Page 655: ...ne must be stopped and made safe for maintenance refer to section 4 1 Do maintenance work general procedure X72DF AA00 6606 00AAA 720A A Maintenance Manual Scavenge air cooler install Winterthur Gas D...

Page 656: ...the supports 003 Figure 11 19 to the receiver 1 7 Attach the support 001 to the receiver 1 8 Attach the lever chain hoist 002 to the middle swivel lug 004 and to the support 001 1 9 If applicable atta...

Page 657: ...example follow up front and rear side II 004 002 008 009 009 008 010 011 II 4 Follow up the scavenge air cooler SAC 4 1 Install the removed pipes 4 2 Open the shut off valves of the cooling water pip...

Page 658: ...rt equipment Description Part No CSN QTY Lifting tool 94667 3 Disassembly tool 94667H 1 Lever chain hoist 94016 x x 1 Shackle 94018C 2 Spur geared chain block 94017 x x 2 Holder 94667G 1 Supplies Desc...

Page 659: ...eparator view 1 001 00445 1 Remove the front cover 001 Figure 11 21 from the housing of the water separator X72DF AA00 6708 00AAA 520A A Maintenance Manual Water separator remove Winterthur Gas Diesel...

Page 660: ...OTE Depending on the specific engine the sight glass beside the blower can interfere with the above step In this case add a 20mm distance plate between the tool and the underslung frame 4 Attach the l...

Page 661: ...7 Attach the shackles 004 and 005 and the spur geared chain blocks 003 and 006 to the lugs of the platform at the exhaust side 8 Put the spur geared chain block 003 into the last hole of the lifting...

Page 662: ...the lever chain hoist 001 and the spur geared chain block 003 until the water separator is fully out of the casing 11 Remove the lever chain hoist 001 and the disassembly tool 002 X72DF AA00 6708 00A...

Page 663: ...it hangs vertical to the spur geared chain block 001 13 1 Loosen or tighten the spur geared chain block 001 13 2 Loosen or tighten the spur geared chain block 002 14 Use the engine room crane to move...

Page 664: ...nt Description Part No CSN QTY Lifting tool 94667 3 Disassembly tool 94667H 1 Lever chain hoist 94016 x x 1 Shackle 94018C 2 Spur geared chain block 94017 x x 2 Holder 94667G 1 Supplies Description QT...

Page 665: ...r cover from the housing of the water separator 2 Install the holder 001 Figure 11 26 to the housing 3 Put the lever chain hoist 002 into the holder 001 X72DF AA00 6708 00AAA 720A A Maintenance Manual...

Page 666: ...ng 5 Make sure that the water separator 003 is in the correct position 6 Put the chain 004 into the lifting tool on the rear side of the water separator 003 7 Operate the lever chain hoist 005 until t...

Page 667: ...water separator 004 9 Operate the spur geared chain block 001 to lift the water separator slightly 10 Operate the lever chain hoist 005 Figure 11 27 until the water separator 004 Figure 11 28 is at t...

Page 668: ...st 003 Figure 11 29 the lifting tool 001 and the holder 002 13 Remove all chain blocks and tools 14 Attach the covers to the water separator CLOSE UP None X72DF AA00 6708 00AAA 720A A Maintenance Manu...

Page 669: ...2 2 Integrated electric balancer remove the bearing engine side 690 12 2 3 Integrated electric balancer remove the bearing outer side 694 12 2 4 Integrated electric balancer do a check of the bearing...

Page 670: ...rs Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PR...

Page 671: ...rts in the cylinder liner while the lubricating system operates 8 Make sure that the lubricating oil flows correctly on to the cylinder liner wall 9 Make sure that the oil that flows has no air If nec...

Page 672: ...ts after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Descrip...

Page 673: ...to the Operation Manual for more data 2 2 Select the applicable cylinder number 2 3 If necessary change the number of lube pulses in the range 0 to 200 2 4 On the pipe 004 use an open ended wrench to...

Page 674: ...Fig 12 2 Cylinder lubrication system bleed X72DF AA00 7218 00AAA 231A A Maintenance Manual Cylinder lubrication system bleed Winterthur Gas Diesel Ltd 674 Issue 002 2020 10...

Page 675: ...CLOSE UP None X72DF AA00 7218 00AAA 231A A Maintenance Manual Cylinder lubrication system bleed Winterthur Gas Diesel Ltd 675 Issue 002 2020 10...

Page 676: ...rsonnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUT...

Page 677: ...tray under the pipes 008 NOTE The number of pipes is related to the engine 10 Remove the pipes 008 11 Hold the weight of the cylinder lubricating pump 009 12 Remove the screws 002 13 Remove the cylin...

Page 678: ...Fig 12 3 Cylinder lubricating pump MK E example remove CLOSE UP None X72DF AA00 7206 00AAA 520A A Maintenance Manual Cylinder lubricating pump remove Winterthur Gas Diesel Ltd 678 Issue 002 2020 10...

Page 679: ...X72DF AA00 7206 00AAA 520A A Maintenance Manual Cylinder lubricating pump remove Page left intentionally blank Winterthur Gas Diesel Ltd 679 Issue 002 2020 10...

Page 680: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 681: ...3 1 Remove the non return valves 3 2 Blow air on the non return valves with your mouth 3 3 If air comes out clean the valve seat 3 4 Install the non return valves 4 Do a function test of the cylinder...

Page 682: ...pecialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Torque wrench A R 1 Supplies Description QTY Mineral oil SAE 50 A R Loctite thread sealant No 542 A R GP grease A R...

Page 683: ...ith the help of the four holes in the center of the main piston 012 NOTE Do not use the holes for the plungers 014 for this step 1 7 Push out the slide rod 008 with an applicable tool 1 8 Remove the O...

Page 684: ...rque it to 25 Nm 3 4 Apply a thin layer of oil to the piston joint ring 009 3 5 Install the piston joint ring 009 to the slide rod 008 3 6 Install the slide rod 008 into the housing in the correct dir...

