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WinGD X82-B, Maintenance Manual

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6.3.1

Main bearing - bearing shell - No. 2 to # - prepare before removal. . . . . . . . . .

118

6.3.2

Main bearing - bearing shell - No. 2 to # - remove. . . . . . . . . . . . . . . . . . . . . . . .

120

6.3.3

Main bearing shell - No.2 to # - examine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130

6.3.4

Main bearing - bearing shell - No. 2 to # - install. . . . . . . . . . . . . . . . . . . . . . . . .

132

6.4

Main bearing cover - No. 1

6.4.1

Main bearing cover - No.1 - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

6.4.2

Main bearing cover - No.1 - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146

6.5

Main bearing cover - No. 2 to #

6.5.1

Main bearing cover - No. 2 to # - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152

6.5.2

Main bearing cover - No. 2 to #- install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

160

6.6

Thrust bearing

6.6.1

Thrust bearing - examine the housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

166

6.6.2

Thrust bearing - do a check of the axial clearance with a dial gauge. . . . . . . .

168

6.6.3

Thrust bearing - do a check of the axial clearance with a inside micrometer.

170

6.6.4

Thrust bearing - remove the pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174

6.6.5

Thrust bearing - install the pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

6.7

Engine stays

6.7.1

Engine stays (friction shims) - do a check of the pre-tension. . . . . . . . . . . . . . .

186

6.7.2

Engine stays (hydraulic) - do a check of the oil pressure. . . . . . . . . . . . . . . . . .

188

6.8

Tie rod

6.8.1

Tie rod - do a check of the pre-tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190

6.8.2

Tie rod - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192

6.8.3

Tie rod - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194

7

Group 2 - Cylinder

7.1

Cylinder liner

7.1.1

Cylinder liner - do a check of the bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200

7.1.2

Cylinder liner - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206

7.1.3

Cylinder liner - preserve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212

7.1.4

Cylinder liner - grind. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216

7.1.5

Cylinder liner - grind the lubricating groove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218

7.1.6

Cylinder liner - grind the scavenge ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220

7.1.7

Cylinder liner - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222

7.2

Lubricating quill

7.2.1

Lubricating quill - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

228

7.2.2

Lubricating quill - do a functional test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230

7.2.3

Lubricating quill - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232

7.3

Piston rod gland

7.3.1

Piston rod gland - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

236

7.3.2

Piston rod gland - do a check of the wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240

7.3.3

Piston rod gland - install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

242

7.4

Cylinder cover

7.4.1

Cylinder cover - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

246

X82-B

Maintenance Manual

Winterthur Gas & Diesel Ltd.

- 4 -

Issue 001 2020-10

Summary of Contents for X82-B

Page 1: ...l X82 B Issue 001 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: ...76 4 General maintenance procedures 4 1 Do maintenance work general procedure 80 4 2 Tighten a round nut with a pre tensioner 82 4 3 Loosen a round nut with a pre tensioner 86 4 4 Do a check of the p...

Page 4: ...ays 6 7 1 Engine stays friction shims do a check of the pre tension 186 6 7 2 Engine stays hydraulic do a check of the oil pressure 188 6 8 Tie rod 6 8 1 Tie rod do a check of the pre tension 190 6 8...

Page 5: ...aust valve remove the seat recommended procedure 308 7 7 4 Exhaust valve remove the seat alternative procedure 310 7 7 5 Exhaust valve do a check of the seat 312 7 7 6 Exhaust valve grind the seat 316...

Page 6: ...iston ring 8 8 1 Piston ring remove 490 8 8 2 Piston ring examine 492 8 8 3 Piston ring groove piston installed do a check with a ring piece 496 8 8 4 Piston ring groove piston removed do a check with...

Page 7: ...4 10 6 3 Injection control unit do the preservation 598 10 7 Supply unit 10 7 1 Supply unit camshaft and bearing shell prepare before removal 600 10 7 2 Supply unit camshaft and bearing shell remove 6...

Page 8: ...08 13 2 2 Hydraulic pipe exhaust valve grind the sealing face 712 13 2 3 Hydraulic pipe exhaust valve install 716 13 3 HP fuel pipe 13 3 1 HP fuel pipe fuel rail to injection valve remove 720 13 3 2 H...

Page 9: ...ecommended tools 814 16 Tightening instructions 16 1 Tightening instructions 824 17 Maintenance overview 17 1 Maintenance overview 826 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 9 Issue 001 20...

Page 10: ...X82 B Maintenance Manual Page left intentionally blank Winterthur Gas Diesel Ltd 10 Issue 001 2020 10...

Page 11: ...s 67 3 10 Piston and piston rings 68 3 11 Supply unit drive wheels 71 3 12 Fuel and servo pump units 73 3 13 Fuel pump 75 3 14 Torque value applicable decrease 76 3 15 Torque values standard screws 77...

Page 12: ...13 1 Distance X for HP servo oil pipe 701 13 2 Distance X for hydraulic pipe exhaust valve 717 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 12 Issue 001 2020 10...

Page 13: ...and servo pump units 72 3 13 Fuel pump 74 4 General maintenance procedures 4 1 Tighten a round nut examples 83 4 2 Loosen a round nut examples 87 4 3 Do a check of the pre tension examples 91 6 Group...

Page 14: ...4 6 39 Engine stays pressure check 189 6 40 Pre tension checks 191 6 41 Tie rod removal 193 6 42 Tie rod install 195 6 43 Tie rod apply tension 196 7 Group 2 Cylinder 7 1 Cylinder liner dimension chec...

Page 15: ...ion 289 7 39 Starting air valve removal 290 7 40 Starting air valve disassemble 293 7 41 Starting air valve grind 295 7 42 Starting air valve assemble 297 7 43 Starting air valve installation 299 7 44...

Page 16: ...88 8 28 Top end bearing remove 391 8 29 Bottom end bearing cover move 394 8 30 Bottom end bearing shell remove 395 8 31 Supports 396 8 32 Bottom end bearing 397 8 33 Top bearing shell remove 398 8 34...

Page 17: ...n install example 486 8 78 Piston rod gland attach example 487 8 79 Piston attach example 488 8 80 Piston ring remove example 491 8 81 Piston rings measure 493 8 82 Equation wear rate 494 8 83 Equatio...

Page 18: ...ve 592 10 24 ICU move 593 10 25 Injection control unit install 595 10 26 ICU connect pipes 596 10 27 Covers 601 10 28 Rollers lift 602 10 29 Oil baffle 603 10 30 Bearing shells remove 605 10 31 Camsha...

Page 19: ...9 676 12 Group 7 Cylinder lubrication 12 1 Cylinder lubrication system example do a functional test 679 12 2 Cylinder lubrication system bleed 682 12 3 Cylinder lubricating pump MK E example remove 68...

Page 20: ...wheel remove 754 14 2 Proximity sensor flywheel install 758 14 3 Proximity sensor remove 762 14 4 Proximity sensor install 766 15 Tools 15 1 Standard Tools 772 15 2 Recommended Tools 814 X82 B Mainten...

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: ...change Status New issue 001 2020 10 All data modules n a Initial issue of the fully new structured Maintenance Manual The existing Maintenance Manual published on 2018 12 is no more applicable X82 B...

Page 23: ...X82 B AA00 0000 00AAA 003B A Maintenance Manual Maintenance Manual change record Page left intentionally blank Winterthur Gas Diesel Ltd 23 Issue 001 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: ...X82 B AA00 0000 00AAA 018A A Maintenance Manual Preface Page left intentionally blank Winterthur Gas Diesel Ltd 25 Issue 001 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: ...X82 B AA00 0000 00AAA 018D A Maintenance Manual Data module codes descriptive data Page left intentionally blank Winterthur Gas Diesel Ltd 31 Issue 001 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: ...X82 B AA00 0000 00AAA 018F A Maintenance Manual Data module codes illustrated parts data Page left intentionally blank Winterthur Gas Diesel Ltd 33 Issue 001 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 X82 B 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: ...X82 B AA00 0000 00AAA 018L A Maintenance Manual About the engine Page left intentionally blank Winterthur Gas Diesel Ltd 41 Issue 001 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 X82 B AA00 0000 00AAA 005A A Maintenance Manual List of abbreviations Winterthur Gas...

Page 47: ...2 Safety 2 1 Safety precautions and safety rules 48 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 47 Issue 001 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: ...for maintenance 3 1 Lifting tools 52 3 2 Jointing compounds 56 3 3 Clearances general 58 3 4 Clearances 60 3 5 Torque values standard screws 76 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 51 Is...

Page 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...X82 B AA00 0000 00AAA 701A A Maintenance Manual Jointing compounds Page left intentionally blank Winterthur Gas Diesel Ltd 57 Issue 001 2020 10...

Page 58: ...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 59: ...X82 B AA00 0000 00AAA 034C A Maintenance Manual Clearances general Page left intentionally blank Winterthur Gas Diesel Ltd 59 Issue 001 2020 10...

Page 60: ...ction Nominal di mension usu al new mm Maximum clearance di mension be cause of wear mm 1203 Thrust bearing 1224 Thrust bearing pad Thickness 130 0 5 0 6 001 Thrust bearing clearance Axial total 0 8 t...

Page 61: ...3 4 2 Crankshaft and main bearings Fig 3 4 Crankshaft and Main Bearing X82 B AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 61 Issue 001 2020 10...

Page 62: ...rings of crank shaft half at free end 001 Bearing clearance Vertical 0 4 to 0 7 0 95 1132 Wide main bearing of crankshaft half at driving end 002 Bearing clearance Vertical 0 4 to 0 7 0 95 NOTE All ma...

Page 63: ...uide rail lateral clearance Total 0 60 to 2 00 2 5 006 Guide shoe lateral clearance Total 0 10 to 0 60 007 Crosshead pin Outer diameter 740 0 0 08 008 Bearing clearance Radial 0 09 to 0 22 0 25 NOTE F...

Page 64: ...Water guide jacket on cylinder cov er 001 Clearance Total 0 60 to 1 00 002 Clearance Total 1 60 to 2 00 003 Clearance Total 0 30 to 0 70 004 Clearance Total 0 60 to 1 00 2124 Cylinder liner 005 Cylin...

Page 65: ...width Radial 24 Minimum 22 20 003 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 NOT...

Page 66: ...mum clearance di mension be cause of wear mm 2754 Valve spindle 001 Spindle Outer diameter 80 0 19 0 23 79 40 2751 Guide bush 002 Bore Inner diameter 80 0 03 0 80 45 003 Bore Inner diameter 80 0 03 0...

Page 67: ...m 3303 3326 Top end bearing 001 Bearing clearance Vertical 0 4 to 0 8 1 0 002 Lateral clearance Total 0 5 to 0 8 003 Lateral clearance Total 0 35 to 0 65 3303 Bottom end bearing 004 Bearing clearance...

Page 68: ...ng grooves 007 Top groove height Vertical 24 0 55 0 50 011 Middle groove height Vertical 16 0 50 0 45 015 Bottom groove height Vertical 16 0 40 0 35 005 Top groove depth Radial 27 0 2 0 009 Middle gro...

Page 69: ...dle ring clearance Vertical 0 45 to 0 53 Point A 0 75 Point B 0 95 014 Bottom ring clearance Vertical 0 45 to 0 53 Point A 0 75 Point B 0 95 008 Top ring width Radial 26 0 40 012 Middle ring width Rad...

Page 70: ...3 4 9 Supply unit drive wheels Fig 3 11 Supply unit drive wheels X82 B AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 70 Issue 001 2020 10...

Page 71: ...ical 0 096 to 0 170 0 27 004 Tooth backlash 0 24 to 0 39 0 61 005 Tooth backlash 0 24 to 0 39 0 59 006 Tooth backlash 0 33 to 0 53 0 76 007 Tooth backlash 0 33 to 0 52 0 75 NOTE The backlash must be m...

Page 72: ...3 4 10 Fuel and servo pump units Fig 3 12 Fuel and servo pump units X82 B AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 72 Issue 001 2020 10...

Page 73: ...ause of wear mm 5581 Fuel pump unit 001 Axial clearance Total 0 30 to 0 65 0 81 002 Bearing clearance Radial 0 153 to 0 237 0 33 5591 Servo pump unit 004 Axial clearance Total 0 30 to 0 70 0 90 005 Ax...

Page 74: ...3 4 11 Fuel pump Fig 3 13 Fuel pump X82 B AA00 0000 00AAA 034C A Maintenance Manual Clearances Winterthur Gas Diesel Ltd 74 Issue 001 2020 10...

Page 75: ...Radial 0 22 to 0 68 0 8 005 Piston bottom spring carrier Axial 0 12 to 0 24 0 3 006 Regulating sleeve top spring car rier Axial 0 5 to 0 7 0 8 5556 Roller guide 003 Pin Outer diameter 80 0 0 013 Guide...

Page 76: ...er Seez NSBT8 Then you have to decrease the torque values refer to Table 3 14 Torque value applicable decrease These torques values do not apply to turbocharger installations Refer to the documents of...

Page 77: ...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 78: ...X82 B AA00 0000 00AAA 034A A Maintenance Manual Torque values standard screws Page left intentionally blank Winterthur Gas Diesel Ltd 78 Issue 001 2020 10...

Page 79: ...aintenance work general procedure 80 4 2 Tighten a round nut with a pre tensioner 82 4 3 Loosen a round nut with a pre tensioner 86 4 4 Do a check of the pre tension 90 X82 B Maintenance Manual Winter...

Page 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...X82 B AA00 0000 00AAA 711A A Maintenance Manual Tighten a round nut with a pre tensioner Page left intentionally blank Winterthur Gas Diesel Ltd 85 Issue 001 2020 10...

