Winterthur Gas X35-B Maintenance Manual Download Page 239

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Maintenance

3303

−

3/A1

Winterthur Gas & Diesel Ltd.

1/ 8

Connecting Rod

Top End Bearing

−

Removal, Inspection and Installation

Tools:

2 Manual ratchets (800 kg) (H1, H2)

94016

1 Platform element

94144

2 Manual ratchets (250 kg) (H3, H4)

94016G

2 Supporting devices

94322

1 Spur-geared chain block (1000kg) (CB)

94017C

1 Lifting plate

94324

2 Shackles (WLL 2000 kg)

94572G

1 Supporting device

94332

2 Eye bolts (EB2)

94045

−

M24 2 Lifting tools

94333

2 Eye bolts (EB1)

94045

−

M16 1 Stop plate

94335

2 Eye bolts (EB)

94045

−

M12 1 Chain (double sling)

94335D

1 Deviation pipe

94117B

1 Lifting tool

94337

1 Platform element

94143

1 Shackle

94572H

Preparation

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

Crosshead

−

Lift (Piston Installed)

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

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

Crosshead

−

Lift (Piston Removed)

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

Bearing Shell

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

Crosshead

−

Lower (Piston Removed)

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

Crosshead

−

Lower (Piston Installed)

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

Bearing Lubrication

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

Bearing Cover

−

Removal

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

8.1

Preparation

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

8.2

Removal

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

Bearing Cover

−

Installation

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

Preparation

WARNING

Injury Hazard: Before you

operate the turning gear,

make sure that no

personnel are near the

flywheel, or in the engine.

1) Read the data in

0012

−

General

Guidelines for Lifting Tools.

2) Record the position of the toggle

lever (1).

3) Disconnect the toggle lever (1,

Fig. 1

)

from the connecting rod.

4) Use a rope to hold the toggle lever in the

position shown.

5) Lift and hold the applicable piston in the

TDC position, refer to

3403

−

Crosshead

−

Lift (Piston Installed)

1) Operate the turning gear to move the applicable crank to BDC.
2) Lock the turning gear to prevent movement.
3) Install the platform elements (94143, 94144) in the positions shown. For more data,

refer to

3301

−

4) Remove the round nuts (4) on the elastic bolts (3), refer to

9403

−

2017

WCH00617

94144

94143

Fig. 1

Summary of Contents for X35-B

Page 1: ...al X35 B Issue 005 2022 01 Winterthur Gas Diesel Ltd Schützenstrasse 3 Tel 41 0 52 264 8844 Winterthur Gas Diesel AG P O Box 414 8401 Fax 41 0 52 264 8866 Winterthur Gas Diesel S A Winterthur Switzerland www wingd com ...

Page 2: ...e copyright 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 for informa tion contained herein Information in this publication is subject to change without notice NO LIABILITY WHETHER DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUEN TIAL IS ASSUMED WITH RESPECT TO THE INFORM...

Page 3: ...3403 2 A1 2018 07 WinGD Input Piston Compression Shims Change Pge 3 Step 13 Torque changed to 120 Nm x Date of publication 2018 07 0380 1 A1 2020 04 WinGD Input Maintenance schedule Inspection and Overhaul Intervals Pge 67 to 75 updated x ToC 2020 04 WinGD Input Table of content ToC upated x Group 2 ToC 2020 04 WinGD Input Installation of Injection Valve with FAST New Title Added 2722 1 A2 x 2722 ...

Page 4: ... Document ID DBAD803076 Winterthur Gas Diesel Ltd 24hrs Support Schützenstrasse 1 3 Wärtsilä Services Switzerland Ltd CH 8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland 41 52 262 80 10 technicalsupport chts wartsila com ...

Page 5: ...e copyright 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 for informa tion contained herein Information in this publication is subject to change without notice NO LIABILITY WHETHER DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUEN TIAL IS ASSUMED WITH RESPECT TO THE INFORM...

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

Page 7: ... Connecting Rod 14 15 Piston Cooling and Crosshead Lubricating Link 16 17 Piston and Piston Rings 18 19 Driving Wheels for Supply Unit 20 21 Supply Unit 22 23 Tightening Values of Important Screwed Connections 0352 1 A1 of Standard Screwed Connections 0352 2 A1 Masses Weights Individual Components per Piece in kg 0360 1 A1 Maintenance Schedule Inspection and Overhaul Intervals Guidelines 0380 1 A1...

Page 8: ... Injection Valve 2708 3 A1 Injection Valve Removal and Installation 2722 1 A1 Disassemble Checks Assemble 2722 2 A1 Installation of Injection Valve with FAST 2722 1 A2 Starting Air Valve Removal Fitting and Dismantling Grinding in Assembling 2728 1 A1 Relief Valve for Cylinder Cover 2745 1 A1 Exhaust Valve Removal and Fitting of Exhaust Valve Replacing of Elastic Bolts 2751 1 A1 Dismantling and As...

Page 9: ...cing the Gear Wheel on the Crankshaft 4104 3 A1 Shut off Valve for Starting Air Cleaning and Function Check 4325 1 A1 Supply Unit Injection and Exhaust Valve Control Group 5 Supply Unit Servo Oil Pump Removal and Fitting 5551 1 A1 Gear Wheel Safety Device to Servo Oil Pump Removal and Fitting 5551 2 A1 Fuel Pump Removal and Fitting 5556 1 A1 Gear Wheel Safety Device to Fuel Pump Removal and Fittin...

Page 10: ...Removing and Fitting of Rising Pipe Package 8752 1 A1 Crank Angle Sensor Unit Tools Group 9 Crank Angle Sensor Unit Replacement of Proximity Sensor 9223 1 A1 Tools Explanation 9403 1 A1 Hydraulic Jacks Tools and Pumps Arrangement and Application 9403 2 A1 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance 9403 3 A1 General Application Instructions 9403 4 A1 Tool List 9403 5 A1 Standa...

Page 11: ...ing 4 5 Crosshead Guide 6 7 Cylinder Liner 8 9 Piston Rod Gland 10 11 Exhaust Valve 12 13 Top and Bottom End Bearings to Connecting Rod 14 15 Piston Cooling and Crosshead Lubricating Link 16 17 Piston and Piston Rings 18 19 Driving Wheels for Supply Unit 20 21 Supply Unit 22 23 Tightening Values of Important Screwed Connections 0352 1 A1 of Standard Screwed Connections 0352 2 A1 Masses Weights Com...

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Page 13: ...r maintenance and operation must be serviceable and in good condition The extent of all supplies and services is set exclusively to the related supply contract 3 Data The specifications and recommendations of the classification societies which are essential for the design are included in this manual The data instructions graphics and illustrations etc in this manual are related to drawings from Wi...

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Page 15: ...ot manufactured in accordance with production drawings from Winterthur Gas Diesel Ltd The Maintenance Manual has the primary data that follow D General Guidelines for Maintenance These give recommendations about precau tions and applicable procedures D Clearance tables tightening values of screwed connections masses weights These give data about usual and maximum permitted clearances engine compo ...

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Page 17: ... END DRIVING END Thrust Bearing Pads FUEL SIDE EXHAUST SIDE Rail Unit Clockwise Rotation Counterclockwise Rotation Supply Unit Turbocharger Cylinder Numbers Auxiliary Blower 2 WCH00958 Main Bearing Numbers Auxiliary Blower 1 1 1 2 3 4 5 6 5 4 3 7 Fig 1 Outline View 2017 General ...

Page 18: ...d 2 2 Servo Oil Pump 1 Fuel Pump 1 Fuel Pump 2 Servo Oil Pump 2 DRIVING END WCH00552 FUEL SIDE WCH00887 Crank Angle Sensor Unit I Proximity Sensors ZS5124C WCH00636 ZS5123C II II I Fig 2 Engine Control System Parts 2017 Engine Control System Parts ...

Page 19: ...fety in the engine room All the engine room staff must follow these general safety precautions and safety guidelines given below as usual procedure Use the data given below as a guide to the personnel D Lighting Make sure that there is good permanent lighting available at applicable places in the engine room Make sure that the sufficient number of portable lamps available at different locations in...

Page 20: ...k area in the engine room Make sure that all tools have protection from corrosion Keep all the tools and devices ready to use and make sure that no large objects are available on the floors and passages near engine area Always keep the engine area clean D Spare Parts Keep the large spare parts near the work area and must be easy to access for the engine room crane Make sure that the spare parts ha...

Page 21: ...tor is shutoff If there is alert from the oil mist alarm before you open the crankcase follow all the precautions D Turning Gear and Slow turning Before you engage the turning gear make sure that the starting air supply is shutoff and the indicator cocks are open When turning gear is engage make sure that the indicator lamp Turning gear in is change to local Make sure that turning gear is locked d...

Page 22: ...arning is used when an operation procedure or use may cause a latently dangerous state of personal injury or loss of life D Caution This warning is used when an operation procedure or use may cause damage to or destruction of equipment and a injury D Note This warning is used when an operation procedure or use may cause damage to or destruction of equipment 2021 Safety Measures and Warnings ...

Page 23: ... cause the oil to fall on the piston crown If the piston is hot this can cause explosion Make sure that the engine is cool down before maintenance WARNING Injury hazard Do not touch the spray holes during the function test of the fuel valves The sudden release of oil can cause injury to personal Always use the correct personal protective equipment WARNING Injury hazard Make sure that the engine is...

Page 24: ...active for oil mist high lube oil temperature no piston colling oil flow or scavenge box fire Injury to personnel can occur CAUTION Damage hazard Always replace the damaged sealing materials with new sealing materials Do not try to repair them CAUTION Damage hazard Do not weld or solder on any part of the fuel system and servo oil system Damage to the system can occur 2021 ...

Page 25: ...rotection equipment Always use the below given personal protection equipment during repair and maintenance work on the engine D Safety helmet D Ear protection D Cotton boiler suite D Safety shoes D Hand gloves D Safety goggles D Safety harness 2021 Safety Measures and Warnings ...

Page 26: ...The work area must be completely isolated before the hot work starts Review the fire safety precautions This includes firefighting equipment preparations designation of a fire watch in all nearby areas and fire extinguishing measures Continue the isolation of the workspaces and the fire safety precautions until the risk of fire no longer exists Protect components like the turbocharger silencer ECS...

Page 27: ...ydraulic tools Check high pressure double walled hydraulic hoses for any damages before operation Check all connection points from the pump to the hydraulic tool for leaks during pressure build up Make sure the pressure gauges are properly calibrated before operation Applied oil pressure must be within a range of 5 bar of the specified pressure for each stud type and size 2021 ...

Page 28: ...edure D Make sure that lifting attachments are tightened properly to the lifting component D Always use correct dedicated lifting points D Do not exceed the lowest safe working load SWL of the lifting equipment in the lifting chain D Keep away lifting equipment from sharp edges D Make sure that loads are attached correctly to the crank hook D When crane carrying a load make sure that the space bel...

Page 29: ...ols and equipment Replace damaged equipment with serviceable items For the safe and correct operation of the engine room crane it is recommended that you do as follows D Make sure that you know the weight of the load D Find the centers of the load D Use only the applicable equipment D Make sure that you correctly attach and remove the the equipment 2 Equipment 2 1 Wire Rope Slings The WLL of the w...

Page 30: ... deformation etc D Is correctly attached D The seating surfaces fully touch i e turned fully in D Is in the correct position 1 The full load is permitted only as shown see Table 1 Distance rings can be used if necessary Also you must make sure that you D Do not apply an angle of more than 45 D Do not apply a lateral load Note If there are through holes put a washer on the opposite side under the n...

Page 31: ...ed D You use the star profile wrench to tighten the inner screw do not use an extension D The seating surfaces fully touch i e the inner screw is turned fully in D The ring can freely turn D Before you attach a load align the ring with the direction of the force Note Do not apply a lateral load to the eye bolt DIRECTION OF FORCE Ring Star profile Wrench Inner Screw 013 444 05 DIRECTION OF FORCE DI...

Page 32: ...CTION OF FORCE DIRECTION OF FORCE DIRECTION OF FORCE I II III Fig 2 RUD Swivel Lugs 2 5 Shackles CAUTION Damage Hazard If tools are used together e g beams with shackles RUD eye bolts or RUD swivel lugs and ropes etc it is always the weakest part which has the maximum lifting capacity Note For more data refer to 9403 5 Tool List Use only shackles that have the standards given in American Standard ...

Page 33: ...ion Fig 3 Strand Angles Note A large angle between the strands gives more tension A small angle between the strands give less tension Put a flat piece of softwood between the sling and the component to prevent movement of the load e g pipes shafts etc Use a wooden pallet or thick cloth to prevent damage to slings ropes etc Sharp edges can cut steel cables Make sure that you can always keep control...

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Page 35: ...olumns Maximum Clearance Dimension are the possible results after a long period of operation The differences in the clearances must not be less than or more than those given On components where the clearance is adjustable changed thickness of shims discs spacers etc the values must be those given in Usual Clearance Where this is not possible you must replace worn parts with standard new parts or r...

Page 36: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 2 23 Crankshaft and Thrust Bearing 2 1 WCH00461 Fig 1 Fig 2 2017 Clearance Table ...

Page 37: ...Description Measured Direction Nominal Dimension usual new mm Maximum Clearance Dimension because of wear mm 1203 1224 Thrust Bearing Thrust bearing pad thickness 55 0 5 0 6 1 Thrust bearing clearance axial total 0 8 to 1 3 2 0 2 Thrust bearing pad lateral clearance total 6 0 2017 Clearance Table ...

Page 38: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 4 23 Crankshaft and Main Bearing MAIN BEARING No 1 MAIN BEARING No 2 AND FOLLOWING 1 1 2 3 WCH00459 Fig 3 Fig 4 2017 Clearance Table ...

Page 39: ...ecause of wear mm 1132 Main bearing No 1 Crankshaft outer 430 0 0 07 Main bearing inner 430 1 Bearing clearance vertical 0 25 to 0 50 0 6 1132 Main bearing No 2 to No Crankshaft outer 430 0 0 07 Main bearing inner 430 1 Bearing clearance vertical 0 15 to 0 40 0 5 All main bearing clearances are only applicable with tie rods and main bearing elastic bolts tightened 2017 Clearance Table ...

Page 40: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 6 23 Crosshead Guide 2 1 FUEL SIDE WCH00464 4 Fig 5 3 5 7 6 8 2017 Clearance Table ...

Page 41: ... transverse 640 0 20 0 30 3 Guide way clearance 0 20 to 0 95 1 50 4 Guide rail longitudinal 390 5 to 391 3 5 Guide rail lateral clearance 0 26 to 0 84 1 30 6 Guide shoe lateral clearance 0 10 to 0 30 0 50 7 Crosshead pin outer 330 0 0 036 Guide shoe bearing bore inner 330 0 084 0 050 8 Bearing clearance radial 0 05 to 0 12 0 15 To measure the clearances refer to the instructions in 3326 1 Clearanc...

Page 42: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 8 23 Cylinder Liner Fig 6 WCH03595 I II WCH03596 II II 1 2 3 4 Fig 7 WCH03594 I 5 Approximately 90 mm to 110 mm 2017 Clearance Table ...

Page 43: ...ter guide jacket Ø 0 4 0 2 520 1 Clearance total 0 2 to 0 4 Water guide jacket Ø 510 0 8 0 6 2 Clearance total 0 4 to 0 6 2124 Water guide jacket on cylinder liner Water guide jacket Ø 505 0 9 0 7 3 Clearance total 0 45 to 0 65 Water guide jacket Ø 515 0 6 0 4 4 Clearance total 0 3 to 0 5 2124 Cylinder liner 5 Cylinder liner bore radial 350 0 140 0 352 50 The cylinder liner bore must be measured a...

Page 44: ...ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ 1 4 5 6 6 6 6 1 3 2 ÇÇ ÇÇ WCH00467 Fig 8 Fig 9 2017 Clearance Table ...

Page 45: ...n rod gland 1 Ring width radial 23 min 19 2 Ring width radial 18 min 16 2 3 Ring width radial 5 min 3 20 4 Ring clearance axial 0 05 to 0 19 0 40 5 Ring clearance axial 0 05 to 0 13 0 35 6 Ring clearance axial 0 08 to 0 14 0 35 Ring wear The different values between the nominal dimension and maximum wear is equal for all rings Also for rings that are less than the nominal dimension 2017 Clearance ...

Page 46: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 12 23 Exhaust Valve 1 3 L 2 3 L 3 2 1 VALVE SPINDLE GUIDE BUSH L LENGTH CHROMIUM LAYER WCH03597 WCH00469 Fig 10 Fig 11 2017 Clearance Table ...

Page 47: ...Measured Direction Nominal Dimension usual new mm Maximum Clearance Dimension because of wear mm 2754 Exhaust valve spindle 1 Spindle outer 35 0 09 0 115 34 55 2751 Guide bush 2 Bore inner 35 0 025 0 35 2 3 Bore inner 35 0 025 0 35 65 Must be measured at the location shown 2017 Clearance Table ...

Page 48: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 14 23 Top and Bottom End Bearings to Connecting Rod 10 mm 10 mm 10 mm 10 mm 5 6 5 6 2 3 2 3 1 4 WCH00470 Fig 12 2017 Clearance Table ...

Page 49: ... 036 Bearing inner 330 1 Bearing clearance vertical 0 15 to 0 45 0 75 2 Lateral clearance total 0 2 to 0 4 3 Lateral clearance total 0 1 to 0 3 3303 Bottom end bearing Crankshaft outer 430 0 0 07 Bearing inner 430 4 Bearing clearance vertical 0 15 to 0 45 0 75 5 Lateral clearance total 0 3 to 0 55 6 Lateral clearance total 0 3 to 0 55 Must be measured at the location shown To measure the clearance...

Page 50: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 16 23 Piston Cooling and Crosshead Lubricating Link 5 5 4 4 1 2 5 3 5 3 1 WCH00508 Fig 13 Fig 14 2017 Clearance Table ...

Page 51: ...ection Nominal Dimension usual new mm Maximum Clearance Dimension because of wear mm 3603 Piston cooling and crosshead lubricating link Pin outer 40 0 025 0 05 1 Bearing clearance radial 0 025 to 0 075 0 15 2 Bearing width 92 3 Lateral clearance total min 2 0 4 Bearing width 93 0 2 0 5 Lateral clearance total min 1 0 2017 Clearance Table ...

Page 52: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 18 23 Piston and Piston Rings 8 8 1 10 2 9 5 3 4 6 7 B A B A DESIGN WITH THREE PISTON RINGS Fig 15 2017 Clearance Table ...

Page 53: ...425 Piston rings Height of the uppermost ring vertical 13 0 0 03 Height of the two lower rings vertical 0 0 03 8 Point A Point B 3425 6 Ring clearance vertical 0 33 0 41 0 63 0 80 7 Ring clearance vertical 0 28 0 36 0 58 0 75 8 Ring width radial 12 5 0 25 3403 Piston skirt 9 Skirt outer 349 4 0 0 1 min 348 4 3403 Piston rod 10 Rod outer 132 0 043 0 083 min 131 50 Piston rings that were installed b...

Page 54: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 20 23 Driving Wheels for Supply Unit 5 1 2 3 4 WCH00471 WCH00588 Fig 16 Fig 17 2017 Clearance Table ...

Page 55: ...sured Direction Nominal Dimension usual new mm Maximum Clearance Dimension because of wear mm 4104 Intermediate wheel 1 Shaft outer 160 2 Bearing clearance vertical 0 082 to 0 147 0 23 3 Axial clearance total 0 6 to 1 1 1 5 4 Tooth backlash 0 16 to 0 29 0 33 5 Tooth backlash 0 23 to 0 37 0 41 2017 Clearance Table ...

Page 56: ...Maintenance 0330 1 A1 Winterthur Gas Diesel Ltd 22 23 Supply Unit 3 2 1 SERVO OIL PUMP FUEL PUMP VIEW FROM DRIVING END 4 5 WCH00509 WCH00510 Fig 18 Fig 19 2017 Clearance Table ...

Page 57: ...irection Nominal Dimension usual new mm Maximum Clearance Dimension because of wear mm 5552 1 Pinion outer 100 0 0 022 2 Bearing clearance radial 0 090 to 0 172 0 25 3 Axial clearance total 0 30 to 0 65 0 85 5556 4 Tooth backlash 0 12 to 0 23 0 25 5 Tooth backlash 0 12 to 0 23 0 25 2017 Clearance Table ...

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Page 59: ...nly When using other hydraulic jacks the required pressure in bar must be calculated in relation to the effective jack piston surface Conversion factor 1 Nm 0 102 mkp 1 bar kp cm2 D The applicable lubricant must be applied to threads and seating surfaces if no other instructions are given D Bostik Findley Inc USA is manufacturer of Never Seez NSBT 8 2017 Tightening Values of Important Screwed Conn...

Page 60: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 2 6 WCH03791 2017 ...

Page 61: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 3 6 WCH03791 2017 ...

Page 62: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 4 6 WCH03791 2017 ...

Page 63: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 5 6 WCH03791 2017 ...

Page 64: ...Maintenance 0352 1 A1 Winterthur Gas Diesel Ltd 6 6 WCH03791 2017 ...

Page 65: ...NEVER SEEZ NSBT8 is used the torque value must be decreased by 20 of the values given in the table These torques values do not apply to turbocharger installations Refer to the documents of the turbocharger manufacturer for the correct torque values Standard thread Grade 8 8 Fine thread Grade 8 8 Torque Value Nm M3 M3 x 0 35 0 9 M4 M4 x 0 5 2 1 M5 M5 x 0 5 4 2 M6 M6 x 0 75 7 2 M8 M8 x 1 18 M10 M10 ...

Page 66: ...Clean the tap hole and the area where the elastic stud will be installed 7 If necessary apply an adhesive primer to the shank of the elastic stud Make sure that no adhesive primer goes on to the threads 8 Use only a stud driver or two nuts locked together to fully install the stud into the tap hole 9 Torque the elastic stud to the applicable value given in the table below TORQUE VALUES FOR ELASTIC...

Page 67: ...elated manufacturer s instructions to mix and apply the jointing compounds hardeners and adhesive primers Materials from other manufacturers are permitted but must have the qualities given below D The materials must not contain acid D The materials must be resistant to oil marine diesel oil heavy fuel oil and water at a temperature of 100_C D A short age hardening time is necessary i e not more th...

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Page 69: ...9 Casing upper part Casing lower part driving end driving end 44 13 5 1720 Oil baffle upper part Oil baffle lower part 20 2 15 5 1903 Tie rod 31 2 2106 Elastic bolt in cylinder block 8 1 2124 Cylinder liner 628 2130 Water guide jacket upper part Water guide jacket lower part 39 47 5 2303 Piston rod gland complete 33 2708 Elastic bolt for valve cage Cylinder cover without valves 3 296 2722 Injectio...

Page 70: ... shell for bottom end bearing 17 3312 Bearing cover for top end bearing 56 3315 Bearing shell for top end bearing 16 3326 Crosshead pin Crosshead with guide shoes Guide shoe complete 270 399 59 3403 Piston with piston rod Piston crown Piston skirt Piston rod with oil pipe complete 306 60 22 208 3603 Toggle lever to piston cooling and crosshead lubrication complete 25 4 4 4106 Gear wheel on cranksh...

Page 71: ...er ABB A165 ABB A165 L ABB A170 L MET42MB MET53MB 2000 2300 3300 1600 4100 6545 Auxiliary blowers with electric motor No Cyl 5 6 Electric motor No Cyl 5 6 Auxiliary blowers with electric motor No Cyl 7 8 Electric motor No Cyl 5 6 complete approx complete approx 480 170 500 190 6606 Scavenge air cooler SAC281 SAC283 592 470 6708 Water separator to SAC281 to SAC283 168 215 8 8103 Expansion piece aft...

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Page 73: ...ate foundation bolts 12000 30000 replacement recommended Engine lifetime Crankcase Visual examination 100 Op h after maintenance look for white metal particles from bearings and for defects 1500 to 3000 1132 2 Main bearing Bearing shell inspection is only necessary if the bearing clearances crankshaft deflection Wire check oil analysis or crankcase inspection shows too much damage or worn areas Do...

Page 74: ... liner removal Each piston removal Water guide jacket replace O rings and transition tubes each liner removal Do a check of the antipolishing ring condition each piston removal 2124 3 Remove unwanted material in the bore each piston removal Dress the lubricating grooves as necessary Clean scavenge ports and dress their edges Estimated service life Cylinder liner as necessary Up to 90 000 2138 1 Lu...

Page 75: ... of the of the solenoid valve Do an overhaul of the solenoid valve 6000 18000 Estimated service life Starting valve Engine lifetime 2745 1 Relief valve to cylinder cover Do a check of the blow off pressure as necessary 2751 1 to Exhaust valve Do a general inspection of valve housing valve spindle and valve seat without disassembly of the exhaust valve each piston removal 2751 4 Look for worn areas...