Page 685: ...X72DF AA00 7206 00AAA 200A A Maintenance Manual Cylinder lubricating pump MK E do a service Page left intentionally blank Winterthur Gas Diesel Ltd 685 Issue 002 2020 10...

Page 686: ...ription Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY Cylinder lubricating pump A R S...

Page 687: ...electrical connection to the 4 2 way valve 011 6 Connect the electrical connection to the pressure transmitter 007 7 Attach the pipes 001 003 and 004 to the cylinder lubricating pump refer to your not...

Page 688: ...rming the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY None Supplies Description Q...

Page 689: ...nder applicable oil pipe 002 5 Remove the applicable oil pipe 002 to get access to the balancer shafts Fig 12 6 Integrated electric balancer 00540 002 001 001 DRIVING END FREE END FUEL SIDE CLOSE UP N...

Page 690: ...fting tool 94704 1 M20 x 140 mm screws NA 2 Supplies Description QTY Oil AR Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Use the correct equipment to lift and...

Page 691: ...o 60 Nm 1 8 Apply oil to the thread and bottom of the head of the clamping screw 009 and the nut 011 1 9 Remove the two screws 003 from the cover 001 1 10 Put the two clamping screws 009 and the nuts...

Page 692: ...ngine side remove the four screws 003 and the locking plates 009 on the bearing cover 2 7 Remove the bearing cover 004 2 8 Remove the eight screws 002 and the locking plates 010 from the bearing 005 F...

Page 693: ...14 Tighten equally the two bolts to push out the bearing 007 NOTE The bearing 007 moves on to the lifting tool 001 2 15 Tighten screw 002 to hold the bearing 007 2 16 Loosen the nut 003 2 17 Operate...

Page 694: ...x 140 mm screws NA 2 Supplies Description QTY Oil AR Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Use the correct equipment to lift and move the bearing This w...

Page 695: ...Nm 1 8 Apply lubricating oil to the thread and bottom of the head of the clamping screw 009 and the nut 011 1 9 Remove the two screws 003 from the cover 001 1 10 Put the two clamping screws 009 and th...

Page 696: ...earing remove I I 003 00580 001 I I OUTER SIDE 002 004 II II ENGINE SIDE 2 4 Attach the lifting tool 002 Figure 12 12 to the engine room crane 001 and move it in front of the bearing 006 2 5 Tighten l...

Page 697: ...bearing moves on to the lifting tool 002 2 9 Tighten the screw 007 to hold the bearing 006 2 10 Operate the engine room crane 001 to hold the weight of the bearing 006 2 11 Carefully remove the screw...

Page 698: ...ompletion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY Feeler gauge 94122 1 Supplies Description QTY Loctite No 640...

Page 699: ...g then continue from Step 8 Refer to 12 2 2 Integrated electric balancer remove the bearing engine side 12 2 3 Integrated electric balancer remove the bearing outer side 12 2 9 Integrated electric bal...

Page 700: ...e 002 Figure 12 14 Fig 12 14 Integrated electric balancer 00540 002 001 001 DRIVING END FREE END FUEL SIDE 16 Open the oil inlet 17 Start the lubricating oil supply CLOSE UP None X72DF AA00 7758 00AAA...

Page 701: ...X72DF AA00 7758 00AAA 360A A Maintenance Manual Integrated electric balancer do a check of the bearing clearance Page left intentionally blank Winterthur Gas Diesel Ltd 701 Issue 002 2020 10...

Page 702: ...te AR Support equipment Description Part No CSN QTY Alignment tools 94705 2 Drill NA 1 Reamer NA 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS NOTE It...

Page 703: ...lignment tool 003 Figure 12 16 with screws 004 to the front and rear of the top bearings 007 4 Torque the four screws 004 to 280 Nm 5 Tighten equally the four screws 002 6 Turn equally the two screw 0...

Page 704: ...cally the bolts 005 007 008 010 refer to Figure 12 15 11 Measure the backlash again refer to section 12 2 8 Integrated electric balancer do a check of the backlash 12 Use a drill and a reamer to drill...

Page 705: ...X72DF AA00 7758 00AAA 271A A Maintenance Manual Integrated electric balancer adjust the bearings Page left intentionally blank Winterthur Gas Diesel Ltd 705 Issue 002 2020 10...

Page 706: ...after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Des...

Page 707: ...3 3 Remove the proximity sensor 002 from the sensor adapter 001 Fig 12 17 Proximity sensor remove ZS5401C DRVING END 00584 002 I I I I ZS5405C FREE END 003 001 CLOSE UP None X72DF AA00 7762 00AAA 520A...

Page 708: ...b completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description...

Page 709: ...If applicable make sure that no failure shows in the control box of the Lenze Drive system NOTE Different designs have a Lenze Drive system installed This system has a control box installed in the co...

Page 710: ...0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY Turning device 94703 1 Supplies Description QTY Lead wire 1 0 mm width...

Page 711: ...the electric motor 006 and the bottom gear wheel 005 NOTE You can get access to the service hole and bottom gear wheel in the engine 5 Use the turning device 004 to turn the bottom bearing and move th...

Page 712: ...CLOSE UP None X72DF AA00 7758 00AAA 360B A Maintenance Manual Integrated electric balancer do a check of the backlash Winterthur Gas Diesel Ltd 712 Issue 002 2020 10...

Page 713: ...X72DF AA00 7758 00AAA 360B A Maintenance Manual Integrated electric balancer do a check of the backlash Page left intentionally blank Winterthur Gas Diesel Ltd 713 Issue 002 2020 10...

Page 714: ...n Part No CSN QTY Lifting tool 94704 1 Lever chain hoist 94016 008 1 Eye bolt 94045 1 Supplies Description QTY Molykote D AR Loctite No 640 AR Spare Parts Description Part No CSN QTY Bearing 1 SAFETY...

