MM WinGD-X72DF PDF

Maintenance Manual
“Marine”
Vessel:
Type:
Engine No.:
Document ID: DBAD226888
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
[email protected]
E 2018−01 Winterthur Gas & Diesel Ltd., Printed in Switzerland – All rights reserved
No part of this publication may be reproduced or copied in any form or by any means (electron-
ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems)
without the prior written permission of the copyright holder.
WinGD makes no representation, warranty (express or implied) in this publication and assumes
no responsibility for the correctness, errors or omissions for information contained herein. Infor-
mation 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 INFORMATION CONTAINED HEREIN. THIS
PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.
Maintenance Manual
“Marine”
Vessel:
Type:
Engine No.:
Document ID: DBAD226888
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
[email protected]
E 2018−01 Winterthur Gas & Diesel Ltd., Printed in Switzerland – All rights reserved
No part of this publication may be reproduced or copied in any form or by any means (electron-
ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems)
without the prior written permission of the copyright holder.
WinGD makes no representation, warranty (express or implied) in this publication and assumes
no responsibility for the correctness, errors or omissions for information contained herein. Infor-
mation 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 INFORMATION CONTAINED HEREIN. THIS
PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.
Modification
Engine Documentation
X72DF Summary for Maintenance Manual

Page No. Modification Title Subject
(MM) Page or
Date No. Manual
new exch.
2016 Maintenance Manual, Issue 2016 x
Date of publication 2016-8-26
2140-1/A1 2018-01 Update WinGD GAV: Removal, Pge 5: Para 5, Steps 10 to 12 changed. x
Desassemble,
Assemble and
Installation
2751-2/A1 2017-02 Update WinGD Exhaust Valve: Pge 6, para 3.4. Table removed. Text changed. x
Disassemble and
Assemble
Group 5 ToC 2018-01 Update WinGD ToC 5555-2/A1 added x
5555-2/A1 2018-01 Update WinGD Fuel Pressure Control New document x

Valve
9403-5/A1 2018-01 Update WinGD Tools List Pge 36: New tool 94573 added. 94844 Lubrication device x
added
Date of publication 2018-01

2138-1/A1 2018-02 WinGD Input Lubricating Quill Pge 1: Dismantling tool 94213 added to tool list. Pge2: x
Replace procedure added.
2722-1/A1 2018-02 WinGD Input Injection Valve: Pge 2: Warning about copper paste added x
Removal and
Installation
2722-2/A1 2018-02 WinGD Input Injection Valve: Pge 8: Warning about copper paste added x
Disassemble, Checks,
Assemble
Group 5 ToC 2018-02 Wartsila Input Lubrication of Supply New Titles Added: 5552-5/A1, 5562-1/A2 x
Unit during
Maintenance
5552-5/A1 2018-02 Wartsila Input Lubrication of Supply New document added x
Unit during
Maintenance
5562-1/A2 2018-02 Wartsila Input Fuel Pressure Control New document added x
Valve: Manual relase
Valve - Clean
9223-1/A1 2018-02 WinGD input Crank Angle Sensor para 2.1: Procedure updated, tolerance changed x
Unit: Proximity Sensor -
Replace
9403-5/A1 2018-02 WinGD Input and Tools List Pge 36: 94929 move to Special Recommended Tools on Pge x
EAAD087159 41. Pge 17: New tool 94289E added.

6606-1/A1 2018-08 WinGD Input Scavenge Air Cooler - Pges 12 and 15. Procedure changed and data added.: x
Removal and
Installation
Grp 2 ToC 2018-10 EAAD087592 Pge 1. 2708-4/A1 and 2708-5/A1 added x
2708-3/A1 2018-10 EAAD087592 Sealing Face for Fuel Pge 1. Procedure changed and data added. x
Injection Valve
Position − Grind
2708-4/A1 2018-10 EAAD087592 Sealing Face for Pilot New procedure. x
Injection Valve
Position − Grind
2018-10 EAAD087592 Sealing Face for the New procedure. x
Prechamber − Grind
9403-5/A1 2018-10 EAAD087592 Tools List Pge15. New tools added (Grinding devices for the pilot x
injection valve bore, fuel injection valve bore and
prechamber),
1/1 24/10/2018
0 General Information
1 Bedplate and Tie Rod
2 Cylinder Liner and Cylinder Cover
3 Crankshaft, Connecting Rod and Piston
4 Driving Wheels and Shut-off Valve for Starting Air
5 Supply Unit, Injection and Exhaust Valve Control
6 Scavenge Air Receiver and Auxiliary Blower
7 Cylinder Lubrication
8 Piping
MM / X72DF / Register
9 Crank Angle Sensor Unit, Tools

Table of Contents
General Information Group 0
For Your Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001−1/A1
Basic Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008−1/A1
General Guidelines
for Maintenance: Safety Precautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011−1/A1
for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012−1/A1
Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Crankshaft and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3
Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9
Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13
Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15
Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
Fuel and Servo Pump Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Electric Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27
Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1

Torque Values and Elastic Stud Replacement − Standard Screws and Elastic Studs . . . . . . . . . . 0352−2/A1
Masses (Weights): Component Weight − Each Piece (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0360−1/A1
Maintenance Schedule: Inspection and Overhaul Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0380−1/A1
Engine Cross Section and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0803−1/A1
Bedplate, Tie Rod, Main Bearings, Engine Stays, Tie Rods Group 1
Work Cards
Bedplate: Foundation Bolts − Pre-tension Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1112−1/A1
Crankcase: Visually Examine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1112−1.1/A1
Bedplate: Rubber Gasket on the Sump Tank − Do a Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1112−1.2/A1
Bedplate: Foundation Bolts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112−1/A1
Winterthur Gas & Diesel Ltd. X72DF / MM / 2016