Page 76: ...est each 2000 hours of engine operation 2000 Check screwed connections first time after one year if necessary tighten again 12 000 Connecting rod bearings Do a check of the bearing clearances refer to 0330 1 6000 Use wire to do a check of the bottom edge 6000 3303 2 Do a inspection of the bottom end bearing only necessary if the bearing clearance wire check oil analysis or crankcase inspection sho...

Page 77: ...grooves Piston head surface Full re manufacture 18 000 to 36 000 72 000 Piston underside Do a check of the condition Clean the piston underside as necessary 1500 to 3000 Make sure that the drains are not blocked 1500 to 3000 3425 1 Piston rings Measure the thickness of chrome ceramic layer Replace piston rings refer to the remaining coating thickness 1500 to 2000 18000 to 30000 condition based Est...

Page 78: ...5562 1 Fuel pressure control valve Do a check of the shut down function refer to the Operation Manual 4003 1 3000 Remove the PCV and a functional check Do a general overhaul 6000 Only necessary if the PCV becomes defective Estimated service life PCV Engine lifetime 5562 2 Fuel overpressure safety valve relief valve Do a functional check on the test bench 24 000 to 36 000 5564 1 Flow limiting valve...

Page 79: ...load refer to the Operation Manual 6510 1 as necessary 6545 1 Auxiliary blower Clean impeller and casing 24 000 to 36 000 Replace ball bearing 24 000 to 36 000 6606 1 Scavenge air cooler Clean the scavenge air cooler air side during operation weekly at first then later if a np pressure decrease through the SAC increases compared to the shop test value at same engine load refer to the Operation Man...

Page 80: ...g a longer operation period at low engine load manually open the butterfly valve a minimum of one time each week refer to the Operation Manual 8135 1 General inspection In accordance with the instructions of the valve manufacturer Starting air pipes Drain remove water before and after every manoeuvring period Pressure gauges and pyrometers Compare and calibrate according to master instruments 6000...

Page 81: ...he indicated maintenance intervals must be taken as guidance and can be different The correct intervals are related to the data below These intervals can be extended or decreased 1 Environmental and operation conditions 2 Heavy fuel oil and lubricating oil qualities refer to the Operation Manual 0710 1 and 0750 1 3 Engine load 4 Fuel lubricating oil and cooling water see Operation Manual 0720 1 an...

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Page 83: ...1 2 Engine Cross Section and Longitudinal Section 1 Cross section 6420 1 3206 1 5556 1 4104 1 WCH00935 1112 1 4104 2 8752 1 8447 1 8460 1 6545 1 5551 1 3326 1 3326 2 8135 1 VIEW FROM DRIVING END WCH00937 5562 1 5612 1 4325 1 Fig 1 Cross Section 2017 ...

Page 84: ...6 2303 1 1132 2 4104 3 2751 1 to 2751 4 2708 1 to 2708 3 3140 1 3303 2 to 3303 4 3130 1 3130 2 1224 1 1132 1 1203 1 6606 1 6708 1 8733 1 2138 1 7218 1 3425 1 3403 1 to 3403 4 1903 1 2124 1 to 2124 3 2722 1 Fig 2 Longitudinal Section Engine Cross Section and Longitudinal Section 2017 ...

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Page 86: ...nsion 1132 1 A1 Main Bearing Removal and Installation 1132 2 A1 Thrust Bearing Axial Clearance Checks 1203 1 A1 Thrust Bearing Pads Removal and Installation 1224 1 A1 Engine Stays with Friction Shims Tension Checks 1715 1 A1 Hydraulic Engine Stays Oil Pressure Checks 1715 1 A2 Tie Rod Tension Checks and Replacement Procedure 1903 1 A1 Winterthur Gas Diesel Ltd X35 B MM 2017 ...

Page 87: ...eneral You must do a pre tension check of the foundation bolts elastic bolts at longer intervals e g during overhauls refer to 0380 1 In the area of the thrust bearing the bedplate can be attached with the elastic bolts 1 Fig 1 and thrust sleeves 3 For the remaining areas the short thrust sleeves 10 are installed as shown in Fig 2 Note Read the data in 9403 4 for the hydraulic pre tensioning jacks...

Page 88: ...e the vent screw 8 10 Operate the HP oil pump 94931 to apply a pressure of 1500 bar to the foundation bolt 6 Keep the pressure constant Note Do not move the piston 1 of the pre tensioning jack 94145 above the red groove 2 11 Use a feeler gauge to do a check for clearance through the slot 4 between the nut 7 and the sleeve 5 12 If there is a clearance do step a to step c If there is no clearance co...

Page 89: ...Maintenance 1112 1 A1 Winterthur Gas Diesel Ltd 3 5 Fig 3 94934A 94931 9 94934A 012 949 05 94935 1 3 2 6 5 8 7 4 94005 6 X WCH03608 2017 Bedplate and Thrust Bearing ...

Page 90: ...31 5 Open the vent screw 8 6 Close the relief valve 9 7 Operate the HP oil pump 94931 until oil that has no air flows from the vent screw 9 8 Close the vent screw 8 9 Operate the HP oil pump 94931 to get a pressure of 1530 bar Note Do not move the piston 1 of the pre tensioning jack 94145 above the red groove 2 10 Turn the nut 8 back one turn 11 Open the relief valve 10 to release the pressure to ...

Page 91: ...al and synthetic in two steps as follows 1 Attach the pre tensioning jack 94145 as given in paragraph 2 step 1 to step 9 2 Apply a pressure of 600 bar to the foundation bolt 3 Apply a pressure of 1500 bar to the foundation bolt Keep the pressure constant 4 Refer to paragraph 2 and do step 11 to step 14 2017 Bedplate and Thrust Bearing ...

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Page 93: ... Note Do not install the thrust device 94110 Note Read the data in 9403 4 General Application Instructions for Pre tensioning Jacks 2 Pre tensioning Jacks Install 1 Put the double pre tensioning jacks 94114 in position on the elastic bolts 4 2 Turn the round nuts 12 up and move the tension sleeves 6 on to the elastic bolts 4 3 Open all vent screws 2 4 Turn the round nuts 12 to push the pistons 11 ...

Page 94: ...42 3 When oil that has no air flows out close the vent screws 2 Fig 1 on the pre tensioning jacks 4 Operate the hydraulic unit until a pressure of approximately 1530 bar shows Note Do not move the pistons 7 11 of the pre tensioning jack above the red groove 10 5 Use the rod 94005 6 to turn back the nuts 4 approximately turn 6 Stop the hydraulic unit 94292 and release pressure to zero 7 Loosen the ...

Page 95: ...05 4 to tighten all the round nuts until they are tight Note Make sure that there is no clearance between main bearing girder 2 Fig 2 and the main bearing cover 1 y x 013 023 05 TIGHTENING ANGLE 1ST STEP 2ND STEP y x 1 Fig 3 7 On the hydraulic unit 94942 decrease the pressure to zero 8 Remove the double pre tensioning jacks 94114 9 Make sure that all round nuts are turned to approximately the same...

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Page 97: ...moval 3 5 Main Bearing Cover No 2 to No Removal 5 5 1 Preparation 5 5 2 Removal 5 6 Main Bearing Shell Removal 7 6 1 Hydraulic Jacks Installation 7 6 2 Crankshaft Lift 8 6 3 Bearing Shell No 1 Removal 9 6 4 Bearing Shell No 2 to No Removal 11 7 Main Bearing Shells Inspection 12 8 Bearing Shell and Bearing Cover Installation 13 8 1 Bottom Bearing Shell Installation 13 8 2 Top Bearing Shell 14 8 3 M...

Page 98: ...check of the bearing clearance refer to 0330 1 Record the clearance 8 Attach the eye bolt EB1 to the column in the position shown 9 Attach the manual ratchet H2 to the eye bolt EB1 3 Thrust Device Install WARNING Injury Hazard Do not use the thrust device 94110 as a lifting device Injury to personnel can occur CAUTION Damage Hazard Use the thrust device 94110 only for the removal of the main beari...

Page 99: ...is in the initial position refer to view I 5 Attach the ring slugging wrench 1 94002 36 to the special screw 5 6 Put the thrust device 94110 in position on the bearing cover 4 7 Turn the ring slugging wrench 1 until the nut 6 of the special screw 5 touches the thrust device 94110 refer to view II 4 Main Bearing Cover No 1 Removal 1 Attach the manual ratchet H2 Fig 5 to the lug 94116B 2 Operate the...

Page 100: ...Connect the HP hoses 94935 Fig 4 to the connection 1 on the hydraulic ram 2 and the HP oil pump 94931 9 Refer to 9403 2 to connect the HP hose 94935 and the pressure gauge 10 Operate the the HP oil pump 94110 to get a pressure of 1530 bar 11 Loosen the special screw 7 to unlock the piston 6 12 On the HP oil pump operate the relief valve to release the pressure 13 Disconnect the HP hose from the co...

Page 101: ... the thrust device 94110 to the applicable main bearing refer to paragraph 3 5 2 Removal 9 Attach the eye bolt EB2 Fig 7 next to the gland box 1 10 Attach the shackle 94572H to the eye bolt EB2 11 Attach the manual ratchet H2 to the eye bolt EB2 and the lug 94116B 12 Attach the shackle 94572H to the column 13 Attach the deviation pipe 94117B to the column 14 Attach the manual ratchet H3 to the sha...

Page 102: ...anual ratchet H2 from the lug 94116B 22 Operate the manual ratchets H1 H3 to move the bearing cover 1 on to the wooden underlay WU 23 Turn the ring slugging wrench 1 Fig 9 until the special screw 2 touches the thrust device 94110 refer to view I 24 Remove the thrust device 94110 from the bearing cover 3 25 Remove the two Allen screws from the bearing cover 3 26 Remove the top bearing shell from th...

Page 103: ...ng gear to turn the applicable crank to the exhaust side approximately 90_ after TDC 3 Lock the turning gear to prevent movement 4 Install the work platforms 94143 94144 Note There are three different sets of pads for the three versions of the crankshaft CV1 has the pads 94141B CV2 has the pads 94141C CV3 has the pads 94141B and 94141C 5 Put the bracket 94141 and the pads 94141C on the two main be...

Page 104: ...he value on the dial gauge is 0 15 mm 6 Make sure that there is no clearance between the adjacent bearing cover and the crankshaft 2 7 Keep the pressure constant 8 Measure the lateral bearing clearances y1 and y2 Compare these values with the values recorded in step 1 9 If the value of the lateral bearing clearance is more than 0 10 mm lower the crankshaft and do step a to step c a Install the hyd...

Page 105: ... the wire ropes 2 along the outer edges of the the bearing shell to the other side Attach the wire ropes to the device 94118 on the other side as shown 6 Use the plate 94119 and the M10x30 screws to hold the ropes in position 7 Torque the M10x30 screws to 40 Nm 8 Attach the manual ratchet H2 to the device 94118 9 Operate the manual ratchet H2 to turn the bearing shell 3 Note If the bearing shell 3...

Page 106: ...nd the plate 94119 12 Attach the lifting tool 94116 to the bearing shell Note During step 13 make sure that each end of the bearing shell 1 does not touch the bearing girder 13 Remove manually the bearing shell 1 14 Put the bearing shell 1 on to a wooden underlay WU on the platform Main Bearing Removal and Installation 2017 94116 1 x Fig 13 WU 1 ...

Page 107: ...m refer to paragraph 6 1 and 6 2 7 Remove the Allen screw 2 from the bearing girder on the exhaust side 8 Attach the device 94118 to the bearing shell 1 9 Put the wire ropes 3 along the outer edges of the the bearing shell to the other side Attach the wire ropes to the device 94118 on the other side 10 Use the plate 94119 and the M10x30 screws to hold the wire ropes in position 11 Torque the M10x3...

Page 108: ...Bearing Shells Inspection CAUTION Damage Hazard Do not use a scraper in the running area of the bearing shell Damage to the bearing shell can occur 1 Use a soft cloth to clean the bearing shell 2 Do a check the bearing shell for damage such as breakouts or cracks 3 Use Scotchbritet to remove light scratches and running marks 4 If the running marks are not symmetrical axial or radial speak to or se...

Page 109: ... 4 Attach the device 94118 to the front face of the bearing shell 2 with the Allen screws 5 Use the tool 94116 to put the bearing shell 2 in position on the crankshaft Make sure that the device 94118 is on the fuel side 6 Put the wire ropes of the device 94118 below the crankshaft journal Attach the wire ropes to the other side with the plate 97119 7 Torque the M10x30 screws of the plate 94119 to ...

Page 110: ...the applicable equipment to get the bearing cover 1 in the correct position above the crankshaft 4 During installation make sure that the spring dowel pins 5 go into the holes in the bearing cover 4 5 Install the round nuts 6 to the elastic studs refer to 1132 1 6 Tighten the round nuts 6 7 Measure the bearing clearance and compare the value measured in paragraph 2 step 7 with the value given in 0...

Page 111: ...e bearing shells more lubricant can be added to prevent damage to the surface of the bearing shells Refer to the Operation Manual 0320 1 Lubricating Oils 1 To fill the bearing shell with the lubricant do the procedure that follows a Remove the blank flange 6 b Remove the screw plug 5 c Fill the bearing shell with the applicable lubricant d Install the screw plug 5 e Install the blank flange 6 2 Re...

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Page 113: ...Stop the engine 7 Put the dial gauge 1 in position on the oil baffle top part 2 Record the value 8 Remove the dial gauge 1 9 Compare the values with those given in the engine documents on the Check Dimensions page refer also to 0330 1 Clearance Table Crankshaft and Thrust Bearing Note If the measured values are more than the nominal values given the thrust pads are worn 10 After maintenance on the...

Page 114: ...ance X and the value given in the engine documents is related to the wear of the thrust pads 3 Fig 1 8 Start the engine in the direction ASTERN to move the crankshaft fully forward The crankshaft must touch the thrust pads 7 9 Stop the engine 10 Make sure that the crankshaft does not move 11 Use the micrometer 94101 Fig 2 to measure the distance between the crankshaft flange 2 and the oil baffle t...

Page 115: ...ing out device 94155 1 Eye bolt 94045 M12 1 Eye bolt 94045 M16 1 Preparation 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Remove the screws 1 Fig 1 and the cover 2 3 Remove the oil baffle 3 4 Record the positions of the thrust bearing pads thrust pads Fig 1 I I WCH03612 6 7 2 3 5 4 WCH03612 I I 9 6 10 7 8 8 4 1 DRIVING END 2017 ...

Page 116: ... pads will keep the crankshaft in position If all thrust pads from the same side are removed e g all the astern pads the crankshaft can move 12 To prevent crankshaft movement do as follows a Get a piece of hardwood that has the same dimensions as a thrust pad b Put the hardwood in the position of the removed thrust pads 3 Installation 1 Make sure that the thrust pads are clean 2 Apply clean engine...

Page 117: ...5 M16 13 Do a check of the clearances between the arbor supports and the the thrust pads refer to 0330 1 Crankshaft and Thrust Bearing 14 For the configuration of the thrust pads refer to Fig 4 4 Completion 1 Install the oil baffle 3 Fig 1 2 Attach the cover 2 with the screws 1 3 Remove all tools and equipment from the work area 2017 Thrust Bearing Pads Removal and Installation ...

Page 118: ... TO PADS AT DRIVING END ASTERN AHEAD SUPPORT SURFACE CONFIGURATION OF THRUST PADS ENGINES WITH FIXED PITCH PROPELLER PADS FOR ASTERN PADS FOR AHEAD WCH03615 PROPELLER THRUST AHEAD PROPELLER THRUST ASTERN ENGINE SIDE DRIVING END WCH03615 WCH03615 Fig 3 CLOCKWISE ROTATION 2017 Thrust Bearing Pads Removal and Installation ...

Page 119: ...GURATION OF THRUST BEARING PADS ENGINES WITH CONTROLLABLE PITCH PROPELLER COUNTERCLOCKWISE ROTATION SUPPORT SURFACE AHEAD ASTERN WITH REVERSIBLE ENGINE ASTERN WCH03615 WCH03615 PADS FOR ASTERN PADS FOR AHEAD WCH03615 PROPELLER THRUST AHEAD PROPELLER THRUST ASTERN ENGINE SIDE DRIVING END Fig 4 2017 Thrust Bearing Pads Removal and Installation ...

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Page 121: ...ine stays are installed on the exhaust side or the fuel side D Two engine stays are installed at the free end The engine stays have friction shims You must do a pre tension check of the bolts 2 at the specified intervals refer to 0380 1 Note To do the pre tension checks on the engine stays you use the same jack 94145 as that used for the the foundation bolts The nameplate has the stamp 1500 bar Th...

Page 122: ... not changed and you can do steps a and step b If there is a clearance do step 6 a Operate the vent screw 1 to release the pressure to zero b Remove all tools and equipment 6 If there is a clearance the tension of the bolt has changed since the last check and you must do step a to step d below a Use the rod 4 to tighten the nut 3 b Use the feeler gauge to make sure there is no clearance c On the H...

Page 123: ...ssure of less than 30 bar defective O rings valves that have leaks defective screwed connections or accumulator you must do the procedure that follows 1 Decrease to 30 bar the pressure in the other hydraulic cylinder 2 Repair the defective engine stay as soon as possible 3 Adjust the oil pressure of the engine stays to the correct setting Refer to the instructions in the manufacturer s manual EXHA...

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Page 125: ...rods a a in the middle of the engine then b b etc 3 Connect the applicable equipment to the double pre tensioning jacks as shown in 9403 2 4 Attach the two double pre tensioner jacks 94180 to four tie rods 3 a a refer to 9403 4 5 Apply a pressure of 1500 bar 6 If possible tighten the round nuts 4 with the rod 94005 6 7 If the round nut 3 cannot move do step a to step b a Put a rod 94005 through th...

Page 126: ... rod 2 6 Attach an M12 eye bolt to the tie rod 2 7 Attach the hook of the engine room crane to the M12 eye bolt 8 Operate the engine room crane to remove the tie rod 2 from the cylinder jacket 5 3 3 Installation 1 Clean the top surfaces of the cylinder jacket 5 2 Apply Molykote paste G to the bottom M42x3 thread of the tie rod 2 3 Make sure that the intermediate ring 4 is installed 4 Attach an M12...

Page 127: ...ion DL of the tie rod 1 must be 6 5 mm to 7 5 mm L1 L 8 Release the pressure in the pre tensioning jacks 94180 9 Remove the pre tensioning jacks 94180 10 Apply a layer of Molykote paste G to the thread of the tie rod 1 and the round nut 2 prevent corrosion 11 Do step 1 to step 10 for the remaining tie rods 1 4 Completion 1 Attach the protection covers 2 Fig 1 to the tie rods 3 with the screws 1 20...

Page 128: ...ing of Cylinder Cover and Water Guide Jacket 2708 1 A1 Machining of Sealing Surface for Injection Valve 2708 3 A1 Injection Valve Removal and Installation 2722 1 A1 Disassemble Checks Assemble 2722 2 A1 Installation of Injection Valve with FAST 2722 1 A2 Starting Air Valve Removal Fitting and Dismantling Grinding in Assembling 2728 1 A1 Relief Valve for Cylinder Cover 2745 1 A1 Exhaust Valve Remov...

Page 129: ... closed position This makes sure that no cooling water can go into the cylinder liner 3 Clean the area above the running surface 4 Put the gauge 94225 in position on the top face of the cylinder liner 1 in line with the longitudinal axis of the engine 5 Make sure that the gauge 94225 is correctly adjusted a Apply Loctite No 243 to the thread of the setting screw SS b Adjust the setting screw SS re...

Page 130: ... the transverse axis of the engine 11 Do the steps above again to measure the bore in the positions F up to A 12 Use the formula below to calculate the rate WR D1 D2 x 1000 T1 Where WR Wear rate mm 1000 hours T1 Total running hours h D1 Maximum liner diameter of running surface point B and below mm D2 Liner diameter of non running surface point A mm 13 For the maximum permitted inner diameter refe...

Page 131: ... Liner Installation 4 4 Bottom Water Guide Jacket Removal 5 5 Bottom Water Guide Jacket Installation 5 6 Cylinder Liner Safe Storage 6 7 Cylinder Liner Preparation 6 1 Preparation 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Drain the cylinder cooling water from the related cylinder see the Operating Manual 8017 1 3 Remove the cylinder cover see 2708 1 4 Remove the piston toget...

Page 132: ...e threads of special screws 3 4 Attach the two holders 94206 to the cylinder liner 1 with the special screws 3 5 Torque the special screws 3 to 120 Nm 2 2 Cylinder Liner Lift 1 Connect the crane hook to the shackle 94202I on the lifting tool 94202 Fig 2 2 Operate the engine room crane to carefully lift the cylinder liner 1 3 Move the cylinder liner 1 over the rail unit 2 4 Lower the cylinder liner...

Page 133: ... tool 94202 from the cylinder liner 1 3 Lower the lifting tool 94202 to an applicable surface 4 Remove the crane hook from the shackle 94202I of the lifting tool 94202 5 Install the two special screws 3 to the storage position 2 in the two holders 94206 2017 Cylinder Liner Removal and Installation 1 I I I I 2 94206 3 94202 94201I 94202 WCH03611 Fig 3 WCH03611 94201I ...

Page 134: ...block 2 5 Carefully lower the cylinder liner 1 almost on to the cylinder block 2 6 Align the hole in the cylinder holder 5 with the pin 4 on the cylinder block 2 7 Fully lower the cylinder liner 1 8 Remove the lifting tool 94202 refer to paragraph 2 3 9 Install the piston together with the piston rod gland see 3403 1 and 2303 1 10 Install the cylinder cover see 2708 1 11 Install all lubricating qu...

Page 135: ...allation D The cylinder holders 7 Fig 5 must be fitted to the cylinder liner 4 1 Clean both sealing surfaces SF and the grooves in the cylinder liner 4 2 Place new O rings 1 and 3 of the specified quality and dimension into the grooves on the cylinder liner Smear O rings 1 and 3 and corresponding sealing surfaces of the bottom water guide jacket 2 with lubricating oil 3 Move the bottom water guide...

Page 136: ...ys 4 in position to prevent movement of the cylinder liner 1 refer to Step 4 10 Fully lower the cylinder liner 1 11 Remove the chain 94335D from the lifting tool 94210A 12 Remove the lifting tool 94202 from the cylinder liner 1 7 Cylinder Liner Preparation 1 Install the lifting tool 94202 Fig 6 on the cylinder liner 1 refer to paragraph 2 1 2 Attach the shackle 94202I of the lifting tool 94202 in ...

Page 137: ...2124 2 A1 Winterthur Gas Diesel Ltd 7 7 Fig 6 94335D 94201I WCH03636 94201A 1 2 I II I WCH03636 3 4 3 Step 1 Step 2 Step 3 Step 4 Centre of gravity min 560 mm Lower Lift Cylinder Liner Removal and Installation 2017 ...

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Page 139: ...ricating quills refer to 2138 1 3 Put applicable protection in the cylinder liner This keeps unwanted particles out of the bore 3 Unwanted Material Remove CAUTION Damage Hazard Make sure that you do no cause damage to the running surface of the cylinder liner when you operate the grinding tool 1 Read the data in the Instruction Manual for the grinding tool 2 Attach the grinding tool 94299 to the c...

Page 140: ...Maintenance 2124 3 A1 Winterthur Gas Diesel Ltd 2 4 Fig 1 94299 WCH03633 Unwanted Material 2 WCH03634 Step 1 Step 2 Step 3 3 2 1 2017 ...

Page 141: ...olish the scavenge ports make sure that you do not cause damage to the running surface of the cylinder liner Note The scavenge ports 1 Fig 2 are as seen in new cylinder liners 1 Use emery cloth to polish the surfaces of the scavenge ports Make sure that you keep the shape of the scavenge ports the same as those shown 2 After the repair is completed fully clean the lubricating grooves and the bore ...

Page 142: ...Maintenance 2124 3 A1 Winterthur Gas Diesel Ltd 4 4 WCH03635 SI WCH03635 SHARP EDGES REMOVED II III Fig 2 I I SHARP EDGES REMOVED II III WCH03635 WCH03635 I I 1 2017 ...

Page 143: ...stallation 3 4 Lubricating Quill Function Check 3 4 1 General 3 4 2 Procedure 3 1 General If it is not necessary to remove the cylinder liner 1 Fig 1 you must not drain the cylinder cooling water For more data refer to 2124 2 Step 1 to step 3 are only necessary if the cylinder liner 1 must be removed 1 Remove the holders 4 2 Disconnect the pipes 2 3 3 Seal the pipes 2 3 with applicable seals to pr...