Page 715: ...the nut 006 through the bearing 007 into the pin 009 10 Tighten the screw 005 11 Find the taper bin holes in the column 008 Fig 12 20 Bearing install 002 ENGINE SIDE 00582 001 003 005 006 009 008 Moly...

Page 716: ...ort equipment Description Part No CSN QTY Lifting tool 94704 1 Supplies Description QTY Molykote D AR Loctite No 640 AR Spare Parts Description Part No CSN QTY Bearing 1 SAFETY PRECAUTIONS CAUTION Inj...

Page 717: ...sition in front of the column 007 8 Apply Molykote D to the bearing surface of the pin 001 9 Attach the screw 004 together with the nut 003 through the bearing 002 to the pin 001 10 Find the taper pin...

Page 718: ...CLOSE UP None X72DF AA00 7758 00AAA 720B A Maintenance Manual Integrated electric balancer install the bearing outer side Winterthur Gas Diesel Ltd 718 Issue 002 2020 10...

Page 719: ...fore removal 744 13 3 2 HP fuel pipe fuel rail to injection valve remove 746 13 3 3 HP fuel pipe fuel rail to injection valve grind the sealing face 748 13 3 4 HP fuel pipe fuel rail to injection valv...

Page 720: ...ours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY...

Page 721: ...our screws 018 from the flange 019 7 Move the flange 019 up 8 Remove the four screws 013 from the flange 012 9 Remove the two screws and nuts 011 from the intermediate piece 016 10 Carefully remove th...

Page 722: ...Fig 13 1 Servo oil pipes remove X72DF AA00 8447 00AAA 520A A Maintenance Manual HP servo oil pipe remove Winterthur Gas Diesel Ltd 722 Issue 002 2020 10...

Page 723: ...CLOSE UP None X72DF AA00 8447 00AAA 520A A Maintenance Manual HP servo oil pipe remove Winterthur Gas Diesel Ltd 723 Issue 002 2020 10...

Page 724: ...hours Support equipment Description Part No CSN QTY Grinding tool 94841 1 Supplies Description QTY Compound grade No 200 A R Compound grade No 500 A R Spare Parts Description Part No CSN QTY O ring 1...

Page 725: ...lange 002 7 Remove the cloth from the opening in the HP servo oil pipe 001 8 Remove the cloth from the opening in the HP servo oil pipe 001 9 Make sure that the claw 004 is correctly attached to the H...

Page 726: ...oil pipe grind and adjust 00960 X mm 005 001 002 004 003 006 001 CLOSE UP None X72DF AA00 8447 00AAA 655A A Maintenance Manual HP servo oil pipe grind the sealing face Winterthur Gas Diesel Ltd 726 I...

Page 727: ...X72DF AA00 8447 00AAA 655A A Maintenance Manual HP servo oil pipe grind the sealing face Page left intentionally blank Winterthur Gas Diesel Ltd 727 Issue 002 2020 10...

Page 728: ...ments after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Oil A R Spare Parts D...

Page 729: ...Attach the intermediate piece 013 to the plate with the two bolts 009 and nuts Do not tighten the bolts and nuts during this step 7 Carefully put the servo oil pipe 006 in position in the intermediate...

Page 730: ...Fig 13 3 Servo oil pipes install X72DF AA00 8447 00AAA 720A A Maintenance Manual HP servo oil pipe install Winterthur Gas Diesel Ltd 730 Issue 002 2020 10...

Page 731: ...CLOSE UP None X72DF AA00 8447 00AAA 720A A Maintenance Manual HP servo oil pipe install Winterthur Gas Diesel Ltd 731 Issue 002 2020 10...

Page 732: ...N QTY None SAFETY PRECAUTIONS WARNING Always put on gloves and safety goggles when you do work on hot components When drain screws and plugs are opened servo oil can come out as a spray and cause inju...

Page 733: ...he six screws 010 from the flange 005 4 Carefully move the flange 005 away from the top housing 001 5 Remove the six screws 008 from the flange 003 6 Carefully move the flange 003 away from the VCU 00...

Page 734: ...alve remove I I 003 004 005 001 002 II II 006 003 004 002 008 00956 009 010 004 005 001 II II I I 007 X72DF AA00 8460 00AAA 520A A Maintenance Manual Hydraulic pipe exhaust valve remove Winterthur Gas...

Page 735: ...CLOSE UP None X72DF AA00 8460 00AAA 520A A Maintenance Manual Hydraulic pipe exhaust valve remove Winterthur Gas Diesel Ltd 735 Issue 002 2020 10...

Page 736: ...Engine crew Basic AR Support equipment Description Part No CSN QTY Grinding tool 94841 1 Template 94841A 1 Hand drill N A 1 Supplies Description QTY Emery cloth A R Molyslip Copaslip paste A R Spare P...

Page 737: ...Nm 11 Put the hydraulic pipe 003 in a vice as vertically as possible 12 Adjust the speed of the hand drill to between 200 rpm and 500 rpm 13 Align the hand drill and the grinding tool 004 accurately w...

Page 738: ...lve grind sealing face 003 004 006 007 004 003 002 002 001 008 005 00957 CLOSE UP None X72DF AA00 8460 00AAA 655A A Maintenance Manual Hydraulic pipe exhaust valve grind the sealing face Winterthur Ga...

Page 739: ...X72DF AA00 8460 00AAA 655A A Maintenance Manual Hydraulic pipe exhaust valve grind the sealing face Page left intentionally blank Winterthur Gas Diesel Ltd 739 Issue 002 2020 10...

Page 740: ...Description QTY Oil A R Spare Parts Description Part No CSN QTY O rings 2 O rings 2 Hydraulic pipe 1 SAFETY PRECAUTIONS CAUTION Injury Hazard Use approved equipment or sufficient personnel to lift an...

Page 741: ...ic pipe exhaust valve 6 Apply oil to the threads of all the screws 008 010 7 Carefully put the hydraulic pipe 004 in position in the top housing 001 and the VCU 002 8 Torque symmetrically the screws 0...