Page 86: ...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 87: ...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 88: ...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 89: ...X82 B AA00 0000 00AAA 510A A Maintenance Manual Loosen a round nut with a pre tensioner Page left intentionally blank Winterthur Gas Diesel Ltd 89 Issue 001 2020 10...

Page 90: ...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 91: ...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 92: ...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 93: ...5 Maintenance schedule 5 1 Maintenance schedule 94 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 93 Issue 001 2020 10...

Page 94: ...rease 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 Coo...

Page 95: ...1 6 4 1 Main bearing cover No 1 remove 140 6 4 2 Main bearing cover No 1 install 146 6 5 Main bearing cover No 2 to 6 5 1 Main bearing cover No 2 to remove 152 6 5 2 Main bearing cover No 2 to install...

Page 96: ...o CSN 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 SAFE...

Page 97: ...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 98: ...nnel Description Specialization QTY Engine crew Intermediate 3 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PREC...

Page 99: ...prevent movement 4 Install the platform refer to the related procedure 5 Set to off the main oil supply pumps 6 Close the oil lubrication to the main bearing CLOSE UP Remove the No 1 bearing shell re...

Page 100: ...5 4 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 Pressure gauge 9493...

Page 101: ...m below the bearing 2 2 Set to zero the dial gauge 006 2 3 Operate the HP oil pump to lift the crankshaft 007 to 0 3 mm 2 4 Make sure that the value on the dial gauge 006 is 0 3 mm 2 5 Make sure that...

Page 102: ...50 mm 50 mm 0 3 mm 004 3 Bearing shell remove 3 1 Attach the shackle WLL 2000 kg 004 Figure 6 3 to the position shown 3 2 Attach the 003 to the shackle 004 X82 B AA00 1132 00AAA 520A A Maintenance Ma...

Page 103: ...ate 008 3 6 Attach the chain block 003 to the middle hole in the lifting plate 008 3 7 Operate the chain block 003 to turn the bearing shell 002 a sufficient distance to attach the lifting tool 3 8 Re...

Page 104: ...07 I 002 003 004 006 007 005 006 009 006 002 I 008 3 10 Attach the lifting tool 002 Figure 6 4 to the bearing shell 003 X82 B AA00 1132 00AAA 520A A Maintenance Manual Main bearing bearing shell No 1...

Page 105: ...o attach the chain block 001 3 12 Attach the chain block 001 to the lifting tool 003 3 13 Operate the chain block 001 to lift the bearing shell 003 a small distance X82 B AA00 1132 00AAA 520A A Mainte...

Page 106: ...the engine 3 16 Remove the chain block 001 3 17 Operate the engine room crane to move the bearing shell 003 to an applicable area CLOSE UP Do an inspection of the bearing shell refer to 6 2 3 Main be...

Page 107: ...X82 B AA00 1132 00AAA 520A A Maintenance Manual Main bearing bearing shell No 1 remove Page left intentionally blank Winterthur Gas Diesel Ltd 107 Issue 001 2020 10...

Page 108: ...s 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 QTY None...

Page 109: ...s 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 shells 6 Do an inspection of the surface of the be...

Page 110: ...ng 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 1 B...

Page 111: ...PRELIMINARY OPERATIONS None X82 B AA00 1132 00AAA 720A A Maintenance Manual Main bearing bearing shell No 1 install Winterthur Gas Diesel Ltd 111 Issue 001 2020 10...

Page 112: ...f 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 002 1 6 Opera...

Page 113: ...e engine room crane from the lifting tool 002 1 10 Operate carefully the chain block 001 to lower the bearing shell 003 on to the crankshaft X82 B AA00 1132 00AAA 720A A Maintenance Manual Main bearin...

Page 114: ...e chain block 004 to the lifting plate 008 1 15 Operate carefully the chain block 001 to move the bearing shell 002 into the bearing girder on the fuel side 1 16 Make sure that the bearing shell 002 i...

Page 115: ...008 2 Crankshaft lower 2 1 On the HP oil pump release the pressure to fully lower the crankshaft 2 2 Remove the hydraulic rams 001 Figure 6 7 and the HP oil pump X82 B AA00 1132 00AAA 720A A Maintena...

Page 116: ...6 7 Crankshaft and flywheel lift 009 810 02 001 00606 Y1 Y2 003 001 005 002 007 008 006 50 mm 50 mm 0 3 mm 004 X82 B AA00 1132 00AAA 720A A Maintenance Manual Main bearing bearing shell No 1 install W...

Page 117: ...stall the No 1 bearing cover refer to 6 4 2 Main bearing cover No 1 install X82 B AA00 1132 00AAA 720A A Maintenance Manual Main bearing bearing shell No 1 install Winterthur Gas Diesel Ltd 117 Issue...

Page 118: ...onnel Description Specialization QTY Engine crew Intermediate 3 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRE...

Page 119: ...ement 4 Install the platform refer to the related procedure 5 Set to off the main oil supply pumps 6 Close the oil lubrication to the main bearing CLOSE UP Remove the applicable bearing shell No 2 to...

Page 120: ...P oil pump 94931 1 Pressure gauge 94934A 1 Steel beam N A 1 Steel plate N A 1 Bracket 94141 1 Roller support 94117A 1 Shackle 8500kg 94019L 1 Lever chain hoist 94016 0 8 5 5 1 Turning out device 94118...

Page 121: ...bearing shells at the same time Damage can occur to the bearing shells PRELIMINARY OPERATIONS Remove the applicable bearing cover refer to 6 5 1 Main bearing cover No 2 to remove X82 B AA00 1132 00AA...

Page 122: ...s install 1 1 Put the bracket 94141 003 Figure 6 8 on the main bearing girder as shown X82 B AA00 1132 00AAB 520A A Maintenance Manual Main bearing bearing shell No 2 to remove Winterthur Gas Diesel L...

Page 123: ...the two hydraulic rams 94936 001 on the bracket 003 as shown 1 3 Put the steel beam 004 in position as shown below the flywheel 005 1 4 Put the other hydraulic jack 001 on the beam 004 X82 B AA00 1132...

Page 124: ...d in Step 2 1 2 8 If the value of the lateral bearing clearance is more than 0 1 mm lower the crankshaft and do Step 2 8 1 to Step 2 8 3 2 8 1 Install the hydraulic rams 001 in position where the late...

Page 125: ...eviation pipes 94117B and 94117C 006 and 007 Figure 6 10 to the column as shown 3 8 Operate the lever chain hoist 003 to turn the bearing shell 002 until the center of the bearing shell is in a vertic...

Page 126: ...h the shackle 94019P 011 to the column 3 17 Attach the other chain block 010 to the shackle 011 and the lifting tool 001 3 18 Operate the chain block 010 to hold the weight of the bearing shell 002 3...

Page 127: ...Fig 6 10 Bearing shell_move X82 B AA00 1132 00AAB 520A A Maintenance Manual Main bearing bearing shell No 2 to remove Winterthur Gas Diesel Ltd 127 Issue 001 2020 10...

Page 128: ...l the bearing shell refer to 6 3 4 Main bearing bearing shell No 2 to install X82 B AA00 1132 00AAB 520A A Maintenance Manual Main bearing bearing shell No 2 to remove Winterthur Gas Diesel Ltd 128 Is...

Page 129: ...X82 B AA00 1132 00AAB 520A A Maintenance Manual Main bearing bearing shell No 2 to remove Page left intentionally blank Winterthur Gas Diesel Ltd 129 Issue 001 2020 10...

Page 130: ...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 QTY None...

Page 131: ...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 shells 6 Do an inspection of the surface of the bea...

Page 132: ...4117A 1 Shackle 8500kg 94019L 1 Lever chain hoist 94016 0 8 5 5 1 Turning out device 94118B 1 Lifting plate 94119A 1 Turning out device 94118C 1 Deviation pipe 94117B 1 Deviation pipe 94117C 1 Lifting...

Page 133: ...hen the platforms tools and or supports are installed This will cause injury to personnel and damage to equipment PRELIMINARY OPERATIONS None X82 B AA00 1132 00AAB 720A A Maintenance Manual Main beari...

Page 134: ...hat follow are clean and in good condition The crankshaft pin The girder bore for the bearing shell The bearing shell 1 2 Apply a very thin layer of Molykote paste G to the rear face of the bearing sh...

Page 135: ...rface of the bearing shell 002 are clean and fully lubricated with clean engine oil 1 4 Attach the lifting tool 001 to the bearing shell 002 X82 B AA00 1132 00AAB 720A A Maintenance Manual Main bearin...

Page 136: ...to lower the bearing shell 002 on to the crankshaft 1 13 Remove the chain block 005 and the lifting tool 002 1 14 Put the wire ropes 008 of the turning out device 010 Figure 6 12 over the bearing shel...

Page 137: ...SIDE EXHAUST SIDE 2 Crankshaft lower 2 1 On the HP oil pump release the pressure to fully lower the crankshaft 2 2 Remove the hydraulic rams 001 Figure 6 13 and the HP oil pump X82 B AA00 1132 00AAB...

Page 138: ...lywheel 009 810 02 001 00606 Y1 Y2 003 001 005 002 007 008 006 50 mm 50 mm 0 3 mm 004 X82 B AA00 1132 00AAB 720A A Maintenance Manual Main bearing bearing shell No 2 to install Winterthur Gas Diesel L...

Page 139: ...tall the bearing cover refer to 6 5 2 Main bearing cover No 2 to install X82 B AA00 1132 00AAB 720A A Maintenance Manual Main bearing bearing shell No 2 to install Winterthur Gas Diesel Ltd 139 Issue...

Page 140: ...500 kg 94017 028 1 Thrust device 94110 1 Lug 94116C 1 Shackle 6500 kg 94019K 1 Shackle 2000 kg 94019G 1 Thrust device 94110 1 HP oil pump 94931 1 Supplies Description QTY Copper paste A R Spare Parts...

Page 141: ...e 003 3 Do a check of the bearing clearance refer to 3 3 Clearances general 4 Remove the round nuts 004 refer to 4 3 Loosen a round nut with a pre tensioner X82 B AA00 1132 01AAA 520A A Maintenance Ma...

Page 142: ...00611 001 003 004 5 Attach the lug 001 Figure 6 15 to the bearing cover 002 6 Make sure that the thrust device 004 is clean X82 B AA00 1132 01AAA 520A A Maintenance Manual Main bearing cover No 1 remo...

Page 143: ...ith the cutouts in the bearing cover 002 13 Operate the HP oil pump 14 When oil that has no air flows out close the vent screw 007 15 Slowly increase the pressure to the correct value refer to the nam...

Page 144: ...ate the engine room crane to put a light tension on the chain 25 Remove the chain block 002 from the lug 94116C 003 26 Operate the engine room crane to move the bearing cover on to an applicable surfa...

Page 145: ...002 003 002 004 CLOSE UP Remove the No 1 bearing shell refer to 6 2 2 Main bearing bearing shell No 1 remove X82 B AA00 1132 01AAA 520A A Maintenance Manual Main bearing cover No 1 remove Winterthur...

Page 146: ...ock 2500kg 94017 028 1 Thrust device 94110 1 Lug 94116C 1 Shackle 6500 kg 94019K 1 Shackle 2000 kg 94019G 1 Thrust device 94110 1 HP oil pump 94931 1 Supplies Description QTY None Spare Parts Descript...

Page 147: ...towage 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 co...

Page 148: ...th two Allen screws 002 The spring dowel pins 001 help to get the bearing cover in position during installation Lower the bearing cover 003 on to the bearing girder 005 Make sure that the two spring d...

Page 149: ...ances 3 3 Clearances general NOTE If 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...

Page 150: ...21 Bearing cover oil pipe 00617 003 004 001 005 002 006 005 006 CLOSE UP None X82 B AA00 1132 01AAA 720A A Maintenance Manual Main bearing cover No 1 install Winterthur Gas Diesel Ltd 150 Issue 001 20...

Page 151: ...X82 B AA00 1132 01AAA 720A A Maintenance Manual Main bearing cover No 1 install Page left intentionally blank Winterthur Gas Diesel Ltd 151 Issue 001 2020 10...

Page 152: ...SN QTY Roller support 94117 1 Platform 94143 1 Deviation pipe 94117B 1 Thrust device 94110 1 Lug 94116C 1 Manual ratchet 94016 012 1 Eye bolt 94045 M56 1 Spur geared chain block 2500 kg 94017 028 2 Sp...

Page 153: ...ipment WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine PRELIMINARY OPERATIONS Do the preparation procedure given in 6 3 1 M...

Page 154: ...uts 001 refer to 4 3 Loosen a round nut with a pre tensioner Fig 6 22 Oil pipe and round nuts 002 001 00618 4 Attach the lug 94116C 001 Figure 6 23 to the main bearing cover 002 5 Make sure that the t...

Page 155: ...ith the cut outs of the bearing cover 002 11 Connect the HP oil pump 94931 to the thrust device 004 12 Operate the HP oil pump 13 When oil that has no air flows out close the vent screw 007 14 Slowly...

Page 156: ...ift the bearing cover 003 24 Attach the eye bolt 94045 M56 005 to the cylinder block 25 Attach the shackle 94019K 007 to the lug 006 on the bearing cover 003 26 Attach the chain block 94017 028 005 to...

Page 157: ...2 36 Remove the chain block 001 from the bearing cover 002 37 Operate the chain blocks 004 003 to move the bearing cover 002 out of the engine 38 When the bearing cover 002 hangs vertically remove the...

Page 158: ...to remove CLOSE UP Remove the applicable bearing shell 6 5 2 Main bearing cover No 2 to install X82 B AA00 1132 01AAB 520A A Maintenance Manual Main bearing cover No 2 to remove Winterthur Gas Diesel...