Page 144: ...Apply protection to the lubricating oil pipe 12 to prevent damage and contamination 3 Remove the screws 9 4 Remove the lubricating quill 4 5 If necessary do a function check of the lubricating quill refer to paragraph 3 9 4 8 SF 1 6 5 7 Fig 2 10 9 12 11 I I WCH03594 WCH03593 1 II II MARKS 2017 Lubricating Quill Removal and Installation ...

Page 145: ...ach the oil pipes 12 to the lubricating quill 4 11 Tighten the nuts of the unions 10 and 11 12 Bleed the oil pipes 12 refer to7218 1 13 Do a function check of the cylinder lubricating system 4 Lubricating Quill Function Check 4 1 General You do a function check to make sure that the non return valve operates correctly The pressure that opens the non return valve is 5 0 bar During the function chec...

Page 146: ...Note The opening pressure must be a minimum of 4 25 bar for correct operation If the opening pressure is less than4 25 bar the non return valve will not operate correctly and must be replaced 2 94935 94931 1 94934H WCH00112 94934I Fig 3 2017 Lubricating Quill Removal and Installation ...

Page 147: ...ng Variant 2 6 1 General CAUTION Damage Hazard Do not turn the crankshaft when the platforms or the supports are installed in the crankcase Damage to equipment can occur Examine the piston rod gland for wear and damage on each overhaul of the piston see 0380 1 If necessary replace the unserviceable parts There are two procedures to remove piston rod gland D Procedure 1 The piston with the piston r...

Page 148: ... the assembly platform 94345H under the piston rod gland 3 Torque the bolts 19 to 32 Nm Fig 3 4 Remove the screws 16 and bolts 17 from the housing 1 5 Push the two parts of the housing away from the piston rod 6 Remove all tension springs scraper rings sealing rings and ring supports 7 Measure the parts that follow D Scraper rings 2 6 D Sealing rings 3 4 Refer to the Clearance Table 0330 1for the ...

Page 149: ...ance 2303 1 A1 Winterthur Gas Diesel Ltd 3 7 I I I III 1 2 I III II II IV IV V V 1 22 20 11 13 14 12 14 15 V V IV IV 16 16 17 WCH00467 Fig 2 2017 Piston Rod Gland Dismantling and Assembling Measuring the Wear ...

Page 150: ...3 Put the three parts of the first ring support 5 on the distance pieces with scraper rings 6 installed Make sure that the distances are equal 4 Use the assembly tools 94345E see 9403 5 to install the tension spring 10 5 Put the two distance pieces 94345F 8 mm on to the ring supports 6 Install the second ring support scraper rings and tension spring 10 D The height of distance pieces 94345F is rel...

Page 151: ...5C to make sure that if all rings are installed in the correct positions 13 Align the two parts of the housing to get the housing partition in line with the axis of the M24 holes in the piston rod foot 14 Push the two parts of the housing together 15 Tighten the screws 16 Fig 2 and bolts 17 of the housing 1 16 Remove the assembly platform 17 Put the gland in the position at level X 400 mm see Fig ...

Page 152: ... remove the piston rod gland from the cylinder block 8 Put the gland foot on the wooden underlay WU 9 Remove the four bolts 13 10 Lower the gland and support on to the assembly platform 11 Operate the turning gear to move the piston to BDC 12 Disassemble the piston rod gland refer to paragraph 2 2 13 Assemble the piston rod gland refer to paragraph 2 3 Note When you operate the turning gear make s...

Page 153: ...Maintenance 2303 1 A1 Winterthur Gas Diesel Ltd 7 7 I I I I 94345H 1 94143 94144 WCH00571 WCH00554 40 mm 60 mm WU 94345H Fig 5 2017 Piston Rod Gland Dismantling and Assembling Measuring the Wear ...

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Page 155: ...ally the starting air valves Refer to the Control Diagram 4003 2 in the Operation Manual 4 Drain the cylinder cooling water refer to the Operation Manual 8017 1 5 Remove the hydraulic pipe to the exhaust valve refer to 8460 1 6 Disconnect all connections to the cylinder cover and the exhaust valve 7 Remove the cooling water pipe 8 Close the starting air valve Disconnect the air pipe from the cylin...

Page 156: ...s can crush body parts Always use correct personal protective equipment 2 Attach the engine room crane to the device 94265 3 Operate the engine room crane to lift the cylinder cover 5 4 Make sure that the connection tube 9 is removed from the holder 8 5 Operate the engine room crane to lower the cylinder cover 5 and top water guide jacket 6 on to the wooden underlays WU 6 Remove and discard all O ...

Page 157: ...Maintenance 2708 1 A1 Winterthur Gas Diesel Ltd 3 6 2 4 1 3 5 WU 94265 WCH00940 EB Fig 1 I I I I 6 8 7 9 5 WCH03627 2022 7 ...

Page 158: ...ine room crane to carefully lift the cylinder cover 1 Note If the top water guide jacket 4 does not stay on the wooden underlay WU use a mallet to loosen the top guide jacket 3 Remove and discard the O rings 3 WU 1 4 WCH00594 Fig 2 I I I I 4 2 1 WCH03627 3 Removal and Installation of Cylinder Cover and Top Water Guide Jacket 2017 ...

Page 159: ...ts Injury to personnel can occur Heavy parts can crush body parts Always use correct personal protective equipment 5 Carefully operate the engine room crane to lower the cylinder cover 1 on to the top water guide jacket 2 Fig 3 I I I I 2 8 WCH03627 7 6 5 3 1 II II 2 13 1 II II 9 10 11 12 4 WCH03627 4 2 Cylinder Cover 1 Make sure that the compression space is free from particles or dirt 2 Make sure...

Page 160: ...nder liner 13 Remove the tool 94265 or the eye bolt EB 14 Attach the round nuts to the elastic bolts on the cylinder liner Make sure that the round nuts move freely 15 Apply tension to the elastic bolts 2 refer to 9403 4 5 Completion 1 Install the expansion piece 2 Install the hydraulic pipe to the exhaust valve refer to 8460 1 3 Install the HP fuel pipes refer to 8733 1 4 Connect all connections ...

Page 161: ...vice 94270 to repair sealing faces that are dirty or have light damage 1 Apply Molykote G paste to the running surface RS Fig 1 2 Apply tacky grease to the profile cutter 94270A This will make sure that shavings do not fall into the combustion chamber 3 Make sure that the two set screws 4 are tight 4 Carefully put the device 94270 and the profile cutter 94270A into the valve bush 2 in the cylinder...

Page 162: ... 2708 3 A1 Winterthur Gas Diesel Ltd 2 2 WCH03640 94270 RS Fig 1 1 5 4 3 WCH03639 WCH03640 94270A 94270 1 2 I I I I Storage position for item 5 Removal and Fitting of Cylinder Cover and Top Water Guide Jacket 2017 ...

Page 163: ... 3 from the injection valve 4 5 Put the two bolts 94270C in the positions as shown in Fig 1 6 Turn equally the two bolts 94270C fully into the valve bush 5 until the shoulder of the bolt touches the bush 7 Turn equally the two bolts 94270C to lift the injection valve 4 for 45 mm or more 8 Remove the injection valve 4 9 Remove and discard the five O rings 7 10 Put protection on the nozzle tip 6 11 ...

Page 164: ... 2722 1 A1 Winterthur Gas Diesel Ltd 2 5 Fig 1 2 WCH03651 3 4 5 1 WCH03652 I I I I approx 12 mm approx 45 mm WCH03652 WCH03652 94270C 4 7 5 Step 1 Step 2 6 Injection Valve Checking Dismantling and Assembling 2017 ...

Page 165: ...tively high force is needed to overcome the resistance of the five O rings When the O Rings are compressed it will become easier to push the injector in Note The injection valve is fully in when the nozzle body of the injector is sealing with the cylinder cover 8 This will be recognized by a suddenly increasing force Theoretically the distance between the injection valve and the valve bush is appr...

Page 166: ...2722 1 A1 Winterthur Gas Diesel Ltd 4 5 2 WCH03651 3 4 5 1 WCH03652 WCH03652 WCH03652 I I I I 4 5 7 94270D 6 approx 12 mm approx 45 mm Step 1 Step 2 Fig 2 8 Injection Valve Checking Dismantling and Assembling 2017 ...

Page 167: ...Maintenance 2722 1 A1 Winterthur Gas Diesel Ltd 5 5 Fig 3 WCH02401 2 1 3 4 5 6 1 8mm 0 2 mm Injection Valve Checking Dismantling and Assembling 2017 ...

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Page 169: ...f a spring pack is not according to the requirements and it is the only available spring pack the same tightening instructions are to be followed The old spring pack must be repaired or replaced as soon as you get the new spring pack Note It is not recommended that diesel oil gas oil is used if the injection valve is put into storage after these checks The injection valve can get corrosion 2020 In...

Page 170: ...jector valve assembly 4 into the chamber 6 Apply a thin layer of Never Seez on the threads of two M12 Hexagon socket head cap screw 2 7 Tighten the screws in two steps a Equally tighten the screws spring guides are flush with each other b Check the screws are tightened to at least 35 Nm 8 Connect the injector cable in the terminal box Fig 2 2 3 1 4 1 8 0 2 2020 Injection Valve Installation Injecti...

Page 171: ...re 3 1 4 Results 4 2 Disassemble 4 3 Assemble 5 4 Nozzle Tip Replace 6 4 1 Removal 6 4 2 Installation 7 5 Spring Cage Assemble 7 6 Injection valve Installation 8 1 Checks 1 1 General The test bench 94272 and calibration fluid must be used for the tasks that follow D To do checks D To disassemble D To assemble The properties of the calibration fluid e g Shell Calibration Fluid S 9365 Univar Calibra...

Page 172: ...ty equipment CAUTION Equipment Damage Do not use welding or grinding equipment near the work area Always make sure that the work area is clean and there are no unwanted materials 1 Read and obey the data in the instruction manual of the test bench manufacturer 2 Make sure that the work station is clean 3 Make sure that the support is removed from the valve holder 94272E 4 Use a brass wire brush to...

Page 173: ... gauges on the test bench If necessary adjust the pressure gauges 3 Read the data in the manufacturer s instructions to set the pressure of the test bench to 200 bar 4 Push the INJECT BUTTON Do a check to make sure that injection valve operates correctly 5 Do a check of the seating surface between the needle seat and the nozzle as follows a Keep the pressure in the test bench constant at approxima...

Page 174: ...the nozzle tip with the needle installed If it is necessary to do this do the procedure carefully Only the injection valve manufacturer or an authorized company can repair or replace nozzle holders Intermediate plates and nozzle bodies that have unsatisfactory sealing surfaces 2 Disassemble 1 Make sure that the test bench and HP hose have no pressure 2 Remove the receiver 2 Fig 1 from the valve ho...

Page 175: ...e or clean diesel oil 2 Put the bush 94289B in position see Fig 3 3 Attach the tool 94289 and turn it counterclockwise to install the pilot valve 11 4 Remove the bush 94289B 5 Put the nut 8 on to the nozzle holder 6 Put the special tool of the test bench on to the nut 8 Fig 2 7 Use the test bench to toque the nut 8 to 500 Nm 8 Remove the sleeve 9 the nozzle tip 10 and the O rings 4 5 6 7 9 Do the ...

Page 176: ...ake sure that specified nozzle tips are used in accordance with the IMO Technical File of the engine 4 1 Removal 1 Put the injection valve in a vice Make sure that the nozzle 1 Fig 4 points up 2 Put two screwdrivers between the recesses in the nut 4 as shown 3 Push the snap ring 3 out of the groove in the nut 4 4 Remove the sleeve 5 5 Remove the nozzle tip 1 2017 Injection Valve Checking Dismantli...

Page 177: ... the hole in the nozzle tip 4 Put the sleeve 5 on the nozzle tip 1 5 Use the two screwdrivers to push the snap ring 3 into the groove of the nut 4 6 Do the function check refer to paragraph 1 SCREWDRIVER 3 5 4 1 013 493 05a 2 WCH00532 Fig 4 5 Spring Cage Assemble 1 Make sure that the cup springs 1 are installed as shown in Fig 5 2 Make sure that the distance X is 1 8 0 2 mm 4 x 6 WCH00654 1 4 x 6 ...

Page 178: ...C 6 Carefully put the injection valve in the cylinder cover Make sure that the dowel pin 6 engages in the holder 1 5 4 3 2 6 94289C 1 WCH00903 Fig 6 7 Put the spring cages 4 Fig 7 in position on the injection valve 8 Apply Never Seez NSBT to the threads and the seating surfaces of Allen screws 2 9 Attach the f Allen screws 2 to the spring cages 4 10 Tighten equally the Allen screws 2 until the spr...

Page 179: ...Maintenance 2722 2 A1 Winterthur Gas Diesel Ltd 9 9 Fig 7 FLUSH WCH00532 2 3 4 1 Injection Valve Checking Dismantling and Assembling 2017 ...

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Page 181: ...es on the starting air bottles b Turn the handwheel 2 10 of the starting air shut off valve 2 03 to the position CLOSED refer to the Operation Manual 4003 2 Control Diagram c Open the ball valves 2 06 and 2 21 to release the pressure 3 Removal 1 Remove the control air pipe from the starting air valve 2 Disconnect the electrical connection from the 3 2 way solenoid valve 13 Fig 1 3 Remove the four ...

Page 182: ...Maintenance 2728 1 A1 Winterthur Gas Diesel Ltd 2 5 6 Lift housing from the valve spindle 4 ...

Page 183: ...ance 2728 1 A1 Winterthur Gas Diesel Ltd 3 5 I I II II I I 13 3 8 SA 9 7 10 16 6 16a 1 4 15 12 14 11 2 WCH00522 12a 3 5 17 Fig 1 91 90 2017 Starting Air Valve Removal Disassemble Grinding Assemble Installation ...

Page 184: ...rts 3 Put a small quantity of oil on the new O rings 15 16 16a and the piston rings 12 12a 4 Put the two new O rings 16 16a in the housing 5 Put the new piston rings 12 12a on the piston 5 6 Put the valve spindle 4 into the housing 2 7 Put the compression spring 6 into the housing 2 8 Put the piston 5 in position on the valve spindle 4 9 Note Do not get Molykote paste G on the thread of the valve ...

Page 185: ... put the starting air valve in the cylinder cover 1 Make sure that the control air pipe 14 goes into the bore of the cylinder cover correctly 6 Apply Never Seez NSBT 8 to the threads of the two M16 bolts 8 7 Put the two M16 bolts 8 in position in the cover 3 8 Torque symmetrically the two bolts 8 to the value given in 0352 2 9 Tighten the connections of the control air pipe 14 10 Connect the elect...

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Page 187: ... cylinder covers that have an indicator valve together with a relief valve see Fig 1 If the pressure in the compression chamber is more than the specified blow off setting of the relief valve the relief valve opens The pressure is immediately released You must then replace the relief valve as soon as possible Relief valves cannot be adjusted or repaired You must replace a relief valve that leaks I...

Page 188: ...e relief valve 2 5 Make sure that the relief valve is set to blow off at 250 bar This relates to a firing pressure of between 176 bar and 180 bar 6 Release the pressure in the test bench 94272 7 Remove the relief valve 2 from the valve holder 94272C 3 2 Procedure Two 1 Attach the relief valve 2 to the valve holder 94272C 2 Connect the HP oil pump 94931 and the hose 94935 to the pressure gauge 9493...

Page 189: ...3 484 05 94935 94934A 94272 94931 RV 017 670 08 10 94272C 2 WCH00652 Fig 2 94272C 4 Installation 1 Apply Never Seez NSBT 8 to the thread of relief valve 2 Fig 1 2 Install new gaskets 7 3 Close the indicator valve 3 Relief Valve Blow off Pressure Check 2017 ...

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Page 191: ...linder cooling water from the respective cylinder see 2708 1 and close the air inlet to the air spring at the control air supply see 0520 1 in the Operating Manual The exhaust valve can be removed from the cylinder cover or transported with the eye bolt RC refer to Fig 1 Pay attention to 1 General Guidelines for Lifting Tools 0012 1 2 General Application Instructions 9403 4 for hydraulic pre tensi...

Page 192: ... of the elastic bolts 4 Fit nuts 2 and tighten them firmly with a rod till fully seated before mounting the pre tensioning jacks check seating with feeler gauge 5 Mark position of the nuts 2 on a corner and their position on valve cage 3 with a felt tip pen for later checks 6 Tighten elastic bolts according to General Application Instructions 9403 4 Note When refitting expansion piece 6 smear its ...

Page 193: ...ace CAUTION Damage Hazard Do not apply adhesive primer and any lubricant to the thread Damage to equipment will occur 1 Screw in the bolt right to the bottom and until it rests on its seating surface 2 Tighten the bolt according to instructions 0352 2 using always a bolt driver or two counter locked nuts CAUTION Damage Hazard Tools eg pipe wrenches or multigrip tongs etc which would cause damages ...

Page 194: ...r Products of other manufacturers are also allowed when fulfilling the below specification 1 Containing no acid e g no acetic acid 2 Resistant to oil marine diesel oil heavy fuel oil and water at a permanent temperature of approximately 100 _C 3 Short age hardening time i e at least 24 hours under ISO standard reference conditions 4 Well flowing to properly fill out the annular space in order to a...

Page 195: ... 1 General The International Association of Classification Societies IACS recommends that there are two exhaust valves on board Only qualified personnel or a Winterthur Gas Diesel Ltd authorized repair workshop can repair defective exhaust valves For the inspection and overhaul intervals refer to 0380 1 Exhaust valve Read the data in 0012 1 General Guidelines for Lifting Tools WARNING Danger Do no...

Page 196: ...Maintenance 2751 2 A1 Winterthur Gas Diesel Ltd 2 9 I I 11 HH 1 4 LO WCH03531 Fig 1 BO 19 24 23 22 2 3 15 RC I I 2017 Exhaust Valve Disassemble and Assemble ...

Page 197: ...Maintenance 2751 2 A1 Winterthur Gas Diesel Ltd 3 9 HU 31 2 7 6 5 4 14 11 33 WCH03656 Fig 2 WCH03656 I I I I WCH03656 2017 Exhaust Valve Disassemble and Assemble ...

Page 198: ... remove the latter 3 Withdraw the piston from the valve spindle 11 4 Remove the disc springs 14 5 Carefully lift the valve cage 1 by means of the engine room crane Ensure that the valve spindle always stands on the wooden underlay while the valve cage is sliding out 2 3 Guide Bush Removal 1 Undo the head screws 18 Fig 3 remove them together with distance ring 16 and rod seal ring 17 2 Screw both j...

Page 199: ...h a new seat or spindle the seats must be checked according to the instructions given in 2751 3 3 1 Guide Bush Installation 1 Clean the bore in valve cage 1 Fig 4 and guide bush 15 2 Oil the guide bush and press it into the valve cage using jack screws 94263 3 2 Valve Spindle Installation 1 Apply oil to the valve spindle and fit it 2 Apply oil to a new rod seal ring 17 Fig 3 fit it with distance r...

Page 200: ...ge measure H from the edge of valve drive housing 2 Fig 6 to the bottom of the damper bore in piston 8 for this the exhaust valve must be closed check with feeler gauge whether the valve plate lies against the valve seat without clearance Note The total thickness h of shim ring s 21 assigned to measure H is shown in the following table Measure H 0 5 mm Total thickness h 79 9 mm 1 mm 78 9 mm 2 mm 7...

Page 201: ...lve stroke sensor bore and collar in lower housing as well as transmitter housing 2 Push valve stroke sensor 28 Fig 7 together with transmitter housing 29 into the bore and fasten it using screws 30 30 28 29 TERMINAL BOX ARRANGED ON RAIL UNIT WCH03656 Fig 7 Exhaust Valve Disassemble and Assemble 2017 ...

Page 202: ...2 together with orifice 23 and check them for fouling 3 7 Non return Valve Check Note In order to remove non return valve 25 Fig 8 unscrew air pipe 27 and its double nipple 1 Undo the non return valve 2 Do a check of the non return valve LE 2 26 27 25 1 15 Fig 8 WCH03531 Exhaust Valve Disassemble and Assemble 2017 ...

Page 203: ...ombustion chamber damper 19 Fig 1 can be removed and the exhaust valve blocked in open position by means of pressure element 94259 Fig 9 The latter must also be fitted if an exhaust valve is jammed in the open position see 0520 1 in the Operating Manual 43 mm 94259 WCH03661 Fig 9 Back up O ring Exhaust Valve Disassemble and Assemble 2017 ...

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Page 205: ...tion it must be suspended on the engine room crane slightly above a wooden underlay Device 94261 can then be attached from below and the valve seat carefully withdrawn until it drops caused by its own weight Therefore the valve seat must be properly secured with additional wooden underlays The distance to the wooden underlay is to be kept as small as possible to avoid any accidents or damage 2 Val...

Page 206: ...Smear new O ring 3 of original specification with the same lubricant 5 Push valve seat as far as possible into the bore then mount valve seat fitting and dismantling device 94261 and by equal tightening of the jack screws press the valve seat down till fully seated Through the control openings in the valve seat fitting and dismantling device check with feeler gauge 94122 all around the circumferen...

Page 207: ...o the operating instructions of the respective manufacturer D The grinding must produce an even and smooth surface Valve seat angle 30_ 2 0 The grinding allowance on the valve seat is maximum 1 5 mm The wear condition can be checked efficiently with gauge 94279 in combination with feeler gauge 94122 Possible burn scars at the inside of the valve seat must not exceed 5 mm The depth of the burn scar...

Page 208: ...he valves makes contact by 50 to100 from the outer edge Fig 6 The blueing check should show that the cold valve makes contact only from inside around the whole circumference The angle difference can be checked at gap S on the outer edge with a feeler gauge Fig 7 1 The blueing on the valve seat must be checked by tapping the valve head three or four times with a hammer on a wooden block Fig 5 Do no...

Page 209: ...r the whole unit has cooled down The devices from the makers HUNGER and CHRIS MARINE are well proven for valve grinding and can also be ordered directly from Winterthur Gas Diesel Ltd 2 Grinding the seating surface D Only as little material as necessary should be ground off the valve seating surface to provide a clean and smooth finished surface Only grind with cooling wet D In order to avoid the ...

Page 210: ...ing surface Valve plates where the seat surface has been ground back by more than 1 5 mm can be recondi tioned by build up welding D On engines with arduous operating conditions corrosion may form at the bottom of the valve plate after a longer operating time Exhaust valves can be reconditioned if the loss of material on the valve plate is less than or equal to 4 5 mm Exhaust valves cannot be reco...

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Page 212: ...d Installation 3303 2 A1 Top End Bearing Removal and Installation 3303 3 A1 Removal and Installation Piston Installed 3303 4 A1 Removal and Installation Piston Removed 3303 4 A2 Top End Bearing Cover Removal and Installation 3303 5 A2 Crosshead Clearance Checks 3326 1 A1 Crosshead Pin Removal and Installation Piston Installed 3326 2 A1 Crosshead Pin Removal and Installation Piston Removed 3326 2 A...

Page 213: ...crank webs can be read from the dial gauge This shows the distance the crank web has opened or closed The smaller the difference the better the crankshaft is aligned But you must think about the function of the crankshaft equipment ie the signs on the dial gauge standard 2 Conditions The conditions to measure crank web deflection are as follows D The indicator valves must be open D The ship must b...

Page 214: ...e 2 Set the dial gauge to zero Make sure that the dial gauge does not show a difference of more than 0 01 mm 3 Use the turning gear to turn the crankshaft Start at BDC and record the indications on the dial gauge for the positions shown BDC FUEL SIDE TDC EXHAUST SIDE BDC Note Make sure that the last value at BDC is almost zero If the difference is more than 0 03 mm the procedure again Fig 2 CRANK ...

Page 215: ...for usual operation D The engine is stopped and is hot or cold D If the engine is in a cold condition the tank heating which is close to or below the main engine and the pre heater of the main lubricating oil separator must not be in operation for a minimum of eight hours before the procedure given in paragraph 2 Usual Operation Crank web Deflection Limits mm Vertical Horizontal Cylinder No 1 Driv...

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Page 217: ... sample containers are available from the vibration damper manufacturer 2 Silicone Oil Sample Preparation WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine Note Read the instructions in the manufacturer s documentation before you do the procedure that follows 1 Remove the casing from the vibration damper 1 Fig 1 2 Operate t...

Page 218: ...ntainer does not touch the flywheel 7 When you see silicone oil in the sample container SC attach the cap nut 1 to the open end 8 Remove the sample container SC from the vibration damper housing Immediately attach the screw plug 2 to the vibration damper housing 9 Attach the other cap nut 1 to the sample container SC 10 Torque the screw plug as follows a Metaldyne Torque the screw plug to 25 Nm b ...