Work Cards
Main Bearing: Bearing Edge and Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1132−2/A1
Main Bearing Shell: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1132−2.1/A1
Main Bearing
Elastic Studs − Loosen and Apply Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−1/A1
Main Bearing − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−2/A1
Work Cards
Thrust Bearing: Axial and Vertical Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1203−1/A1
Thrust Bearing: Bottom Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1203−1.1/A1
Thrust Bearing Pads: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1224−1.1/A1
Thrust Bearing
Axial Clearance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203−1/A1
Thrust Bearing Pads − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224−1/A1
Work Cards
Engine Stays (Friction Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1715−1/A1
Engine Stays (Hydraulic Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1715−1.1/A1
Engine Stays with Friction Shims: Pre-tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A1
Hydraulic Engine Stays: Oil Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A2
Work Cards
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1903−1/A1
Tie Rod: Pre-tension Check and Tie Rods Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1903−1/A1
Cylinder Liner, Cylinder Cover and Fuel Injection Group 2
Work Cards
Cylinder Liner: Measure the Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2124−1/A1
Cylinder Liner − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2124−1.1/A1
Antipolishing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2124−1.5/A1
Cylinder Liner: Remove Unwanted Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2124−3/A1
Cylinder Liner
Measure the Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−1/A1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−2/A1
Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports . . . . . . . . . . . . . . 2124−3/A1
Work Cards
Cylinder Lubricating Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2138−1/A1
Lubricating Quill: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A1
2016 / MM / X72DF Winterthur Gas & Diesel Ltd.

Work Cards
Gas Admission Valve: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2140−1/A1
Gas Admission Valve: Do an Overhaul of the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2140−1.1/A1
Gas Admission Valve: Check of the Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2140−1.2/A1
Gas Admission Valve: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2140−1.3/A1
Gas Admission Valve (GAV): Removal, Disassemble, Assemble and Installation . . . . . . . . . . . . . 2140−1/A1
Work Cards
Piston Rod Gland: Clean the Rings and Measure Worn Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2303−1/A1
Piston Rod Gland: Replace the Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2303−1.1/A1
Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation . . . . . . 2303−1/A1
Work Cards
Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2708−1/A1
Cylinder Cover
Cylinder Cover and Top Water Guide Jacket − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 2708−1/A1
Injection Valve: Grind Sealing Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−3/A1
Pilot Injection Valve: Grind Sealing Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−4/A1
Prechamber: Grind Sealing Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−5/A1
Work Cards
Injection Valve: Replace the Nozzle Body and Nozzle Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2722−1/A1
Injection Valve: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2722−1.1/A1
Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722−1/A1
Injection Valve: Disassemble, Checks, Assemble (Injection Valve with FAST) . . . . . . . . . . . . . 2722−2/A1
Work Cards
Starting Air Valve: Remove and Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2728−1.1/A1
Starting Air Valve: Check of the function of the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . WC2728−1.3/A1
Starting Air Valve: Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2728−1.4/A1
Starting Valve: Removal, Disassemble, Grinding, Assemble, Installation . . . . . . . . . . . . . . . . . . . . 2728−1/A1
Work Cards
Exhaust Valve: General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1/A1
Exhaust Valve Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1.1/A1
Exhaust Valve: Valve Drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1.2/A1
Exhaust Valve: Check the Condition of the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1.3/A1
Exhaust Valve: Random Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1.4/A1
Exhaust Valve
Exhaust Valve − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−1/A1
Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−2/A1
Valve Seat − Removal, Grind and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−3/A1
Valve Head − Seating Surface − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−4/A1
Winterthur Gas & Diesel Ltd. X72DF / MM / 2018−10

Work Cards
Pilot Injection Valve: Replace the Nozzle Spare Parts Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2790−1/A1
Pilot Injection Valve: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2790−1.1/A1
Pilot Injection Valve: Replace the Pre-chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2790−1.2/A1
Pilot Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2790−1/A1
Crankshaft, Connecting Rod and Piston Group 3
Work Cards
Crankshaft: Crank Deflection − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3103−1/A1
Crankshaft: Crank Deflection − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103−1/A1
Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−1/A1
Vibration Damper
Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−2/A1
Axial Damper: Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3140−1/A1
Turning Gear: Teeth and Screwed Connections − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3206−1/A1
Crankcase: Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−1/A1
Work Cards
Connecting Rod: Check the Bearing Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3303−2/A1
Connecting Rod
Bottom End Bearing − Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−2/A1
Top End Bearing − Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−3/A1
Top End Bearing Cover − Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−5/A1
Work Cards
Crosshead and Guide Shoe: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3326−1/A1
Crosshead
Clearance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−1/A1
Crosshead Pin − Removal ad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−2/A1
Crosshead Pin − Removal and Installation (Engines with Integrated ELBA) . . . . . . . . . . . . . . . . . . . 3326−2/A2
2016 / MM / X72DF Winterthur Gas & Diesel Ltd.

Work Cards
Piston: Remove and Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−1/A1
Piston: Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−3/A1
Piston: Check the Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−4/A1
Piston: Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−4.1/A1
Piston: Fully Re-manufacture the Piston Head Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−4.2/A1
Piston Underside: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3404−1/A1
Piston
Top Surface − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403−4/A1
Work Cards
Piston Rings: Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3425−1/A1
Piston Rings: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3425−1.1/A1
Piston Rings: Piston Rings and Ring Grooves − Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425−1/A1
Driving Wheels and Shut-off Valve for Starting Air Group 4
Work Cards
Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC4003−1/A1
Driving Wheels
Running and Backlash Clearances and Tooth Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−1/A1
Crankshaft Gear Wheel − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−2/A1
Work Cards
Starting Air Shut-off Valve: Remove and Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC4325−1/A1
Starting Air Shut-off Valve: Remove the Common Start Valve . . . . . . . . . . . . . . . . . . . . . . . . . . WC4325−1.1/A1
Starting Air Shut-off Valve: Cleaning and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325−1/A1

Supply Unit and Rail Unit Group 5
Work Cards
Servo Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5551−1/A1
Servo Oil Pump Drive: Remove the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−1/A1
Servo Oil Pump Drive: Remove the servo oil pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−1.3/A1
Fuel Pump Drive: Camshaft Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−2/A1
Fuel Pump Drive: Check Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−2.1/A1
Fuel Pump Drive: Check Thrust Bearing Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−2.2/A1
Fuel Pump Drive: Replace the Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−2.3/A1
Pilot Fuel Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5555−1/A1
Pilot Fuel Supply Unit − Pilot Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5555−1.1/A1
Pilot Fuel Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−1/A1
Work Cards
Fuel Pump: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5556−1/A1
Fuel Pump: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5556−1.1/A1
Fuel Pump
Removal, Disassemble, Assemble, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−1/A1
Seized Pump Plunger − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−2/A1
Fuel Pressure Control Valve: Removal, Check, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A1
Fuel Pressure Control Valve: Manual Release Valve − Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A2
Work Cards
Fuel Overpressure Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5562−2/A1
Fuel Overpressure Safety Valve: Removal, Check and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−2/A1
Flow Limiting Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−3/A1
Work Cards
Flow Limiting Valve (FLV): Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5564−1/A1
Flow Limiting Valve (FLV): Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5564−1.1/A1
Exhaust Valve Control Unit (VCU): Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5612−1/A1
Exhaust Valve Control Unit (VCU): Replace the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . WC5612−1.1/A1
Supply Unit
Camshaft and Bearing Shells − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5581−1/A1
Lubrication of Supply Unit during Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−5/A1
Fuel Pump Actuator

Connection to Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5583−1/A1
Servo Pump Unit

Servo Oil Pump − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5591−1/A1
Servo Oil Rail: Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation . . . . . 5612−1/A1
X72DF / MM / 2018−02 Winterthur Gas & Diesel Ltd.