Page 159: ...X82 B AA00 1132 01AAB 520A A Maintenance Manual Main bearing cover No 2 to remove Page left intentionally blank Winterthur Gas Diesel Ltd 159 Issue 001 2020 10...

Page 160: ...chet 94016 012 1 Eye bolt 94045 M56 1 Spur geared chain block 2500 kg 94017 028 2 Spur geared chain block 2500 kg 94017 029 1 Deviation pipe 94117C 1 Sling 94039 015 1 Shackle 6500 kg 94019K 1 Shackle...

Page 161: ...work area and all tools and equipment must be clean and in good condition X82 B AA00 1132 01AAB 720A A Maintenance Manual Main bearing cover No 2 to install Winterthur Gas Diesel Ltd 161 Issue 001 202...

Page 162: ...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 002 8 Operate the HP oil pump 9 When...

Page 163: ...ing cover No 2 to _move 22 Attach the manual ratchet 004 Figure 6 29 to the column 23 Put the chain of the manual ratchet 004 through the roller 002 Attach the manual ratchet to the lug 006 on the bea...

Page 164: ...ackle 007 from the lug 006 29 Remove the lug 006 30 Install the round nuts 010 on the elastic studs 012 refer to 4 2 Tighten a round nut with a pre tensioner Fig 6 29 Bearing cover No 2 to install 31...

Page 165: ...nd compare the value measured in 6 5 1 Main bearing cover No 2 to remove with the value given in 3 3 Clearances general NOTE If the clearance is in the limits given the bearing can be removed and inst...

Page 166: ...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 167: ...essary remove particles from the area 001 4 Make sure th the channel 002 is clear 5 Install the cover 003 Fig 6 31 Visual examination 00624 002 003 001 CLOSE UP None X82 B AA00 1203 00AAA 310A A Maint...

Page 168: ...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 169: ...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 170: ...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 171: ...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 172: ...CLOSE UP None X82 B AA00 1203 00AAA 360B A Maintenance Manual Thrust bearing do a check of the axial clearance with a inside micrometer Winterthur Gas Diesel Ltd 172 Issue 001 2020 10...

Page 173: ...X82 B 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 173 Issue 001 2020 10...

Page 174: ...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 175: ...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 176: ...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 177: ...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 X82 B AA00 1203 00A...

Page 178: ...e same dimensions as a thrust pad 23 2 Put the hardwood in the position of the removed thrust pads CLOSE UP None X82 B AA00 1203 00AAA 520A A Maintenance Manual Thrust bearing remove the pads Winterth...

Page 179: ...X82 B AA00 1203 00AAA 520A A Maintenance Manual Thrust bearing remove the pads Page left intentionally blank Winterthur Gas Diesel Ltd 179 Issue 001 2020 10...

Page 180: ...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 181: ...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 182: ...ck of the clearances between the arbor supports and the thrust pads refer to section 6 6 2 Thrust bearing do a check of the axial clearance with a dial gauge or X82 B AA00 1203 00AAA 720A A Maintenanc...

Page 183: ...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 6 1 Thrust bearing examine the housing 19 For the configuration...

Page 184: ...Fig 6 38 Cover install 00020 001 CLOSE UP None X82 B AA00 1203 00AAA 720A A Maintenance Manual Thrust bearing install the pads Winterthur Gas Diesel Ltd 184 Issue 001 2020 10...

Page 185: ...X82 B AA00 1203 00AAA 720A A Maintenance Manual Thrust bearing install the pads Page left intentionally blank Winterthur Gas Diesel Ltd 185 Issue 001 2020 10...

Page 186: ...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 187: ...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 X82 B AA00 1715 00AAA 360A A Maintenance Manual Engine stays friction...

Page 188: ...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 189: ...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 190: ...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 191: ...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 192: ...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 193: ...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 194: ...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 195: ...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 196: ...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 197: ...nstall 256 7 5 Conventional injection valve 7 5 1 Conventional injection valve remove 262 7 5 2 Conventional injection valve prepare before the test 264 7 5 3 Conventional injection valve do a functio...

Page 198: ...aust valve grind the seat 316 7 7 7 Exhaust valve install the seat 318 7 7 8 Exhaust valve assemble 320 7 7 9 Exhaust valve install 328 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 198 Issue 001...

Page 199: ...X82 B Maintenance Manual Page left intentionally blank Winterthur Gas Diesel Ltd 199 Issue 001 2020 10...

Page 200: ...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 201: ...do work in areas where there are hot parts PRELIMINARY OPERATIONS The cylinder cover must be removed refer to section 7 4 1 Cylinder cover remove X82 B AA00 2124 00AAA 360A A Maintenance Manual Cylin...

Page 202: ...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 X82 B AA00 2124 00AAA 360A A Maintenance Manual Cylinder liner do a...

Page 203: ...4 Clean the area 001 above the running surface 002 5 Remove the bottom part of the measuring gauge 005 X82 B AA00 2124 00AAA 360A A Maintenance Manual Cylinder liner do a check of the bore Winterthur...

Page 204: ...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 205: ...X82 B AA00 2124 00AAA 360A A Maintenance Manual Cylinder liner do a check of the bore Page left intentionally blank Winterthur Gas Diesel Ltd 205 Issue 001 2020 10...

Page 206: ...pplies 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 refer...

Page 207: ...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 208: ...the pipes to the lubricating quills as follows 2 1 Remove the applicable pipe holders 2 2 Disconnect the related pipes X82 B AA00 2124 00AAA 520A A Maintenance Manual Cylinder liner remove Winterthur...

Page 209: ...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 210: ...Fig 7 4 Cylinder liner example move CLOSE UP None X82 B AA00 2124 00AAA 520A A Maintenance Manual Cylinder liner remove Winterthur Gas Diesel Ltd 210 Issue 001 2020 10...

Page 211: ...X82 B AA00 2124 00AAA 520A A Maintenance Manual Cylinder liner remove Page left intentionally blank Winterthur Gas Diesel Ltd 211 Issue 001 2020 10...

Page 212: ...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 213: ...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 214: ...Fig 7 6 Cylinder liner storage 2 CLOSE UP None X82 B AA00 2124 00AAA 810A A Maintenance Manual Cylinder liner preserve Winterthur Gas Diesel Ltd 214 Issue 001 2020 10...

Page 215: ...X82 B AA00 2124 00AAA 810A A Maintenance Manual Cylinder liner preserve Page left intentionally blank Winterthur Gas Diesel Ltd 215 Issue 001 2020 10...

Page 216: ...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 217: ...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 218: ...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 219: ...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 220: ...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 221: ...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 222: ...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 223: ...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 224: ...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 225: ...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 X82 B AA00 2124 00AAA 720A...

Page 226: ...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 227: ...X82 B AA00 2124 00AAA 720A A Maintenance Manual Cylinder liner install Page left intentionally blank Winterthur Gas Diesel Ltd 227 Issue 001 2020 10...

Page 228: ...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 229: ...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 230: ...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 231: ...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 232: ...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 233: ...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 234: ...example CLOSE UP Bleed the cylinder lubrication system refer to 12 1 2 Cylinder lubrication system bleed X82 B AA00 2138 00AAA 720A A Maintenance Manual Lubricating quill install Winterthur Gas Diesel...

Page 235: ...X82 B AA00 2138 00AAA 720A A Maintenance Manual Lubricating quill install Page left intentionally blank Winterthur Gas Diesel Ltd 235 Issue 001 2020 10...

Page 236: ...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 237: ...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 17 Piston rod gland remove and install 6 Remove the parts that follow Tension springs 0...

Page 238: ...Fig 7 18 Piston rod gland disassemble CLOSE UP None X82 B AA00 2303 00AAA 520A A Maintenance Manual Piston rod gland remove Winterthur Gas Diesel Ltd 238 Issue 001 2020 10...

Page 239: ...X82 B AA00 2303 00AAA 520A A Maintenance Manual Piston rod gland remove Page left intentionally blank Winterthur Gas Diesel Ltd 239 Issue 001 2020 10...

Page 240: ...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 241: ...d the O rings 008 are serviceable 3 If necessary replace the worn or the unserviceable parts Fig 7 19 Piston rod gland example Legend 001 4 part scraper ring 005 Spring 002 4 part gaskets 006 Ring sup...

Page 242: ...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 243: ...PRELIMINARY OPERATIONS None X82 B AA00 2303 00AAA 720A A Maintenance Manual Piston rod gland install Winterthur Gas Diesel Ltd 243 Issue 001 2020 10...

Page 244: ...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 245: ...the two parts of the housing 001 and 005 Figure 7 21 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 246: ...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 247: ...ngine must be stopped and made safe for maintenance refer to section 4 1 Do maintenance work general procedure X82 B AA00 2708 00AAA 520A A Maintenance Manual Cylinder cover remove Winterthur Gas Dies...

Page 248: ...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 23 and the pre tensioners in position abov...

Page 249: ...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 250: ...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 251: ...Fig 7 25 Cylinder cover and exhaust valve cage example CLOSE UP None X82 B AA00 2708 00AAA 520A A Maintenance Manual Cylinder cover remove Winterthur Gas Diesel Ltd 251 Issue 001 2020 10...

Page 252: ...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 253: ...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 254: ...26 Fuel injection valve position grind CLOSE UP None X82 B AA00 2708 00AAA 655A A Maintenance Manual Cylinder cover grind the sealing face for injection valve Winterthur Gas Diesel Ltd 254 Issue 001 2...

Page 255: ...X82 B AA00 2708 00AAA 655A A Maintenance Manual Cylinder cover grind the sealing face for injection valve Page left intentionally blank Winterthur Gas Diesel Ltd 255 Issue 001 2020 10...

Page 256: ...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 257: ...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 258: ...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 X82 B AA00 2708 00AAA 720A A Maintenan...

Page 259: ...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 28 Lifting tool pre tensioner example 26 Attach the cooling water pipe 2...

Page 260: ...CLOSE UP None X82 B AA00 2708 00AAA 720A A Maintenance Manual Cylinder cover install Winterthur Gas Diesel Ltd 260 Issue 001 2020 10...

Page 261: ...X82 B AA00 2708 00AAA 720A A Maintenance Manual Cylinder cover install Page left intentionally blank Winterthur Gas Diesel Ltd 261 Issue 001 2020 10...

Page 262: ...SN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury to personnel can occur Use applicable equipment or two persons to lift and move...

Page 263: ...an the injection valve 003 5 Attach protection to the nozzle tip Fig 7 29 Injection valve removal 001 002 003 004 005 00700 CLOSE UP If it is necessary to disassemble the injection valve refer to sect...

Page 264: ...gine crew Intermediate 1 Support equipment Description Part No CSN QTY Injector test bench 94272 1 Valve holder 94273 1 HP hose 94272E 1 Connecting piece 94272B 1 Leakage oil hose 94272D 1 Brass wire...

Page 265: ...ch the injection valve 004 to the valve holder 005 with the two spring cages 009 and the screws 010 6 Attach the connecting piece 007 to the injection valve 004 with the screws 011 7 Connect the leaka...

Page 266: ...akage oil hose 94272D 1 Supplies Description 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...

Page 267: ...han others If the test bench flow is not sufficient to open the needle of the injection valve you can use a clean additive type crankcase oil of SAE 30 viscosity PRELIMINARY OPERATIONS The test prepar...

Page 268: ...nd the nozzle as follows 7 1 Set the pressure of the test fluid at approximately 50 bar below the opening pressure 7 2 Monitor the injection valve for 30 seconds Look to see if test fluid comes out of...

Page 269: ...X82 B AA00 2722 01AAA 340A A Maintenance Manual Conventional injection valve do a functional test Page left intentionally blank Winterthur Gas Diesel Ltd 269 Issue 001 2020 10...

Page 270: ...se 94272E 1 Connecting piece 94272B 1 Leakage oil hose 94272D 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Do not put your fing...

Page 271: ...10 bar specified opening pressure p1 359 bar example of measured opening pressure C 39 bar mm ratio pressure spring deflection Thus H 6 375 359 39 6 4 mm 5 Install the related shim rings 001 with the...

Page 272: ...ic AR Support equipment Description 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...

Page 273: ...005 Figure 7 32 4 Make sure that the HP hose is disconnected from the connecting piece 5 Put the injection valve 005 in position in the valve holder 006 6 Attach the injection valve to the valve hold...

Page 274: ...00704 7 Turn the valve holder through 180 so that the nozzle tip 008 points up 8 Use the torque spanner 94011A 002 and adapter to carefully loosen the locknut 001 9 Remove the locknut 001 X82 B AA00 2...

Page 275: ...le 009 Tappet 013 NOTE The needle 009 and nozzle body 011 are machined together so that their sealing surfaces have the same differential angle and the same running clearance You must keep these items...

Page 276: ...lace 001 005 006 004 002 003 001 002 003 004 14 2 Attach the hexagonal nut 003 to the coupling nut 004 14 3 Put the plate 002 in the clearance between the nozzle body 006 and the nozzle tip 001 14 4 C...

Page 277: ...X82 B AA00 2722 01AAA 530A A Maintenance Manual Conventional injection valve disassemble Page left intentionally blank Winterthur Gas Diesel Ltd 277 Issue 001 2020 10...

Page 278: ...rs Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Torque spanner 94011A 1 Wrench extension 94022D 55 1 Wrench extension 94022D 70 1 Supplie...

Page 279: ...he cylinder 001 and the nozzle tip 008 into the guide bush 002 7 Use copper or rubber hammer to tap the cylinder 001 fully down 8 Turn the guide bush 002 counterclockwise to remove the guide bush and...

Page 280: ...ve to the center of the hand grip D2 the distance from the center of the square drive to the center of the adapter 18 Use the torque spanner 94011A 012 and wrench extension 94022D 70 to torque the cou...