Page 219: ... SC fully into the vibration damper housing then turn the sample container back one turn This will make sure that the sample container does not touch the flywheel 7 When you see silicone oil flow out of the sample container SC attach the cap nut 1 to the open end 8 Remove the sample container SC from the vibration damper housing Immediately attach the screw plug 2 to the vibration damper housing 9...

Page 220: ...ted screw plugs to all withdrawal openings 8 Torque the screw plugs as given in step a and step b a For Metaldyne and STE vibration dampers paragraph 3 1 step 10 b For Hasse and Wrede vibration dampers paragraph 3 2 step 10 9 Use a center punch to lock the screw plugs 3 in position Note The sample container lets you get a specified quantity of silicone oil from the damper The total number of sampl...

Page 221: ... the crankshaft The service life of a vibration damper is related to the speed range in which the engine operates Sea water and other types of water in the lubricating oil can cause the internal parts to become worn and decrease the effect of the vibration damper 1 General WCH03625 1 2 3 4 I I Fig 1 Vibration Damper front view 1 Vibration damper monitor 3 Monitor pipe 2 Damper casing 4 Oil supply ...

Page 222: ... specified limits You must speak to the manufacturer for instructions Note Only specialists can make adjustments of the vibration damper The torsional vibrations and these adjustments must be done at the same time To do a check of the inner spring tips and groove flanks do the procedure that follows 1 Stop the engine 2 Remove the inspection cover from the vibration damper casing 3 Examine the inne...

Page 223: ...940 93 OIL SUPPLY 6 FREE END DATA FOR STEEL SPRING DAMPER 2 3 4 5 WCH03625 I I 1 1 Fig 2 Vibration Damper section view 1 Vibration damper 4 Crankshaft 2 Damper casing 5 Coupling bolt 3 Oil supply pipe 6 Vent nozzle 2017 Inspection GEISLINGER Vibration Damper ...

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Page 225: ... removed from the axial damper do the procedure that follows 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Stop the engine 3 Set to off the bearing oil pump 4 Remove the pipes 11 12 5 Remove the top casing 1 6 Remove the two hose clips 2 7 Remove the pipes 3 10 8 Remove the non return valves 4 5 9 Remove the four bolts 7 the six bolts 8 and the four bolts 9 from the cylinder hal...

Page 226: ...make sure that the cylinder half 1 moves up freely to prevent damage to the 2 part gaskets 15 Operate the manual ratchet 94016G to carefully lift the cylinder half 1 Note Engine operation does not usually cause the 2 part gaskets to become worn The 2 part gaskets must be replaced if they become worn or if contamination causes damage 16 Operate the manual ratchet 94016G to move the cylinder half 1 ...

Page 227: ...erate the manual ratchet 94016G to carefully lower the cylinder half 1 on to the bottom cylinder half 2 Make sure that you do not cause damage to the 2 part gaskets 6 Apply Molykote paste G n to the threads of the six bolts 8 Fig 1 7 Torque the six bolts 8 to 250 Nm see 0352 1 8 Install the four bolts 7 and the four bolts 9 9 Install the non return valves 4 5 Make sure that the flow direction is c...

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Page 230: ... the turning gear 1 Fig 1 you must examine D The condition of the tooth flanks D The lubrication of the pinion 2 D The flywheel teeth 3 For more data about the turning gear refer to the Operation Manual 0320 1 For maintenance of the turning gear 1 refer to the manufacturer s instructions Fig 1 WCH03623 2 3 1 WCH03623 I 2017 ...

Page 231: ...A In order to reach a very thin shiny layer of lubri cant it is recommended to warm up Klüberfluid to approx 35 _C in a small tin which is put into warm water 2 2 Lubrication Intervals Examine the teeth approximately each 2000 operation hours or more frequently if necessary When there is a minimum of lubricant remaining on the teeth e g when the teeth are almost dry lubricate the teeth 2 3 Recomme...

Page 232: ...re installed This will cause injury to personnel and damage to equipment You use the grid 94142 Fig 1 and platform elements 94143 94144 when you do work in the crank area and between the columns The grid and platform elements help to prevent accidents in these areas Make sure that the grid and platform elements are correctly installed Attach the grid 94142 94143 94144 94143 94144 PLATFORM ELEMENT ...

Page 233: ...ting Tools 2 Operate the turning ear to move the applicable crank pin 4 Fig 1 to TDC 3 Lock the turning gear 4 Install two shackles 94572G to the positions shown on the column 5 Attach the two eye bolts 94045 M16 to the bottom bearing cover 3 6 Attach the two shackles 94572H to the eye bolts 94045 M16 2 Bearing Cover Removal 1 Attach the manual ratchets H1 H2 to the shackles 94572G on the column a...

Page 234: ...move the crank to the exhaust side approximately 45_ 12 Carefully remove the manual ratchet H2 13 Attach the chain block H3 to the same shackle as the manual ratchet H1 14 Operate the manual ratchet H1 and the chain block H3 to remove the bearing cover 1 from the engine 15 Carefully remove the manual ratchet H1 16 Operate the chain block H3 to lower the bearing cover 1 on to the platform 3 Bottom ...

Page 235: ... turning gear to move the crank to the fuel side At the same time operate the manual ratchet H1 to keep the clearances at X This will prevent damage to the bearing shell 8 Do an inspection of the bearing shell 8 If necessary remove the bearing shell as follows a Hold the bearing shell in position with your hands b Remove the two screws 7 c Remove the bearing shell 8 5 Installation 1 If the bearing...

Page 236: ...step c a Clean the seating surfaces of the bearing cover 4 and the bearing shell b Apply a thin layer of oil to the seating surface of the bearing shell c Attach the bearing shell to the bearing cover 4 with the two screws 6 9 Attach the chain block H3 and the manual ratchet H1 to the eye bolts 94019F on the bearing cover 4 10 Operate the manual ratchet H1 and the chain block H3 to lift and move t...

Page 237: ...y bearing oil b If the engine has stopped for some days use a mixture of high viscosity oil steam engine cylinder oil ISO VG 1000 1500 and bearing oil The ratio is two thirds ISO VG 1000 1500 to one third bearing oil Note A list of suppliers for ISO VG 1000 1500 high viscosity oils is given in Table 1 19 Operate the the manual ratchets H1 H2 Fig 6 to fully lift the bearing cover Make sure that the...

Page 238: ...to 9403 4 5 To lubricate new bearing shells and prevent dry running refer to 3303 3 Table 1 ISO G 1000 1500 Suppliers Supplier Type Viscosity at 40 C mm2 s Viscosity at 100 C mm2 s Weight at 15 C g ml BP ENERGOL DC 1000 980 49 0 0 913 BP ENERGOL DCW 1000 920 40 0 0 913 CHEVRON CYLINDER OIL 1000 1000 43 1 0 937 EXXON ESSO CYLESSO 1000 950 44 0 EXXON ESSO CYLESSO TK 1000 925 46 7 MOBIL EXTRA HECLA S...

Page 239: ...ower Piston Removed 4 6 Crosshead Lower Piston Installed 5 7 Bearing Lubrication 6 8 Bearing Cover Removal 6 8 1 Preparation 6 8 2 Removal 7 9 Bearing Cover Installation 8 1 Preparation WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Record the position of t...

Page 240: ...ntly to install the two supports 94322 13 Attach the two supports 94322 to the position shown on the column 14 Torque the four screws 5 and the two screws 6 to 150 Nm 15 Operate carefully the manual ratchets H1 H2 to lower the crosshead 3 on to the supports 94322 16 Adjust the two screws 7 to get an equal load 2 1 Bearing Shell Inspection 1 Do an inspection of the bearing shell 9 2 If it is necess...

Page 241: ...e 2 10 Attach the stop plate 94335 to the bearing cover 8 with the screw 11 Attach the tool 94337 to the connecting rod 13 12 Attach the support tool 94332 to the tool 94337 with the two screws 12 and the column door 13 Torque the two screws 12 to 290 Nm 14 Attach the chain block CB to the engine room crane and the shackle on the lifting plate 94324 15 Operate the chain block to lift the crosshead...

Page 242: ...il to the surfaces of the bearing shell 6 Attach the bearing shell 1 to the connecting rod with the two screws 2 Make sure that each end of the the bearing shell is the same distance above the connecting rod 5 Crosshead Lower Piston Removed 1 Make sure that the crosshead pin 7 Fig 3 is in good condition 2 During installation make sure that dirt does not go on the running surface of the bearing she...

Page 243: ...nd bar to tighten equally the round nuts 5 7 Measure the distance X1 and X2 Fig 5 between the ends of the bearing shell and the connecting rod 4 Note For a new bearing shell the dimensions X1 and X2 must be 0 12 mm to 0 20 mm 8 Apply tension to the elastic bolts refer to 9403 4 9 Connect the toggle lever 1 Fig 2 to the connecting rod Make sure that the toggle lever is in the correct position 10 Re...

Page 244: ...he engine does not operate for some weeks 6 Before you operate the engine do step a to step d a Make sure that the hose 3 has no pressure b Disconnect the hose 3 from the flange 94336 c Remove the flange 94336 d Install the oil inlet pipe 4 to the support 1 Note The steam engine cylinder oil can stay in the oil system 94336 4 2 WCH00626 3 Fig 6 1 8 Bearing Cover Removal 8 1 Preparation 1 Make sure...

Page 245: ...arefully lift the bearing cover 2 Make sure that the bearing cover does not catch on the elastic bolts 1 9 Attach the chain block CB to the double sling chain 94335D 10 Operate the chain block CB to apply a light tension to the chain 11 Carefully remove the manual ratchet H4 from the double sling chain 94335D 12 Operate the chain block CB and the manual ratchet H3 to remove the bearing cover 2 fro...

Page 246: ... to the double sling chain 94335D 7 Operate the manual ratchet H4 to apply a light tension 8 Carefully remove the chain block CB from the double sling chain 94335D 9 Operate the manual ratchets H3 H4 to align the holes in the bearing cover 2 with the elastic bolts 1 10 Lower carefully the bearing cover 2 on to the crosshead pin 3 Make sure that the elastic bolts 1 are not caught 11 Remove the manu...

Page 247: ...ols 2 Record the position of the toggle lever 1 Fig 1 3 Disconnect the toggle lever 1 from the connecting rod 4 Use a rope to hold the toggle lever in the position shown 5 Lift and hold the applicable piston in the TDC position refer to 3403 2 6 Remove the bottom end bearing cover from the connecting rod refer to 3303 2 paragraph 1 and paragraph 2 7 Attach the tool 94337 and the support 94332 8 Op...

Page 248: ...nder block 1 3 Attach the manual ratchets H1 H2 to the eye bolts EB1 4 Operate the manual ratchet H1 H2 to lift the crosshead abve the bottom position in the column 5 5 Attach the two supports 94322 to the bottom position in the column 5 6 Torque the two screws 6 and the screw 7 to 150 Nm 7 Lower carefully the crosshead 9 on to the two supports 94322 8 Adjust the two screws 8 to get an equal load ...

Page 249: ...e top of the column and the bottom shackle on the tool 94337 exhaust side 14 Remove the manual ratchet H3 15 Remove the manual ratchet H4 WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel Note During step 15 operate the manual ratchet H5 Fig 4 to hold the weight of the connecting rod 16 Operate the turning gear to move the applicable crank ...

Page 250: ...ain block H6 to hold the weight of the connecting rod The connecting rod is at an angle of 80 20 Attach the shackle 94572H Fig 6 to the holder 94334 21 Attach the manual ratchet H4 to the shackle 94572H 22 Remove the bottom part of the holder holder 94334 23 Attach the connecting element 94334A to the top part of the holder 94334 as shown 24 Attach the manual ratchet H5 to the shackle on the conne...

Page 251: ...l ratchet H5 and the chain block H6 to remove the connecting rod from the engine 28 Remove the manual ratchet H5 29 Use the chain blocks H6 and H7 Fig 8 to move the connecting rod along the engine 30 Operate the chain blocks H6 H7 to lower the connecting rod on to an applicable surface 31 If the connecting rod is to be replaced removed the tools 94337 Removal and Installation Piston Installed 2017...

Page 252: ...onnecting rod along the engine to the applicable position 4 Attach the manual ratchet H5 Fig 9 to the shackle on the connecting element 94334A 5 Operate the manual ratchet H5 and the chain block H6 to move the connecting rod a small distance into the engine 6 Attach the manual ratchet H4 Fig 10 to the shackle 94572H 7 Operate carefully the manual ratchets H4 H5 and the chain block H6 to move the c...

Page 253: ...al ratchet H5 to the tool 94337 Make sure that the manual ratchet H5 holds the weight of the connecting rod 13 Remove the chain block H6 from the tool 94337 14 Attach the manual ratchet H3 Fig 12 to the column 15 Operate the turning gear to move the connecting rod and crankshaft to the BDC position 16 Attach the manual ratchet H4 to the tool 94337 17 Remove the manual ratchet H5 Removal and Instal...

Page 254: ...igned with the related holes in the crosshead This prevents damage to equipment 24 Operate carefully the manual ratchets H1 H2 to lower the crosshead on to the connecting rod 25 Remove the manual ratchets H1 H2 H3 H4 26 Remove the tools 94337 94332 27 Remove the eye bolts EB1 EB2 28 Attach the four round nuts 2 to the elastic studs refer to 9403 4 4 Completion 1 Remove the holder 94334 from the co...

Page 255: ...position of the toggle lever 1 Fig 1 3 Disconnect the toggle lever 1 from the connecting rod 4 Use a rope to hold the toggle lever in the position shown 5 Remove the piston refer to 3403 1 6 Remove the bottom end bearing cover from the connecting rod refer to 3303 2 paragraph 1 and paragraph 2 7 Operate the turning gear to move the applicable crank to BDC 8 Attach the lifting tools 94337 exhaust s...

Page 256: ...ne room crane 9 2 Attach the engine room crane to the shackle on the lifting plate 94324 3 Operate the engine room crane 9 manual ratchet H2 to lift the crosshead above the bottom position in the column 5 4 Attach the two supports 94322 to the bottom position in the column 5 5 Torque the two screws 6 and the screw 7 to 150 Nm 6 Lower carefully the crosshead 9 on to the two supports 94322 7 Adjust ...

Page 257: ...lumn and the bottom shackle on the tool 94337 exhaust side 13 Remove the manual ratchet H4 14 Remove the manual ratchet H3 WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel Note During step 15 operate the manual ratchet H1 Fig 4 to hold the weight of the connecting rod 15 Operate the turning gear to move the applicable crank pin countercloc...

Page 258: ...hain block H5 to hold the weight of the connecting rod The connecting rod is at an angle of 80 19 Attach the shackle 94019F Fig 6 to the holder 94334 20 Attach the manual ratchet H4 to the shackle 94019F 21 Remove the bottom part of the holder holder 94334 22 Attach the connecting element 94334A to the top part of the holder 94334 as shown 23 Attach the manual ratchet H1 to the shackle on the conn...

Page 259: ... the chain block H6 to remove the connecting rod from the engine 27 Remove the manual ratchet H1 28 Use the chain blocks H5 and H6 Fig 8 to move the connecting rod along the engine 29 Operate the chain blocks H5 H6 to lower the connecting rod on to an applicable surface 30 If the connecting rod is to be replaced removed the tools 94337 94337A Removal and Installation Piston Removed 2017 Fig 7 Fig ...

Page 260: ...onnecting rod along the engine to the applicable position 4 Attach the manual ratchet H1 Fig 9 to the shackle on the connecting element 94334A 5 Operate the manual ratchet H1 and the chain block H5 to move the connecting rod a small distance into the engine 6 Attach the manual ratchet H4 Fig 10 to the shackle 94019F 7 Operate carefully the manual ratchets H4 H1 and the chain block H5 to move the c...

Page 261: ...ual ratchet H1 to the tool 94337 Make sure that the manual ratchet H5 holds the weight of the connecting rod 13 Remove the chain block H5 from the tool 94337 14 Attach the manual ratchet H3 Fig 12 to the column 15 Operate the turning gear to move the connecting rod and crankshaft to the BDC position 16 Attach the manual ratchet H4 to the tool 94337 17 Remove the manual ratchet H1 Removal and Insta...

Page 262: ... crosshead a small distance 23 Remove the supports 94322 from the column CAUTION Damage Hazard During step 24 make sure that the elastic studs are aligned with the related holes in the crosshead This prevents damage to equipment 24 Operate carefully the engine room crane 9 manual ratchet H2 to lower the crosshead on to the connecting rod 25 Remove the manual ratchets H2 H3 H4 and the engine room c...

Page 263: ... the bottom end bearing cover refer to 3303 2 paragraph 5 3 Install the piston refer to 3403 1 4 Attach the toggle lever 1 Fig 1 to the connecting rod 5 Measure the top and bottom end bearing clearances refer to 0330 1 Clearances 6 Remove all tools and equipment from the work area Removal and Installation Piston Removed 2017 ...

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Page 265: ...4143 1 Platform element 94144 1 Preparation 1 2 Removal 2 3 Installation 3 4 Completion 4 1 Preparation 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Lift and hold the applicable piston in the TDC position refer to 3403 2 3 Install the platform elements as necessary 94143 and 94144 Fig 1 4 Install the deviation pipe 94117B to the top of the column opening 5 Make sure that the tu...

Page 266: ...6 Attach the two manual ratchets 94016F to the shackles 94572H 7 Attach the two manual ratchets 94016F to the chain 94335D Make sure that the chain lengths of the manual ratchets are equal CAUTION Damage Hazard Before you operate the manual ratchets make sure that the chain is vertically aligned with the center of the bearing cover This will prevent damage to the elastic bolts 8 Operate the two ma...

Page 267: ...n block 94017C to move the bearing cover 1 to a position near the crosshead 4 Carefully remove the chain block 94017C from the chain 94335D 5 Operate the manual ratchets 94016F to move the bearing cover 1 Fig 5 to a position directly above the elastic bolts CAUTION Damage Hazard Before you operate the manual ratchets make sure that the bearing cover is level and vertically aligned with the center ...

Page 268: ...the elastic bolts 1 9 Use the pre tensioning jacks 94315 to tighten the four round nuts 3 refer to 9403 4 4 Completion 1 Attach the piston to the crosshead refer to 3403 2 2 Remove all tools and equipment from the area 2017 Top End Bearing Cover Removal and Installation WCH02662 1 2 Fig 6 ...

Page 269: ...ay 3 Note The clearance C is applicable for the full length of the guide way 3 and measured at the position shown in Fig 2 2 2 Crosshead 1 Measure the lateral clearance D at each position of the crosshead as follows a Use an applicable hardwood wedge or an item that is almost the same to push the crosshead axially to one side Make sure that you apply the pressure only to the guide shoe 2 3 Guide S...

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Page 271: ...operate the turning gear make sure that no personnel are near the flywheel or in the engine 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Operate the turning gear to move the crank of the related cylinder to BDC 3 Keep the turning gear engaged to prevent an accidental engine start 4 Install the platform elements 94143 and 94144 Fig 1 refer to 3301 1 5 Disconnect the toggle lever...

Page 272: ...Attach the eye bolts EB2 to the guide shoes 2 5 Attach the two shackles 94572G to the lugs in the column 6 Attach the manual ratchets H4 H5 to the shackles 94572G 7 Attach the link 94321 to the manual ratchets H4 H5 8 Attach the manual ratchet H1 to the link 94321 and the shackle 94572G on the plate 94324 2017 Crosshead Pin Removal and Installation Fig 2 H4 H5 H1 94572G WCH00620 94321 I I I I EB1 ...

Page 273: ...m 15 Lower carefully the crosshead until the guide shoes touch the two supports 94322 16 Turn the screws 7 to get an equal load 17 Attach the two shackles 94572H to the lugs in the column 18 Attach the manual ratchets H2 H3 to the shackles 94572H and the tools 94337 19 Operate the manual ratchets H2 H3 to apply a light tension 20 Remove the support 94332 21 Put a wooden block 1 in position as show...

Page 274: ...e manual ratchet H1 28 Operate the manual ratchets H2 H3 to apply a light tension on the chains 29 Remove the bolts 2 locking plates 1 and holding plates 3 from the guide shoes 4 30 Move the crosshead pin until the lifting plate 94324 touches the guide shoe 4 31 Operate the manual ratchet H2 to lift the guide shoe 5 32 Move the crosshead pin fully to the opposite side 33 Operate the manual ratchet...

Page 275: ...rd the positions of the guide shoes The shims of the guide shoes can have different dimensions This will help you during the installation procedure 2 Operate the applicable manual ratchet H2 or H3 Fig 4 to lower the guide shoe to the door frame 3 Attach the chain block H1 Fig 6 to the eye bolt EB2 on the guide shoe 4 Remove carefully the manual ratchet H2 Fig 4 from the guide shoe 5 Operate the ma...

Page 276: ... H2 H1 to align the guide shoe in the column 7 Remove the manual ratchet H1 8 Operate the manual ratchet H2 to lift the guide shoe Note When you do step 9 use the manual ratchet H3 for the other guide shoe 9 Do steps 1 to 8 for the other guide shoe 5 Crosshead Pin Installation 1 Clean the crosshead pin and the guide and bearing surfaces 2 Apply bearing oil to the crosshead pin and all guide and be...

Page 277: ...ate the manual ratchet H2 to lower and align the guide shoe 5 with the crosshead pin 12 Move the crosshead pin into position between the two guide shoes 4 5 13 Attach the two holding plates 3 to the guide shoe 4 with the locking plates 1 and the bolts 2 14 Make sure that there is no clearance between the holding plates 3 and the crosshead pin 15 Remove the manual ratchets H2 H3 Crosshead Pin Remov...

Page 278: ...ts 94322 20 Turn the screws 7 to get an equal load 21 Attach the two manual ratchets H2 H3 to the shackles 94572H and the shackles on the lifting tools 94337 22 Operate the manual ratchets H2 H3 to move the connecting rod to the vertical position Make sure that the connecting rod aligns with the crosshead 23 Remove the wooden block 1 24 Attach the tool 94332 to the column and the tool 94337 25 Ope...

Page 279: ...e chain block 32 Remove all protection from the the openings in the crosshead pin 33 Do the clearance checks refer to 3326 1 6 Completion 1 Install the round nuts to the elastic studs on the connecting rod refer to 9403 4 2 Install the top bearing cover refer to 3303 5 3 Disengage the turning gear 4 Set the lubricating oil pump to on 5 Make sure that the crosshead and the bottom end bearings of th...

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Page 281: ...4 Keep the turning gear engaged to prevent an accidental engine start 5 Install the platform elements 94143 and 94144 Fig 1 refer to 3301 1 6 Disconnect the toggle lever 1 from the crosshead pin 6 Hold the toggle lever in the position shown with a rope 7 Remove the round nuts 7 from the elastic studs on the connecting rod refer to 9403 4 8 Remove the top bearing cover refer to 3303 5 9 Put protect...

Page 282: ...the bottom position on the column with the screws 4 and the bolts 5 8 Torque the screws 4 and the bolts 5 to 150 Nm 9 Lower carefully the crosshead until the guide shoes touch the two supports 94322 10 Turn the screws 6 to get an equal load 11 Attach the manual ratchets H2 H3 to the shackles on the tools 94337 12 Operate the manual ratchets H2 H3 to apply a light tension 13 Remove the support 9433...

Page 283: ...load is on the manual ratchet H1 21 Operate the manual ratchets H2 H3 to apply a light tension on the chains 22 Remove the bolts 2 locking plates 1 and holding plates 3 from the guide shoes 4 23 Move the crosshead pin until the lifting plate 94324 touches the guide shoe 4 24 Operate the manual ratchet H3 to lift the guide shoe 4 25 Move the crosshead pin fully to the opposite side 26 Operate the m...

Page 284: ...chet H4 3 Guide Shoes Removal 1 Record the positions of the guide shoes The shims of the guide shoes can have different dimensions This will help you during the installation procedure 2 Operate the applicable manual ratchet H2 or H3 Fig 3 to lower the guide shoe to the door frame 3 Attach the chain block H1 Fig 5 to the eye bolt EB2 on the guide shoe 4 Remove carefully the manual ratchet H2 or H3 ...

Page 285: ...lock H1 to align the guide shoe in the column 8 Remove the manual ratchet H1 9 Operate the manual ratchet H2 to lift the guide shoe Note When you do step 9 use the manual ratchet H3 for the other guide shoe 10 Do steps 1 to 9 for the other guide shoe 5 Crosshead Pin Installation 1 Clean the crosshead pin and the guide and bearing surfaces 2 Apply bearing oil to the crosshead pin and all guide and ...

Page 286: ...Operate the manual ratchet H2 to lower and align the guide shoe 5 with the crosshead pin 12 Move the crosshead pin into position between the two guide shoes 4 5 13 Attach the two holding plates 3 to the guide shoe 4 with the locking plates 1 and the bolts 2 14 Make sure that there is no clearance between the holding plates 3 and the crosshead pin 15 Remove the manual ratchets H2 H3 Crosshead Pin R...