Scavenge Air Receiver 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
Cylinder Lubrication and Balancer Group 7
Cylinder Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7218−1/A1
Integrated Electric Balancer (iELBA)

Bearing Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7758−1/A1
Replacement of Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7762−1/A1
Piping Group 8
Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8135−1/A1

HP Servo Oil Pipe: Removal, Grind the Sealing Faces and Installation . . . . . . . . . . . . . . . . . . . . . . 8447−1/A1
Hydraulic Pipe − Exhaust Valve Drive: Removal, Grind the Sealing Faces and Installation . . . . 8460−1/A1
HP Fuel Pipe (Injection Valve): Removal, Grind the Sealing Faces and Installation . . . . . . . . . . . 8733−1/A1
HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8752−1/A1
HP Fuel Pipe − Pilot Fuel Pipe: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8790−1/A1
Crank Angle Sensor Unit, Tools Group 9
Crank Angle Sensor Unit: Replacement of Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9223−1/A1

Cylinder Pressure Sensor: Replacement of Cylinder Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . 9258−1/A1
Tools: Description of Tool Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−1/A1
Hydraulic Pre-tensioning Jacks and Pumps

Configuration and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−2/A1
Overview, Storage, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−3/A1
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−4/A1
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−5/A1

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1 to 35
Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 36 to 38

Intentionally blank
Maintenance Group0
General Information Group 0
For Your Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001−1/A1
Basic Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008−1/A1
General Guidelines
for Maintenance: Safety Precautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011−1/A1
for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012−1/A1
Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Crankshaft and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3
Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9
Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13
Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15
Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
Fuel and Servo Pump Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Electric Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27
Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1

Torque Values and Elastic Stud Replacement − Standard Screws and Elastic Studs . . . . . . . . . . 0352−2/A1
Masses (Weights): Component Weight − Each Piece (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0360−1/A1
Maintenance Schedule: Inspection and Overhaul Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0380−1/A1
Engine Cross Section and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0803−1/A1
Winterthur Gas & Diesel Ltd. 1/ 1 X72DF / MM / 2016

Intentionally blank
Maintenance 0000−1/A1
For Your Attention
1. General
This manual is for the operator and is for use only for the related type of diesel engine
(the engine described in this manual). The data in this manual is confidential.
Make sure that you read carefully the Operation Manual before you operate the
engine.
Make sure that you know the Inspection and Overhaul intervals in the Maintenance
Manual before you operate the engine.
Make sure that you read the data in Group 0 in the Maintenance Manual before you
do maintenance work on the engine.
2. Spare Parts
Use only original spare parts and components to make sure that the engine will
continue to operate satisfactorily. All equipment and tools for maintenance and
operation must be serviceable and in good condition.
All supplies and services are set only 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 WinGD. These data relate to the date of issue of the manual (the year
of the issue is shown on the title page). All instructions, graphics and illustrations etc.
can change because of continuous new development and modifications.
4. Personnel
Only qualified personnel that have the applicable knowledge and training are
permitted to do work on the engine, its systems and related auxiliary equipment.
Data related to protection against danger and damage to equipment are specified in
this manual as Warnings and Cautions.
Winterthur Gas & Diesel Ltd. 1/ 1 2016

Intentionally blank
Preface
The instructions in this Maintenance Manual are to help make sure that maintenance
is done correctly at the specified intervals.
It is a condition that the personnel who do important work have the applicable training
and experience.
Data about the operation of the engine and descriptions of the function of the different
systems are part of the Operation Manual. Chapter 0010−1 in the Operation Manual,
gives descriptions about the Operation and Maintenance Manuals and data about
symbols, signs and special characters.
More instructions about the operation and maintenance of components from
sub-suppliers are found in the instruction leaflets of the related manufacturers (for
example, engine components, tools or devices that are not manufactured in
accordance with production drawings from WinGD).
The Maintenance Manual has the primary data that follow:

D General Guidelines for Maintenance. These give recommendations about
precautions and applicable procedures.
D Clearance tables, tightening values of screwed connections, masses (weights).
These give data about usual and maximum permitted clearances, engine
components, type and use of different sealing rings etc.
D Maintenance Schedule. This schedule shows the nominal intervals when the
different maintenance operations must be done during standard operation
conditions.
D Design Groups give the instructions and procedures for maintenance work on
specified engine parts.
D Tool Lists give data about the applicable tools and devices necessary to do the
maintenance work. The tools and devices are usually supplied wit the engine.
All data in this manual (text and illustrations) are correct at the date of issue.
Modification of data is done regularly.

Intentionally blank
General
Basic Engine Data
6−Cylinder Engine
Turbocharger
Auxiliary
Auxiliary Blower 2
Blower 1
1 2 3 4 5 6
Cylinder
Number
1 2 3 4 5 6 7 8
DRIVING END FREE END
Main Bearing
Number
WCH03234
Thrust Bearing Pads
Rail Unit
FUEL SIDE EXHAUST SIDE
Supply Unit
Counterclockwise Clockwise Rotation

Rotation
WCH03234
Fig. 1: Outline View

0008−1/A1 Maintenance
Unic Parts:
Fuel Pumps
Fuel Pump Actuators
Servo Oil Pump 2
FUEL SIDE
Servo Oil Pump 1
Supply Unit
DRIVING
END
WCH03235
EXHAUST SIDE Crank Angle Sensors
WCH03236
Fig. 2: ECS Parts
2016 2/ 2 Winterthur Gas & Diesel Ltd.