Page 281: ...94022D 70 007 010 009 011 TS TT x D1 TS for coupling nut 002 200 x 530 D2 D1 175 Nm 223 Nm X 002 Example D2 D1 75 530 65 530 TS for lock nut 011 250 x 530 X82 B AA00 2722 01AAA 710A A Maintenance Manu...

Page 282: ...l the injection valve refer to section 7 5 7 Conventional injection valve install X82 B AA00 2722 01AAA 710A A Maintenance Manual Conventional injection valve assemble Winterthur Gas Diesel Ltd 282 Is...

Page 283: ...X82 B AA00 2722 01AAA 710A A Maintenance Manual Conventional injection valve assemble Page left intentionally blank Winterthur Gas Diesel Ltd 283 Issue 001 2020 10...

Page 284: ...crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY White spirit A R Never Seez NSBT A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION I...

Page 285: ...The distance Y is approximately 5 mm 7 Make sure that there are three groups of four cup springs 002 inside the bush 004 8 Make sure that the spring guide 001 holds the cup springs 002 9 Make sure th...

Page 286: ...HP fuel pipe refer to section 13 3 3 HP fuel pipe fuel rail to injection valve install X82 B AA00 2722 01AAA 720A A Maintenance Manual Conventional injection valve install Winterthur Gas Diesel Ltd 2...

Page 287: ...X82 B AA00 2722 01AAA 720A A Maintenance Manual Conventional injection valve install Page left intentionally blank Winterthur Gas Diesel Ltd 287 Issue 001 2020 10...

Page 288: ...pment Description Part No CSN QTY Long special screw recommended 942719B 2 Short special screw recommended 942719C 2 Cap recommended 942719D 2 Supplies Description QTY None Spare Parts Description Par...

Page 289: ...3 2 way solenoid valve 003 Figure 7 39 4 Remove the four screws 004 5 Carefully remove the starting air valve from the cylinder cover 001 NOTE If available you can use the long special screws 942719B...

Page 290: ...ig 7 39 Starting air valve removal 00710 004 I I I I 003 002 001 CLOSE UP None X82 B AA00 2728 01AAA 520A A Maintenance Manual Starting air valve remove Winterthur Gas Diesel Ltd 290 Issue 001 2020 10...

Page 291: ...X82 B AA00 2728 01AAA 520A A Maintenance Manual Starting air valve remove Page left intentionally blank Winterthur Gas Diesel Ltd 291 Issue 001 2020 10...

Page 292: ...n 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 QTY Non...

Page 293: ...from the valve spindle 004 6 Remove the compression spring 006 from the housing 003 7 Remove the valve spindle 004 from the housing 003 8 Remove and discard the O rings 002 005 Fig 7 40 Starting air v...

Page 294: ...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 295: ...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 296: ...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 Oil A R Spare P...

Page 297: ...ach the hexagon nut 008 to the valve spindle 004 9 Torque the hexagon nut 008 to 600 Nm 10 Tap the top of the valve spindle 004 with a soft mallet The valve spindle must spring back to its initial pos...

Page 298: ...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 299: ...r valve to the cylinder cover 002 with the four M20 bolts 004 4 Torque symmetrically the four M20 bolts 004 to the value given in 3 5 Torque values standard screws Fig 7 43 Starting air valve installa...

Page 300: ...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 301: ...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 302: ...011 from the valve cage and valve seat Fig 7 45 Exhaust valve removal 007 008 009 011 010 00718 003 004 005 001 006 002 X82 B AA00 2751 00AAA 520A A Maintenance Manual Exhaust valve remove Winterthur...

Page 303: ...CLOSE UP None X82 B AA00 2751 00AAA 520A A Maintenance Manual Exhaust valve remove Winterthur Gas Diesel Ltd 303 Issue 001 2020 10...

Page 304: ...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 305: ...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 306: ...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 307: ...Fig 7 47 Guide bush removal CLOSE UP None X82 B AA00 2751 00AAA 530A A Maintenance Manual Exhaust valve disassemble Winterthur Gas Diesel Ltd 307 Issue 001 2020 10...

Page 308: ...ecialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Valve seat tool 94261 1 Wooden support N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY N...

Page 309: ...e seat 001 5 Install the bottom two halves of the valve seat tool 005 into the groove of the valve cage 002 6 Turn equally the three jack screws 004 to push out the valve seat 001 from the valve cage...

Page 310: ...AR Support equipment Description Part No CSN QTY Eye bolts 94045 M24 2 Valve seat tool 94261 1 Wooden support N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PR...

Page 311: ...valve seat tool 004 into the groove of the valve seat 002 CAUTION Injury hazard Be careful when you do this step 6 Turn equally the four jack screws 005 until the valve seat 002 falls out of the valve...

Page 312: ...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 313: ...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 1 Exhaust valve clearance X Tab 7 1 Exhaust valve clearance X Engine type Cl...

Page 314: ...clearance I 00725 Engineer s blue paste mark I X 001 004 002 004 005 003 CLOSE UP None X82 B AA00 2751 01AAA 360A A Maintenance Manual Exhaust valve do a check of the seat Winterthur Gas Diesel Ltd 31...

Page 315: ...X82 B AA00 2751 01AAA 360A A Maintenance Manual Exhaust valve do a check of the seat Page left intentionally blank Winterthur Gas Diesel Ltd 315 Issue 001 2020 10...

Page 316: ...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 317: ...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 318: ...nel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY Valve seat tool 94261 1 Feeler gauge 94122 1 Supplies Description QTY Oil A R Never Seez NBST 8 A...

Page 319: ...e valve cage 003 7 Install the top two halves of the valve seat tool 001 into the groove of the valve seat 005 8 Install the bottom two halves of the valve seat tool 001 into the groove of the valve c...

Page 320: ...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 321: ...e 002 1 9 Put oil on the rod joint ring 007 1 10 Put the rod joint ring 007 in position Fig 7 53 Guide bush installation 2 Install the valve spindle 2 1 Measure the dimensions of the valve spindle 015...

Page 322: ...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 323: ...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 324: ...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 X82 B AA00 2...

Page 325: ...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 326: ...CLOSE UP Install the exhaust valve refer to section 7 7 9 Exhaust valve install X82 B AA00 2751 00AAA 710A A Maintenance Manual Exhaust valve assemble Winterthur Gas Diesel Ltd 326 Issue 001 2020 10...

Page 327: ...X82 B AA00 2751 00AAA 710A A Maintenance Manual Exhaust valve assemble Page left intentionally blank Winterthur Gas Diesel Ltd 327 Issue 001 2020 10...

Page 328: ...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 329: ...of oil to the new O rings 002 003 10 Attach the engine room crane 005 Figure 7 58 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 330: ...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 58 Expansion piece installation 22 Complete the insta...

Page 331: ...59 Exhaust valve complete the installation 001 003 004 005 006 00719 002 CLOSE UP None X82 B AA00 2751 00AAA 720A A Maintenance Manual Exhaust valve install Winterthur Gas Diesel Ltd 331 Issue 001 20...

Page 332: ...X82 B AA00 2751 00AAA 720A A Maintenance Manual Exhaust valve install Page left intentionally blank Winterthur Gas Diesel Ltd 332 Issue 001 2020 10...

Page 333: ...aring 390 8 5 5 Connecting rod remove the bottom end bearing 392 8 5 6 Connecting rod examine the bearing shells 400 8 5 7 Connecting rod install the bottom end bearing 402 8 5 8 Connecting rod instal...

Page 334: ...8 4 Piston ring groove piston removed do a check with a calliper gauge 498 8 8 5 Piston ring groove piston removed do a check 500 8 8 6 Piston ring install 502 8 8 7 Piston ring do the preservation 5...

Page 335: ...X82 B Maintenance Manual Page left intentionally blank Winterthur Gas Diesel Ltd 335 Issue 001 2020 10...

Page 336: ...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 337: ...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 338: ...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 339: ...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 340: ...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 341: ...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 X82 B AA00 3103 00AAA 360A A Maintenance Manual Crankshaft do a check o...

Page 342: ...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 343: ...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 X82 B AA00 3103 00AAA...

Page 344: ...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 345: ...columns 005 2 Remove the platform 004 from the crankshaft 002 and the longitudinal beam 003 Fig 8 6 Platforms CLOSE UP None X82 B AA00 3103 00AAA 520A A Maintenance Manual Crankshaft remove the work p...

Page 346: ...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 347: ...the torsional vibration damper related to the manufacturer s instructions CLOSE UP None X82 B AA00 3130 00AAA 310A A Maintenance Manual Torsional vibration damper examine Winterthur Gas Diesel Ltd 34...

Page 348: ...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 349: ...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 350: ...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 351: ...Fig 8 9 Axial vibration damper move CLOSE UP None X82 B AA00 3140 00AAA 530A A Maintenance Manual Axial vibration damper disassemble Winterthur Gas Diesel Ltd 351 Issue 001 2020 10...

Page 352: ...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 353: ...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 354: ...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 X82 B AA00 3140 00AAA 710A A Maintenance Manual Axial vibration damper assemble...

Page 355: ...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 356: ...Fig 8 12 Axial vibration damper housing and pipes CLOSE UP None X82 B AA00 3140 00AAA 710A A Maintenance Manual Axial vibration damper assemble Winterthur Gas Diesel Ltd 356 Issue 001 2020 10...

Page 357: ...X82 B AA00 3140 00AAA 710A A Maintenance Manual Axial vibration damper assemble Page left intentionally blank Winterthur Gas Diesel Ltd 357 Issue 001 2020 10...

Page 358: ...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 359: ...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 360: ...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 361: ...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 362: ...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 363: ...X82 B AA00 3206 00AAA 240A A Maintenance Manual Turning gear lubricate the teeth Page left intentionally blank Winterthur Gas Diesel Ltd 363 Issue 001 2020 10...

Page 364: ...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 365: ...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 366: ...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 X82 B AA00 3303 00AAA 523A A Mai...

Page 367: ...X82 B AA00 3303 00AAA 523A A Maintenance Manual Connecting rod prepare before removal Page left intentionally blank Winterthur Gas Diesel Ltd 367 Issue 001 2020 10...

Page 368: ...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 369: ...e connecting rod must be prepared for removal refer to section 8 5 1 Connecting rod prepare before removal X82 B AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winterthur Gas Diesel L...

Page 370: ...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 371: ...d move 15 NOTE During this step operate the chain block 002 Figure 8 20 to get the connecting rod to 45 X82 B AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winterthur Gas Diesel Ltd...

Page 372: ...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 373: ...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 X82 B AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winte...

Page 374: ...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 375: ...Fig 8 21 Connecting rod move 2 X82 B AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winterthur Gas Diesel Ltd 375 Issue 001 2020 10...

Page 376: ...CLOSE UP None X82 B AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Winterthur Gas Diesel Ltd 376 Issue 001 2020 10...

Page 377: ...X82 B AA00 3303 00AAA 520A A Maintenance Manual Connecting rod remove Page left intentionally blank Winterthur Gas Diesel Ltd 377 Issue 001 2020 10...

Page 378: ...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 Descrip...

Page 379: ...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 380: ...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 X82 B AA00 3303 00AAA 720A A Maintenance Manual Connecti...

Page 381: ...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 382: ...ck 002 Figure 8 24 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 X82 B AA00 3303 00AAA 720A A Maintenance...

Page 383: ...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 384: ...23 Operate the chain block 006 Figure 8 25 to lift the crosshead a small distance 24 Remove the two supports 001 X82 B AA00 3303 00AAA 720A A Maintenance Manual Connecting rod install Winterthur Gas...

Page 385: ...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 X82 B AA00 3303 00AAA 720A A Maintenance M...

Page 386: ...l lever chain hoists chain blocks eye bolts shackles and other equipment 28 Remove the protection from the crosshead pin X82 B AA00 3303 00AAA 720A A Maintenance Manual Connecting rod install Winterth...

Page 387: ...s in the position shown Fig 8 26 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 388: ...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 389: ...X82 B AA00 3303 00AAA 720A A Maintenance Manual Connecting rod install Page left intentionally blank Winterthur Gas Diesel Ltd 389 Issue 001 2020 10...

Page 390: ...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 391: ...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 392: ...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 393: ...nd bearing must be removed refer to section 8 5 4 Connecting rod remove the top end bearing X82 B AA00 3303 03AAA 520A A Maintenance Manual Connecting rod remove the bottom end bearing Winterthur Gas...

Page 394: ...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 395: ...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 30 Bottom end bearing shell r...

Page 396: ...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 397: ...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 398: ...ll remove 005 001 002 003 003 004 004 006 009 004 008 010 011 002 005 007 008 00768 X82 B AA00 3303 03AAA 520A A Maintenance Manual Connecting rod remove the bottom end bearing Winterthur Gas Diesel L...

Page 399: ...CLOSE UP None X82 B AA00 3303 03AAA 520A A Maintenance Manual Connecting rod remove the bottom end bearing Winterthur Gas Diesel Ltd 399 Issue 001 2020 10...

Page 400: ...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 401: ...2 If you find damage remove the bearing shell 001 refer to section 8 5 2 Connecting rod remove Fig 8 34 Visual examination CLOSE UP None X82 B AA00 3303 05AAA 310A A Maintenance Manual Connecting rod...

Page 402: ...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 403: ...you operate the turning gear make sure that no personnel are near the flywheel PRELIMINARY OPERATIONS None X82 B AA00 3303 03AAA 720A A Maintenance Manual Connecting rod install the bottom end bearing...

Page 404: ...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 405: ...he turning gear to move the crank 002 Figure 8 36 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 X82 B AA00 3303 03AAA 72...

Page 406: ...7 Loosen the screws 003 Figure 8 37 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 X82 B AA00 3303 03AAA 720A A Maintena...