Page 287: ...upports 94322 20 Turn the screws 6 to get an equal load 21 Attach the two manual ratchets H2 H3 to the shackles 94572H and the shackles on the lifting tools 94337 22 Operate the manual ratchets H2 H3 to move the connecting rod to the vertical position Make sure that the connecting rod aligns with the crosshead 23 Remove the wooden block 1 24 Attach the tool 94332 to the column and the tool 94337 2...

Page 288: ...block 32 Remove all protection from the the openings in the crosshead pin 33 Do the clearance checks refer to 3326 1 6 Completion 1 Install the round nuts to the elastic studs on the connecting rod refer to 9403 4 2 Install the top bearing cover refer to 3303 5 3 Disengage the turning gear 4 Set the lubricating oil pump to on 5 Make sure that the crosshead and the bottom end bearings of the connec...

Page 289: ...t the engine temperature become cold before you start the removal procedure 5 Remove the cylinder cover refer to the procedure in 2708 1 6 Operate the turning gear to move the applicable crank to BDC 7 Look at the area of the piston ring stroke If there is unwanted material do the procedure given in 2124 3 8 Use carefully a plastic hammer and a screwdriver to remove the antipolishing ring 1 Fig 1 ...

Page 290: ...e 94341 11 Operate the engine room crane to lift the piston sufficiently to get access to the crosshead pin and top end bearing 12 Apply protection to the crosshead pin and top end bearing to prevent contamination 13 Make sure that the two parts of the device 94350 are open 14 Operate the engine room crane to fully remove the piston and gland box from the cylinder liner 15 Lower the piston and gla...

Page 291: ...n D The piston rod gland D The piston and the piston rings 9 Make sure that the O rings in the piston rod gland are in a satisfactory condition 10 Put oil on the bore and the O rings of the piston rod gland 11 Remove the cover plate 94345D Fig 3 from the piston rod bore 12 Attach the device 94341 Fig 4 to the piston crown 2 with the four bolts 1 13 Torque the four bolts 1 to 80 Nm 14 Make sure tha...

Page 292: ...25 Remove the platform elements 94143 94144 26 Operate the turning gear to move the crank in the BDC direction until the gland box 2 is immediately above the housing 27 Align the hole in the gland box 2 with the spring dowel pin 3 28 Continue to operate the turning gear to lower fully the piston to BDC Make sure that the piston rod foot 6 continues to touch the crosshead 29 Remove the clamp 94345G...

Page 293: ...c On the fuel side look through the scavenge space to the piston underside Make sure that the piston rod and running surface of the cylinder liner stay dry Note If there is an increase in the dirty oil level in the piston underside an O ring in the gland box is defective 5 Completion 1 Install the cylinder cover refer to 2708 1 2 Remove all tools and equipment from the work area Piston Removal and...

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Page 295: ...2 Remove the platform elements 94143 94144 3 Operate the turning gear to move the piston to TDC 4 Install the platform elements 94143 and 94144 as applicable 5 Put oil on the threads of the two Allen screws 3 6 Attach the tools 94333 to the piston rod foot 2 with the two Allen screws 3 7 Torque the two Allen screws 3 to 350 Nm 8 Attach the tools 94333 to the cylinder block with the two screws 4 9 ...

Page 296: ...2 Attach the compression shim 3 to the crosshead 4 with the screw 1 3 Remove the eye bolts 94045 4 Remove the platform elements 94143 94144 Note During step 3 make sure that t he elastic bolts 2 align with the holes in the piston rod foot 5 Operate the turning gear to move the crosshead 4 up until the crosshead touches the piston rod foot 6 Install the platform elements 94143 and 94144 as applicab...

Page 297: ...hreads of the four nuts 1 Fig 4 12 Attach the four nuts 1 to the crosshead 13 Torque the four nuts 1 to 120 Nm 4 Completion 1 If the new compression shim is thicker than the removed item remove unwanted material from the cylinder liner bore refer to 2124 3 paragraph 2 and paragraph 3 Note Refer to data between the new compression shim and the related setting screw ST on the gauge shown in 2124 1 2...

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Page 299: ...the piston refer to 3403 1 paragraph 1 and paragraph 2 Note You disassemble a piston to clean the cooling chamber in the piston head do an overhaul of the ring grooves etc 2 Disassemble 1 Remove the eight collar nuts 2 Fig 1 2 Attach the device 94341 to the piston crown 1 as shown 3 Attach the engine room crane to the device 94341 4 Operate the engine room crane to lift the piston crown 1 5 Lower ...

Page 300: ...iscard the two gaskets 5 Note If it is necessary to remove the eight elastic studs 9 you must use the correct tools Incorrect tools can cause damage to the shank 3 Assemble 1 If necessary install the elastic studs 9 as follows a Put oil on the threads of the elastic studs b Torque symmetrically the elastic studs to 25 Nm 2 Apply oil to the O ring 6 and the two gaskets 5 3 Install the new O ring 6 ...

Page 301: ... and oil distributor to the piston rod as follows a Apply oil to the threads and surfaces that touch of the eight collar nuts 3 b Attach the eight collar nuts 3 to the elastic studs 9 c In the sequence shown in Fig 4 Torque symmetrically the eight collar nuts to 30 Nm d Use a felt pen to make a mark on each collar nut and the piston rod e Subsequently tighten symmetrically the eight collar nuts to...

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Page 303: ...the top piston ring 1 2 Turn the template 94366 around the axis of the piston head 3 Use the feeler gauge 94122 to measure the depth of the burn scar s 4 Remove the template 94366 Note You can also use a depth gauge to measure the depth of the burn scar s 5 If the burn scar s are less than 5 0 mm do step a and step b a Use an applicable tool to grind the burn scars b Use emery paper to make sharp ...

Page 304: ...burn scar s 5 Remove the template 94366A 6 If there are more burn scars put the template 94366A through the related scavenge port 1 and do step 3 and 4 again 7 If the burn scars are less than 5 0 mm do step a and step b a Use an applicable tool to grind the burn scars b Use emery paper to make sharp edges smooth 8 If the burn scars are more than 5 0 mm do step a to step d a Remove the piston refer...

Page 305: ...Clearance Piston Removed 6 3 4 Used Piston Rings Installation 8 3 5 New Piston Rings Installation 9 4 Piston Rings Storage 9 1 General Use the data in paragraph 2 1 and paragraph 2 3 to make an analysis of the of the condition of the cylinder liner piston and piston rings The wear rates are related to the type of fuel used the engine load profile ambient conditions etc during engine operation Visu...

Page 306: ... to move the piston almost to BDC so that you can see the piston rings 4 Clean the surface of the piston ring 1 Fig 1 at the locations P1 to P9 5 Put the sensor of the Permascope MP0 94356 against the middle of the piston ring 1 6 Record the value on the digital display of the Permascope MP0 94356 7 Compare the measured data with the limits given in 0330 1 Clearance Table Piston and Piston Rings I...

Page 307: ...ig 2 Chrome ceramic Layer With regular procedures to measure the chrome ceramic layer you can calculate the wear rate for each piston ring You can continue to use the piston rings if the remaining chrome ceramic layer is more than the limits that follow D Top piston ring more than 0 05 mm D Middle and bottom piston rings more than 0 02 mm If the thickness of the chrome ceramic layer is less than t...

Page 308: ...lts Table 1 Examples of Wear Rate D1 D2 T1 T2 WR 0 382 0 367 0 new 1500 0 01 0 351 0 340 3500 5000 0 0073 Use the formula below to calculate the remaining piston ring service life LT D2 Dmin x 1000 WR Where D LT Remaining in service time hrs D D2 second recorded thickness of chrome ceramic layer mm D Dmin Minimum thickness of the chrome ceramic layer mm refer to paragraph 2 2 D WR Calculated wear ...

Page 309: ...e sure that the feeler gage will touch the inner diameter of the groove 2 Measure the clearance X1 at Point A If there is a wear step on the chrome ceramic layer you can push the feeler gage only to that point 3 Measure the clearance at X2 4 Do step 2 and step 3 at between two and four different locations around the piston 2 The sum of each value from X1and X2 will give the total piston ring clear...

Page 310: ... ring paragraph 3 3 2 to measure the piston ring grooves 3 3 1 Procedure with Calliper Gauge or Inside Micrometer Set 1 Use the calliper gage 1 Fig 5 or inside micrometer set 94101 to measure the groove height at point A and point B You must measure the groove height at a minimum of four locations around the circumference of the piston head 2 Record the value from the calliper gage 1 or inside mic...

Page 311: ...nd the circumference of the piston head 2 4 Use the data that follow to calculate the piston ring clearance C GH RT mm Where D C Clearance D GH the measured height of the piston ring groove mm D RT the nominal piston ring thickness mm Note If the clearance at X1 is more than the permitted value you must repair the piston head For the maximum wear values 0330 1 Piston and Piston Rings For the repai...

Page 312: ...n rings too far This will cause damage to the piston rings Note Only install piston rings that are in a satisfactory condition Make sure that the mark TOP on the piston ring points up Note The piston rings must be installed in the same position as before Use your recorded notes Note Make sure that you use the tools 94338 and 94338A Fig 4 to install the piston rings 1 Use the tool 94338 bottom pist...

Page 313: ...om piston ring 4 Fig 7 to the piston crown 3 Use the tool 94338 to install the middle piston ring 3 to the piston crown 4 Use the tool 94338A to install the top piston ring 1 to the piston crown Make sure that the ring clearance 5 is opposite the ring clearance 2 of the middle piston ring 3 5 Refer to the Operation Manual 0410 1 for the running in procedure for new piston rings 4 Piston Rings Stor...

Page 314: ...rting Air Group 4 Drive Wheels Running and Backlash Clearances and Tooth Condition 4104 1 A1 Intermediate Wheel Removal and Installation 4104 2 A1 Crankshaft Gear Wheel Replace 4104 3 A1 Starting Air Shut off Valve Cleaning and Function Check 4325 1 A1 Winterthur Gas Diesel Ltd X35 B MM 2017 ...

Page 315: ...the crankshaft while you do an inspection of all teeth 2 Set to on the service pump 3 Make sure that oil flows freely from all nozzles 4 Set to off the service pump 5 Make sure that all screws are correctly locked 6 After the running in period do a check of the drive wheels each three months as given above If faults show during this period repair them 7 If you hear unusual noises in the area of th...

Page 316: ...of the gear wheel moves between the profiles of two gear wheel teeth 3 3 Lead wire Note Use a new lead wire of 1 5 mm diameter Pb 9 99 fine for each measurement 1 Attach three lengths of lead wire approximately 200 mm in the positions shown with Scotch tape 2 Put marks 0 to 9 on the tooth profiles 7 as shown 3 Operate the turning gear to turn the gear wheel so that the lead wire goes once through ...

Page 317: ...oss the width of the tooth 4 Performance Do a check of the performance of the gear train after commissioning as follows 1 Apply a thin layer of oil resistant engineer s blue ink to three of the teeth on each of the gear wheels 2 Operate the turning gear to move the gear wheels 3 Do a check of the marks on the gear wheel teeth and driving wheel teeth This is make sure that the teeth engage correctl...

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Page 319: ...ke sure that the turning gear is locked to prevent accidental engine start This prevents injury to personnel 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Remove the fuel pumps 5 Fig 1 refer to 5556 1 3 Remove the servo oil pumps 2 refer to 5551 1 4 Record the backlash data of the intermediate wheel 1 5 Remove all applicable remaining oil pipes to get sufficient access 6 Remove ...

Page 320: ...diate wheel 5 from the drive column 10 Lower the intermediate wheel on to an applicable surface 11 Remove the four bolts 10 and the locking plates 4 12 Remove the four locking bars 3 Make sure that the bearing pin 2 is horizontal 13 Make a mark on each bearing 1 to identify their positions 14 Remove the two bearings 1 from the bearing pin 2 3 Installation 1 Apply clean oil to the two bearings 1 No...

Page 321: ...ices 94410 Fig 3 through the covers as shown Make sure that the holes for the taper pins are aligned 12 Use carefully a copper rod to install the taper pins 13 Remove the eight adjusting devices 94110 14 Use a wrench to tighten lightly and equally the 12 bolts 8 Fig 2 15 Torque symmetrically the 12 bolts 8 to 1000 Nm tightening angle of 55 16 Lock the bolts with lockwire as shown in Fig 4 17 Do a ...

Page 322: ...ch on the casing 3 and the column 3 Apply Loctite Type C to the threads of the 27 studs 6 4 Attach the casing 3 to the column 3 with the 27 nuts 4 5 Tighten symmetrically the 27 nuts 4 6 Install the servo oil pumps 2 refer to 5551 1 7 Install the fuel pumps 5 refer to 5556 1 8 Install all applicable remaining oil pipes 5 2 1 4 3 WCH03664 Fig 5 I I I I 4 6 2017 Drive Wheels Intermediate Wheel Remov...

Page 323: ...place the gear wheel you must do the procedures that follow When when you order a 2 part spare wheel you must give the engine type engine number and the engine supplier This data is necessary because the the hole of the 2 part gear wheel is made in accordance with these dimensions 1 Remove the intermediate wheel refer to 4104 2 2 Divide the gear wheel 5 Fig 1 into two halves 3 Disassemble the gear...

Page 324: ...ner diameter d is between 0 05 mm and 0 11 mm If the minimum diameter is not in the range given do not assemble the gear wheel You must first do step a a Use applicable heat treatment and tools etc to get the correct diameter 4 Make sure that there is a mark 2 on crankshaft flange 1 Fig 2 This will help you when you install the gear wheel 5 Remove all grease Make sure that all items are clean and ...

Page 325: ... that the Loctite 262 is fully cured 8 Tighten the M27x2 castle nuts 2 to the value given in 0352 2 4 Procedure WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine 1 Operate the turning gear to get the mark on the crankshaft flange approximately horizontal Note During step 2 make sure that the mark DRIVING END faces the flywh...

Page 326: ...tc to get the correct diameter 9 Attach temporarily the four screws 6 to each side of the top half of the gear wheel 10 Lightly tighten the M27x2 castle nuts 8 11 Make sure that there is no clearance between the gear wheel 7 and the crankshaft 12 Apply Molykote paste G to the seating surfaces and the remaining threads of the elastic bolts 13 Attach the remaining M27x2 castle nuts 8 to the elastic ...

Page 327: ...pins 5 If you cannot attach the split pin turn the castle nut 3 sufficiently to align the applicable hole in the elastic bolt 4 21 Apply Loctite 262 to the threads of the eight screws 1 22 Attach the eight screws 1 to the gear wheel in the positions shown 23 Torque symmetrically the eight screws 1 to the value given in 0352 2 5 Completion 1 Install the intermediate wheel refer to 4104 2 2 Do a che...

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Page 329: ...Initial Position 5 6 2 Test Procedure 5 6 3 Automatic Mode 6 7 Completion 6 1 General Read the data in 0380 1 Maintenance Schedule Starting Air Shut off Valve for the applicable maintenance intervals on the starting air shut off valve shut off valve For data about the codes e g 30 8605_E0_6 refer to the data in the Operation Manual 4003 2 Engine Control Diagram and 4003 9 Pipe Diagram Air Systems ...

Page 330: ...ir in the system 4 Disconnect the electrical connections from the pressure transmitter 6 Fig 1 and the solenoid valves 1 5 Remove the pipe 4 6 Remove the pipe that is attached to the ball valve 8353_E0_2 7 Remove the pipe that is attached to the 2 2 way valve 35 4325_E0_5 8 Remove the four screws 2 9 Remove the four screws 3 10 Remove the shut off valve from the engine 11 Do a check of the two gas...

Page 331: ...4 valve 1 and piston 21 from the control valve 3 11 Remove the two bolts 2 from the control valve 3 12 Remove the control valve 3 from the cover 6 4 Servicing 1 If necessary clean the items that follow D Valve 1 D Piston 21 D Spring 4 2 If necessary clean the items that follow D Springs 9 and 19 D Stopper 18 D Valve body 20 D Valve guide 16 D Valve 12 D Spindle 7 3 If you find corrosion on the spr...

Page 332: ...Winterthur Gas Diesel Ltd 4 7 Fig 2 WCH00541 3 22 1 21 19 20 18 14 15 16 11 12 9 4 7 6 13 I I 23 To Ball Valve 35 8353_E0_2 27 PS5017C PT5017C ZV7014C ZV7013C 10 8 17 24 25 26 II II 28 16 5 2 2017 Cleaning and Function Check ...

Page 333: ...ut the spindle 7 and spindle guide 11 into the valve 12 10 Attach the valve 12 together with spindle 7 and piston joint ring 10 to the housing 15 11 Apply Molykote paste to the inner cylinder of the cover 6 12 Put the spring 9 on to the spindle 7 in the cover 6 13 Attach the cover 6 spring 9 and spindle 7 to the housing 5 with the eight M10 screws 27 14 Torque the eight M10 screws 27 to value give...

Page 334: ...o the control valve 28 Install the pipe that is attached to the ball valve 8353_E0_2 29 Install the pipe that is attached to the 2 2 way valve 35 4325_E0_5 6 Shut off Valve Test 6 1 Initial Position Note You must only do this test on a fully assembled engine that is ready to start 1 Make sure that the stop valves 930 V03 and 930 V04 are closed 2 Use the handwheel 9 to move the shut off valve in th...

Page 335: ... the bore of the screw plug 16 When no air flows the automatic function of the shut off valves operates correctly 6 3 Automatic Mode 1 Make sure that the shut off valve is in the position AUTOMAT Note When you do the step below air will flow through the pipe This activates the control valve 17 which shows that the valve body and valve operate 2 Open the ball valve 35 8353_E0_2 to activate the cont...

Page 336: ...tion 5551 2 A1 Fuel Pump Removal and Installation 5556 1 A1 Gear Wheel Safety Device to Fuel Pump Removal and Installation 5556 2 A1 Fuel Rail Flow Limiting Valve Removal Inspection and Installation 5562 1 A1 Pressure Control Valve Removal Check Installation 5562 2 A1 Servo Oil Rail Exhaust Valve Control Unit Removal Disassemble Assemble Installation Relief Valve 5612 1 A1 Winterthur Gas Diesel Lt...

Page 337: ...Removal 4 4 Servo Oil Pump Installation 6 5 Completion 6 6 Storage 7 1 General CAUTION Injury Hazard The weight of the servo oil pump is 121 kg Make sure that you use the correct equipment to lift and move the servo oil pump This will prevent injury to personnel Data about operation maintenance and servicing of the servo oil pumps are given in the related documentation of the servo oil pump manufa...

Page 338: ...x30screws and M12x60 to 58 Nm 4 Attach the manual ratchets H1 H2 to the lugs of the tube 94581B H 5 Put the protection plate 94435D on the cover of fuel pump No 1 6 Put the sling 94435C around the servo oil pump No 1 two times 7 Attach the manual ratchets H1 H2 to the sling 94435C Apply a light tension to the manual ratchet H1 8 Loosen the four screws 4 H1 H2 94581B H 94581I FS 2 94435D WCH00602 4...

Page 339: ...e the manual ratchets H1 H2 until the servo oil pump is below the manual ratchet H2 11 Remove manual ratchet H1 12 Attach the engine room crane to the servo oil pump 13 Remove the manual ratchet H2 14 Operate the engine room crane to move the servo oil pump to an applicable area Note To remove and install the gear wheel 2 refer to 5551 2 H1 H2 94435D WCH00602 1 2 Fig 3 DRIVING END Servo Oil Pump R...

Page 340: ...ws and M12x60 to 58 Nm 4 Attach the manual ratchets H1 H2 to the lugs of the tube 94581B H 5 Put the protection plate 94435D on the cover of fuel pump No 2 6 Put the sling 94435C around the servo oil pump No 1 two times 7 Attach the manual ratchets H1 H2 to the sling 94435C Apply a light tension to the manual ratchet H1 8 Loosen the four screws 4 94435B 94435A 3 WCH00602 2 I 94435E 94581A 5 I 9443...

Page 341: ...ue to operate the manual ratchets H1 H2 until the servo oil pump is below the manual ratchet H2 11 Remove manual ratchet H1 12 Attach the engine room crane to the servo oil pump 13 Remove the manual ratchet H2 14 Operate the engine room crane to move the servo oil pump to an applicable area Note To remove and install the gear wheel refer to 5551 2 H1 H2 WCH00602 Fig 5 Servo Oil Pump Removal and In...

Page 342: ...ine room crane from the sling 94435C 8 Operate the manual ratchets H21 H2 to move the servo oil pump into the casing 2 Make sure that you do not cause damage to the gear wheel 4 and the thread on the connection sleeve 3 9 Attach the servo oil pump to the casing with the four M20 Allen screws 10 Torque the four M20 Allen screws to the value given in 0352 2 11 Do step 1 to step 10 for the other serv...

Page 343: ...ite spirit can cause damage to your skin and eyes Keep the servo oil pump in its original packing in a horizontal position in a clean dry area The area must have no contamination Be careful when you move the servo oil pump To clean the servo oil pump use white spirit e g Shellsol TD Shellsol T or Solvent FP68 Servo Oil Pump Removal and Installation 2017 ...

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Page 345: ...eral 1 2 Gear Wheel Removal 2 3 Connection Sleeve Installation 3 4 Gear Wheel Installation 4 1 General WARNING Danger Do not weld or grind materials in the area The sparks from welding equipment and grinding tools can cause a fire Note When you replace a servo oil pump the gear wheel must be removed The same gear wheel is attached to the new servo oil pump You use the tool 94582 for these tasks No...

Page 346: ...n the stop bolt 8 and the connection sleeve 11 12 Fill the HP oil pump 94931 with engine oil that has a viscosity of SAE30 to SAE40 Note In unusual conditions you can use cylinder lubricating oil 13 Connect the hydraulic connecting piece 94582A to the HP oil pump 94931 refer to 9403 2 14 Apply a maximum pressure of 2000 bar until oil flows out between the shaft and the hydraulic connecting piece 9...

Page 347: ...on sleeve 6 Fill the HP oil pump 94931 with engine oil that has a viscosity of SAE30 to SAE40 Note In unusual conditions cylinder lubricating oil can also be used 7 Connect the connecting piece 94582A to the HP oil pump 94931 refer to 9403 2 8 Apply a maximum pressure of 2000 bar until oil flows out between the shaft and the connection piece 94582A 9 Put oil on the special nut 4 10 Torque the spec...

Page 348: ...eel 3 the disc 2 and the connection sleeve 6 2 Apply oil to the threads of the 12 screws 1 3 Torque the 12 screws 1 in the sequence given as follows a Torque the 12 screws to 5 Nm b Torque the 12 screws to 10 Nm c Torque the 12 screws to 20 Nm 4 Attach the plug 4 5 Apply oil to the thread of the screw 5 6 Torque the screw 5 to 40 Nm Servo Oil Pump Gear Wheel Removal and Installation 2017 Fig 4 5 4...

Page 349: ...81D 1 Holder front 94581C FS 1 Tube 7 to 8 Cyl 94581J 1 Holder rear 94581C RS 1 Chain 94581F 1 Lifting plate 94581E 1 General 1 2 Fuel Pump No 1 Removal 2 3 Fuel Pump No 2 Removal 4 4 Fuel Pump No 2 Installation 5 5 Fuel Pump No 1 Installation 7 6 Storage 10 1 General Replace the fuel pump with a new item or a fuel pump that had a servicing in a Winterthur Gas Diesel Ltd authorized workshop Do a c...

Page 350: ...nual ratchets H1 H2 to the lugs of the tube 94581B H 5 Attach the plate 94581G 1 to the cover of the fuel pump with its two M10x25 screws 6 Attach the lifting plate 94581E to the plate 94581G 1 and with the three M10x30 Allen screws 7 Attach the manual ratchet H1 to the link on the lifting plate 94581E Apply a light tension to the manual ratchet H1 8 Remove the nine Allen screws 4 2017 Supply Unit...

Page 351: ...hown 10 Continue to operate the manual ratchets H1 and H2 Fig 4 until the fuel pump is under the manual ratchet H2 11 Remove the manual ratchet H1 12 Attach the engine room crane to the link on the lifting plate 94581F 13 Remove the manual ratchet H2 14 Operate the engine room crane to move the fuel pump to an applicable area Note To remove the gear wheel refer to 5556 2 A1 2017 Supply Unit Fuel P...

Page 352: ...h the M12x30 screws 5 Torque the M12x30 screws to 58 Nm 6 Attach the manual ratchets H1 H2 to the lugs of the tube 94581B H 7 Attach the plate 94581G 2 to the cover of the fuel pump with M10x25 screws 8 Attach the lifting plate 94581E and the chain 94581F to the plate 94581G 2 and chain 94581F with the M10x30 screws 9 Attach the manual ratchet H1 to the chain 94581F Apply a light tension to the ma...