General Guidelines for Maintenance

Safety Precautions and Warnings
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Precautions before the Start of Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Special Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. General
The maintenance work, which must be done on the engine at regular intervals, is
given in the Maintenance Schedule 0380−1. The maintenance intervals are related to
the mode of operation, the power and the quality of the fuel used. For more data,
refer to the Maintenance Schedule.
The maintenance intervals can be extended or decreased.
Note: The recommendations related to safety procedures and maintenance
given below are mandatory. All other safety recommendations not given
here must also be obeyed.
2. General Safety Precautions

The general safety conditions are as follows:
D All personnel must know the fire fighting procedures.
D All personnel must know the health and safety data and environment protection
data related to the operation and maintenance of dual fuel engines.
D All personnel must know the dangers, functions and operation of cranes and
lifting devices.
D The safety officer must make sure that all precautions are done to prevent
dangerous conditions.
D The operator must select a supervisor to give work tasks to each person who
does maintenance work.
D Make sure that fluids that drain or are released cannot cause explosions, fires or
accidents during maintenance. Keep the engine and the areas around the engine
clean to help prevent accidents and increase the quality of the work.
D Before you start maintenance on the engine make sure that, if necessary, the
pressure in the related systems is released and fluids are drained. Make sure
that you record the pressures and quantities.
D Some media, e.g. fuel, oil are very flammable, thus you must keep such media
away from fire, hot parts etc.
D Make sure that personnel do not smoke in the engine room.
D To prevent injury, make sure that all surfaces where personnel can walk or stay
do not have oil, fuel etc and are kept clean and dry.

3. Precautions before the Start of Maintenance

CAUTION
Damage Hazard: Do not use water or cleaning fluid to clean the
electronic components and control boxes on the engine and the rail
unit. Damage can occur if water goes into these electronic
components or control boxes.
CAUTION
Damage Hazard: When electric welding is done near or on the
engine, electromagnetic fields or peak voltage can occur. this can
cause damage to the electronic components of the Engine Control
System.
Before you do electric welding, you must do the procedure that follows:
1) Stop the engine.
2) Set to off the electronic system. There must be an elapsed time of one minute
before you continue.
3) If the welding area is in a radius of two meters from an electronic module and/or
a sensor, disconnect the modules and/or sensors.
4) Close the covers of all electronic boxes and apply protection to the cables,
sensors, etc. to prevent damage from sparks and heat.
5) Use a conductive material connected to earth to give protection to the check and
control units.
6) Make sure that the welding cable goes directly to the welding point without
unnecessary loops. Also, make sure that the welding cables are not parallel to
cables of the electronic units.
Before you start the maintenance on the engine, specially the running gear, do the
procedure that follows:
1) Close the shut-off valves on the starting air bottles.
2) Close all the shut-off valves in the control air supply unit.
3) Open the drains on each starting air bottle to release all the pressure.
4) On the starting air shut-off valve, operate the handwheel to move the shut-off
valve to the position CLOSED.
5) On the main starting air pipe, open the vent and drain valve. Keep the vent and
drain valve in the open position until maintenance is completed.
6) On the starting air shut-off valve, open the vent valves. Keep the vent valves in
the open position until maintenance is completed.
7) Open all indicator valves on the cylinder covers. Keep the indicator valves in the
open position until maintenance work is completed.
8) Engage the turning gear and lock the lever. The gear pinion must be in the
engaged position.
Note: If the engine was stopped because the running gear or bearings have
become too hot, do not open the crankcase doors before an elapsed time
of 20 minutes.
Note: During all engine operations (short or usual), the crankcase doors must
be locked with the clamps.
Note: Where carbon dioxide (CO2) is used to extinguish a fire in the engine,
there is a risk of suffocation. Make sure that all related spaces have good
airflow to remove all CO2 gas before

4. Special Safety Procedures

WARNING
Injury Hazard: After engine operation in gas mode, gas can stay in
the gas inlet pipes. There is a risk of explosion. You must replace
the unwanted gas with inert gas (e.g. nitrogen). For the procedure,
refer to the documentation of the gas valve unit manufacturer.
WARNING
Danger: Gas Hazard. Poisonous gas can stay in the cylinder liner.
There is a risk of suffocation. You must put on protective
equipment, a respirator and a harness before you do work in
cylinders where gas can stay.
WARNING
Injury Hazard: Make sure that no personnel and components are in
the danger areas (crankcase, piston underside, propeller shaft,
etc). The propeller coupling also turns.
WARNING
Injury Hazard: Before you operate the turning gear, make sure that
no personnel are near the flywheel, or in the engine.
A safety person must be in a position when personnel do work in the engine. If

necessary, the safety person can give the applicable aid.
Personnel who do work in the engine must put on the correct safety equipment.
Safety equipment to prevent suffocation must also be included.
The permitted load capacity of the equipment that follows must be sufficient for the
parts to be lifted:
D The engine room crane.
D Lifting tools, ropes, slings and chains.
You must make sure that the lifting equipment is correctly attached the the item (i.e.
balanced to make sure that the equipment does not tilt or fall).
For more data, refer to 0012−1 and 0360−1.
Use wood, leather or guards between the item and the rope or chain to give
protection to sharp edges, mating faces etc.
Always put on gloves, a face shield and safety goggles when you operate hydraulic
tools.
Keep your hands away from ropes, slings and chains that have tension. Do not go
under loads that hang.
Parts removed from the engine must be safely attached in the engine room to prevent
movement.
Make sure that when engine components are removed, covers are put in position
over the openings.
Note: For more data, refer to the Operation Manual, 0100−1 Safety Precautions
and Warnings (General Information).