Page 407: ...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 408: ...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 409: ...bearing install 006 007 004 008 009 001 002 003 004 005 002 X X 2 1 010 00773 X82 B AA00 3303 03AAA 720A A Maintenance Manual Connecting rod install the bottom end bearing Winterthur Gas Diesel Ltd 40...

Page 410: ...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 411: ...X82 B AA00 3303 03AAA 720A A Maintenance Manual Connecting rod install the bottom end bearing Page left intentionally blank Winterthur Gas Diesel Ltd 411 Issue 001 2020 10...

Page 412: ...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 413: ...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 414: ...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 415: ...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 416: ...Fig 8 41 Bearing lubrication CLOSE UP None X82 B AA00 3303 02AAA 720A A Maintenance Manual Connecting rod install the top end bearing Winterthur Gas Diesel Ltd 416 Issue 001 2020 10...

Page 417: ...X82 B AA00 3303 02AAA 720A A Maintenance Manual Connecting rod install the top end bearing Page left intentionally blank Winterthur Gas Diesel Ltd 417 Issue 001 2020 10...

Page 418: ...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 419: ...stopped and made safe for maintenance refer to section 4 1 Do maintenance work general procedure X82 B AA00 3303 01AAA 520A A Maintenance Manual Connecting rod remove the top end bearing cover Winter...

Page 420: ...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 421: ...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 422: ...emoval 001 002 003 004 005 006 007 008 001 003 009 006 010 009 003 001 011 012 00740 X82 B AA00 3303 01AAA 520A A Maintenance Manual Connecting rod remove the top end bearing cover Winterthur Gas Dies...

Page 423: ...CLOSE UP None X82 B AA00 3303 01AAA 520A A Maintenance Manual Connecting rod remove the top end bearing cover Winterthur Gas Diesel Ltd 423 Issue 001 2020 10...

Page 424: ...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 425: ...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 426: ...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 X82 B AA00 3303 01AAA 720A A...

Page 427: ...ing cover install 001 002 003 004 005 006 001 005 007 008 007 009 00742 X82 B AA00 3303 01AAA 720A A Maintenance Manual Connecting rod install the top end bearing cover Winterthur Gas Diesel Ltd 427 I...

Page 428: ...CLOSE UP None X82 B AA00 3303 01AAA 720A A Maintenance Manual Connecting rod install the top end bearing cover Winterthur Gas Diesel Ltd 428 Issue 001 2020 10...

Page 429: ...X82 B AA00 3303 01AAA 720A A Maintenance Manual Connecting rod install the top end bearing cover Page left intentionally blank Winterthur Gas Diesel Ltd 429 Issue 001 2020 10...

Page 430: ...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 431: ...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 432: ...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 433: ...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 434: ...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 435: ...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 436: ...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 437: ...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 438: ...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 439: ...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 440: ...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 X82 B AA00 3326 00AAA 520A A Maintenance Manual Crosshe...

Page 441: ...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 442: ...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 443: ...X82 B AA00 3326 00AAA 520A A Maintenance Manual Crosshead remove Page left intentionally blank Winterthur Gas Diesel Ltd 443 Issue 001 2020 10...

Page 444: ...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 445: ...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 446: ...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 447: ...X82 B AA00 3326 00AAA 360A A Maintenance Manual Crosshead do a check of the clearances Page left intentionally blank Winterthur Gas Diesel Ltd 447 Issue 001 2020 10...

Page 448: ...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 449: ...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 X82 B AA00 3326 00AAA 720A A Mainte...

Page 450: ...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 451: ...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 452: ...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 453: ...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 X82 B AA00 3326 0...

Page 454: ...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 X82 B AA00 3326 00AA...

Page 455: ...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 456: ...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 X82 B AA00 3326 00A...

Page 457: ...e top bearing cover refer to section section not applicable for this engine 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 458: ...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 459: ...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 460: ...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 461: ...X82 B AA00 3403 00AAA 360A A Maintenance Manual Piston installed do checks of the surface and clearances Page left intentionally blank Winterthur Gas Diesel Ltd 461 Issue 001 2020 10...

Page 462: ...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 463: ...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 464: ...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 465: ...ation before removal example 001 002 003 002 001 004 005 006 007 008 009 007 009 010 I X I 00780 X82 B AA00 3403 00AAA 523A A Maintenance Manual Piston prepare before removal Winterthur Gas Diesel Ltd...

Page 466: ...CLOSE UP None X82 B AA00 3403 00AAA 523A A Maintenance Manual Piston prepare before removal Winterthur Gas Diesel Ltd 466 Issue 001 2020 10...

Page 467: ...X82 B AA00 3403 00AAA 523A A Maintenance Manual Piston prepare before removal Page left intentionally blank Winterthur Gas Diesel Ltd 467 Issue 001 2020 10...

Page 468: ...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 469: ...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 470: ...CLOSE UP None X82 B AA00 3403 00AAA 520A A Maintenance Manual Piston remove Winterthur Gas Diesel Ltd 470 Issue 001 2020 10...

Page 471: ...X82 B AA00 3403 00AAA 520A A Maintenance Manual Piston remove Page left intentionally blank Winterthur Gas Diesel Ltd 471 Issue 001 2020 10...

Page 472: ...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 473: ...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 474: ...iston disassemble example 001 002 003 002 002 004 001 005 006 007 008 009 003 010 011 012 00781 X82 B AA00 3403 00AAA 530A A Maintenance Manual Piston disassemble Winterthur Gas Diesel Ltd 474 Issue 0...

Page 475: ...CLOSE UP None X82 B AA00 3403 00AAA 530A A Maintenance Manual Piston disassemble Winterthur Gas Diesel Ltd 475 Issue 001 2020 10...

Page 476: ...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 477: ...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 478: ...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 479: ...X82 B AA00 3403 00AAA 360B A Maintenance Manual Piston removed do checks of the surface and clearances Page left intentionally blank Winterthur Gas Diesel Ltd 479 Issue 001 2020 10...

Page 480: ...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 481: ...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 482: ...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 483: ...X82 B AA00 3403 00AAA 710A A Maintenance Manual Piston assemble Page left intentionally blank Winterthur Gas Diesel Ltd 483 Issue 001 2020 10...

Page 484: ...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 485: ...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 486: ...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 487: ...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 488: ...Fig 8 79 Piston attach example 001 002 003 002 004 005 006 007 00786 CLOSE UP None X82 B AA00 3403 00AAA 720A A Maintenance Manual Piston install Winterthur Gas Diesel Ltd 488 Issue 001 2020 10...

Page 489: ...X82 B AA00 3403 00AAA 720A A Maintenance Manual Piston install Page left intentionally blank Winterthur Gas Diesel Ltd 489 Issue 001 2020 10...

Page 490: ...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 491: ...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 492: ...pport equipment Description Part No CSN QTY Permascope MP0 with instruments to measure chrome ceramic layers 94356 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY P...

Page 493: ...ermascope MP0 001 against the middle of the piston ring 002 1 6 Record the value on the digital display of the Permascope MP0 001 1 7 Compare the measured data with the limits given in 3 3 Clearances...

Page 494: ...ulate the remaining service life of the piston Fig 8 83 Equation service time Where ST remaining service time hrs D2 second recorded thickness of the chrome ceramic layer mm Dmin Minimum thickness of...

Page 495: ...he chrome ceramic layer Fig 8 84 Chrome ceramic layer 4 If the thickness of the chrome ceramic layer is less than the limits given below replace the applicable piston ring Top piston ring more than 0...

Page 496: ...ne crew Intermediate AR Support equipment Description Part No CSN QTY feeler gauge 94122 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury...

Page 497: ...e of worn material on the chrome ceramic layer you can push the feeler gauge only to that point 5 Measure the clearance at X2 6 Do Step 4 and Step 5 at between two and four different locations around...

Page 498: ...Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY Calliper gauge N A 1 Inside micrometer set 94101 1 Supplies Description QTY None Spare Parts D...

Page 499: ...e calliper gauge 2 Record the value from the calliper gauge or the inside micrometer set NOTE If the clearance at point A or point B is more than the permitted value you must repair the piston head 3...

Page 500: ...hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY feeler gauge 94122 1 Supplies Description QTY None Spare Parts Description Part...

Page 501: ...he piston ring clearance C GH RT Where C Clearance GH the measured height of the piston ring groove mm RT the nominal piston ring thickness mm 5 Refer to 3 3 Clearances general for the maximum dimensi...

Page 502: ...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 503: ...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 504: ...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 Spare Pa...

Page 505: ...n rings are in a horizontal position on a flat surface 2 To prevent damage be careful when you prepare the piston rings for installation and during movement CLOSE UP None X82 B AA00 3425 01AAA 810A A...

Page 506: ...X82 B AA00 3425 01AAA 810A A Maintenance Manual Piston ring do the preservation Page left intentionally blank Winterthur Gas Diesel Ltd 506 Issue 001 2020 10...

Page 507: ...the teeth backlash 510 9 1 3 Driving wheel gear train monitor the condition 514 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 start...

Page 508: ...rmediate 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 th...

Page 509: ...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 510: ...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 511: ...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 512: ...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 X82 B AA00 4106 00AAA 360A A Maintenance Manual Gear wheel crankshaft do a check of the teeth backlash Wi...

Page 513: ...CLOSE UP None X82 B AA00 4106 00AAA 360A A Maintenance Manual Gear wheel crankshaft do a check of the teeth backlash Winterthur Gas Diesel Ltd 513 Issue 001 2020 10...

Page 514: ...port 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 turning gear...

Page 515: ...on each of the gear wheels 1 2 Operate the turning gear to turn the engine 1 3 Do a check of the marks on the gear wheel teeth and driving wheel teeth This makes sure that the teeth engage correctly a...

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 X82 B AA00 4325 00AAA 530A A Maintenance Manual Shut off valve for starting air disas...

Page 520: ...CLOSE UP None X82 B AA00 4325 00AAA 530A A Maintenance Manual Shut off valve for starting air disassemble Winterthur Gas Diesel Ltd 520 Issue 001 2020 10...

Page 521: ...X82 B AA00 4325 00AAA 530A A Maintenance Manual Shut off valve for starting air disassemble Page left intentionally blank Winterthur Gas Diesel Ltd 521 Issue 001 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 X82 B AA00 4325 00AAA 710A A Maintenance Manual Shut off...

Page 525: ...CLOSE UP None X82 B AA00 4325 00AAA 710A A Maintenance Manual Shut off valve for starting air assemble Winterthur Gas Diesel Ltd 525 Issue 001 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 X82 B AA00 4325 00AAA 320A A Maintenance Manual Shut off valve for starting air do a test of the operation Winte...

Page 529: ...ve 582 10 5 2 Fuel rail do a check of the overpressure safety valve 584 10 5 3 Fuel rail install the overpressure safety valve 588 10 6 Injection control unit 10 6 1 Injection control unit remove 590...

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 X82 B AA00 5551 00AAA 520A A Maintenance Manual Servo oil pump remove Winterthur Gas Diesel Ltd 533 Issue 001...

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: ...X82 B AA00 5551 00AAA 520A A Maintenance Manual Servo oil pump remove Page left intentionally blank Winterthur Gas Diesel Ltd 535 Issue 001 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 X82 B 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: ...X82 B AA00 5551 00AAA 720A A Maintenance Manual Servo oil pump install Page left intentionally blank Winterthur Gas Diesel Ltd 539 Issue 001 2020 10...

Page 540: ...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 541: ...closed 1 9 Remove the applicable HP fuel pipe s refer to section not applicable for this engine and section not applicable for this engine Fig 10 1 Fuel pump 003 004 006 008 007 00421 002 001 005 2 R...

Page 542: ...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 10 Remove the lifting equipment from th...

Page 543: ...X82 B AA00 5556 00AAA 520A A Maintenance Manual Fuel pump remove Page left intentionally blank Winterthur Gas Diesel Ltd 543 Issue 001 2020 10...

Page 544: ...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 545: ...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 2 Guide pin removal 003 00422 004 0...

Page 546: ...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 547: ...nger 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 548: ...he 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 Remo...

Page 549: ...ced 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 550: ...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 551: ...ble 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 552: ...09 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 the...

Page 553: ...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 follow...

Page 554: ...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 555: ...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 11 to the position shown 10 2 Put the spacer 003 in the positio...

Page 556: ...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 557: ...X82 B AA00 5556 00AAA 710A A Maintenance Manual Fuel pump assemble Page left intentionally blank Winterthur Gas Diesel Ltd 557 Issue 001 2020 10...

Page 558: ...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 559: ...tion 8 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 connec...

Page 560: ...ng gear to move the cam Make sure that there are no leaks or an unusual temperature increase CLOSE UP None X82 B AA00 5556 00AAA 720A A Maintenance Manual Fuel pump install Winterthur Gas Diesel Ltd 5...

Page 561: ...X82 B AA00 5556 00AAA 720A A Maintenance Manual Fuel pump install Page left intentionally blank Winterthur Gas Diesel Ltd 561 Issue 001 2020 10...

Page 562: ...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 563: ...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 564: ...CLOSE UP None X82 B AA00 5556 00AAA 320A A Maintenance Manual Fuel pump do a test of the operation Winterthur Gas Diesel Ltd 564 Issue 001 2020 10...

Page 565: ...X82 B AA00 5556 00AAA 320A A Maintenance Manual Fuel pump do a test of the operation Page left intentionally blank Winterthur Gas Diesel Ltd 565 Issue 001 2020 10...

Page 566: ...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 567: ...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 568: ...CLOSE UP None X82 B AA00 5583 00AAA 273A A Maintenance Manual Fuel pump actuator calibrate Winterthur Gas Diesel Ltd 568 Issue 001 2020 10...

Page 569: ...X82 B AA00 5583 00AAA 273A A Maintenance Manual Fuel pump actuator calibrate Page left intentionally blank Winterthur Gas Diesel Ltd 569 Issue 001 2020 10...