Page 353: ...ttach the engine room crane to the chain 94581F 16 Remove the manual ratchet H2 17 Operate the engine room crane to move the fuel pump to an applicable area Note To remove the gear wheel refer to 5556 2 A1 4 Fuel Pump No 2 Installation 1 Make sure that the housing gear wheel and safety device are clean and have no damage 2 Make sure that all sealing surfaces are clean and have no damage 3 Attach t...

Page 354: ...chets H1 H2 to move the fuel pump to the position shown Note During step 10 make sure that you do not cause damage to the gear wheel 3 Fig 11 and the thread of the connection sleeve 2 10 Operate carefully the manual ratchets H1 H2 to move the fuel pump into the supply unit casing 1 Supply Unit Fuel Pump Removal and Installation 2017 Fig 9 H2 94581D 94581A WCH00603 H1 H2 Fig 10 WCH00603 94581F Fig ...

Page 355: ...ump No 1 Installation 1 Make sure that the housing gear wheel and safety device are clean and have no damage 2 Make sure that all sealing surfaces are clean and have no damage 3 Attach the engine room crane to the link on the lifting plate 94581E Fig 13 4 Operate the engine room crane to move the fuel pump to the position shown 5 Attach the manual ratchet H2 to the link on the lifting plate 94581E...

Page 356: ...fuel pump into the position shown Note During step 9 make sure that you do not cause damage to the gear wheel 3 Fig 15 and the thread of the connection sleeve 2 9 Operate carefully the manual ratchets H1 H2 to move the fuel pump into the supply unit casing 1 2017 Supply Unit Fuel Pump Removal and Installation H1 H2 1 2 94581E Fig 14 3 2 1 Fig 15 WCH00603 94581G 1 94581L H2 H1 94581F ...

Page 357: ...que symmetrically the nine M12 Allen screws 1 to the value given in 0352 2 12 Remove all tools and equipment 13 Install the pipes that you removed before refer to 8752 1 14 Apply the applicable lubrication to the fuel pump before you start the engine 2017 Supply Unit Fuel Pump Removal and Installation WCH00603 94581G 1 H2 H1 1 I 94581E I Fig 16 ...

Page 358: ...it White spirit can cause damage to your skin and eyes Keep the fuel pump in its original packing in a horizontal position in a clean dry area The area must have no contamination Be careful when you move the fuel pump To clean the fuel pump use white spirit e g Shellsol TD Shellsol T or Solvent FP68 Supply Unit Fuel Pump Removal and Installation 2017 ...

Page 359: ... General 1 2 Gear Wheel Removal 2 3 Connection Sleeve Installation 3 4 Gear Wheel Installation 4 1 General WARNING Danger Do not weld or grind materials in the area The sparks from welding equipment and grinding tools can cause a fire Note When you replace a fuel pump the gear wheel must be removed The same gear wheel is attached to the new fuel pump You use the tool 94582 for these tasks Note The...

Page 360: ...m between the stop bolt 8 and the connection sleeve 11 12 Fill the HP oil pump 94931 with engine oil that has a viscosity of SAE30 to SAE40 Note In unusual conditions you can use cylinder lubricating oil 13 Connect the hydraulic connecting piece 94582A to the HP oil pump 94931 refer to 9403 2 14 Apply a maximum pressure of 2000 bar until oil flows out between the shaft and the hydraulic connecting...

Page 361: ...onnection sleeve 6 Fill the HP oil pump 94931 with engine oil that has a viscosity of SAE30 to SAE40 Note In unusual conditions cylinder lubricating oil can also be used 7 Connect the connecting piece 94582A to the HP oil pump 94931 refer to 9403 2 8 Apply a maximum pressure of 2000 bar until oil flows out between the shaft and the connection piece 94582A 9 Put oil on the special nut 4 10 Torque t...

Page 362: ... gear wheel 3 the disc 2 and the connection sleeve 6 2 Apply oil to the threads of the 12 screws 1 3 Torque the 12 screws 1 in the sequence given as follows a Torque the 12 screws to 5 Nm b Torque the 12 screws to 10 Nm c Torque the 12 screws to 20 Nm 4 Attach the plug 4 5 Apply oil to the thread of the screw 5 6 Torque the screw 5 to 40 Nm Gear Wheel Removal and Installation 2017 Fig 4 5 4 3 2 1 ...

Page 363: ... 6 Completion 4 7 Storage 5 1 General It is possible to do the maintenance of the flow limiting valve FLV on board Speak to or send a message to Winterthur Gas Diesel Ltd to get a repair kit and instructions Maintenance must only be done by approved personnel who have special knowledge of the FLV If personnel are not approved send the FLV to a Wärtsilä Service Center for an overhaul 2017 ...

Page 364: ... the injection refer to the Operation Manual 0510 1 2 Let the engine temperature decrease 3 Let the pressure in the fuel rail decrease to zero 4 Make sure that the fuel injection system has no pressure 5 Make sure that all tools and equipment are clean and in good condition 6 Clean the work area adjacent to the FLV 4 Fig 1 7 Remove the HP fuel pipes 1 refer to 8733 1 paragraph 1 8 Remove the leaka...

Page 365: ... flange 2 together with the piston rod 11 and the piston 12 5 Use Scotch Britet and a solvent e g brake cleaner NeovalR or WD40R to clean the piston rod 11 6 Remove the piston 12 together with the piston rod 11 from the flange 2 If you feel a light resistance push the piston and piston rod back and clean the piston rod again 7 Do an inspection of the running surfaces RS 8 If you find damage speak ...

Page 366: ...ver Seez NSBT8 to the threads and surfaces that touch on the two Allen screws 4 19 Attach the cover 5 to the flange 2 with the two Allen screws 4 to 7 0 Nm 5 Installation 1 Make sure that the dowel pins 7 are in the fuel rail 2 Clean the sealing surface of the FLV 1 and the fuel rail 13 3 Put a new lip seal 9 in position 4 Carefully put the FLV 1 in position on the fuel rail 13 5 Apply Never Seez ...

Page 367: ...sel oil For more data refer to the Operation Manual 0510 1 7 Storage Before you put an FLV into storage do the procedure that follows 1 Use a vacuum cleaner to remove dirt from all openings 2 Clean the FLV 3 Lubricate the FLV correctly 4 Put the FLV in a plastic bag 5 Remove as much air as possible from the plastic bag 6 Seal the plastic bag Flow Limiting Valve Removal Inspection and Installation ...

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Page 369: ...To prevent failure of the pressure control valve PCV Winterthur Gas Diesel Ltd recommends that you only do the procedures that follow D Do a check and adjust the PCV D Replace the PCV For the maintenance intervals of the PCV refer to the Maintenance Schedule 0380 1 Pressure control valve 2 Preparation WARNING Injury Hazard Use gloves and eye protection Hot fuel can come out as a spray and cause in...

Page 370: ...connection from the solenoid valve 2 3 Loosen the angle union 5 4 Remove the fuel return pipe 4 from the PCV 1 5 Remove the four screws 6 6 Remove the PCV 1 from the valve block 8 7 Put protection on the valve block 8 to prevent contamination Fig 1 1 1 1 7 8 3 5 4 WCH3794 6 2 WCH3794 WCH3794 2017 Pressure Control Valve Removal Check Installation ...

Page 371: ...nce given in view I a Tighten the screws with your hand b Torque the screws to 80 Nm c Torque the screws to 190 Nm 7 Attach the flexible tube 94556C to the PCV outlet 2 Put the other end of the flexible tube into an applicable container 3 8 Connect the HP oil pump 94931 pressure gage 94932 and HP hose 94935 to the test block 94556 9 Identify each of the two pressure control set screws 10 On the se...

Page 372: ...ase the pressure to zero 4 3 Set point Check 1 On the HP oil pump 94931 close the relief valve 2 Operate the HP oil pump 3 Make sure that the PCV opens at 1050 30 bar 4 If the PCV opens at less than 1020 bar or more than 1080 bar do the procedure in paragraph 4 2 again If the PCV does not open at less than 1300 bar or opens at less than 1020 bar when the SAV 7 is fully closed the PCV has a malfunc...

Page 373: ... Put the PCV 1 in position on valve block 8 5 Put oil on the threads of the four screws 6 6 Put the four screws 6 in position in the PCV 7 Tighten the screws in the sequence given in Fig 2 view I as follows a Tighten the screws with your hand b Torque the screws to 80 Nm c Torque the screws to 190 Nm 8 Attach the fuel return pipe 4 Fig 1 to the PCV 1 9 Tighten the angle union 5 10 Connect the elec...

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Page 375: ...tion WARNING Danger Do not weld or grind materials in the area The sparks from welding equipment and grinding tools can cause a fire 1 Stop the engine 2 Release the pressure in the servo oil rail refer to the Operation Manual 0520 1 paragraph 2 3 3 Remove the related hydraulic pipe refer to 8460 1 paragraph 1 and paragraph 2 4 Make sure that the servo oil rail 1 Fig 1 has no pressure Fig 1 1 WCH03...

Page 376: ...les in the servo oil rail 7 Install blanks to the ports in the VCU 4 Disassemble 1 Remove the pan head screw 4 Fig 3 2 Remove the plug 5 3 Remove and discard the O ring 3 and back up ring 2 4 Make sure that the inner piston 7 and outer piston 6 move freely 5 Assemble 1 Put a new O ring 3 and back up ring 2 on then plug 5 2 Push the plug 5 into the valve control block 1 3 Install the pan head screw...

Page 377: ...10x130 Allen screws 1 D Two M10x160 Allen screws 5 7 Tighten symmetrically with your hand the Allen screws 1 5 and 6 8 Torque the M16x100 Allen screws 6 the M10x130 Allen screws 1 and the M10x160 Allen screws 5 to the value given in 0352 2 7 Completion 1 Install the related hydraulic pipe refer to 8460 1 paragraph 5 2 Put the replaced VCU in its original package 3 Put the replaced VCU in an applic...

Page 378: ... a factory set opening pressure of 350 bar 1 At each primary engine overhaul do a check of the relief valve Note A relief valve that has damage or has a leak must be replaced with a new item A relief valve that has an incorrect set point can be adjusted 1 WCH03795 Fig 5 1 2017 Exhaust Valve Control Unit Removal Disassemble Assemble Installation ...

Page 379: ...ver and Auxiliary Blower Group 6 Scavenge Air Receiver Clean and do Checks 6420 1 A1 Auxiliary Blower Maintenance 6545 1 A1 Scavenge Air Cooler Removal and Installation 6606 1 A1 Water Separator Removal and Installation 6708 1 A1 Winterthur Gas Diesel Ltd X35 B MM 2017 ...

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Page 381: ... the pins 6 7 to prevent movement 3 Clean the scavenge air receiver SAC Note The level switches LS4071A and LS4075A monitor the water level in the condensate collectors 4 For more data refer to the Operation Manual 4003 4 Pipe Diagram Water Systems 4 At regular intervals look at the sight glasses of the condensate collector 4 to make sure that water flows 5 Do a check of the flaps 3 for damage fre...

Page 382: ...hur Gas Diesel Ltd 2 4 7 If necessary clean the filters 1 Fig 2 the orifices 2 3 and the drain pipes 4 5 For more data refer to the Operation Manual 8345 1 Fig 2 WCH03796 EXHAUST SIDE DRIVING END 1 2 3 4 5 2017 Clean and do Checks ...

Page 383: ... and flap 9 in position 2 Put the support 6 stop plate 10 support 11 new locking plates 1 2 and screws 5 in position Do not tighten the screws at this step 3 Put the screw 3 and new locking plates 2 in position Do not tighten the screws at this step 4 Make sure that the axle 8 and the flap 9 can move freely 5 Tighten the screws 5 3 6 Bend the tab washers 1 2 to lock the screws 5 3 II II III III IV...

Page 384: ...damage or a malfunction speak to the manufacturer of the relief valve or Winterthur Gas Diesel Ltd 1 Do a check of the relief valve during each engine overhaul as follows a Do a visual check for damage and corrosion If necessary replace the relief valve 1 Fig 4 b Make sure that the usual distance is 133 mm i e the pressure of the disc springs 2 is sufficient Fig 4 Maximum 178 mm 1 133 mm 2 WCH0376...

Page 385: ...r Operate 4 1 General Two auxiliary blowers 2 Fig 1 are attached to the scavenge air receiver 1 For more data about the auxiliary blower refer to the Operation Manual 6545 1 Auxiliary Blower and Switch Box Auxiliary blowers that do not operate for a long period must be started for a short time twice each month Where this is not possible turn the impeller with your hand to make sure that the bearin...

Page 386: ...ension to the manual ratchet H2 4 Attach the manual ratchet H3 to the strong point 5 and the sling 94435C 5 Remove the 12 screws that attach the auxiliary blower 1 to the casing 3 6 Operate the manual ratchet H3 to remove the auxiliary blower 1 from the casing 2 7 Remove the manual ratchet H2 from the sling 94435C 8 Attach the manual ratchet H1 to the strong point 4 and the sling 94435C Note If ne...

Page 387: ...ach the manual ratchet H2 to the shackle 94572H and the sling 94435C 12 Operate the manual ratchets H1 H2 and H3 to move the auxiliary blower 1 away from the engine 13 Lower the auxiliary motor 1 on to an applicable support to prevent damage to the impeller 4 Installation 4 1 Bottom Auxiliary Blower 1 Attach the sling 94435C to the auxiliary blower 1 2 Attach the manual ratchets H1 H2 to the sling...

Page 388: ...et H2 to the sling 94335C 7 Operate the manual ratchets H2 H3 to move the auxiliary blower 1 into the casing 2 8 Attach the auxiliary blower 1 to the casing with the 12 bolts removed before 5 Completion 1 Connect the electrical connections to the electric motor 2 Set to on the power supply 3 Remove all tools and equipment 6 Auxiliary Blower Operate 1 In the LDU 20 get the MAIN page refer to 4002 2...

Page 389: ...port 94663E 1 Preparation 1 2 Removal 2 3 Installation 5 4 Completion 7 1 Preparation 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Stop the engine 3 Stop the cooling water pump 4 Close the butterfly valves 1 Fig 1 5 Drain the water from the scavenge air cooler SAC 6 6 Remove the drain pipes 4 7 Remove the vent pipes 5 8 Remove the inlet pipe 3 9 Remove the outlet pipe 2 10 Remo...

Page 390: ...4663 or 94666 8 Apply a light tension to the manual ratchet H1 to lift the SAC a small distance above the roller 3 9 Operate the the manual ratchet H3 to pull the SAC approximately 600 mm Keep the tension on the manual ratchet H1 10 Attach the two supports 94663A 94663B to the left and right sides of the receiver frame as shown 11 Attach the two lugs 94663C to the SAC 1 12 Attach the safety chains...

Page 391: ...er sufficiently to attach the swivel lugs 94048 M16 19 Remove the manual ratchet H3 20 Remove the support 94663E from the platform 21 Attach the tool 94663 or 94666 to the rear of the SAC 1 22 Attach the manual ratchet H2 to the platform and the tool 94663 23 Operate the crane 1 and the manual ratchet H2 to pull the SAC 1 a maximum of 70 mm from the supports 94663A 94663B See View II 2017 Removal ...

Page 392: ...3A 94663B lugs 94663C and safety chains 94663D 26 Operate the manual ratchet H2 to lower the rear of the SAC 1 to the vertical position 27 Use applicable equipment to make sure that the SAC 1 does not turn 28 Remove the manual ratchet H2 29 Operate the crane 2 to move the SAC to an applicable area 2017 Removal and Installation H2 2 1 Fig 4 2 2 H2 H2 WCH00954 WCH00954 WCH00954 ...

Page 393: ... temperature silicon compound to the sealing surfaces of the SAC 1 8 Operate the manual ratchets H3 H2 and the crane 2 to move the SAC 1 on to the supports 94663A 94663B 9 Attach the safety chains 94663C 94663D to the SAC 1 10 Operate the crane 2 and the manual ratchets H2 H3 to move the SAC sufficiently to attach the manual ratchet H1 11 Attach the manual ratchet H1 12 Remove the manual ratchet H...

Page 394: ...72H 18 Operate the manual ratchets H2 H3 to move the SAC 1 fully into the charging unit 19 Remove the manual ratchets H2 H3 20 Install the bottom plates and the parts of the platform removed before 21 Attach the SAC 1 to the frame of the charging unit with the 40 screws 2 22 Attach the cover 3 to the SAC 1 Removal and Installation 2017 Fig 6 H2 H3 Fig 7 EXPANSION SIDE 3 FIXED SIDE 2 1 WCH03763 WCH...

Page 395: ... 4 4 Install the vent pipes 5 5 Open the butterfly valves 1 6 Release the air in the SAC 6 7 Start the cooling water pump 8 Make sure that there are no leaks 9 Make sure that no scavenge air flows between the SAC 6 and the SAC housing 10 Stop the cooling water pump Removal and Installation 2017 FUEL SIDE FREE END 4 6 5 4 3 2 1 Fig 8 WCH03798 WCH03798 ...

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Page 397: ... 10 1 Preparation CAUTION Injury Hazard The cover 1 Fig 1 weighs 53 kg Use sufficient personnel to lift and move the cover 1 Read the data in 0012 1 General Guidelines for Lifting Tools 2 Remove the applicable bottom plates and parts of the platform for access 3 For safety put covers over the spaces of the bottom plates 4 Remove the cover 1 5 Remove all screws 1 Fig 2 together with their intermedi...

Page 398: ...e manual ratchet H2 to the strong point and the plate 94667A 7 Continue to operate the manual ratchet H1 to pull the water separator 1 a sufficient distance to attach the plate 94667 8 Attach the plate 94667 to the water separator 1 9 Remove the manual ratchet H1 the support 94667B and the lug 94667C 10 Attach the manual ratchet H1 to the strong point and the plate 94667 11 Remove the manual ratch...

Page 399: ...4 to the plate 94667 14 Operate the manual ratchets H1 H2 to move the water separator almost out of the charging unit 15 Move the manual ratchet H1 to the position on the platform as shown Water Separator Removal and Installation 2017 94667 H1 H2 H1 H2 H1 H2 Fig 4 WCH00583 WCH00583 WCH00583 ...

Page 400: ...he charging unit 17 Turn the water separator 1 90_ 18 Attach the crane to the middle shackle of the plate 94667 19 Apply a light tension to the crane 20 Remove the manual ratchet H1 21 Operate the crane to move the water separator to a clean dry area Water Separator Removal and Installation 2017 Fig 5 WCH00583 H1 H2 H1 H1 2 1 1 Crane 94667 WCH00583 ...

Page 401: ...rd the rubber seals 2 and 3 Fig 6 23 Clean the guide bars 1 4 24 Lubricate the new rubber seals 2 3 25 Attach the new rubber seal 2 Note The rubber seal 3 is attached after the water separator is installed Water Separator Removal and Installation 2017 3 2 Fig 6 4 1 WCH00583 ...

Page 402: ... ratchet H1 to the shackle on the plate 94667 5 Turn the water separator 1 90_ 6 Apply sufficient tension to the manual ratchet H1 to hold the weight of the water separator 1 7 Remove the crane from the water separator 1 8 Attach the manual ratchet H2 to the water separator 1 9 Operate the manual ratchets H1 H2 to move the water separator 1 to the position shown Water Separator Removal and Install...

Page 403: ...atchets H1 H2 to move the water separator 1 to the position shown 12 Attach the plate 94667A to the water separator 1 13 Attach the manual ratchet H2 to the plate 94667A 14 Attach the assembly tool 94667D as shown Water Separator Removal and Installation 2017 94667 H1 H2 H1 H2 Fig 8 1 H1 H2 1 94667D 94667A 1 WCH00583 WCH00583 WCH00583 ...

Page 404: ...he assembly tool 94667D to move the water separator 1 to the position shown 18 Remove the manual ratchets H1 H2 19 Remove the plate 94667A 20 Operate the assembly tool 94667D to push fully in in the water separator 21 Attach the new rubber seal 3 Fig 6 Water Separator Removal and Installation 2017 Fig 9 H1 H2 94667 94667A 1 H1 H2 94667A 1 94667D 94667D WCH00583 WCH00583 WCH00583 ...

Page 405: ...r separator 3 24 Torque symmetrically the 18 screws 1 to the value given in 0352 2 25 Attach the cover 4 to the charging unit with the 22 screws 5 26 Remove all tools and equipment 27 Install the supports and the applicable bottom plates you removed before Water Separator Removal and Installation 2017 4 5 WCH00583 Fig 10 III III I I I I II II 3 III III 2 1 WCH00583 ...

Page 406: ...er System for the tasks that follow D Make sure that the condensate drains 1 Fig 11 operate correctly D Make sure that the throttle discs are not blocked For the intervals to do checks refer to 0380 1 Maintenance Schedule Water separator 2 3 EXHAUST SIDE DRIVING END WCH03761 1 WCH03761 Fig 11 Water Separator Removal and Installation 2017 ...

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Page 408: ...Maintenance Group7 Winterthur Gas Diesel Ltd 1 5 Cylinder Lubrication Group 7 Cylinder Lubrication System 7218 1 A1 Winterthur Gas Diesel Ltd X35 B MM 2017 ...

Page 409: ...rication System For more data about the cylinder lubricating system refer to the Operation Manual 7218 1 1 1 Cylinder Lubricating System Operate For more data see the Operation Manual 4002 2 paragraph 3 2 and paragraph 3 9 1 In the LDU 20 get the MAIN page 2 In the navigation menu select Cylinder Lubrication 3 In the CYL LUBRICATION page field Manual lub to Cyl select the applicable cylinder numbe...

Page 410: ...1 If necessary bleed the cylinder lubricating system see paragraph 3 2 Make sure that the applicable piston is in the TDC position If the piston is not in the TDC position do the steps that follow a Engage the turning gear b Operate the turning gear to get the applicable piston to the TDC position c Disengage the turning gear 3 Set to on the cylinder lubricating system for the related cylinder ref...

Page 411: ...ting system 3 1 Cylinder Lubrication Pump To bleed the cylinder lubrication pump 4 Fig 1 do the steps that follow Note When you bleed the cylinder lubricating system always start at the first cylinder at the free end The hydrostatic pressure in the cylinder lubricating system helps you bleed the cylinder lubrication pump 4 1 Make sure that the cylinder lubrication pump 4 is set to off 2 Loosen the...

Page 412: ...screw 5 to release the pressure in the filter housing 3 4 Close the vent screw 5 5 Open the drain screw 6 to release the oil from the filter chamber 3 6 Remove the filter chamber 3 from the housing 7 Attach the new filter chamber 3 to the housing 8 Clean the external surface of the duplex filter 1 9 Open the ball valve 4 4 2 Filter Element Clean For data about the procedure to clean the filter ele...

Page 413: ...Maintenance 7218 1 A1 Winterthur Gas Diesel Ltd 5 5 Fig 2 WCH03799 I 1 4 2 3 2 5 3 5 3 6 6 1 x I WCH03799 WCH03799 WCH03799 2017 Cylinder Lubrication System ...

Page 414: ...g 8135 1 A1 Servo Oil Pipe Removal and Installation 8447 1 A1 Hydraulic Pipe Exhaust Valve Drive Removal Grind Installation 8460 1 A1 HP Fuel Pipe HP Fuel Pipe Injection Valve Removal and Installation 8733 1 A1 HP Fuel Pipe Removal and Installation 8752 1 A1 Winterthur Gas Diesel Ltd X35 B MM 2017 ...

Page 415: ...best decreased part load BSFC in LLT For more data about the exhaust waste gate and LLT refer to the Operation Manual 8135 1 2 Maintenance Special maintenance of the butterfly valve 1 Fig 1 is not necessary For a general inspection refer to the instructions in the documentation of the manufacturer The indicator 8 shows the closed position of the butterfly valve 1 To do a function check refer to th...

Page 416: ...ur Gas Diesel Ltd 2 2 4 2 1 I 10 8 7 5 9 6 WCH03800 I 3 Fig 3 Exhaust Waste Gate 1 Butterfly valve 6 Control air pipe 2 Exhaust pipe 7 Coupling 3 Exhaust manifold 8 Indicator 4 Orifice 9 Shaft 5 Air spring air pipe 10 Actuator 2017 ...

Page 417: ...tallation 1 Preparation 1 2 Removal 3 3 Adjustment 4 4 Installation 4 5 Completion 4 1 Preparation 1 Stop the engine 2 Close the trace heating supply 3 Make sure that there is no pressure in the servo oil system 4 Remove all of the screws 1 3 and 4 Fig 1 5 Remove the five clamps 2 2017 ...