Page 742: ...Fig 13 6 Hydraulic pipe exhaust valve install X72DF AA00 8460 00AAA 720A A Maintenance Manual Hydraulic pipe exhaust valve install Winterthur Gas Diesel Ltd 742 Issue 002 2020 10...

Page 743: ...CLOSE UP None X72DF AA00 8460 00AAA 720A A Maintenance Manual Hydraulic pipe exhaust valve install Winterthur Gas Diesel Ltd 743 Issue 002 2020 10...

Page 744: ...tion Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None...

Page 745: ...panel make sure that the pressure shows zero 2 Set to OFF the electrical trace heating system 3 On the applicable HP fuel pipe remove the insulation 001 Figure 13 7 4 Disconnect the electrical connec...

Page 746: ...onnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRE...

Page 747: ...9 and the and flow limiting valve 005 4 Apply protection to the sealing faces 002 006 and the open ends of the HP fuel pipe 001 Fig 13 8 HP fuel pipe removal I 001 00555 I II II III I I III II II 008...

Page 748: ...Intermediate 1 Support equipment Description Part No CSN QTY Grinding tool 94871 1 Stencil 94871A 1 Hand drill NA 1 Supplies Description QTY Emery paper different grades AR Polishing cloth AR Spare P...

Page 749: ...ded end of the HP fuel pipe 004 10 Attach the screw on sleeve 002 to the HP fuel pipe 004 11 Lock the screw on sleeve 002 to the HP fuel pipe 004 with the hexagon nut 003 12 Attach the grinding tool 0...

Page 750: ...et a smooth finish 21 Replace the emery cloth with a polishing cloth to polish the HP fuel pipe 004 22 Remove the tools from the HP fuel pipe 004 23 Clean the HP fuel pipe 004 24 Attach the claw to th...

Page 751: ...X72DF AA00 8733 00AAA 655A A Maintenance Manual HP fuel pipe fuel rail to injection valve grind the sealing face Page left intentionally blank Winterthur Gas Diesel Ltd 751 Issue 002 2020 10...

Page 752: ...nts after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Never Seez NSBT A...

Page 753: ...the correct value refer to section 16 1 Tightening instructions 6 Torque symmetrically the four Allen screws 007 to the correct value refer to section 16 1 Tightening instructions 7 Make sure that th...

Page 754: ...hers and nuts 005 9 Torque the bolts 004 10 Install the insulation 001 to the HP injection pipe 11 Connect the electrical connection 007 to the injection valve 006 X72DF AA00 8733 00AAA 720A A Mainten...

Page 755: ...pe completion 00560 007 001 001 I I I I 004 003 005 002 006 CLOSE UP None X72DF AA00 8733 00AAA 720A A Maintenance Manual HP fuel pipe fuel rail to injection valve install Winterthur Gas Diesel Ltd 75...

Page 756: ...No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Damage Hazard Make sure that you do not damage the sealing faces or the HP fuel pi...

Page 757: ...ge 007 a maximum of three turns 8 Move the HP fuel pipe 005 up Make sure that there is a distance of approximately 3 0 mm between the fuel pump cover 007 and the HP fuel pipe NOTE The fuel will drain...

Page 758: ...ew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Use approved eq...

Page 759: ...om the intermediate piece 010 7 Carefully remove the HP fuel pipe 001 8 Apply protection to the sealing faces to prevent damage and contamination 9 Remove the four screws 007 from the flange 009 10 Ca...

Page 760: ...1 Support equipment Description Part No CSN QTY Grinding tool 94870F 1 Screw on sleeve 94870E 1 Hexagon nut 94870G 1 Stencil 94870H 1 Hand drill NA 1 Supplies Description QTY Emery cloth AR Polishing...

Page 761: ...f the HP fuel pipe 004 7 Attach the HP fuel pipe 004 to a vice in a horizontal position 8 Attach the hexagon nut 003 to the HP fuel pipe 004 9 Turn the hexagon nut 003 to the threaded end of the HP fu...

Page 762: ...emery cloth for a smoother grade then do Step 1 to Step 19 again until you get a smooth finish 21 Replace the emery cloth with a polishing cloth to polish the HP fuel pipe 004 22 Remove the tools fro...

Page 763: ...X72DF AA00 8752 00AAA 655A A Maintenance Manual HP fuel pipe fuel pump to fuel rail grind the sealing face Page left intentionally blank Winterthur Gas Diesel Ltd 763 Issue 002 2020 10...

Page 764: ...ription Part No CSN QTY None Supplies Description QTY Never Seez NSBT AR Spare Parts Description Part No CSN QTY O rings HA1 58 8752 02 006 pc 8 HP fuel pipe HA1 58 8752 01 002 pc 1 HP fuel pipe HA1 5...

Page 765: ...aws with an open ended wrench 4 Make sure that the distance X between the ends of the HP fuel pipes 002 007 and their related claws 001 004 006 010 refers to Table 13 4 Distance X for HP fuel pipe Tab...

Page 766: ...5 Apply Never Seez NSBT to the threads of all the screws 002 005 007 and 012 Figure 13 16 X72DF AA00 8752 00AAA 720A A Maintenance Manual HP fuel pipe fuel pump to fuel rail install Winterthur Gas Di...

Page 767: ...screws 007 to the correct value refer to section 16 1 Tightening instructions 9 Carefully put the HP fuel pipe 001 in position in the intermediate piece 010 and the valve housing 004 10 Torque symmet...

Page 768: ...iption Part No CSN QTY Oil tray N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Damage Hazard Make sure that you do not cause damage to the...

Page 769: ...openings 3 6 Attach protection to the sealing faces of the pilot fuel pipe 005 or 008 3 7 Put the pilot fuel pipe 005 or 008 in a clean dry area 4 Remove the pilot fuel pipe 001 4 1 Put an oil tray un...