5. Recommendations
1) Read the data in 3301−1 Work Platform.
2) Do the work carefully. Make sure that all parts and equipment are clean. Use only
the applicable tools and equipment for the maintenance tasks. For data about the
tools and equipment, refer to 9403−5 Tool List.
3) Make sure that the tools and equipment are serviceable before you use them.
4) Calibrate gauges before you use them. Also, calibrate gauges at regular
intervals.
5) Do regular checks of hydraulic tools to make sure they are serviceable.
6) Apply protection to the running surfaces and sealing faces of parts that were
removed to prevent damage.
7) When pipes are removed, dirt can go into the openings. Apply protection to the
openings in the pipe and the related part.
8) Before you start the engine, make sure that repaired parts, replaced parts, or
parts that had an overhaul are serviceable.
9) Make sure that all pipes that were removed and installed are tightened correctly.
10) Do regular checks of parts that move. If the maximum permitted value is the
same or more than that given in 0330−1 Clearance Tables, the parts must be
replaced.
11) Use spare parts from the spares stock on board. When you order new parts, get
the code numbers and description from the Spare Parts Catalog.
12) When you tighten nuts, bolts or screws, make sure that you do not cause
damage to the thread. Turn the nut, bolt or screw with your hand until the metal
parts touch. Use only the specified lubricants on the threads.
13) Where torque values are shown, refer to the data given in 0352−1 and 0352−2.
14) Devices that lock nuts, bolts etc must be correctly installed. Use lockwire, tab
washers and lock plates once only.
15) For threads of screws and studs in very hot areas, (e.g. exhaust pipe or
turbocharger) apply a lubricant that is resistant to high temperatures before
assembly. This will help you when it becomes necessary to remove these items.
16) Always replace O-rings during an overhaul of components, or during removal and
installation procedures. The O-rings must be of the correct dimensions in
accordance with WinGD specifications.
17) The installation of piston sealing rings and rod seal rings must be done carefully
to prevent deformation and distortion. Before installation, put the rings into very
hot water.

General Guidelines for Lifting Tools

Wire Rope Slings, Span Sets, Eye Bolts, etc.
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Wire Rope Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Span Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.3 Eye Bolts and Eye Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.4 Eye Bolts and Swivel Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.5 Shackles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Lifting Equipment − Attach and Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
The permitted capacities of the engine room crane, lifting equipment, ropes, chains,
eye bolts, etc must always be related to the weights of the parts to be lifted. For more
data, refer to 0360−1 Masses (Weights).
Note: The maximum permitted load in kg is related to the Work Load Limit
(WLL).
For the removal, installation and movement of engine components, use only the
correct serviceable tools 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 wire rope slings is given with their tool numbers in 9403−5 Tool List.
2.2 Span Sets

Span sets are easy to use. The code and the color usually show the maximum
permitted load. Loops and knots in the span-sets decrease their WLL by one third.
2.3 Eye Bolts and Eye Nuts

Use only eye bolts and eye nuts that have the standards given in DIN 580 and
DIN 582: 2003−08.
Where eye bolts and eye nuts are used, the standards are calculated from DIN 580
and DIN 582: 2003−08 and the results shown in Table 1 below.

Wire Rope Slings, Span-sets, Eye Bolts, etc.
Table 1: Lifting capacity (for data only)
Lifting Capacity (kg)

Eye Bolts and Double Strand
Eye Nuts: Single Strand (45°)1)
Thread Size
45 _
M8 140 100
M10 230 170
M12 340 240
M16 700 500
M20 1200 860
M24 1800 1290
M30 3200 2300
M36 4600 3300
M42 6300 4500
M48 8600 6100
M56 11 500 8300
Note: The data given in Table 1 above are from DIN 580 and 582:2003−08
You must make sure that the eye bolt / eye nut:
D Has no damage e.g. corrosion, 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
nut or screw head.
2.4 Eye Bolts and Swivel Lugs

Only those RUD-eye bolts and RUD-swivel lugs can be used with a safety factor of 4.
Manufacturer:
RUD Ketten
Rieger & Dietz GmbH u. Co
Friedensinsel
D−73432 Aalen
Germany
http://www.rud.com

2.4.1 RUD Eye Bolts

These eye bolts (Fig. 1) have an inner screw that can be turned independently of the
ring part. You must make sure that:
D The eye bolt has no damage e.g. corrosion, deformation etc
D The eye bolt is correctly attached
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
DIRECTION
Star-profile OF FORCE
Wrench
DIRECTION
OF FORCE
Inner Screw
013.444/05
Fig. 1: RUD Eye Bolts

2.4.2 RUD Swivel Lugs

When you use these swivel lugs (Fig. 2), you must make sure that:
D The swivel lug has no damage e.g. corrosion, deformation etc
D You use an open-ended wrench to correctly attach the swivel lug
D The seating surfaces fully touch
D Before you attach a load, align the swivel lug with the direction of the force.
Note: Do not apply a force to the swivel as shown in View III.
DIRECTION
OF FORCE
DIRECTION
DIRECTION OF FORCE
OF FORCE
013.445/05
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 RR−C−271A.
Where shackles are used, the standards are calculated from American Standard
RR−C−271A, which includes the safety factor.
Usually, the permitted lifting capacity of the shackles is specified for one item.

3. Lifting Equipment − Attach and Remove

WARNING
Danger: Do not go under a load that hangs. If the lifting equipment
has a failure, the load can kill you or cause serious injury.
Read the data that follow:

D A sling with one strand has the total weight of the load (Fig. 3).
D With two strands of equal distance from the center, each strand has half the
weight of the load when the sling is in a middle position.
D With four strands of equal distance from the center , each strand has one quarter
of the load when the sling is in a middle position.
One Strand: Two Strands: Four Strands:

Total Load Half the Load One Quarter of
Weight Weight the Load Weight
Strands have
less Tension
Strands have
° more Tension
°
Fig. 3: Strand Angles
Note: A small angle between the strands gives more tension. A large 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. for 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 always keep control of the load.
When slings or ropes are wound around the load two times, friction increases. This
prevents movement of loads that have oil on their surfaces.
Hemp rope strands wound around the crane hook prevent movement. Do not wind
steel ropes around the hook. As an alternative, cross the steel ropes.
Hold the ropes in the flat of your hands and keep your fingers straight.
Hold the load at the side. Do not hold the load at the bottom.
Always lower the load on to a flat area of sufficient dimensions.

Intentionally blank
Clearance Table
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Crankshaft and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . 14
Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . 16
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel and Servo Pump Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Integrated Electric Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1. General
The clearances in the columns Nominal Dimension in the tables that follow are related
to design and manufacturing values, or to the settings on a new engine.
The values given in the columns Maximum Clearance Dimension are the possible
results after a long period of operation. The differences in the clearances must not be
less than or more than those given.
On components where the clearance is adjustable (changed thickness of shims,
discs, spacers etc) the values must be those given in Usual Clearance. Where this is
not possible, you must replace worn parts with standard new parts, or reconditioned
with applicable material buildup.
If, during an overhaul, clearances are measured that are almost at the permitted limit
personnel must make a decision to:
D Replace a component part, or
D Let the item stay installed until the next overhaul.
This is related, for example, on the length of the next operation period until the next
overhaul and what the rate of wear will be.