Page 418: ...P servo oil pipes Fig 2 as follows a Put a drip tray below the applicable screw plug 11 or 12 b Remove the four screws 1 of the applicable servo oil pipe 16 or 17 c Carefully move the applicable flange 2 up to let in air d Loosen carefully the applicable screw plug 11 or 12 to drain the servo oil e Make sure that the servo oil pipes are empty 2017 Servo Oil Pipe Removal and Installation ...

Page 419: ...lange 6 5 Remove the four screws 9 from the applicable flange 10 6 Remove the four screws 14 from the applicable flange 13 7 Remove the applicable servo oil pipe 8 15 8 Apply protection to all openings to prevent damage and contamination 9 Remove and discard all O rings from the applicable servo oil pipes Fig 2 16 17 8 15 8 V V VI VI I I II II V V 1 VI _ VI 2 3 4 5 6 7 III III IV IV II II 11 8 9 1...

Page 420: ...4 to the applicable flange 6 10 13 3 Torque symmetrically the fours screws 7 9 14 to 20 Nm 4 Put the applicable servo oil pipe 16 17 in position 5 Attach the four screws 1 3 to the applicable flange 2 4 6 Torque symmetrically the fours screws 1 3 to 20 Nm 7 Attach the outer half of the connection block 5 to the inner half with the three screws removed before 5 Completion 1 Attach the servo oil pip...

Page 421: ...ve Removal Grind the Sealing Faces and Installation Tools 1 Grinding tool 94841 1 Stencil 94841A 1 Preparation 2 2 Removal 3 3 Sealing Faces Grind 4 4 Adjustment 5 5 Installation 5 Fig 1 I I II II 1 4 4 3 WCH03802 For View I I see Fig 3 and Fig 7 For View II II see Fig 4 and Fig 7 2017 ...

Page 422: ...to the data given in the Operation Manual 0600 1 4 Set to off the main bearing oil supply WARNING Injury Hazard 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 injury 5 Put an oil tray under the applicable hydraulic pipe 1 Fig 2 6 Loosen the screws 2 on the flange 3 to drain the applicable...

Page 423: ...ully move the flange 4 away from the top housing 3 CAUTION Injury Hazard The weight of the hydraulic pipe is approximately 11 kg Use approved equipment or sufficient personnel to lift and move the hydraulic pipe 5 Carefully remove the hydraulic pipe 1 6 Remove and discard all O rings from the hydraulic pipe 1 7 Apply protection to the sealing faces SF to prevent damage and contamination 2017 Hydra...

Page 424: ...lly the the four screws T2 to 2 0 Nm 11 Put the hydraulic pipe 1 in a vice as horizontally as possible 12 Adjust the speed of the hand drill to between 200 rpm and 500 rpm 13 Align the hand drill and the grinding tool 94841 accurately with the hydraulic pipe 1 as shown 14 Use light pressure and start grinding 15 Regularly remove the unwanted material from the grinding tool 94841 16 Make sure that ...

Page 425: ...l of the protection from the sealing faces SF Fig 7 in the top housing 3 Fig 9 and the VCU 6 2 Apply oil to the threads of the screws 2 5 3 Carefully put the hydraulic pipe 1 in position in the top housing 3 and the VCU 6 4 Torque symmetrically the four screws 2 to 40 Nm 5 Make sure that there is a distance of 11 mm between the flange 4 and the top housing 3 6 Torque symmetrically the four screws ...

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Page 427: ...1 Stop the engine refer to the Operation Manual refer to the Operation Manual 0600 1 2 Make sure that there is no pressure in the fuel rail as follows a Set to off the fuel booster pump plant b Close the shut off valves to the fuel inlet and return pipes c On the LDU make sure that the pressure shows zero 3 Set to off the trace heating system 4 If necessary remove the insulation from the HP inject...

Page 428: ...g valve 5 remove the four screws 7 flange 6 3 Carefully remove the HP injection pipe 1 from the injection valve 4 and the and flow limiting valve 5 4 Carefully remove the HP injection pipe 1 from the injection valve 4 and the flow limiting valve 5 5 Apply protection to the sealing faces SF and the open ends of the HP injection pipe 1 2017 Fuel Pressure Pipe Removal and Installation Fig 2 2 I I 3 S...

Page 429: ...pe 2 with the lock nut 94870G 12 Attach the tool 94870 to the hand drill 3 13 Put the hand drill 3 and tool 94870 accurately into the screw on sleeve 94870E 14 Adjust the speed of the hand drill 3 to a maximum of 500 rpm 15 Use light pressure and operate the hand drill 3 for approximately 5 seconds 16 Regularly remove unwanted material from the grinding tool 94871 17 Remove the tool 94870 from the...

Page 430: ... and the claws 6 10 5 Apply Never Seez NSBT to threads of the screws 2 7 6 Carefully put the HP injection pipe 1 in position in the injection valve 4 and the flow limiting valve 9 7 Torque symmetrically the four screws 2 to 20 Nm 8 Make sure that there is a distance of 17 3 mm between the flange 10 and the flow limiting valve 9 5 Completion 1 If necessary install the insulation to the HP injection...

Page 431: ...crews and plugs are opened steam or fuel can come out and cause injury 1 Stop the engine refer to the Operation Manual 4002 2 2 Set to off the fuel supply pump 3 Set to off the trace heating 4 If necessary disconnect the trace heating pipes 5 Remove the servo oil pipes for access refer to 8447 1 paragraph 1 and paragraph 2 6 Remove the insulation from the applicable HP fuel pipe 7 Put an oil tray ...

Page 432: ...Maintenance 8752 1 A1 Winterthur Gas Diesel Ltd 2 7 Fig 1 I I II II III III IV IV V V VI VI Note Illustration shown with servo oil pipes removed VII VII VII VII 1 4 5 3 6 2 3 IX IX WCH03792 WCH03792 ...

Page 433: ...ve the screw 7 and the clamp 6 3 Remove the three screws 8 and the clamp 9 4 Remove the three screws 10 and the clamp 11 5 Remove the four screws 15 from the applicable flange 6 Carefully remove the applicable HP fuel pipe 14 7 Remove the four screws 13 from the applicable HP fuel pipe 12 2017 HP Fuel Pipe Removal and Installation III III 10 A A 2 3 5 4 4 2 11 Fig 2 WCH03792 8 9 II II WCH03792 IV ...

Page 434: ...law 2 4 Lubricate the new O rings 7 11 with oil 5 Apply Never Seez NSBT8 to the threads of the four screws 4 and the screw 9 6 Attach the new O rings 7 11 to the screw 9 7 Put the screw 9 in position 8 Put the HP fuel pipe 1 in position 9 Torque the screw 9 to 250 Nm 10 Torque the four screws 4 to 20 Nm 11 Attach the fuel leakage pipe 8 to the sleeve 5 12 Attach the sleeve 5 to the screw 9 with th...

Page 435: ... 1 is in the correct position e Put the two slide rings 9 steel rings 10 cup springs 11 and steel rings 12 on the two M12x120 bolts 5 f Attach the clamp 4 to the clamp 3 with the parts assembled in step e and the M12x 60 bolt 6 15 Attach the clamp 14 to the clamp 13 with the two M12x90 bolts 15 and the M12x60 bolt 16 16 Attach the clamp 18 to the clamp 17 with the three M12x60 bolts 19 2017 HP Fue...

Page 436: ...len screws 2 23 Torque the four Allen screws 2 to 20 Nm 24 Torque the four Allen screws 11 to 20 Nm 25 Make sure that there is a distance of 18 0 mm between the flange 4 and the non return valve 26 Make sure that there is a distance of 18 0 mm between the flange 8 and the connecting block 9 27 Torque the two M12x120 bolts 5 Fig 4 to the value given in 0352 2 28 Torque the M12x60 bolt 6 16 19 to th...

Page 437: ... Attach the insulation to the applicable HP fuel pipe 2 Install the HP servo oil pipes refer to 8447 1 paragraph 4 3 If necessary connect the trace heating pipes 4 Set to on the trace heating 5 Set to on the fuel supply pump 2017 HP Fuel Pipe Removal and Installation ...

Page 438: ...ools Data 9403 1 A1 Hydraulic Jacks Tools and Pumps Configuration 9403 2 A1 Hydraulic Pre tensioning Jacks Storage Servicing and Maintenance 9403 3 A1 General Instructions 9403 4 A1 Tool List 9403 5 A1 Standard Tools Pages Pages 1 to 26 30 Recommended Special Tools Pages 27 to 29 30 Special Tools Page 30 30 Winterthur Gas Diesel Ltd X35 B MM 2017 ...

Page 439: ...There are two crank angle systems for redundancy that monitor the teeth on the intermediate wheel 2 The holder 2 is installed with screws to the cover 3 on the drive column Two more proximity sensors ZS5123 34C are used to find the crank angle marks on the flywheel for TDC and BDC For the Inspection and Overhaul Intervals refer to 0380 1 Crank Angle Sensor Unit 2 1 4 II Fig 1 III III WCH03774 I Fo...

Page 440: ...oximity sensor 5 5 Loosen the locknut 4 6 Remove the proximity sensor 5 from the adaptor 7 or 8 7 Attach the new proximity sensor 5 to the holder 8 Turn the proximity sensor 5 fully into the adaptor 7 or 8 Note During installation commissioning the clearance between the tooth 2 of the intermediate wheel and the adaptor 7 or 8 is set to 2 0 mm 9 Carefully tighten the lock nut with your fingers 10 C...

Page 441: ...osen the lock nut 3 5 Remove the proximity sensor 4 from the holder 1 6 Attach the new proximity sensor to the holder 1 7 Make sure that the proximity sensor 4 touches the applicable crank angle mark 2 8 Loosen the proximity sensor 4 four turns of 360 to get a clearance of 4 0 mm between the crank angle mark and the bottom face of the proximity sensor 9 Carefully tighten the lock nut 3 with your f...

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Page 443: ...tools have special screws and or devices that must be kept together Thus tapped holes are bored into these tools The screws and or devices must always be kept at the correct storage positions on the tools when they are not in use 2 Standard Tools These tools and devices are necessary for usual maintenance on the engine Some of these tools and devices given in the references above are not necessary...

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Page 445: ... 21 13 14 C 13 14 18 18 15 2 5 18 20 B 16 14 4 15 18 18 18 18 F 12A 18 E 18 11 14 1 WCH03775 A To apply and remove tension to the elastic bolts of the main bearing D Set up of pre tensioning jacks 94215 B To apply and remove tension to the tie rods E Removal and installation of gear wheel to servo oil pump and fuel pump 2017 ...

Page 446: ...Maintenance 9403 2 A1 Winterthur Gas Diesel Ltd 2 4 C To apply and remove tension to the elastic bolts of the cylinder cover F Disassemble and assemble of the main bearing cover ...

Page 447: ...nd remove tension to the elastic bolts on the top and bottom end bearings of the connecting rod H To apply and remove tension to the foundation bolts on the engine stays K Adjustment tool for the pressure control valve 5562 2 I To apply and remove tension to the foundation bolts on the exhaust valve cage L Adjustment tool for the safety valve 2745 1 in the cylinder cover 2017 Hydraulic Jacks Tools...

Page 448: ...nsioning jack bottom end bearing 94314 9 Pre tensioning jack top end bearing 94315 10 Adjustment device 94556 11 Disassemble and assemble tool 94582 12 HP oil pump 2800 bar 94931 12A Adaptor piece 94934F 13 Connection block 94934 14 Hydraulic distributor 94934A 15 Coupling element 94934G 16 Distributing piece 94934C 17 Hydraulic distributor with pressure gauge 0 bar to 25 bar 94934H 18 High pressu...

Page 449: ...ing jack Part Back up ring uncut O ring Dimension mm o x i x t i x s 94114 Elastic bolts to main bearing piston D cylinder 61 x 54 8 x 1 4 53 2 x 47 x 1 4 53 57 x 3 53 47 22 x 3 53 lower Cyl 7 52 x 3 53 94145 Foundation bolts and engine stays piston cylinder 75 x 68 8 x 1 4 60 2 x 54 x 1 4 66 27 x 3 53 53 57 x 3 53 94180 Tie rods piston D cylinder 68 x 61 8 x 1 4 58 2 x 52 x 1 4 59 92 x 3 53 53 57...

Page 450: ...ng Sealing ring 8 Adapter piece 3 9 Closing valve 4 4a Double cylinder 10 O ring 5 Back up ring O ring Sealing ring 11 Backing bush 6 12 Tension sleeve 13 Round nut 94114 KJ Kit with back up and O rings for double pre tensioning Jack MAX STROKE 8 MM I I I 2 1 I 9 8 10 7 4 11 12 3 5 6 13 4a 4a 4 94114 KJ WCH00473 1a Fig 2 Fig 3 Fig 4 2017 Hydraulic Pre tensioning Jacks Storing Servicing and Mainten...

Page 451: ...on 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 5 Back up ring O ring Sealing ring 6 94145 KJ Kit with back up and O rings for pre tensioning Jack 2 3 5 6 MAX STROKE 5 MM 1 4 7 9 8 94145 KJ WCH00474 Fig 5 Fig 6 2017 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance ...

Page 452: ...ce 3 9 Closing valve 4 4a Double cylinder 10 O ring 5 Back up ring O ring Sealing ring 11 Backing bush 6 12 Tension sleeve 13 Round nut 94180 KJ Kit with back up and O rings for double pre tensioning Jack 2 3 5 6 MAX STROKE 18 MM 1 4 11 12 13 4a I I I I 9 8 7 10 94180 KJ WCH00475 1a Fig 7 Fig 8 Fig 9 Fig 10 2017 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance ...

Page 453: ... 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 5 Back up ring O ring Sealing ring 6 94215 KJ Kit with back up and O rings for pre tensioning Jack 1 4 7 MAX STROKE 10 MM 2 3 5 6 8 9 94215 KJ WCH00476 Fig 11 Fig 12 2017 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance ...

Page 454: ...n 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 5 Back up ring O ring Sealing ring 6 94252 KJ Kit with back up and O rings for pre tensioning Jack 1 4 7 9 8 2 3 5 6 MAX STROKE 6 MM 94252 KJ WCH00477 Fig 13 Fig 14 x 2017 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance ...

Page 455: ...ton 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 5 Back up ring O ring Sealing ring 6 94314 KJ Kit with back up and O rings for pre tensioning Jack 1 4 7 9 8 MAX STROKE 8 MM 2 3 5 6 94314 KJ WCH00956 Fig 15 Fig 16 2017 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance ...

Page 456: ...n 7 Vent screw 2 Back up ring O ring Sealing ring 8 Adapter piece 3 9 Closing valve 4 Cylinder 5 Back up ring O ring Sealing ring 6 94315 KJ Kit with back up and O rings for pre tensioning Jack 2 3 5 6 MAX STROKE 7 MM 1 4 7 9 8 94315 KJ WCH00957 Fig 17 Fig 18 2017 Hydraulic Pre tensioning Jacks Storing Servicing and Maintenance ...

Page 457: ... 5 Fig 1 D Version 2 the nut 3 Fig 2 is used to apply tension to the elastic bolt elastic stud 1 Make sure that the threads of elastic bolts and hydraulic jacks are smooth and clean 2 Make sure that you add lubricant to the elastic bolts and hydraulic jacks refer to 0352 1 3 Connect the hydraulic components to the hydraulic jacks refer to 9403 2 4 Fully tighten the high pressure HP hoses to make s...

Page 458: ...ulic jack to the HP oil pump or the hydraulic unit 4 Put a hose on the vent screw 6 and a container below the hose to drain the oil 5 Operate the HP oil pump 6 Close the vent screw 6 when oil that has no air flows out Note Do not move the piston 2 above the limit of the red groove 9 7 Operate the HP oil pump to slowly increase the pressure to approximately 20 bar to 30 bar more than the value give...

Page 459: ...Connect the hydraulic jack to the HP oil pump or the hydraulic unit 3 Operate the HP oil pump 4 Close the vent screw 6 when oil that has no air flows out 5 Slowly increase the pressure to the nominal value then keep the pressure con stant see the Table for the pressure values 6 Make sure that there are no leaks 7 Operate the HP oil pump to slowly increase the pressure to approximately 20 bar to 30...

Page 460: ... 1903 12 94180 1st step 100 1500 from 100 to 1500 bar 6 5 7 5 mm 2 2708 2 94215 1500 380_ 1 2751 1 94252 1500 132_ 3303 1 94314 1st step 1100 1500 1st to 2nd step 30_ 94315 1st step 1100 1500 1st to 2nd step 10_ 1 To do a check of the tension refer to 1112 1 and 1715 1 2 For the applicable installation of the double pre tensioning jack refer to 1132 1 and 1903 1 2017 Hydraulic Pre tensioning Jacks...

Page 461: ... 1 Piece AF41 1 Piece AF36 1 Piece AF46 1 Piece AF75 94003 94003 6 94003 12 Allen keys set complete consisting of 9 Allen keys AF3 to AF17 for ordering single Allen keys state AF Example 94003 6 94003 12 000 381 93 94005 94005 4 94005 6 Rod for pre tensioning jacks 1 Pieces Ø 4 mm 1 Pieces Ø 6 mm 016 702 08 Ø 94007 94007 A19 94007 A40 Tong 1 Piece Type A 19 1 Piece Type A 40 000 375 93 94008 94008...

Page 462: ...16 94016F 94016G 3 2 2 Manual ratchets WLL 800 kg 2 5 m chain length Manual ratchets WLL 500 kg 2 5 chain length Manual ratchets WLL 250 kg 2 5 chain length 012 233 04 94022 94022A 1 1 Adapter piece 3 8 Socket wrench insert AF3 010 233 02 94022B 94022B 36 94022B 41 94022B 46 94022B 60 94022D 94022F 94022H 46 94024 4 Socket wrench insert AF36 AF41 AF46 AF60 Adapter piece 1 Adapter piece Socket wren...

Page 463: ...D 94050E 94050F Tool for pressure measurement for pneumatic elements 1 Pressure gauge 0 100 bar 1 Pressure gauge 0 10 bar 1 Adapter 1 HP hose 2 Screw couplings G1 4 x62 mm 2 Screw couplings G1 4 B A D F WCH00643 E E C 94051 94051A 94051B 94051C 94051D Tool for pressure measurement for pneumatic elements 1 Pressure generator 700 bar 1 HP hose 1 1 4 connector 1 1 4 NPT connector B A D C WCH00644 940...

Page 464: ... to main bearing including a metal box X 281 mm Kit with back up and O rings for double pre tensioning Jack X WCH00473 94116 1 Lifting tool for removal and fitting of main bearing shell X 135 mm X WCH00480 94116B 1 Lifting lug for removal and fitting of main bearing cover X 75 mm X WCH00480 94117 1 Roller support for removal and fitting of main bearing X 390 mm WLL 4000 N 400 kg X WCH00480 2017 ...

Page 465: ...emoval and fitting of main bearing shell X 155 mm X WCH00480 94118F 1 Fitting and dismantling device guide rail for removal and fitting of main bearing cover and shell No 1 X 1612 mm X WCH00480 94119 1 Lifting plate with 10 screws M10x30 for removal and fitting of main bearing shell X 157 mm WLL 500 kg X WCH00480 94122 1 Feeler gauge 000 361 93 94123 1 Special feeler gauge for main bearing X 620 m...

Page 466: ...ls X 548 mm Y 159 mm Version FCV1 bracket combined with Pads Y1 73 mm Y3 232 mm total Version FCV2 bracket combined with Pads Y2 103 mm Y3 262 mm total Version FCV3 bracket combined with Pads Pads Y4 335 mm total X 94141C 94141B Y2 Y1 Y3 Y Y4 94142 2 Grids X 252 mm Y 536 mm X Y WCH00482 94143 1 Platform element X 270 mm Y 553 mm Y X WCH00482 94144 1 Platform element X 371 mm Y 570 mm X Y WCH00482 ...

Page 467: ...0483 94180 94180 KJ 2 1 Double pre tensioning jacks for tie rods including a metal box X 427 mm Kit with back up and O rings for double pre tensioning Jack X WCH00475 94201 1 Device for removal and installation of the cylinder liner Mass approx 25 7 kg consisting of 94201A B D 94201A 1 Lifting tool X 304 mm 94201B 2 Holder 94201D 1 Shackle X 94201A 94201B 94201D WCH03535 94202L 1 Chain X 321 mm X ...

Page 468: ...ng of Distance sleeve Supporting plate Screws X WCH02730 94215 94215 KJ 6 1 Pre tensioning jacks for cylinder cover elastic bolts X 173 mm Kit with back up and O rings for pre tensioning Jack X WCH03553 94216 1 Clamp 2 part tilted removal see 3403 1 A2 for positioning clamps with O ring on elastic bolt X 122 mm X WCH00869 94219 1 Cylinder pressure measuring tool indicator including a wooden box X ...

Page 469: ...d 9 32 94225 1 Measuring gauge for measuring cylinder liner bore accessory for it inside micrometer tool 94226 X 1475 mm X 000 419 93 94226 1 Tool cylinder liner measuring complete with extension and case Measuring range 150 600 mm 018 223 09 2017 ...

Page 470: ...0477 94259 1 Pressure element for exhaust valve with a back up and O ring X 139 mm X 016 765 08 94261 1 Valve seat fitting and extracting device X 340 mm X WCH00893 94263 2 Jack screws to guide bush for exhaust valve M8x80 000 413 93 94265 1 Suspension device for cylinder cover X 230 mm WLL 540 kg X WCH00485 94265D 1 Lifting tool tilted removal see 2708 1 A2 for removal a cylinder cover X 574 mm W...

Page 471: ...6 mm X X WCH00657 94272 94272B 94272C 1 1 1 OBEL test bench power supply 115V AC or 230V AC for testing and checking of injection valve relief valve cylinder cover X 1498 mm including Connecting piece for testing injection valve X 136 mm Valve holder for checking relief valve to cylinder cover X 68 mm 94272B X 94272C X X WCH00652 94272E 94272F 1 1 Valve holder for testing and checking of injection...

Page 472: ...l pin for dismantling and assembling injection valve X 80 mm WCH00896 X 94289A 1 Bush for assembling injection valve X 45 mm WCH00897 X 94289B 1 Bush for dismantling injection valve X 30 mm WCH00897 X 94289C 1 Bush for assembling O rings of injection valve X 65 mm WCH00896 X 94292 1 Gauge for checking wear on disc of exhaust valve spindle X 118 mm X WCH00488 2017 ...

Page 473: ... to bottom end bearing including a metal box X 152 mm Kit with back up and O rings for pre tensioning Jack Pre tensioning jacks for connecting rod elastic bolts to top end bearing including a metal box X 140 mm Kit with back up and O rings for pre tensioning Jack X X WCH00478 WCH00479 94321 1 Link with shackles for crosshead lifting X 119 mm WLL 2000 kg X WCH00492 94322 2 Supporting devices to pro...

Page 474: ...for top end bearing inspection X 814 836 mm Y 478 mm X Y WCH00492 94333 2 Lifting tools with 2 screws M16x90 and M20x50 to piston for removal and fitting of crosshead pin changing compression shim X 141 mm WLL 360 kg X WCH00495 94334 1 Holder for removal and fitting of a connecting rod complete X 677 mm X WCH00493 94334A 1 Connecting element with shackle X 20 mm X 2017 ...

Page 475: ...top end bearing cover X 183 mm WCH00494 X 94337 2 Lifting tools with 4 shackles and screws M16x70 for the connecting rod X 208 mm WLL 540 kg X WCH00493 94338 94338A 1 1 Piston ring tensioning device for straight cut piston rings Piston ring tensioning device for gastight piston ring X 329 mm Y 378 mm X Y 94341 1 Piston suspension device X 280 mm WLL 750 kg X WCH00496 94342 1 Inserting cone for pis...

Page 476: ...ing bore of piston rod gland in cylinder jacket when piston and gland are removed with an O ring and 4 screws M12x130 X 283 mm X WCH00490 94345E 2 Assembly tools for tensioning springs to piston rod gland X 160 mm 004 284 98 X 94345F 2 Distance pieces for fitting rings to piston rod gland X 182 5 mm Y 8 mm X Y WCH00490 94345G 1 Clamping sleeve two parts for piston rod gland X 200 mm X WCH00490 201...

Page 477: ...for cleaning carbon deposits in threaded holes of piston crown X 110 mm X 94350 1 Device usual removal see 3403 1 A1 for removal and fitting a piston X 460 mm Y 647 mm X Y WCH00496 Tools 94351 to 94354 for tilted removal and fitting a piston see 3403 1 A2 94351 1 Device X 610 mm Y 360 mm X Y WCH00869 94352 1 Lifting boss Including 2 bolts M16x90 1 plate X 188 mm X WCH00869 2017 ...