Page 770: ...Fig 13 17 Pilot fuel pipe remove X72DF AA00 8790 00AAA 520A A Maintenance Manual HP pilot fuel pipe remove Winterthur Gas Diesel Ltd 770 Issue 002 2020 10...

Page 771: ...CLOSE UP None X72DF AA00 8790 00AAA 520A A Maintenance Manual HP pilot fuel pipe remove Winterthur Gas Diesel Ltd 771 Issue 002 2020 10...

Page 772: ...CSN QTY Torque wrench 94014 1 Supplies Description QTY Oil A R Never Seez NSBT8 A R Spare Parts Description Part No CSN QTY Pilot fuel pipe 1 Pilot fuel pipe 1 Pilot fuel pipe 1 O ring type FKM A R O...

Page 773: ...correctly attached 5 Apply oil to all applicable coupling nuts 002 Figure 13 18 6 Make sure that the distance X between the ends of the pilot fuel pipes 001 and the claws 003 refers to Table 13 5 Dis...

Page 774: ...nstructions 8 Install the pilot fuel pipe 001 8 1 Attach the pilot fuel pipe 001 to the distributor block 006 and the connection on the rail unit 8 2 Apply Never Seez NSBT8 to surfaces that touch 8 3...

Page 775: ...Fig 13 19 Pilot fuel pipe install X72DF AA00 8790 00AAA 720A A Maintenance Manual HP pilot fuel pipe install Winterthur Gas Diesel Ltd 775 Issue 002 2020 10...

Page 776: ...CLOSE UP None X72DF AA00 8790 00AAA 720A A Maintenance Manual HP pilot fuel pipe install Winterthur Gas Diesel Ltd 776 Issue 002 2020 10...

Page 777: ...sensor unit flywheel install the proximity sensor 790 14 2 Selective catalytic reduction system SCR 14 2 1 SCR remove the valve 794 14 2 2 SCR install the valve 796 14 3 Electronic components 14 3 1...

Page 778: ...Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Before you operate the...

Page 779: ...applicable cable to identify its position 3 Disconnect the applicable electrical connection from the applicable proximity sensor 001 4 Loosen the locknut 003 5 Remove the proximity sensor 001 from the...

Page 780: ...II ST5133C ST5132C ST5131C ST5136C ST5135C ST5134C 001 002 004 S T 5131 36C 002 003 001 00969 X72DF AA00 9223 00AAA 520A A Maintenance Manual Crank angle sensor unit supply unit remove the proximity...

Page 781: ...CLOSE UP None X72DF AA00 9223 00AAA 520A A Maintenance Manual Crank angle sensor unit supply unit remove the proximity sensor Winterthur Gas Diesel Ltd 781 Issue 002 2020 10...

Page 782: ...ription Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY Proximity sensor A R SAFETY PRE...

Page 783: ...4 0 0 2 mm 3 Loosen the proximity sensor 001 a half turn to get a clearance of 4 0 0 2 mm between the flywheel tooth 004 and the bottom face of the proximity sensor 4 Carefully tighten the locknut 003...

Page 784: ...T5133C ST5132C ST5131C ST5136C ST5135C ST5134C 001 002 004 S T 5131 36C 002 003 001 00970 40 0 2 mm X72DF AA00 9223 00AAA 720A A Maintenance Manual Crank angle sensor unit supply unit install the prox...

Page 785: ...CLOSE UP None X72DF AA00 9223 00AAA 720A A Maintenance Manual Crank angle sensor unit supply unit install the proximity sensor Winterthur Gas Diesel Ltd 785 Issue 002 2020 10...

Page 786: ...AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Before you operate the turning gear make sur...

Page 787: ...the applicable cable to identify its position 3 Disconnect the applicable electrical connection from the proximity sensor 005 4 Loosen the locknut 002 5 Remove the proximity sensor 005 from the holder...

Page 788: ...r flywheel remove I 001 ZS 5125C ZS 5124C 003 004 002 005 II 00971 X72DF AA00 9223 00AAA 520B A Maintenance Manual Crank angle sensor unit flywheel remove the proximity sensor Winterthur Gas Diesel Lt...

Page 789: ...CLOSE UP None X72DF AA00 9223 00AAA 520B A Maintenance Manual Crank angle sensor unit flywheel remove the proximity sensor Winterthur Gas Diesel Ltd 789 Issue 002 2020 10...

Page 790: ...ription Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY Proximity sensor A R SAFETY PRE...

Page 791: ...40 0 2 mm between the crank angle mark 003 and the bottom face of the proximity sensor 005 4 Carefully tighten the locknut 002 with your fingers 5 Connect the electrical connection to the proximity se...

Page 792: ...wheel install I 001 ZS 5125C ZS 5124C 003 004 002 005 I 00972 40 0 2 mm X72DF AA00 9223 00AAA 720B A Maintenance Manual Crank angle sensor unit flywheel install the proximity sensor Winterthur Gas Die...

Page 793: ...CLOSE UP None X72DF AA00 9223 00AAA 720B A Maintenance Manual Crank angle sensor unit flywheel install the proximity sensor Winterthur Gas Diesel Ltd 793 Issue 002 2020 10...

Page 794: ...the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Lifting tool 94815 1 Supplies Des...

Page 795: ...d the screws from the flange to the SCR system 10 Remove the hexagon nuts and the screws from the flanges of the SCR valve 11 Remove the screws from the SCR valve on the SCR system side 12 Carefully o...

Page 796: ...rsonnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Lifting tool 94815 1 Supplies Description QTY None Spare Parts Description Part No CSN Q...

Page 797: ...licable sling in position on the connection pipe 13 Attach the sling to the hook of the engine room crane 14 Put the gasket in position 15 Carefully operate the engine room crane to put the connection...

Page 798: ...apter 94891 03 1 Valve 94891 04 1 Terminal block 94891 07 5 Extension cable 94891 05 1 Splash guard 94891 01 1 FKM hose 94891 06 1 Gas cylinder N A 1 Magnet 94891 08 1 Supplies Description QTY Calibra...