Clearance Table
Crankshaft and Thrust Bearing
WCH01221
Fig. 1 Fig. 2
1 1

Clearance Table
Crankshaft and Thrust Bearing
Description Measured Nominal Maximum Clearance,

Direction Dimension Dimension
(usual, new) (because of worn
Key No.
Group
[mm] parts)
[mm]
1203 Thrust bearing

1224
− 0.5
Thrust bearing pad thickness 115 − 0.6
1 Thrust bearing clearance axial (total) 0.8 to 1.3 2.5

2 Clearance between thrust pad and total 6
bracket

Clearance Table
Crankshaft and Main Bearing
Fig. 3
MAIN BEARING No. 2,

MAIN BEARING
No. 3 ETC.
No. 1
1 2 3
Fig. 4 WCH01220

Clearance Table
Crankshaft and Main Bearing
Description Measured Nominal Maximum Clearance

Key No.
Group
[mm] parts)
[mm]
1132 Main bearing No. 1

0
Crankshaft outer ∅ 880 − 0.09
Main bearing inner ∅ 880

1 Bearing clearance vertical 0.4 to 0.7 0.90
1132 Main bearing No. 2, No. 3 etc.
0
Crankshaft outer ∅ 880 − 0.09
Main bearing inner ∅ 880

All main bearing clearances are only applicable when the tie rods and main bearing
studs are tight.

Clearance Table
Crosshead Guide
7
1 2
FUEL SIDE
5
Fig. 5 4 WCH02888

Clearance Table
Crosshead Guide

Key No.
Group
[mm] parts)
[mm]
3326 Crosshead guide

+ 0.25
1 Guide bar (column) transverse 1270 0
− 0.20
2 Guide shoe transverse 1270 − 0.30
*3 Guide way clearance 0.20 to 1.05 1.25

4 Guide rail longitudinal 823.52 to 824.28
5 Guide rail, lateral clearance total 0.76 to 1.34 1.85
6 Guide shoe, lateral clearance total 0.22 to 0.60 0.9
0
7 Crosshead pin outer ∅ 670 − 0.08
+ 0.084
Guide shoe, bearing bore inner ∅ 670 + 0.05
8 Bearing clearance radial 0.05 to 0.164 0.20
To meaure the clearances, refer to the data given in 3326−1.

* This clearance is applicable only with the tie rods tightened.

Clearance Table
Cylinder Liner
Approx. 160 mm
5 to 220 mm
WCH02224
Fig. 6

Clearance Table
Cylinder Liner

Direction dimension Dimension
Key No.
Group
[mm] parts)
[mm]
2130 Water guide jacket on cylinder

cover
Water guide jacket top part Ø + 0.30

1010 + 0.10
1 Clearance total 0.40 to 0.80
Water guide jacket top part Ø + 0.30

989 + 0.10
Water guide jacket bottom part Ø + 0.10

1016 − 0.10
Water guide jacket bottom part Ø + 0.30

962 + 0.10

2124 Cylinder liner
*5 Cylinder liner bore radial 720 725.0
* Make sure of the correct location to measure the cylinder liner bore.

Clearance Table
Piston Rod Gland
4
1
1
5
2
6
99.7406
WCH02225
Fig. 7

Clearance Table
Piston Rod Gland
Description Measured Nominal Maximum clearance,

Direction dimension dimension
Key No.
Group
[mm] parts)
[mm]
2303 Piston rod gland

*1 Ring width radial 31 min. 25
*2 Ring width radial 24 min. 20.20
*3 Ring width radial 5 min. 3.20
4 Ring clearance axial 0.05 to 0.19 0.40
* Ring wear
The different values between the nominal dimension and maximum wear is equal for
all rings, (also for smaller rings).

Clearance Table
Exhaust Valve
VALVE SPINDLE
GUIDE BUSH
1
2 ~ 2/3 L
3
~ 1/3 L
016.995/08
Fig. 9 L = LENGTH
016.994/08
Fig. 8

Clearance Table
Exhaust Valve

Key No.
Group
[mm] parts)
[mm]
2754 Valve spindle
1 Spindle outer ∅ − 0.26 69.50

70 − 0.29
2751 Guide bush
*2 Bore inner ∅ + 0.030 70.40

70 0.0
*3 Bore inner ∅ + 0.030 71.25

70 0.0
* Make sure that you measure the bore at the correct location.

Clearance Table
Top and Bottom End Bearings to Connecting Rod
2 10 mm
3 10 mm
6 10 mm
7 10 mm
7
016.993/08
Fig. 10 5

Clearance Table
Top and Bottom End Bearings to Connecting Rod

Direction Dimension dimension
Key No.
Group
[mm] parts)
[mm]
3303 Top end bearing

3326
Crosshead pin outer ∅ 0

670 − 0.08
Bearing inner ∅ 670

*2 Lateral clearance total 0.45 to 0.65
3303 Bottom end bearing
Crankshaft outer ∅ 0
880 − 0.09
Bearing inner ∅ 880

* Make sure that you measure the clearances at the correct locations.