Page 570: ...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 571: ...move the screws 009 Figure 10 16 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 572: ...Fig 10 16 Actuator adjust 2 009 008 007 006 CLOSE UP None X82 B AA00 5583 00AAA 360A A Maintenance Manual Fuel pump actuator adjust Winterthur Gas Diesel Ltd 572 Issue 001 2020 10...

Page 573: ...X82 B AA00 5583 00AAA 360A A Maintenance Manual Fuel pump actuator adjust Page left intentionally blank Winterthur Gas Diesel Ltd 573 Issue 001 2020 10...

Page 574: ...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 575: ...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 17 Pressure control valve rem...

Page 576: ...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 577: ...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 578: ...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 579: ...X82 B 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 579 Issue 001 2020 10...

Page 580: ...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 581: ...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 582: ...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 583: ...001 as a new item 2 Make sure that there is no damage to the housing 003 Fig 10 20 Fuel overpressure safety valve II II I Applicable pressure that opens the relief valve 001 001 002 003 004 005 004 12...

Page 584: ...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 585: ...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 586: ...ety valve pressure check 001 002 003 004 001 005 006 007 008 00827 CLOSE UP None X82 B AA00 5562 01AAA 360A A Maintenance Manual Fuel rail do a check of the overpressure safety valve Winterthur Gas Di...

Page 587: ...X82 B 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 587 Issue 001 2020 10...

Page 588: ...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 589: ...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 22 Fuel overpressure safety valve installation 001 001 002...

Page 590: ...M10 1 long hexagonal head driver 94022A 10L 1 chain 94327 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Fire Hazard Do not weld or grind mate...

Page 591: ...must have no pressure The fuel injection system must have no pressure The HP fuel pipes must be removed refer to 13 3 1 HP fuel pipe fuel rail to injection valve remove X82 B AA00 5562 03AAA 520A A Ma...

Page 592: ...e six Allen screws 003 Figure 10 24 from the ICU 002 8 Attach the eye bolt 001 to the ICU 002 9 Attach the chain to the eye bolt 001 CAUTION Injury Hazard The weight of the ICU is 127 kg Use the corre...

Page 593: ...10 24 ICU move CLOSE UP If necessary do the preservation procedure refer to 10 6 3 Injection control unit do the preservation Install the ICU refer to 10 6 2 Injection control unit install X82 B AA00...

Page 594: ...chain 94327 1 Supplies Description QTY Never Seez NSBT8 A R Spare Parts Description Part No CSN QTY Injection control unit 1 SAFETY PRECAUTIONS WARNING Fire Hazard Do not weld or grind materials in t...

Page 595: ...7 Remove the chain 8 Remove the eye bolt 005 9 Apply Never Seez NSBT8 to the threads of the six Allen screws 009 10 Put the six Allen screws 009 in position 11 Torque symmetrically the six Allen screw...

Page 596: ...tion valve install Cut in the injection refer to the Operation Manual Operate the engine for a minimum of 1 5 hours with marine diesel oil For more data refer to the Operation Manual X82 B AA00 5562 0...

Page 597: ...X82 B AA00 5562 03AAA 720A A Maintenance Manual Injection control unit install Page left intentionally blank Winterthur Gas Diesel Ltd 597 Issue 001 2020 10...

Page 598: ...s after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY vacuum cleaner N A 1 Supplies Description QTY plastic b...

Page 599: ...bricate correctly the ICU 4 Put the ICU in a plastic bag 5 Remove as much air as possible from the plastic bag 6 Seal the plastic bag CLOSE UP None X82 B AA00 5562 03AAA 810A A Maintenance Manual Inje...

Page 600: ...QTY roller lifting tool 94569B 6 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped and made safe for...

Page 601: ...the rollers refer to Step 3 and Step 4 3 Make sure that the bearing covers at positions No 3 to No 10 Figure 10 28 and the casing 00X have marks to identify them as a set NOTE The bearing at position...

Page 602: ...8 screws to loosen the oil baffle 11 Remove the two M8 screws 12 From the segment 003 remove the four screws 006 and the locking tabs 13 Remove the segment 003 14 Turn the remaining segments countercl...

Page 603: ...shaft and bearing shells refer to 10 7 2 Supply unit camshaft and bearing shell remove X82 B AA00 5581 01AAA 523A A Maintenance Manual Supply unit camshaft and bearing shell prepare before removal Win...

Page 604: ...ent Description Part No CSN QTY pre tensioning jacks 94557 2 support 94566 2 support 94566A 1 assembly template 94567 1 screw jack 94567B 1 Supplies Description QTY None Spare Parts Description Part N...

Page 605: ...ut the assembly template 007 in position on the top bearing shell 006 of bearing No 5 10 Use the assembly template 007 to turn the top and bottom bearing shells 005 006 90 11 NOTE If you cannot turn t...

Page 606: ...the camshaft 007 and the gear wheel 001 on to the two supports 004 005 21 Make sure that the camshaft 007 and gear wheel 001 do not move 22 Make a mark on the remaining bottom bearing shells to identi...

Page 607: ...X82 B AA00 5581 01AAA 520A A Maintenance Manual Supply unit camshaft and bearing shell remove Page left intentionally blank Winterthur Gas Diesel Ltd 607 Issue 001 2020 10...

Page 608: ...Description Part No CSN QTY pre tensioning jacks 94557 2 support 94566 2 support 94566A 1 assembly template 94567 1 assembly template 94567A 1 screw jack 94567B 1 Supplies Description QTY oil A R Loct...

Page 609: ...between 0 05 mm and 0 15 mm Fig 10 32 Camshaft 9 Attach the assembly template 005 Figure 10 33 on the bottom elastic bolt 003 with the round nut 003 10 Tighten with your hand the round nut 003 11 Put...

Page 610: ...s 006 and 008 Figure 10 34 have locking tabs Clean the four segments and the interfaces of the oil baffle 25 Apply the Loctite 5399 or an approved alternative to the segments and interfaces of the oil...

Page 611: ...the supply unit casing with the three Allen screws 010 39 Torque the three Allen screws 010 to 20 Nm 40 Apply oil to the new O ring 009 41 Put the new O ring 009 in the position shown 42 Attach the pi...

Page 612: ...ption Part No CSN QTY eye bolt M20 94045 M20 1 eye bolt M16 94045 M16 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION The weight of the pinion a...

Page 613: ...the disc 003 1 3 Remove the eight M16 screws 001 1 4 Use the eye bolt M20 and an applicable lifting tool to remove the pump support 002 1 5 Use the eye bolt M16 to remove the shaft 009 1 6 Carefully...

Page 614: ...pport equipment Description Part No CSN QTY None Supplies Description QTY oil A R Spare Parts Description Part No CSN QTY O ring 1 bearing bushes 2 pinion 1 shaft 1 SAFETY PRECAUTIONS CAUTION The weig...

Page 615: ...position in the casing 010 5 Attach the pump support 002 to the casing 010 with the eight M16 screws 001 6 Torque the eight M16 screws 001 to the value given in 3 5 Torque values standard screws 7 In...

Page 616: ...n 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate AR Support equipment Description Part No CSN QTY None Supplies Description QTY sealing compound A R Spare Parts Descri...

Page 617: ...en screws 002 Fig 10 37 Filling piece 5 If the fuel pumps 001 Figure 10 38 were not removed do Step 5 1 If the fuel pumps were removed do Step 5 2 5 1 Remove the roller lifting tools 5 2 Install the f...

Page 618: ...Fig 10 38 Covers CLOSE UP None X82 B AA00 5581 01AAA 724A A Maintenance Manual Supply unit camshaft and bearing shell do the follow on work Winterthur Gas Diesel Ltd 618 Issue 001 2020 10...

Page 619: ...X82 B AA00 5581 01AAA 724A A Maintenance Manual Supply unit camshaft and bearing shell do the follow on work Page left intentionally blank Winterthur Gas Diesel Ltd 619 Issue 001 2020 10...

Page 620: ...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 621: ...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 622: ...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 623: ...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 624: ...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 625: ...section 16 1 Tightening instructions 6 Put a new O ring 006 and back up ring 005 on the plug 008 Fig 10 41 Exhaust valve control unit disassemble assemble 001 002 003 004 005 006 FLUSH 007 008 009 010...

Page 626: ...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 627: ...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 628: ...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 629: ...CLOSE UP None X82 B AA00 5612 00AAA 720A A Maintenance Manual Exhaust valve control unit VCU install Winterthur Gas Diesel Ltd 629 Issue 001 2020 10...

Page 630: ...X82 B AA00 5612 00AAA 720A A Maintenance Manual Exhaust valve control unit VCU install Page left intentionally blank Winterthur Gas Diesel Ltd 630 Issue 001 2020 10...

Page 631: ...638 11 1 4 Scavenge air receiver install the flaps 640 11 2 Auxiliary blower 11 2 1 Auxiliary blower remove 642 11 2 2 Auxiliary blower install 648 11 3 Scavenge air cooler 11 3 1 Scavenge air cooler...

Page 632: ...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 633: ...003 Figure 11 1 2 Lock the covers 002 003 in position with the pins 001 004 3 Clean the scavenge air receiver X82 B AA00 6420 00AAA 310A A Maintenance Manual Scavenge air receiver examine Winterthur G...

Page 634: ...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 X82 B AA00 6420 00AAA 31...

Page 635: ...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 X8...

Page 636: ...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 637: ...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 638: ...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 639: ...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 640: ...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 641: ...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 642: ...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 643: ...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 644: ...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 645: ...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 646: ...crane to move the electric motor 004 to an applicable surface Fig 11 9 Auxiliary blower remove CLOSE UP None X82 B AA00 6545 00AAA 520A A Maintenance Manual Auxiliary blower remove Winterthur Gas Dies...

Page 647: ...X82 B AA00 6545 00AAA 520A A Maintenance Manual Auxiliary blower remove Page left intentionally blank Winterthur Gas Diesel Ltd 647 Issue 001 2020 10...

Page 648: ...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 649: ...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 650: ...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 651: ...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 652: ...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 653: ...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 X82 B AA00 6545 00AAA 720A A Ma...

Page 654: ...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 655: ...ne must be stopped and made safe for maintenance refer to section 4 1 Do maintenance work general procedure X82 B AA00 6606 00AAA 520A A Maintenance Manual Scavenge air cooler remove Winterthur Gas Di...

Page 656: ...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 657: ...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 658: ...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 659: ...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 660: ...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 661: ...X82 B AA00 6606 00AAA 520A A Maintenance Manual Scavenge air cooler remove Page left intentionally blank Winterthur Gas Diesel Ltd 661 Issue 001 2020 10...

Page 662: ...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 663: ...ne must be stopped and made safe for maintenance refer to section 4 1 Do maintenance work general procedure X82 B AA00 6606 00AAA 720A A Maintenance Manual Scavenge air cooler install Winterthur Gas D...

Page 664: ...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 665: ...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 666: ...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 667: ...eparator view 1 001 00445 1 Remove the front cover 001 Figure 11 21 from the housing of the water separator X82 B AA00 6708 00AAA 520A A Maintenance Manual Water separator remove Winterthur Gas Diesel...

Page 668: ...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 669: ...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 670: ...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 X82 B AA00 6708 00A...

Page 671: ...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 672: ...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 673: ...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 X82 B AA00 6708 00AAA 720A A Maintenance Manual...

Page 674: ...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 675: ...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 676: ...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 X82 B AA00 6708 00AAA 720A A Maintenance Manu...

Page 677: ...n system do a functional test 678 12 1 2 Cylinder lubrication system bleed 680 12 1 3 Cylinder lubricating pump remove 684 12 1 4 Cylinder lubricating pump pulse examine 688 12 1 5 Cylinder lubricatin...

Page 678: ...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 679: ...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 680: ...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 681: ...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 682: ...Fig 12 2 Cylinder lubrication system bleed X82 B AA00 7218 00AAA 231A A Maintenance Manual Cylinder lubrication system bleed Winterthur Gas Diesel Ltd 682 Issue 001 2020 10...

Page 683: ...CLOSE UP None X82 B AA00 7218 00AAA 231A A Maintenance Manual Cylinder lubrication system bleed Winterthur Gas Diesel Ltd 683 Issue 001 2020 10...

Page 684: ...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 685: ...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 686: ...Fig 12 3 Cylinder lubricating pump MK E example remove CLOSE UP None X82 B AA00 7206 00AAA 520A A Maintenance Manual Cylinder lubricating pump remove Winterthur Gas Diesel Ltd 686 Issue 001 2020 10...

Page 687: ...X82 B AA00 7206 00AAA 520A A Maintenance Manual Cylinder lubricating pump remove Page left intentionally blank Winterthur Gas Diesel Ltd 687 Issue 001 2020 10...

Page 688: ...ements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY Case for CLU4 A R 1 Supplies Description QTY None S...

Page 689: ...r 2 6 Close valve A 3 If the gas pressure is too small fill the accumulator 001 as follows 3 1 Attach the pressure reducing valve 003 to the nitrogen bottle 014 NOTE Use only super clean class 4 0 nit...

Page 690: ...4 Close the screw plug on the last cylinder lubricating pump 5 Do a function test of the cylinder lubricating system refer to section 12 1 1 Cylinder lubrication system do a functional test CLOSE UP N...

Page 691: ...X82 B AA00 0000 00AAA 310A A Maintenance Manual Cylinder lubricating pump pulse examine Page left intentionally blank Winterthur Gas Diesel Ltd 691 Issue 001 2020 10...

Page 692: ...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 693: ...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 694: ...X82 B AA00 7206 00AAA 720A A Maintenance Manual Cylinder lubricating pump install Page left intentionally blank Winterthur Gas Diesel Ltd 694 Issue 001 2020 10...