Page 799: ...detector 001 7 Put the gas detector 001 on a clean dry surface 8 If necessary attach the extension cable 004 to the electrical cable 002 NOTE If you use the extension cable 004 make sure that you use...

Page 800: ...valve 002 Figure 14 7 to the gas bottle 001 13 Attach the FKM hose 003 to the connection on the adapter 004 and the valve 002 X72DF AA00 9223 00AAA 273A A Maintenance Manual Gas detector calibrate Win...

Page 801: ...to OFF the power to the gas detector 16 Remove the adapter 001 Figure 14 8 17 Remove the splash guard 002 from the gas detector 003 18 Remove the indicator 004 19 Remove the terminal blocks 005 and t...

Page 802: ...Fig 14 8 Gas detector completion X72DF AA00 9223 00AAA 273A A Maintenance Manual Gas detector calibrate Winterthur Gas Diesel Ltd 802 Issue 002 2020 10...

Page 803: ...CLOSE UP None X72DF AA00 9223 00AAA 273A A Maintenance Manual Gas detector calibrate Winterthur Gas Diesel Ltd 803 Issue 002 2020 10...

Page 804: ...ompletion 0 0 man hours Personnel Description Specialization QTY Electronic Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN...

Page 805: ...1 3 Remove and discard the four cable ties 004 1 4 Disconnect the plugs X21 007 and X22 005 1 5 Disconnect the cables from the Ethernet connection 003 1 6 Disconnect the cables from the service connec...

Page 806: ...2 2 Do Step 1 2 to Step 1 11 CLOSE UP None X72DF AA00 9606 00AAA 520A A Maintenance Manual LDU 20 remove Winterthur Gas Diesel Ltd 806 Issue 002 2020 10...

Page 807: ...X72DF AA00 9606 00AAA 520A A Maintenance Manual LDU 20 remove Page left intentionally blank Winterthur Gas Diesel Ltd 807 Issue 002 2020 10...

Page 808: ...man hours Personnel Description Specialization QTY Electronic Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY LDU 20 H...

Page 809: ...the Ethernet connection 003 1 6 Connect the plugs X21 007 and X22 005 to the connections on the LDU 20 1 7 Attach four new cable ties 004 to the positions shown 1 8 Attach a new label to identify the...

Page 810: ...icable start the engine at the remote control system RCS refer to the Operation Manual NOTE The engine will do a standard start 2 To install an LDU 20 in the engine control room do the steps that foll...

Page 811: ...X72DF AA00 9606 00AAA 720A A Maintenance Manual LDU 20 install Page left intentionally blank Winterthur Gas Diesel Ltd 811 Issue 002 2020 10...

Page 812: ...ompletion 0 0 man hours Personnel Description Specialization QTY Electronic Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN...

Page 813: ...k up from the LDU 20 This will make sure that the correct configuration is loaded For more data speak to or send a message to WinGD 2 Remove the defective CCM 20 3 Attach an UNSERVICEABLE label to the...

Page 814: ...man hours Personnel Description Specialization QTY Electronic Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY CCM 20 H...

Page 815: ...download on the LDU 20 at the local control panel 4 If applicable start the engine refer to the Operation Manual NOTE The engine does an air run to find the crank angle for the installed CCM 20 After...

Page 816: ...ompletion 0 0 man hours Personnel Description Specialization QTY Electronic Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN...

Page 817: ...k up from the LDU 20 This will make sure that the correct configuration is loaded For more data speak to or send a message to WinGD 2 Remove the defective MCM 11 3 Attach an UNSERVICEABLE label to the...

Page 818: ...man hours Personnel Description Specialization QTY Electronic Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY MCM 11 H...

Page 819: ...TE You can monitor the software download on the MCM 11 at the local control panel 4 If applicable start the engine at the remote control system RCS refer to the Operation Manual NOTE The engine will d...

Page 820: ...ompletion 0 0 man hours Personnel Description Specialization QTY Electronic Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN...

Page 821: ...k up from the LDU 20 This will make sure that the correct configuration is loaded For more data speak to or send a message to WinGD 2 Remove the defective IOM 10 3 Attach an UNSERVICEABLE label to the...

Page 822: ...man hours Personnel Description Specialization QTY Electronic Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY IOM 10 H...

Page 823: ...TE You can monitor the software download on the IOM 10 at the local control panel 4 If applicable start the engine at the remote control system RCS refer to the Operation Manual NOTE The engine will d...

Page 824: ...X72DF AA00 9606 00ADA 720A A Maintenance Manual IOM 10 install Page left intentionally blank Winterthur Gas Diesel Ltd 824 Issue 002 2020 10...

Page 825: ...15 Tools 15 1 General for tools 826 15 2 Standard tools 828 15 3 Recommended tools 874 X72DF Maintenance Manual Winterthur Gas Diesel Ltd 825 Issue 002 2020 10...

Page 826: ...ll standard tools together with the engine Recommended tools Recommended tools are specially made for the engine They help to do the related maintenance work easier WinGD supplies these tools only if...

Page 827: ...X72DF AA00 0000 00AAA 018O A Maintenance Manual General for tools Page left intentionally blank Winterthur Gas Diesel Ltd 827 Issue 002 2020 10...

Page 828: ...Standard tools 002 027 001 041 037 058 070 075 029 036 038 039 042 056 059 069 071 074 081 084 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 828 Issue 002 20...

Page 829: ...096 076 077 080 087 095 097 099 102 103 104 X X 105 106 107 108 109 110 111 113 114 120 121 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 829 Issue 002 2020...

Page 830: ...112 115 116 117 118 119 X 123 126 127 128 129 130 132 133 136 140 141 142 143 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 830 Issue 002 2020 10...

Page 831: ...X X 144 145 146 147 149 151 152 153 154 155 156 157 158 159 161 162 165 164 163 166 167 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 831 Issue 002 2020 10...