Page 478: ... X 600 mm Ring halves WCH00869 X 94353A 94354 2 Support X 505 mm WCH00869 X 94363 3 Jacking screws M8 for separating piston crown from piston skirt X 90 mm X WCH00497 94366 1 Template for shape of top of piston crown X 349 mm X WCH00497 94410 8 Adjusting devices for alignment of intermediate wheel X 177 2 mm X 2017 ...

Page 479: ...g straight length 2 m WLL 1000 kg Protection plate with 2 screws M10x25 X 296 mm 94435D 94435B E X X X 94435C 94435A WCH00498 94556 94556A 94556B 94556C 94556D 1 1 1 1 1 Adjusting device for pressure control valve with 4 Allen screws M16x120 X 954 mm Y 104 mm Adapter piece G Closing valve Socket and Hydr flexible tube O ring WCH00827 B C A D X Y 94572G 94572H 94572I 1 2 2 Shackle for SAC283 WLL 85...

Page 480: ... FS 94581C RS 1 1 Holder Front Side 5 6 Cyl combined with 94581B with 4 screws M12x30 X 205 mm Holder Rear Side combined with 94581D 94581J with 4 screws M12x30 X 205 mm X X 94581C FS 94581C RS 94581E 94581F 1 1 Lifting plate with 3 screws M10x30 WLL 160 kg X 134 mm Chain with 3 screws M10x30 WLL 160 kg X 284 mm X 94581E X 94581F 94581G 1 94581G 2 1 1 Plate with 2 screws M10x25 WLL 160 kg X 112 mm...

Page 481: ...mm X 94582 94582A 94582B 94582C 94582D 1 1 1 1 1 Fitting and dismantling device complete for servo oil and fuel pumps X 203 mm Hydr connecting piece Adapter piece Closing valve Holding device X 700 mm X B C A WCH00500 X In case of a turbocharger breakdown engines with ABB A165 turbocharger engines with MET 42MB turbocharger 94653 1 Cover to air connection at diffuser X 430 mm ABB A165 type X 356 m...

Page 482: ... WCH00502 94663A 94663B 1 1 Support LEFT including 1 Lug 1 Safety chain 5 Screws M16x40 X 336 mm Support RIGHT including 1 Lug 1 Safety chain 5 Screws M16x40 X 336 mm X 94663B DP 94663A 94663C 94663D 94663C 94663D 2 2 Lugs X 120 mm Safety chains X 1025 mm WLL 1000 kg X 016 822 08 X 94663E 1 Support X 1558 mm Y 435 mm X Y 94666 2 Chains double sling for SAC 281 only including 2 shackles each X 334 ...

Page 483: ...94667A 1 Lifting plate for removal and fitting of water separator including 4 screws M12x25 and 1 shackle X 322 5 mm X DP 94667B 1 Support for fitting of water separator including 6 screws M16x30 X 1024 mm Y 530 mm DP X Y 94667C 1 Lifting lug for fitting of water separator including 4 screws M12x25 X 100 mm X DP 94667D 1 Angle support for fitting of water separator including 4 screws M16x55 and 2 ...

Page 484: ...aling faces X 55 mm Stencil Y 55 mm X WCH02756 Y 94841A 94841 94845 1 Hydraulic pump unit for checking servo oil system during engine standstill including 3 hoses with coupling sockets X 300 mm Y 600 mm WCH00514 X Y 94871 1 Grinding device for sealing surfaces on HP fuel pip 8733 1 X 97 mm including 94871A 1 Screw on sleeve AF 32 94871B 1 Grinding tool with countersunk screw M4 94871C 1 Lock nut M...

Page 485: ...r lubrication Connector plug C Plug B with cable lenght 0 5 m Plug C with cable lenght 2 5 m WCH01087 94930 94930A 94930B 94930C 1 SW download package to UNIC for uni tool consisting of 1 UBS to CAN adapter 1 CAN cable ca 2 5 m 1 Ethernet adapter cable software tool 1 Connection diagram ca 1000 80 018 127 09 2017 ...

Page 486: ...iece max operating pressure 2800 bar 015 677 07 94934 1 Connection block 00 7201 94934A 2 Hydr distributors with pressure gauges 015 677 07 94934B 4 Coupling elements 015 678 07 94934C 1 Distributing piece 94934H 1 Hydr distributor with pressure gauge 0 to 25 bar WCH00724 94934I 1 Connection nipple G WCH00724 2017 ...

Page 487: ...es 2000 bar with closing valves and coupling sockets X approx 1210 mm 00 7203 X 94935C 1 Hose compl with coupling sleeve for set up of pre tensioning jacks 015 679 07 94942 1 Hydraulic unit max operating pressure 2000 bar 015 680 07 94950 94950A 2 1 Hydraulic rams 295 kN 30t Working pressure 700 bar Connection nipple G 2000 bar X 42 5 mm WCH00891 X WCH00892 2017 ...

Page 488: ...s WLL 1000 kg 016 621 08 94101 1 Inside micrometer with case Measuring range 50 1010 mm 000 366 93 94291 94291A 1 2 Valve grinding device complete for valve spindle and valve seat Grinding discs C M No 11373 01 01 WCH03339 WCH03339 94291A 94299 1 Grinding device X 400 mm X WCH02384 2017 ...

Page 489: ... mm 93 7602 X 94336 1 Connecting flange for pre lubrication of crosshead and bottom end bearing X 120 mm X 015 682 07 94349 1 Pressure testing device for piston X 164 mm X 94350 1 Device tilted removal see 3403 1 A2 for removal and fitting a piston X 460 mm Y 647 mm X Y WCH00496 2017 ...

Page 490: ...ss of chrome ceramic layer on piston rings WCH01216 94357 1 Calliper gauge for measuring piston ring grooves 94366A 1 Template for shape of top of piston crown for use with piston installed X 373 mm X WCH00497 94831 1 Blank flange for blanking off starting air pipe during emergency operation X 185 mm X 00 7199 2017 ...

Page 491: ...X X X A B C D WCH00504 M3x40 94870 94870A 94870B 94870C 94870D 1 1 1 1 1 Regrinding device for HP fuel pipe X 101 mm consisting of 94870E 1 Screw on sleeve SW32x49 94870F 1 Grinding tool with countersunk screw M4x12 94870G 1 Lock nut M18x2 AF46 94870H 1 Template X 35 mm 94870G 94870E 94870F WCH03803 X 94870H X WCH03803 94324C 1 Fixing device with 2 screws M12x30 for measuring lateral clearance 3 d...

Page 492: ... 5 A1 Winterthur Gas Diesel Ltd 32 32 94099 1 Lifting tool for lifting a complete engine WLL 60 tones WCH02731 94599 1 Lifting tool for transporting a complete rail unit X 1691 mm Y 614 mm WLL 2400 kg X Y WCH00501 2017 ...

Page 493: ...Maintenance manual PCO D010_E_02 High pressure fuel pump Flow control valve High pressure fuel pump PCO G108 R V1 Spare parts set PCO U10012 PCO U10018 ...

Page 494: ...ubject to a natural wearing and aging process This document is protected by copyright Any further processing or use requires the prior written consent of L Orange GmbH This applies particularly to reproduction dissemination processing translation microfilming and saving and or processing in electronic systems including databases and online services The front page depicts a configuration example Th...

Page 495: ...12 3 Overview 13 3 1 Design 13 3 1 1 High pressure fuel pump 13 3 1 2 Flow control valve 14 4 Transportation and storage 15 4 1 Transportation 15 4 1 1 Corrosion protection 15 4 1 2 Packaging 15 4 1 3 Transport lock for pumps 16 4 1 4 Marking 16 4 2 Storage 17 5 Tools and resources 18 5 1 Tools 18 5 2 Spare parts 20 5 2 1 PCO U10012 Replacing the O rings 20 5 2 2 PCO U10018 Replacing the flow cont...

Page 496: ...ing the flow control valve 33 7 4 Inspecting flow control valve with pin and shim 37 7 4 1 Dismantling the flow control valve 37 7 4 2 Inspecting the control unit 41 7 4 3 Reassembling the flow control valve 44 7 5 Mounting the flow control valve 48 7 6 Checking the throttle 49 8 Disposal 51 9 Appendix 52 9 1 Abbrevations 52 9 2 History 52 9 3 Internal release 53 ...

Page 497: ...nt stoppages or damage to property This document is to be used while the system is being installed and dismantled This document is not to be used duplicated or passed to third parties without explicit con sent for other purposes outside this area of application 1 2 How the information is displayed For easier handling and better understanding of the information in this document consis tent safety i...

Page 498: ...f risk which if not prevented will result in death or serious injury WARNING Type and source of the risk Consequences of non compliance Risk prevention Refers to a hazard with a medium degree of risk which if not prevented can result in death or serious injury CAUTION Type and source of the risk Consequences of non compliance Risk prevention Refers to a hazard with a low degree of risk which if no...

Page 499: ... started Actions are indicated by a numbered list These must be completed in sequence This symbol indicates an interim result within a set of instructions Interim results can be a nominal value or a measured value or a condition which must be achieved Relevant points within a graphic are indicated with this symbol The numbers are referred to in the following text or in a table below the graphic 1 ...

Page 500: ...quired personal safety equipment must be worn 2 2 Important measures Ĥ Please read this document Ĥ Use this document to identify spare parts during assembly and disassembly work Ĥ Only assembly and disassembly work as described in this document is permitted If Woodward L Orange components are opened for other reasons all guarantee claims shall be rendered invalid Ĥ Components or assemblies may onl...

Page 501: ... than the intended purpose Operation and maintenance by unqualified personnel Alterations or modifications Non compliance with the safety instructions 2 4 Safety instructions 2 4 1 General hazards Flammable Fuel Death or life threatening burns Ĥ Avoid open flames Ĥ Avoid electric sparks and ignition sources Ĥ Keep fuel lines away from heat sources Ĥ No smoking Standing under suspended loads Death ...

Page 502: ...ine manufacturer s documentation Failure to observe the sequence of actions Damages to components due to incorrect assembly Ĥ Follow the given sequence of actions Incomplete scope of delivery or spare parts sets Interruption of the assembly process Ĥ Make sure the scope of delivery and all necessary spare parts sets are complete be fore starting the installation and disassembly 2 4 2 Mechanical ha...

Page 503: ...refully during disassembly Ĥ Set up a collector below the working area Tension of cables Damage to components and cables Ĥ Assemble cables and fastening points tension free Ĥ Observe the installation location and position of components and cables 2 4 3 Electrical hazards High voltage Death or life threatening injuries by fatal electrical shock Ĥ Complete tests on non conductive materials Ĥ Do not ...

Page 504: ... Ĥ Wear safety goggles Ĥ Follow the processing instructions of the cleaning agent manufacturer Aggressive cleaning agents Corroded O rings Ĥ Make sure the cleaning agents do not corrode the O rings Excessive exposure of components to cleaning agents Damage to components due to corroded surfaces Ĥ Observe the information of the cleaning agent manufacturer ...

Page 505: ... description The graphical representation does not refer to a possible delivery of WLO but describes the component in its immediate environment to provide a visual understanding in ad vance 3 1 Design 3 1 1 High pressure fuel pump 1 2 3 4 5 7 6 Illustration 1 PCO G108 R V1 pump design 1 Cheese head screw 2 Sleeve 3 O ring 4 Connection piece complete 5 Flow control valve complete 6 Bolt 7 Plunger s...

Page 506: ...14 54 3 1 2 Flow control valve 1 2 3 4 5 6 7 8 9 10 11 Illustration 2 Flow control valve design 1 Control solenoid compl 2 O ring 3 Plate 4 O ring 5 Control unit compl 6 Control piston 7 Pressure spring 8 Pin 9 Shim 10 O ring 11 Screw plug ...

Page 507: ...ctive and safe in order to protect the products from mechanical and environmental influences as well as loss of content The illustrations in this chapter are examples and may differ from the actual packaging Defective components must be returned to Woodward L Orange Observe the following packaging instructions to avoid further damage Woodward L Orange only accepts correctly packaged returns Ĥ When...

Page 508: ...closed with a suitable screw plug Ĥ Use dividers and supports wood strips and specially cut blanks to prevent the com ponents from sliding around and to protect them from damage Ĥ If filling material is required use packing paper 4 1 4 Marking Ĥ Mark the package with two delivery notes on different sides Ĥ Enclose a third delivery note in the package ...

Page 509: ...downloads reklamations management_ _questionnaire_01 pdf la en hash 52F61C7F942 DA9F5A4E8CB1E3E31B7190576C2C6 Information about package size and package weight Adress of sender and supplier Freight forwarder Contact details of the contact person telephone and email 4 2 Storage NOTICE Damage caused by improper storage Damage due to rust formation Store components in the original packaging Ensure th...

Page 510: ...e scope of delivery The tools described here are to be used for assembly and disassembly work The illustrations are purely symbolical and may differ from the tools used If additional information is not provided for the tools refer to the engine manufacturer s documentation Tools Additional in formation Application Illustration Torque wrench Range 10 100 Nm Tighten screws and nuts to the fi nal tor...

Page 511: ...For tightening bolts to final torque and loosening bolts Internal hex socket A F 6 mm For tightening bolts to final torque and loosening bolts Vise Fixing for dis assembly and assembly work Lubricant Engine oil Lubricate components before instal lation Vaseline Prevents components falling out during mount ing Benzine Cleaning components Nylon brush Remove loose dirt from compo nents Lint free clea...

Page 512: ...s must be checked at the beginning of the assembly steps If damaged or incomplete spare parts have been delivered do not use these parts for the following assembly steps and contact the WLO Customer Service 5 2 1 PCO U10012 Replacing the O rings 1 2 3 4 Illustration 3 Spare parts set PCO U10012 Spare part Additional information 1 O Ring 2 O Ring 3 O Ring 4 O Ring Qty 3 ...

Page 513: ...evision 02 PCO D010_E Page 21 54 5 2 2 PCO U10018 Replacing the flow control valve 1 2 3 Illustration 4 Spare parts set PCO U10018 Spare part Additional information 1 Bolt Qty 3 2 Flow control valve complete 3 O ring Qty 3 ...

Page 514: ... a chapter The preventative steps must be followed to avert the dangers 6 1 Removing the flow control valve Tool Additional In formation Application Tools Hex socket wrench A F 6 mm Loosen bolts Illustration 5 Flow control valve on HPFP 1 Bolt 2 Flow control valve ü The engine is switched off and secured against being switched on again 1 Remove the fuel line and the ECU cable connection from the f...

Page 515: ...ts Vaseline Fix O rings in place WLO Mat Nr Spare parts set WLO Mat Nr Part Part description Spare parts PCO U10018 Replacement set for FCV Illustration 6 Flow control valve position of O rings 1 O ring 1 Take a new flow control valve 2 Insert new O rings in the flow control valve and fix them in place with Vaseline 3 Lubricate the threads of the new bolts with lubricant ...

Page 516: ...ation 7 Flow control valve on HPFP 1 Bolt 2 Flow control valve 1 Position the flow control valve on the mounting surface of the HPFP 2 Hold the FCV with one hand to prevent the FCV from falling down and make sure that the O rings do not fall out of the grooves 3 Screw in the bolts 4 Tighten the bolts alternately to final torque using a torque wrench and an internal hex socket ð Tightening torque 3...

Page 517: ... Tool Additional In formation Application Tools Hex socket wrench A F 6 mm Loosen bolts Illustration 8 Flow control valve on HPFP 1 Bolt 2 Flow control valve ü The engine is switched off and secured against being switched on again 1 Remove the fuel line and the ECU cable connection from the flow control valve 2 Loosen and remove the bolts Prevent the flow control valve from falling down 3 Place th...

Page 518: ...lustration 9 Flow control valve bottom view 1 Location of marking 1 Check the marking on the FCV ð If the marking is PCO U288V6 then proceed with section Inspecting flow control valve without pin and shim Page 27 ð If the marking is PCO U10030 then proceed with section Inspecting flow control valve with pin and shim Page 37 ...

Page 519: ...ication Tools Wrench A F 30 mm Loosen the screw plug Hex socket wrench A F 5 mm Loosen the bolts on the FCV Vise Fix the FCV 1 2 3 4 5 6 Illustration 10 Flow control valve exploded view 1 Control unit 2 Control piston 3 Pressure spring 4 O ring screw plug 5 Screw plug 6 O ring HPFP 1 Carefully remove the O rings HPFP and put them down in a safe place 2 Clamp the flow control valve in a vise with p...

Page 520: ...Inspection and corrective actions Revision 02 PCO D010_E Page 28 54 Illustration 11 Flow control valve bolts 1 Bolt 5 Remove the bolts and place them on a clean working surface ...

Page 521: ...010_E Page 29 54 Illustration 12 Flow control valve setup of control solenoid 1 Control solenoid 2 O ring 3 Plate 4 O ring 5 Control unit 6 Remove the control solenoid the O rings and the plate from control unit and place them on a clean working surface ...

Page 522: ...an the control unit components Benzine Clean the control unit components Lubricant Engine oil Lubricate the control piston 1 Inspect all flow control valve components for impurities such as particles and solid or sticky deposits Illustration 13 Control solenoid membrane NOTICE Damage to the solenoid membrane Do not use brushes or other cleaning materials 2 Clean the control solenoid membrane arrow...

Page 523: ... 54 Illustration 14 Control unit components 1 Control unit 2 Control piston 3 Pressure spring 5 Carefully clean the control piston bore on the control unit the control piston the pressure spring the pin and the shim with a nylon brush a lint free cloth and ben zine ...

Page 524: ...02 PCO D010_E Page 32 54 1 2 Illustration 15 Control unit position of control piston 1 Control piston 2 Control unit 6 Inspect all components for residual dirt 7 Lubricate the control piston and check that it can move freely in the control unit ...

Page 525: ...y components designated for the specific flow control valve The flow control valve must be reassembled in the reverse order to dismantling Tool Additional In formation Application Tools Torque wrench Tighten bolts and screw plug to final torque Open end torque wrench head A F 30 mm Tighten the screw plug to final torque Internal hex socket A F 5 mm Tighten bolts to final torque Lubricant Engine oi...

Page 526: ...ration 16 Flow control valve setup of control solenoid 1 Control solenoid 2 O ring 3 Plate 4 O ring 5 Control unit 1 Clamp the control unit in a vise with protective jaws 2 Put the O rings of the spare parts set and the plate between the control solenoid and the control unit ...

Page 527: ...PCO D010_E Page 35 54 Illustration 17 Flow control valve bolts 1 Bolt 3 Lubricate the bolts with lubricant and screw them in 4 Tighten the bolts alternately to final torque using a torque wrench and an internal hex socket ð Tightening torque 10 Nm ...

Page 528: ...ring HPFP 5 Lubricate the control piston with lubricant and insert it into the control unit 6 Insert the pressure spring into the control piston 7 Lubricate a new O ring with lubricant and put it on the screw plug 8 Tighten the screw plug to final torque using a torque wrench and an open end torque wrench head ð Tightening torque 50 Nm 9 Mount the O rings HPFP on the control unit and fix them in p...

Page 529: ...ling down Malfunction of the flow control valve due to missing components Handle the flow control valve with care during assembly or disassembly 7 4 1 Dismantling the flow control valve Tool Additional In formation Application Tools Wrench A F 30 mm Loosen the screw plug Hex socket wrench A F 5 mm Loosen the bolts on the FCV Vise Fix the FCV ...

Page 530: ... O ring screw plug 7 Screw plug 8 O ring HPFP 1 Carefully remove the O rings HPFP and put them down in a safe place 2 Clamp the flow control valve in a vise with protective jaws 3 Loosen and remove the screw plug with O ring and shim 4 Ensure that the shim is in the screw plug 5 Remove the pressure spring the pin and the control piston from the flow control valve and place it on a clean working su...

Page 531: ...Inspection and corrective actions Revision 02 PCO D010_E Page 39 54 Illustration 20 Flow control valve bolts 1 Bolt 6 Remove the bolts and place them on a clean working surface ...

Page 532: ...010_E Page 40 54 Illustration 21 Flow control valve setup of control solenoid 1 Control solenoid 2 O ring 3 Plate 4 O ring 5 Control unit 7 Remove the control solenoid the O rings and the plate from control unit and place them on a clean working surface ...

Page 533: ...an the control unit components Benzine Clean the control unit components Lubricant Engine oil Lubricate the control piston 1 Inspect all flow control valve components for impurities such as particles and solid or sticky deposits Illustration 22 Control solenoid membrane NOTICE Damage to the solenoid membrane Do not use brushes or other cleaning materials 2 Clean the control solenoid membrane arrow...

Page 534: ... 5 Illustration 23 Control unit components 1 Control unit 2 Control piston 3 Pressure spring 4 Pin 5 Shim 5 Carefully clean the control piston bore on the control unit the control piston the pressure spring the pin and the shim with a nylon brush a lint free cloth and ben zine ...

Page 535: ...02 PCO D010_E Page 43 54 1 2 Illustration 24 Control unit position of control piston 1 Control piston 2 Control unit 6 Inspect all components for residual dirt 7 Lubricate the control piston and check that it can move freely in the control unit ...

Page 536: ...y components designated for the specific flow control valve The flow control valve must be reassembled in the reverse order to dismantling Tool Additional In formation Application Tools Torque wrench Tighten bolts and screw plug to final torque Open end torque wrench head A F 30 mm Tighten the screw plug to final torque Internal hex socket A F 5 mm Tighten bolts to final torque Lubricant Engine oi...

Page 537: ...ration 25 Flow control valve setup of control solenoid 1 Control solenoid 2 O ring 3 Plate 4 O ring 5 Control unit 1 Clamp the control unit in a vise with protective jaws 2 Put the O rings of the spare parts set and the plate between the control solenoid and the control unit ...

Page 538: ...PCO D010_E Page 46 54 Illustration 26 Flow control valve bolts 1 Bolt 3 Lubricate the bolts with lubricant and screw them in 4 Tighten the bolts alternately to final torque using a torque wrench and an internal hex socket ð Tightening torque 10 Nm ...

Page 539: ...t it into the control unit 6 Insert the pressure spring into the control piston 7 Insert shim and pin into the screw plug 8 Lubricate a new O ring with lubricant and put it on the screw plug 9 Insert the screw plug into the control unit ensuring a centered position of the pin in the pressure spring 10 Tighten the screw plug to final torque using a torque wrench and an open end torque wrench head ð...

Page 540: ...ts Illustration 28 Flow control valve on HPFP 1 Bolt 2 Flow control valve 1 Position the flow control valve on the mounting surface of the HPFP 2 Hold the FCV with one hand to prevent the FCV from falling down and make sure that the O rings do not fall out of the grooves 3 Screw in the bolts 4 Tighten the bolts alternately to final torque using a torque wrench and an internal hex socket ð Tighteni...

Page 541: ...f insufficient fuel cooling quantity drained Install throttle in the connection piece Fit the low pressure lines to throttle in the connection piece Drain hot fuel through the low pressure lines into a tank Illustration 29 HPFP position of throttle 1 Throttle ü Connection piece replaced 1 Locate the throttle in both pumps and check for an engraving ...

Page 542: ...ngraving B Throttle with engraving 2 Check whether a replacement of the throttle is necessary Ĥ Variant A Old throttle without engraving and with 1 0 mm Throttle replacement is necessary See the installation instructions of the engine manufacturer Ĥ Variant B New throttle with engraving and with 1 5 mm Throttle replacement is not necessary ...

Page 543: ...ispose of process materials in accordance with local regulations Ĥ Do not dispose of the device together with domestic waste Ĥ Recyclable packaging materials should be used whenever possible Ĥ To dispose of the system use the local collection containers and return points Ĥ Careless disposal of the product may lead to environmental pollution Ĥ In the event of defective components contact the respon...

Page 544: ...ions Abbrevation Meaning ECU Engine Control Unit FCV Flow control valve HPFP High pressure fuel pump Qty Quantity VCI Volatile corrosion inhibitor WLO Woodward L Orange 9 2 History Revision Date Author Changes 00 April 2013 Reth 01 April 2018 Alff Wagner 02 August 2020 Stein metz Revision of chapter structure Revision of safety chapter Safety Page 8 Corrective actions described for FCV variants wi...

Page 545: ...se This is to confirm that the technical content and the logic of the individual steps are cor rect The signatures confirm the release of the document PCO D010 Stuttgart 26 08 2020 p p Thomas Ziegler p p Horst Ressel Place Date Product Design HFO Test Application ...

Page 546: ...Woodward L Orange GmbH Porschestraße 8 D 70435 Stuttgart Tel 49 711 82609 0 Fax 49 711 82609 61 www lorange com ...

Page 547: ...arget is to set the industry standard for reliability efficiency and environmental friendliness WinGD provides designs licences and technical support to manufacturers shipbuilders and ship operators worldwide The engines are manufactured under licence in four shipbuilding countries WinGD has its headquarters in Winterthur Switzerland where its activities were founded in 1898 www wingd com ...

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Winterthur Gas X35-B, Maintenance Manual

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