Page 695: ...2 3 Hydraulic pipe exhaust valve install 716 13 3 HP fuel pipe 13 3 1 HP fuel pipe fuel rail to injection valve remove 720 13 3 2 HP fuel pipe fuel rail to injection valve grind the sealing face 724 1...

Page 696: ...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 697: ...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 698: ...Fig 13 1 Servo oil pipes remove X82 B AA00 8447 00AAA 520A A Maintenance Manual HP servo oil pipe remove Winterthur Gas Diesel Ltd 698 Issue 001 2020 10...

Page 699: ...CLOSE UP None X82 B AA00 8447 00AAA 520A A Maintenance Manual HP servo oil pipe remove Winterthur Gas Diesel Ltd 699 Issue 001 2020 10...

Page 700: ...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 701: ...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 702: ...oil pipe grind and adjust 00960 X mm 005 001 002 004 003 006 001 CLOSE UP None X82 B AA00 8447 00AAA 655A A Maintenance Manual HP servo oil pipe grind the sealing face Winterthur Gas Diesel Ltd 702 I...

Page 703: ...X82 B AA00 8447 00AAA 655A A Maintenance Manual HP servo oil pipe grind the sealing face Page left intentionally blank Winterthur Gas Diesel Ltd 703 Issue 001 2020 10...

Page 704: ...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 705: ...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 706: ...Fig 13 3 Servo oil pipes install X82 B AA00 8447 00AAA 720A A Maintenance Manual HP servo oil pipe install Winterthur Gas Diesel Ltd 706 Issue 001 2020 10...

Page 707: ...CLOSE UP None X82 B AA00 8447 00AAA 720A A Maintenance Manual HP servo oil pipe install Winterthur Gas Diesel Ltd 707 Issue 001 2020 10...

Page 708: ...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 709: ...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 710: ...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 X82 B AA00 8460 00AAA 520A A Maintenance Manual Hydraulic pipe exhaust valve remove Winterthur Gas...

Page 711: ...CLOSE UP None X82 B AA00 8460 00AAA 520A A Maintenance Manual Hydraulic pipe exhaust valve remove Winterthur Gas Diesel Ltd 711 Issue 001 2020 10...

Page 712: ...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 713: ...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 714: ...lve grind sealing face 003 004 006 007 004 003 002 002 001 008 005 00957 CLOSE UP None X82 B AA00 8460 00AAA 655A A Maintenance Manual Hydraulic pipe exhaust valve grind the sealing face Winterthur Ga...

Page 715: ...X82 B AA00 8460 00AAA 655A A Maintenance Manual Hydraulic pipe exhaust valve grind the sealing face Page left intentionally blank Winterthur Gas Diesel Ltd 715 Issue 001 2020 10...

Page 716: ...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 717: ...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 718: ...Fig 13 6 Hydraulic pipe exhaust valve install X82 B AA00 8460 00AAA 720A A Maintenance Manual Hydraulic pipe exhaust valve install Winterthur Gas Diesel Ltd 718 Issue 001 2020 10...

Page 719: ...CLOSE UP None X82 B AA00 8460 00AAA 720A A Maintenance Manual Hydraulic pipe exhaust valve install Winterthur Gas Diesel Ltd 719 Issue 001 2020 10...

Page 720: ...Y 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 CAUTION Damage Hazard Make sure...

Page 721: ...rom the applicable HP injection pipe 002 Figure 13 7 3 Remove the applicable pipe bracket 001 4 On the injection valve 003 remove the four screws 006 from the flange 005 5 On the flange 008 remove the...

Page 722: ...n valve remove I I II II III III III III 001 002 002 003 009 007 008 010 004 005 006 I I 003 00959 X82 B AA00 8733 01AAA 520A A Maintenance Manual HP fuel pipe fuel rail to injection valve remove Wint...

Page 723: ...CLOSE UP None X82 B AA00 8733 01AAA 520A A Maintenance Manual HP fuel pipe fuel rail to injection valve remove Winterthur Gas Diesel Ltd 723 Issue 001 2020 10...

Page 724: ...crew Basic AR Support equipment Description Part No CSN QTY grinding tool 94871 1 template 94871A 1 electric hand drill N A 1 Supplies Description QTY emery cloth A R Molyslip copaslip paste A R Spar...

Page 725: ...the HP injection pipe 003 in a vice as vertically as possible 12 Adjust the speed of the electric hand drill between 200 and 500 rpm 13 Align the hand drill and the grinding tool 004 accurately with t...

Page 726: ...03 002 002 001 008 005 CLOSE UP Install the HP fuel pipe refer to 13 3 3 HP fuel pipe fuel rail to injection valve install X82 B AA00 8733 01AAA 655A A Maintenance Manual HP fuel pipe fuel rail to inj...

Page 727: ...X82 B AA00 8733 01AAA 655A A Maintenance Manual HP fuel pipe fuel rail to injection valve grind the sealing face Page left intentionally blank Winterthur Gas Diesel Ltd 727 Issue 001 2020 10...

Page 728: ...cription Specialization QTY Engine crew Basic AR Support equipment Description Part No CSN QTY None Supplies Description QTY Never Seez NSBT A R oil A R Spare Parts Description Part No CSN QTY HP fuel...

Page 729: ...jection pipe and the claws 007 013 6 Apply Never Seez NSBT to threads of the screws 009 015 7 Carefully put the HP injection pipe in position in the injection valve 006 and the ICU 012 8 Torque symmet...

Page 730: ...HP fuel pipe fuel rail to injection valve install CLOSE UP None X82 B AA00 8733 01AAA 720A A Maintenance Manual HP fuel pipe fuel rail to injection valve install Winterthur Gas Diesel Ltd 730 Issue 00...

Page 731: ...X82 B AA00 8733 01AAA 720A A Maintenance Manual HP fuel pipe fuel rail to injection valve install Page left intentionally blank Winterthur Gas Diesel Ltd 731 Issue 001 2020 10...

Page 732: ...ys put on gloves and safety goggles when you do work on hot components When screws and plugs are opened steam or fuel can come out and cause injury CAUTION Damage Hazard Make sure that you do not dama...

Page 733: ...The trace heating must be set to off X82 B AA00 8752 01AAA 520A A Maintenance Manual HP fuel pipe fuel pump to fuel rail remove Winterthur Gas Diesel Ltd 733 Issue 001 2020 10...

Page 734: ...III III IV and V in Figure 13 10 are shown in Figure 13 11 and Figure 13 12 If necessary disconnect the trace heating pipes 2 Remove the applicable pipe brackets 003 008 3 Put an oil tray under the a...

Page 735: ...6 Loosen the four screws 010 on the flange 009 a maximum of three turns 7 Move the flange 009 down and make sure that air goes into the HP fuel pipe 008 8 Open the screw plug 003 If there is no fuel t...

Page 736: ...nt damage and contamination 21 Remove the four screws 017 from the flange 018 22 Carefully move the flange 018 up 23 Remove the four screws 021 from the flange 022 24 Carefully remove the HP fuel pipe...

Page 737: ...Fig 13 12 HP fuel pipe fuel pump to fuel rail remove X82 B AA00 8752 01AAA 520A A Maintenance Manual HP fuel pipe fuel pump to fuel rail remove Winterthur Gas Diesel Ltd 737 Issue 001 2020 10...

Page 738: ...the HP fuel pipe refer to 13 3 6 HP fuel pipe fuel pump to fuel rail install X82 B AA00 8752 01AAA 520A A Maintenance Manual HP fuel pipe fuel pump to fuel rail remove Winterthur Gas Diesel Ltd 738 I...

Page 739: ...X82 B AA00 8752 01AAA 520A A Maintenance Manual HP fuel pipe fuel pump to fuel rail remove Page left intentionally blank Winterthur Gas Diesel Ltd 739 Issue 001 2020 10...

Page 740: ...ipment Description Part No CSN QTY grinding tool 94870F 1 template 94870H 1 sleeve 94870E 1 locknut 94870G 1 electric drill N A 1 Supplies Description QTY emery cloth 30 to 80 CAMI A R emery cloth 100...

Page 741: ...c drill 007 to a maximum of 1500 rpm 13 Operate the electric drill 007 for between 3 seconds to 5 seconds 14 Remove the grinding tool 001 from the sleeve 003 15 Use a low pressure air supply to remove...

Page 742: ...7 005 008 Minimum 0 5 mm 00966 005 005 CLOSE UP Install the applicable HP fuel pipe refer to 13 3 6 HP fuel pipe fuel pump to fuel rail install X82 B AA00 8752 01AAA 655A A Maintenance Manual HP fuel...

Page 743: ...X82 B AA00 8752 01AAA 655A A Maintenance Manual HP fuel pipe fuel pump to fuel rail grind the sealing face Page left intentionally blank Winterthur Gas Diesel Ltd 743 Issue 001 2020 10...

Page 744: ...escription QTY oil A R Never Seez NSBT A R Spare Parts Description Part No CSN QTY O ring A R O ring A R HP fuel pipe 1 HP fuel pipe 1 HP fuel pipe 1 HP fuel pipe 1 HP fuel pipe 1 SAFETY PRECAUTIONS C...

Page 745: ...views I I II II III III and IV IV in Figure 13 14 are shown in Figure 13 15 X82 B AA00 8752 01AAA 720A A Maintenance Manual HP fuel pipe fuel pump to fuel rail install Winterthur Gas Diesel Ltd 745 Is...

Page 746: ...5 and O ring 002 3 Remove all of the protection from the sealing faces 011 020 4 Make sure that the claw 024 is correctly attached to the HP fuel pipe 026 X82 B AA00 8752 01AAA 720A A Maintenance Manu...

Page 747: ...and the four screws 017 to 80 Nm 10 Make sure that there is a distance of X 36 5 mm between the flange 006 and the connecting block 007 11 Make sure that there is a distance of Z 36 5 mm between the f...

Page 748: ...1 002 003 004 005 006 007 008 009 010 011 X X Y Z 012 005 013 014 015 002 016 017 018 019 020 002 023 005 024 026 00967 002 005 005 002 025 X82 B AA00 8752 01AAA 720A A Maintenance Manual HP fuel pipe...

Page 749: ...CLOSE UP None X82 B AA00 8752 01AAA 720A A Maintenance Manual HP fuel pipe fuel pump to fuel rail install Winterthur Gas Diesel Ltd 749 Issue 001 2020 10...

Page 750: ...X82 B AA00 8752 01AAA 720A A Maintenance Manual HP fuel pipe fuel pump to fuel rail install Page left intentionally blank Winterthur Gas Diesel Ltd 750 Issue 001 2020 10...

Page 751: ...mity sensor remove 752 14 1 2 Crank angle sensor unit flywheel proximity sensor install 756 14 1 3 Crank angle sensor unit supply unit proximity sensor remove 760 14 1 4 Crank angle sensor unit supply...

Page 752: ...iption 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 WARNING...

Page 753: ...n 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 hold...

Page 754: ...sor flywheel remove I 001 ZS 5125C ZS 5124C 003 004 002 005 II 00971 X82 B AA00 9223 01AAA 520B A Maintenance Manual Crank angle sensor unit flywheel proximity sensor remove Winterthur Gas Diesel Ltd...

Page 755: ...ity sensor refer to 14 1 2 Crank angle sensor unit flywheel proximity sensor install X82 B AA00 9223 01AAA 520B A Maintenance Manual Crank angle sensor unit flywheel proximity sensor remove Winterthur...

Page 756: ...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 pr...

Page 757: ...f 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...

Page 758: ...lywheel install I 001 ZS 5125C ZS 5124C 003 004 002 005 I 00972 40 0 2 mm X82 B AA00 9223 01AAA 720B A Maintenance Manual Crank angle sensor unit flywheel proximity sensor install Winterthur Gas Diese...

Page 759: ...CLOSE UP None X82 B AA00 9223 01AAA 720B A Maintenance Manual Crank angle sensor unit flywheel proximity sensor install Winterthur Gas Diesel Ltd 759 Issue 001 2020 10...

Page 760: ...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 WARNING Injury Hazard Before y...

Page 761: ...e 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 t...

Page 762: ...I II ST5133C ST5132C ST5131C ST5136C ST5135C ST5134C 001 002 004 S T 5131 36C 002 003 001 00969 X82 B AA00 9223 01AAA 520A A Maintenance Manual Crank angle sensor unit supply unit proximity sensor re...

Page 763: ...sensor refer to 14 1 4 Crank angle sensor unit supply unit proximity sensor install X82 B AA00 9223 01AAA 520A A Maintenance Manual Crank angle sensor unit supply unit proximity sensor remove Wintert...

Page 764: ...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 pr...

Page 765: ...t to 40 0 2mm 3 Loosen the proximity sensor 001 a half turn to get a clearance of 40 0 2mm between the flywheel tooth 004 and the bottom face of the proximity sensor 4 Carefully tighten the locknut 00...

Page 766: ...ST5133C ST5132C ST5131C ST5136C ST5135C ST5134C 001 002 004 S T 5131 36C 002 003 001 00970 40 0 2 mm X82 B AA00 9223 01AAA 720A A Maintenance Manual Crank angle sensor unit supply unit proximity sens...

Page 767: ...CLOSE UP None X82 B AA00 9223 01AAA 720A A Maintenance Manual Crank angle sensor unit supply unit proximity sensor install Winterthur Gas Diesel Ltd 767 Issue 001 2020 10...

Page 768: ...X82 B AA00 9223 01AAA 720A A Maintenance Manual Crank angle sensor unit supply unit proximity sensor install Page left intentionally blank Winterthur Gas Diesel Ltd 768 Issue 001 2020 10...

Page 769: ...15 Tools 15 1 General for tools 770 15 2 Standard tools 772 15 3 Recommended tools 814 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 769 Issue 001 2020 10...