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Page 833: ...Y X Z X X X X X 205 206 207 208 209 210 211 212 X X X Z 217 218 216 215 214 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 833 Issue 002 2020 10...

Page 834: ...220 221 X Y Z X X Y Y Z Z 223 229 225 231 227 233 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 834 Issue 002 2020 10...

Page 835: ...X X Y X X X Y X Y 235 237 239 242 240 243 245 253 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 835 Issue 002 2020 10...

Page 836: ...Y Y Y X Y 247 248 249 250 251 252 255 256 257 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 836 Issue 002 2020 10...

Page 837: ...259 261 262 264 263 265 266 267 268 269 275 276 270 273 271 272 274 277 278 279 280 281 282 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 837 Issue 002 2020...

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Page 839: ...X X X X X Y Y 310 311 312 313 314 315 318 319 320 321 322 X 323 X 324 325 328 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 839 Issue 002 2020 10...

Page 840: ...X X 326 X 327 X 330 332 334 336 337 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 840 Issue 002 2020 10...

Page 841: ...Y X X X 338 340 342 345 346 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 841 Issue 002 2020 10...

Page 842: ...X Y 348 349 350 352 353 354 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 842 Issue 002 2020 10...

Page 843: ...X X X Y Y 356 358 360 362 367 363 368 365 370 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 843 Issue 002 2020 10...

Page 844: ...X X X Y Y Y 364 369 371 373 375 377 376 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 844 Issue 002 2020 10...

Page 845: ...Y Y X X 379 380 382 383 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 845 Issue 002 2020 10...

Page 846: ...X X Y Z Y X Y 385 386 388 397 389 398 390 399 391 400 392 401 393 402 394 403 395 404 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 846 Issue 002 2020 10...

Page 847: ...X X X Y X Y X 406 409 415 410 416 411 417 412 418 414 420 421 423 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 847 Issue 002 2020 10...

Page 848: ...426 446 427 447 428 448 430 450 431 451 432 452 434 454 435 455 436 456 437 457 439 459 440 460 441 461 442 462 443 463 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Di...

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Page 850: ...Y X 517 X 515 518 Y 519 521 X X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 850 Issue 002 2020 10...

Page 851: ...523 Y Y 527 525 526 529 530 531 532 Y X X 534 537 538 535 536 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 851 Issue 002 2020 10...

Page 852: ...Y 540 544 546 547 548 549 X Y 551 552 X 554 555 556 557 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 852 Issue 002 2020 10...

Page 853: ...X 559 563 Y 565 566 567 568 Y 570 577 572 574 579 581 Y 575 582 X 571 578 573 580 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 853 Issue 002 2020 10...

Page 854: ...584 589 585 590 586 591 Y 587 592 X 597 Y 594 595 596 Y 598 599 600 601 X X X X 603 604 X X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 854 Issue 002 2020 1...

Page 855: ...Y 606 X 607 609 610 Y Y 611 Y 612 613 X 615 616 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 855 Issue 002 2020 10...

Page 856: ...619 618 620 621 X X 622 Y X 623 624 X X 626 625 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 856 Issue 002 2020 10...

Page 857: ...628 629 630 632 X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 857 Issue 002 2020 10...

Page 858: ...ination wrench SW26 023 3 94000 27 1 Piece Combination wrench SW27 024 3 94000 28 1 Piece Combination wrench SW28 025 3 94000 29 1 Piece Combination wrench SW29 026 3 94000 30 1 Piece Combination wren...

Page 859: ...1 Piece Special hexagon socket screw key SW17 070 1 94005 Tool general rods 071 1 94005 06 1 Piece Rod 6 mm 072 1 94005 08 1 Piece Rod 8 mm 073 1 94005 10 1 Piece Rod 10 mm 074 1 94005 15 1 Piece Rod...

Page 860: ...94934G 4 Pieces Coupling element 114 3 94935C 1 Piece Oil pipe drain For set up of pre tensioning jacks Length 2000 mm 115 3 94934 01 1 Piece Distributing piece 116 3 94934J 1 Piece Tredo joint For l...

Page 861: ...oot wrench SW30 156 2 KX 94111 1 Piece Socket wrench set AF10 24 26 28 30 32 33 34 36 157 2 KX 94112 1 Piece Hex head drivers AF5 10 12 14 17 158 2 94022H 1 Piece Dismantling and assembling tool AF12...

Page 862: ...of bearing cover 205 3 94117 1 Piece Roller support Y 327 mm 206 3 94117B 1 Piece Deviation pipe X 700 mm Z 140 mm 207 3 94118A 1 Piece Dismantling tool X 234 mm 208 3 94118B 1 Piece Dismantling tool...

Page 863: ...iece Platform X 240 mm Z 770 mm nil 1 Tool tie rod pre tensioning 245 2 94180 2 Pieces Pre tensioner X 308 mm nil 1 Tool cylinder liner assembly 247 2 94201 1 Piece Assembly tool Y 1195 mm 248 3 94201...

Page 864: ...91 2 94230 1 Piece Distance Y 1100 mm 292 2 94233 1 Piece Assembly tool Y 150 mm nil 1 Tool gland box assembly JIS nil 2 1 Piece Tool gland box assembly 295 3 94231D 2 Pieces Distance piece Thickness...

Page 865: ...mantling and assembling tool 337 3 TN 94114 1 Piece Assembly tool 338 3 TN 94115 1 Piece Valve seat dismantling device nil 1 Tool valve seat machining 340 2 94279 1 Piece Template Y 160 mm nil 1 Tool...

Page 866: ...1 Tool connec rod bearing assy 382 2 94333 1 Piece Lifting tool X 800 mm 383 4 94333A 2 Pieces Bolt Y 291 mm nil 1 Tool bear shell crank pin assy 385 2 94326 1 Piece Fitting and dismantling device X...