Clearance Table
Piston Cooling and Crosshead Lubricating Link
3 2 3
4 2
EXHAUST SIDE
5 2
016.996/08
1
Fig. 11
003.314/00

Clearance Table
Piston Cooling and Crosshead Lubricating Link

Key No.
Group
[mm] parts)
[mm]
3603 Piston cooling and crosshead lu-

bricating link
Pin outer ∅ 55
2 Bearing width 146
3 Lateral clearance each side min. 0.5

Clearance Table
Piston and Piston Rings
3 A B
2
8
4 A B
8
10
7a
11
4a A B
Fig. 12

Clearance Table
Piston and Piston Rings

Key No.
Group
[mm] parts)
[mm]
3406 Piston head
1 Head (tapered part) outer ∅ − 0

714.6 − 0.2
2 Head outer ∅ − 0
716.5 − 0.2
3406 Piston ring grooves
3 Height of the uppermost groove vertical + 0.55

22 + 0.50
4 Height of the middle groove vertical + 0.50

13 + 0.45
4a Height of the lowest groove vertical + 0.50

13 + 0.45
5 Groove depth radial + 0.2

24 + 0
3425 Piston rings
3 Ring height vertical 0

22 − 0.03
4 Ring height vertical 0

13 − 0.03
4a Ring height vertical 0

13 − 0.03
Point A Point B
6 Ring clearance vertical 0.50 to 0.58 0.80 1.00
7 Ring clearance vertical 0.45 to 0.53 0.75 0.95
7a Ring clearance vertical 0.45 to 0.53 0.75 0.95
8 Ring width radial 23 ±0.25
3403 Piston skirt
9 Skirt outer ∅ − 0 min. 717.9

719 − 0.1
10 Rubbing ring outer ∅ − 0

719.3 − 0.1
3403 Piston rod
11 Rod outer ∅ − 0.056 min. 277.05

278 − 0.108
Used piston rings can be installed again if they are in their minimum ring width until the
next overhaul (to estimate and install piston rings, refer to also 3425−1).
To make an analysis and to use piston heads again, refer to 3425−1.

Clearance Table
Drive Wheels for Supply Unit

4
INTERMEDIATE WHEEL
FOR SUPPLY UNIT
5 3
Fig. 12
INTERMEDIATE WHEEL
FOR SERVO PUMP UNIT
Fig. 14 WCH02228
Fig. 13

Clearance Table
Driving Wheels for Supply Unit

Key No.
Group
[mm] parts)
[mm]
4103 Intermediate wheel

1 Shaft outer ∅ 240
2 Bearing clearance vertical *0.121 to 0.21 0.30
3 Axial clearance total 0.6 to 1.1 1.5
4 Tooth backlash 0.24 to 0.40 0.43
*This clearance can only be measured when the intermediate wheel is disassembled.
Measure the tooth flanks in a longitudinal direction.
Winterthur Gas & Diesel Ltd. 21/ 27 2018−02

Clearance Table
Fuel and Servo Pump Units

FUEL PUMP UNIT
2 2
4
1
Fig. 15
6 SERVO PUMP UNIT
WCH02232
Fig. 16

Clearance Table
Fuel and Servo Pump Units

Direction Dimension dimension
Key No.
Group
[mm] parts)
[mm]
5552 Fuel pump unit

0
1 Gear Wheel outer ∅ 180 − 0.025
2 Bearing clearance radial 0.153−0.237 0.33

3 Axial clearance total 0.30−0.65 0.81
0
4 Cam shaft outer ∅ 180 − 0.025
5552 Servo pump unit

0
5 Pinion outer ∅ 120 − 0.022

Clearance Table
Fuel Pump
40
PLUNGER and 42
CYLINDER
44
29 mm
1 1
4
149 mm
73 mm
WCH02233
Fig. 18
2
6
5
WCH00832
Fig. 17

Clearance Table
Fuel Pump

Key No.
Group
[mm] parts)
[mm]
5556 Fuel pump

Plunger (40, 42 and 44 mm)
1 Clearance (plunger / cylinder) A to B radial 0.035 to 0.038 0.045
Clearance (plunger / cylinder) B to C radial 0.025 to 0.028 0.035
* Clearance (plunger / cylinder) C to D radial 0.040 to 0.043 0.5
Guide piston outer ∅ 185
Lower housing inner ∅ 185
2 Clearance radial 0.22 to 0.68 0.8
3 Piston / lower spring carrier axial 0.12 to 0.24 0.3
4 Regulating sleeve / upper spring car- axial 0 .5 to 0.7
0.8
rier
5556 Roller guide
0
Pin outer ∅ 80 − 0.013
+ 0.04
Guide piston (bore) inner ∅ 80 + 0.01
5 Clearance radial 0.010 to 0.053 0.08

6 Total clearance between guide piston axial 0.26 to 0.54
0.7
and roller with pressure discs
* The plunger is machined in the range C to D; i.e. there is an increase in the

clearance diameter of 0.015 mm.

Clearance Table
Integrated Electric Balancer
I 3
I-I
1 1
WCH03469
Fig. 19

Clearance Table

Key No.
Group
[mm] parts)
[mm]
7758 Bearing
1 Bearing pin outer ∅ 200
7758 Compensating shaft
3 Tooth backlash* 0.20 to 0.25
3 Difference over width 0.02
4 Tooth backlash* 0.30 to 0.35
4 Difference over width 0.02
*Measure the tooth backlash longitudinally along the tooth crown. Use lead wire of
Pb99.9 fine and 1 mm diameter

Intentionally blank
Tightening Values of Important Screwed Connections
WCH03398

WCH03398

WCH03398

WCH03398

WCH03398

WCH03398

WCH03398

or reference torque
Control angle from

step 1 to step 2 [*]
(in brackets) [Nm]
Tightening torque
Tightening angle
or control angle
(in brackets) [*]
Pre-tensioning
pressure (bar)
Delta L [mm]
Thread size
Comments
Lubricant
Position
Step 1
Step 2
1 1500 (645) O M85
2 20 Nm 45° K M12
3 0.5 ±0.04 O M56 See on page 1 position 3
4 225 O M30 Or hand-tight with a spanner
5 136 O M16
6 136 O M16
7 1500 700 bar 1500 bar 65 O M80
8 1500 All screws to All screws to O M48 See on page 1 position 8

600 bar 1500 bar
9 170 K M64 Hydraulic jack Group 9710
10 1500 1000 bar 1500 bar K M64
11 1500 1100 bar 1500 bar 15 O M56
12 14−15 M G¾“
13 5 K −
14 150 O M16
15 10 O M10
16 1500 (75) O M33 See on page 1 position 16
17 1500 (165) O M80
18 1500 1000 bar 1500 bar 20 O M33
19 (15800) 41 M M85
20 (900) 50 M M30
21 1.3 ±0.06 M M39
22 1600 (80) K M30
23 3900 (25) M M56
24 (15000) 57 M M85
25 1500 O M60
26 (1200) 65 M M30
27 1500 14.0 to 16.0 M M105
28 300 K M24
29 N M12 See on page 3 position 29
30 100Nm 35° to 40° N M72
31 190 N M36x1.5
M MOLYKOTE PASTE G−N C MOLYSLIP COPASLIP N NEVER SEEZ NSBT8