Page 770: ...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 771: ...X82 B AA00 0000 00AAA 018O A Maintenance Manual General for tools Page left intentionally blank Winterthur Gas Diesel Ltd 771 Issue 001 2020 10...

Page 772: ...01 006 000 007 052 060 008 011 013 026 028 031 032 043 045 046 047 051 053 059 061 063 064 065 068 065 066 067 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd...

Page 773: ...076 070 075 077 084 087 088 089 X 091 090 092 094 095 096 097 098 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 773 Issue 001 2020 10...

Page 774: ...093 099 100 101 103 107 106 108 112 111 110 114 116 119 120 121 122 124 125 126 127 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 774 Issue 001 2020 10...

Page 775: ...28 129 131 132 133 134 135 136 137 137 138 139 140 141 142 143 152 159 148 151 145 146 147 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 775 Issue 001 2020 1...

Page 776: ...162 163 X 165 173 174 175 176 177 179 180 183 187 184 188 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 776 Issue 001 2020 10...

Page 777: ...1 X X 192 205 X 199 212 X X 193 206 194 207 X X 195 208 196 209 197 210 X X 191 204 200 213 210 214 X X X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 777 Iss...

Page 778: ...216 218 217 X X 220 223 221 222 Z Y X X Y 226 230 227 231 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 778 Issue 001 2020 10...

Page 779: ...X Y 233 X Y Z 236 235 X Z X Z 240 238 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 779 Issue 001 2020 10...

Page 780: ...X Y 242 X Y Y X 244 245 246 248 X Y X 250 251 252 254 253 255 256 257 258 259 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 780 Issue 001 2020 10...

Page 781: ...263 261 X X X 266 274 267 275 268 276 Y 269 277 270 278 Y Y 271 279 X Y 282 290 X Y Z 284 292 286 294 287 295 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 7...

Page 782: ...304 314 306 316 305 315 X Y X X Y 297 307 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 782 Issue 001 2020 10...

Page 783: ...0 331 318 319 320 321 322 300 310 301 311 302 312 303 313 332 333 323 328 334 339 X X X X Y Y Y X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 783 Issue 001 2...

Page 784: ...355 347 345 343 351 353 349 X X Y Y Y X X X X X X X 357 358 360 363 362 365 372 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 784 Issue 001 2020 10...

Page 785: ...X X X X X1 X X2 Y 368 369 371 374 376 375 377 378 380 382 384 385 386 388 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 785 Issue 001 2020 10...

Page 786: ...48 395 408 420 438 396 409 421 439 397 398 410 411 422 423 440 441 399 412 424 442 400 413 431 449 401 414 432 450 418 436 419 437 425 443 426 444 427 445 452 X82 B AA00 0000 00AAA 941A C Maintenance...

Page 787: ...X X X X X X 452 457 456 459 475 490 476 491 479 494 480 495 477 492 470 485 456 467 458 460 462 463 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 787 Issue...

Page 788: ...6 481 496 500 524 501 502 526 527 510 534 504 528 513 537 514 538 515 539 517 541 512 536 516 540 508 509 532 533 505 529 506 530 507 531 472 487 473 488 X82 B AA00 0000 00AAA 941A C Maintenance Manua...

Page 789: ...X X X X Y X X X 511 535 511 535 554 556 558 560 548 549 550 552 562 563 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 789 Issue 001 2020 10...

Page 790: ...589 590 603 605 593 594 650 630 632 643 645 660 662 675 677 612 648 665 680 621 651 634 647 664 571 575 572 576 595 598 600 608 611 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winte...

Page 791: ...670 618 627 640 657 672 620 629 642 659 674 649 668 683 691 688 684 692 685 693 686 694 633 646 633 678 616 626 639 656 671 619 628 641 658 673 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard...

Page 792: ...X X X X X 687 695 702 702 706 698 700 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 792 Issue 001 2020 10...

Page 793: ...X X Y Y X X X 709 714 716 715 718 723 724 717 711 720 721 726 X82 B AA00 0000 00AAA 941A C Maintenance Manual Standard tools Winterthur Gas Diesel Ltd 793 Issue 001 2020 10...

Page 794: ...002 65 1 Piece Slugging wrench ring SW65 024 3 94002 70 1 Piece Slugging wrench ring SW70 025 3 94002 85 1 Piece Slugging wrench ring SW85 026 3 94002 110 1 Piece Slugging wrench ring SW110 nil 1 Tool...

Page 795: ...1 Piece Handle screw 071 3 94009 M4 2 Pieces Handle screw M4x150 072 3 94009 M5 2 Pieces Handle screw M5x150 073 3 94009 M6 2 Pieces Handle screw M6x150 074 3 94009 M8 2 Pieces Handle screw M8x150 075...

Page 796: ...Range of adjustment 140 750 Nm 110 3 94012 1 Piece Torque spanner 111 3 94012A 1 Piece Adapter piece 112 2 94012T 1 Piece Assembly tool To non return valve nil 1 Tool general spanners 114 2 94022G 1...

Page 797: ...0 kg 157 3 94019H 2 Pieces Shackle WLL 3250 kg 158 3 94019G 2 Pieces Shackle WLL 2000 kg 159 3 94019F 2 Pieces Shackle WLL 1000 kg nil 1 Tool open end torque wrench nil 2 1 Piece Torque spanner 162 3...

Page 798: ...X 286 mm WLL 130 kg 197 3 94119 1 Piece Lifting plate for removal and installation of a main bearing shell X 411 mm WLL 130 kg 198 3 94120K 2 Pieces Wire rope sling with shackle with a shackle for re...

Page 799: ...bearing X 360 mm 221 3 94114A 1 Piece Double cylinder Top cylinder 222 3 94114B 1 Piece Double cylinder Bottom cylinder 223 2 94110 1 Piece Assy and dismantling device for removal and installation of...

Page 800: ...94202F 2 Pieces Hexagon nut M48 257 3 94202A 1 Piece Angled lever X 417 mm 258 3 94206 2 Pieces Holder with 2 screws each Y 349 mm 259 3 94207 2 Pieces Screw M56 nil 1 Tool cylinder liner measuring 26...

Page 801: ...valve includes 2 hexagon nut M12 nil 1 Tool cyl cover exh valve assy JIS nil 2 1 Piece Removal of cylinder cover 290 3 94265 1 Piece Lifting tool for cylinder cover X 930 mm Y 300 mm nil 2 1 Piece Re...

Page 802: ...ng tool for cylinder cover studs 319 3 94215G 1 Piece Lifting tool 320 3 94215D 8 Pieces Connecting element 321 3 94215I 8 Pieces Hook 322 3 94209A 1 Piece Wire rope sling with hook X 1252 323 2 94215...

Page 803: ...Tool crankshaft measuring 360 2 94305 1 Piece Crankshaft checking equipment To measure the crank deflection X 364 mm nil 1 Tool turning gear pre tensioning 362 2 94230 1 Piece Pre tensioner For screwe...

Page 804: ...WLL 10750 kg Mass approximately 71 kg 396 3 94341C 1 Piece Pin 397 3 94341A 2 Pieces Distance plate 398 3 94341B 4 Pieces Guide plate 399 3 94341D 1 Piece Double spring clip 400 2 94209 1 Piece Disma...

Page 805: ...ool 429 3 94342 1 Piece Inserting cone X 1035 mm Y 155 mm Mass approximately 51 kg 430 3 94343 2 Pieces Locking device X 655 mm 431 2 94209 1 Piece Dismantling and assembling tool X 1000 mm WLL 800 kg...

Page 806: ...ar 466 3 94410 8 Pieces Adjusting gear To align the intermediate wheel X 207 mm 467 3 94410a 8 Pieces Adjusting gear To align the intermediate wheel X 262 mm nil 1 Tool supply unit assembly ISO nil 2...

Page 807: ...ces Tool camshaft assembly 494 3 94569A 1 Piece Flange to intermediate piece including screws M14x50 X 116 mm 495 3 94569 1 Piece Flange to fuel pump Includes screws M14x25 X 120 mm 496 3 94430 1 Piec...

Page 808: ...ces Guide rod 530 5 94593D 2 Pieces Hexagon head screw 531 5 94593E 2 Pieces Step rod 532 3 94597 1 Piece Mandrel To install the seal in the bottom spring carrier and bottom housing of the fuel pump X...

Page 809: ...Mass approximately 97 kg nil 1 Tool auxiliary blower assembly 562 2 94652 1 Piece Tool auxiliary blower assembly X 540 mm 563 2 94651C 1 Piece Trolley WLL 2000 kg nil 1 Tool tc failure ABB A175 nil 2...

Page 810: ...X 690 mm Tool TC failure cover in case of suction pipe nil 1 Tool tc failure ABB A265 nil 2 1 Piece Arrangement of covers 598 3 94653G A265 2 Pieces Cover Engine with 1 TC X 475 mm Cover to TC outlet...

Page 811: ...34 3 94663E 1 Piece Dismantling tool X 290 mm nil 1 Tool sac assembly SAC275 IL Engines with 3 TC nil 2 1 Piece Tool sac assembly 637 3 TN 94209 1 Piece Support X 697 mm WLL 870 kg Mass approximately...

Page 812: ...pe sling with shackle X 2605 5mm 678 3 94663F 1 Piece Dismantling tool X 180 mm 679 3 94663E 1 Piece Dismantling tool X 290 mm 680 3 TN 94214 1 Piece Support Y 946 mm nil 1 Tool water separator assemb...

Page 813: ...831 1 Piece Blind flange X 280 mm nil 1 Tool high pressure pipe grinding nil 2 1 Piece Regrinding device 714 3 94870 1 Piece Regrinding device X 166 mm 88 conical 715 4 94870E 1 Piece Screw on sleeve...

Page 814: ...15 3 Recommended tools Y 001 004 006 007 009 011 013 X Y 015 016 X82 B AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Winterthur Gas Diesel Ltd 814 Issue 001 2020 10...

Page 815: ...Y 018 021 022 X Z Y 026 025 X82 B AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Winterthur Gas Diesel Ltd 815 Issue 001 2020 10...

Page 816: ...028 Y X Y Y Y X Y X X 030 031 033 031 032 034 035 037 039 041 045 X82 B AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Winterthur Gas Diesel Ltd 816 Issue 001 2020 10...

Page 817: ...X X 043 Y X 048 049 052 059 Y 053 054 060 061 056 063 055 062 065 067 069 071 073 076 080 078 X82 B AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Winterthur Gas Diesel Ltd 817 Issue 001...

Page 818: ...X X X X 082 084 086 087 088 089 090 X82 B AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Winterthur Gas Diesel Ltd 818 Issue 001 2020 10...

Page 819: ...p threads of tie rods during installation of a cylinder jacket X 140 mm 016 2 94177 1 Piece Thread protector For the bottom thread of the tie rod Y 140 mm nil 1 Tool cylinder liner grinding 018 2 9429...

Page 820: ...053 4 94595B 1 Piece Push rod to jack 94595 Y 222 mm 054 4 94595C 1 Piece Push rod to jack 94595 Y 344 mm 055 3 TN 94048 1 Piece Piston reset device to jack 94595 X 173 mm with 12 hole pump cover 056...

Page 821: ...rail unit transport for 6 9 Cyl 080 2 94691 1 Piece Tool rail unit transport X 6160 mm Mass approximately 1793 kg nil 1 Tool box oil filter 082 2 94481 1 Piece Metal box for storage of spare filter ca...

Page 822: ...X82 B AA00 0000 00AAA 941B C Maintenance Manual Recommended tools Page left intentionally blank Winterthur Gas Diesel Ltd 822 Issue 001 2020 10...

Page 823: ...16 Tightening instructions 16 1 Tightening instructions 824 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 823 Issue 001 2020 10...

Page 824: ...the document Tightening instructions for important connections of the engine Use the number of the design group to find the related connection X82 B AA00 0000 00AAA 018N A Maintenance Manual Tightenin...

Page 825: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 1 9...

Page 826: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 2 9...

Page 827: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 3 9...

Page 828: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 4 9...

Page 829: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 5 9...

Page 830: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 6 9...

Page 831: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 7 9...

Page 832: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 8 9...

Page 833: ...Approved TIGHTENING INSTRUCTIONS Rev B Page 9 9...

Page 834: ...17 Maintenance overview 17 1 Maintenance overview 826 X82 B Maintenance Manual Winterthur Gas Diesel Ltd 825 Issue 001 2020 10...

Page 835: ...e pages that follow you find the document Maintenance Intervals Lifetime for the related components of the engine X82 B AA00 0000 00AAA 280C A Maintenance Manual Maintenance overview Winterthur Gas Di...

Page 836: ...ing 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 lifetime Thrust...

Page 837: ...6000 initial inspection 18000 Check condition and wear of valve seat 36000 initial inspection 18000 Random check of valve drive outer and inner pistons damper thrust piece 18000 Estimated lifetime Exh...

Page 838: ...g thickness 36000 Estimated lifetime Piston rings 36000 Start interlock Check electric and pneumatic interlocks see Operating Manual 4003 1 quarterly Driving wheels Group 41xx Check condition of teeth...

Page 839: ...time Fuel pump actuator Group 55xx Check for free movement of regulating linkage lubricate movable parts 3000 Check condition of the carbon brushes and replace if required for StG 16 and StG 30 6000 1...

Page 840: ...ore the engine Drain remove water before and after every manoeuvring period Pressure gauges and pyrometers Compare and calibrate according to master instruments 6000 8000 Pipe holders Group 8xxx Check...

Page 841: ...s and estimated lifetimes are estimates only They are based on past experience and valid for engines fully according to currently applicable Winterthur Gas Diesel Ltd and W rtsil Services Switzerland...

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