Page 867: ...ntermediate wheel assembly 423 2 94410 1 Piece Adjusting device X 248 mm nil 1 Tool supply unit assembly ISO 6 to 8 Cyl nil 2 1 Piece Tool camshaft assembly 426 3 94566 2 Pieces Supporting device X 92...

Page 868: ...593A 1 Piece Ring 468 5 94593B 1 Piece Ring 2 parts 469 4 94593C 2 Pieces Guide rod 470 4 94593D 2 Pieces Hexagon head bolt M12x130 471 4 94593E 4 Pieces Hexagon head bolt M12x130 472 3 94597 1 Piece...

Page 869: ...rts X 210 mm nil 1 Tool rail unit maintenance 515 3 KF 94256 1 Piece Adjusting device X 954 mm nil 1 Tool supply unit maintenance 517 2 TN 94075 1 Piece Assembly tool X 181 mm 518 3 TN 94164 1 Piece F...

Page 870: ...rger outlet and Scavenge air receiver 548 3 94653A A265 1 Piece Cover X 680 mm 600 mm Cover to exhaust manifold outlet 549 3 94653B A265 1 Piece Cover X 680 mm 600 mm Cover to turbocahrger inlet nil 1...

Page 871: ...ce Tool water separator assembly 585 3 94667H 1 Piece Disassembling tool X 540 mm 586 3 94667G 1 Piece Assembly tool Y 420 mm 587 3 94667 3 Pieces Lifting tool X 300 mm WLL 240 kg nil 1 Tool water sep...

Page 872: ...8 621 4 94870G 1 Piece Hexagon nut M36x2 AF46 622 3 94870H 1 Piece Stencil X 70 mm 623 2 94871 1 Piece Regrinding device Y 60 mm R30 624 3 94871A 1 Piece Stencil X 50 mm 625 2 TN 94079 1 Piece Regrind...

Page 873: ...X72DF AA00 0000 00AAA 941A C Maintenance Manual Standard tools Page left intentionally blank Winterthur Gas Diesel Ltd 873 Issue 002 2020 10...

Page 874: ...5 3 Recommended tools 001 X X 003 006 004 007 X 009 010 015 016 011 017 012 018 013 019 X72DF AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Winterthur Gas Diesel Ltd 874 Issue 002 2020 1...

Page 875: ...X 021 X 023 025 027 X 029 X 031 033 X72DF AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Winterthur Gas Diesel Ltd 875 Issue 002 2020 10...

Page 876: ...Y Y 036 035 X X X 038 042 039 043 040 044 X Y 046 047 X72DF AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Winterthur Gas Diesel Ltd 876 Issue 002 2020 10...

Page 877: ...element X 243 mm nil 1 Tool connecting rod assembly 023 2 TN 94129 1 Piece Fixing device X 750 mm nil 1 Tool Piston Assembly JIS 025 2 TN 94170 1 Piece Fixing device nil 1 Tool Piston Assembly ISO 027...

Page 878: ...X72DF AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Page left intentionally blank Winterthur Gas Diesel Ltd 878 Issue 002 2020 10...

Page 879: ...16 Tightening instructions 16 1 Tightening instructions 880 X72DF Maintenance Manual Winterthur Gas Diesel Ltd 879 Issue 002 2020 10...

Page 880: ...the document Tightening instructions for important connections of the engine Use the number of the design group to find the related connection X72DF AA00 0000 00AAA 018N A Maintenance Manual Tightenin...

Page 881: ...Approved Tightening Instructions Rev I Page 1 14...

Page 882: ...Approved Tightening Instructions Rev I Page 2 14...

Page 883: ...Approved Tightening Instructions Rev I Page 3 14...

Page 884: ...Approved Tightening Instructions Rev I Page 4 14...

Page 885: ...Approved Tightening Instructions Rev I Page 5 14...

Page 886: ...Approved Tightening Instructions Rev I Page 6 14...

Page 887: ...Approved Tightening Instructions Rev I Page 7 14...

Page 888: ...Approved Tightening Instructions Rev I Page 8 14...

Page 889: ...Approved Tightening Instructions Rev I Page 9 14...

Page 890: ...Approved Tightening Instructions Rev I Page 10 14...

Page 891: ...Approved Tightening Instructions Rev I Page 11 14...

Page 892: ...Approved Tightening Instructions Rev I Page 12 14...

Page 893: ...Approved Tightening Instructions Rev I Page 13 14...

Page 894: ...Approved Tightening Instructions Rev I Page 14 14...

Page 895: ...17 Maintenance overview 17 1 Maintenance overview 882 X72DF Maintenance Manual Winterthur Gas Diesel Ltd 881 Issue 002 2020 10...

Page 896: ...e pages that follow you find the document Maintenance Intervals Lifetime for the related components of the engine X72DF AA00 0000 00AAA 280C A Maintenance Manual Maintenance overview Winterthur Gas Di...

Page 897: ...Thrust bearing pads inspection is only necessary if bearing clearance oil analysis or crankcase inspection indicates excessive wear or damage at indications of excessive wear or damage Estimated life...

Page 898: ...Solenoid valve overhaul on board 18000 Estimated lifetime Starting valve engine lifetime Relief valve to cylinder cover Check blow off pressure as necessary Exhaust valve Group 27xx General inspectio...

Page 899: ...on piston in installed position and with running oil pump visual check through scavenge ports after installation Disassembly and assembly open cooling space and clean same min one piston each three y...

Page 900: ...0 Fuel pump Group 55xx Random flow check of lubricating oil 6000 Do a check of the fuel oil leakage from the fuel pump cover the O ring in the non return valve can become weak weekly Remanufacture fue...

Page 901: ...oard 45000 Cylinder lube oil filter Replace filter element before the cylinder lubricating system as necessary Electric balancer iElba Group 77xx Check bearing clearance see 0330 1 6000 Exhaust waste...

Page 902: ...to change without further notice Detail maintenance schedule is included in Maintenance Manuals for specific engine type 2 Intervals for inspection or overhauls and estimated lifetimes are estimates o...

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