On threads and surfaces that On threads and surfaces that On threads and surfaces that
touch touch touch
K DO NOT ADD LUBRICATION O LUBRICATING OIL SAE 30
On threads and surfaces that
touch

or reference torque
Control angle from

(in brackets) [Nm]
Tightening torque
Tightening angle
or control angle
(in brackets) [*]
Pre-tensioning
pressure (bar)
Delta L [mm]
Thread size
Comments
Lubricant
Position
Step 1
Step 2
32 600 N M60
33 300 N M30
34 45 O G¼“
35 45 O G¼“
36 1.6 K M8
37 40 O M12
38 60 N M12
39 290 O M20
40 40 O M12
41 80 N M14
42 80 N M14
43 80 N M14
44 1500 O M39
45 100 O M39
46 80 N M14
47 600 O M24
48 600 O M24
49 600 O M24
50 600 O M24
51 600 O M24
52 1500 84 K M36
53 1250 64 O M30
54 480 N M27
55 20 O M10
56 20 O M10
57 20 O M10
58 20 O M10
59 300 N M30
60 190 N M16
61 110 N M14
62 350 O M20
M MOLYKOTE PASTE G−N C MOLYSLIP COPASLIP N NEVER SEEZ NSBT

touch touch touch
touch

or reference torque
Control angle from

(in brackets) [Nm]
Tightening torque
Tightening angle
or control angle
(in brackets) [*]
Pre-tensioning
pressure (bar)
Delta L [mm]
Thread size
Comments
Lubricant
Position
Step 1
Step 2
63 350 O M20
64 9 O M5
65 225 O M33x2
66 350 O M20
67 25 O G¼“
68 25 N M14
69 70 N M16
70 960 C M30
71 290 C M56
72 150 O M20
73 7 K M6 Locked with Loctite 2701
74 45 O G¼“
75 45 O G¼“
76 105 O G¼“
77 145 O M16
78 45 O G¼“
79 45 O G¼“
80 600 O M24
81 600 O M24

touch touch touch
touch

or reference torque
Control angle from

(in brackets) [Nm]
Tightening torque
Tightening angle
or control angle
(in brackets) [*]
Pre-tensioning
pressure (bar)
Delta L [mm]
Thread size
Comments
Lubricant
Position
Step 1
Step 2
82 60 O M16
83 60 O M33
87 90 C M42
88 500 K M30 Lug locked with Loctite 268
89 300 O M30
90 45 K G¼“ Valve sealed with Loctite 542
91 45 O G¼“
92 260 M M30
93 35 C M10
94 18 O M8
95 45 O G¼“
96 30 N M24x1.5
97 40 N M10
98 40 M M10
99 4 O M4
100 170 N M16M24
101 815 M M56x1.5 Min. 800 Nm to max. 830 Nm
102 55 O M42
103 280 O M20
104 190 O M20
105 90 N M30x1.5
106 45 O G¼“
107 35 C M10
108 215 O M16
109 10 K M10
110 290 O M20
111 140 N M16
117 50 N M12


touch touch touch
touch
Name: LUBRICATION OIL SAE 30 Name: MOLYSLIP COPASLIP

Short form: 0 Short form: C
K factor: 0.16
Manufacturer: Molyslip Atlantic Ltd

A1 Danebrook Court
Oxford Office Village
Langford Lane, Kidlington
Oxfordshire OX5 1LQ
England
Name: MOLYKOTE PASTE G−N Plus Name: NEVER SEEZ NSBT8

Short form: M Short form: N
Coefficient of friction: Thread: 0.12 K factor: 0.13
(M12, 8.8 blackened) Head: 0.06
Manufacturer: Bostik, Inc.
Manufacturer: Dow Corning Corporation Bostik Americas Technology Center
Corporate Center 11320 W. Watertown Plank Road
PO Box 994 Wauwatosa, VI 53226 414
MIDLAND MI 48686−0994 United States
United States

Torque Values and Elastic Stud Replacement
Torque Values − Standard Screws and Elastic Studs
1. Torque Values − Standard Screws

We recommend the torque values given in the table below for aII standard metric
screws of grade 8.8. This applies to all threaded connections not shown in 0352−1.
The threads and base of the head must be lubricated with oil SAE 30.
For the screws in high temperature areas (exhaust pipes, expansion pieces etc), a
heat resistant lubricant, e.g. NEVER SEEZ NSBT8, is recommended.
If you use NEVER SEEZ NSBT8, there must be a decrease of 20% of the torque
values given in the table below.
These torques values do not apply to turbocharger installations. Refer to the
documents of the turbocharger manufacturer for the correct torque values.
Standard Thread Fine Thread Torque Value

Grade 8.8 Grade 8.8 [Nm]
M3 M3 x 0.35 0.9
M4 M4 x 0.5 2.1
M5 M5 x 0.5 4.2
M6 M6 x 0.75 7.2
M8 M8 x 1 18
M10 M10 x 1.25 35
M12 M12 x 1.25 60
M14 M14 x 1.5 94
M16 M16 x 1.5 145
M18 M18 x 1.5 200
M20 M20 x 1.5 280
M22 M22 x 1.5 380
M24 M24 x 2 490
M27 M27 x 2 720
M30 M30 x 2 980
M33 M33 x 2 1300
M36 M36 x 3 1700
M39 M39 x 3 2200
M42 M42 x 3 2700
M45 M45 x 3 3400
M48 M48 x 3 4100
M52 M52 x 3 5300
M56 M56 x 4 6600
M60 M60 x 4 8100

2. Elastic Studs − Replace
2.1 Procedure
1) Read the data in the manual of the jointing compound manufacturer.
2) Remove the unserviceable elastic stud.
3) Remove the grease and clean the sealing surfaces of the new elastic stud.
4) Remove the grease and other unwanted material from the tap hole and the area
where the elastic stud will be installed.
5) Clean the tap hole and the area where the elastic stud will be installed.
6) If necessary, apply an adhesive primer to the shank of the elastic stud. Make
sure that no adhesive primer goes on to the threads.
7) Use only a stud driver (or two nuts locked together) to fully install the stud into the
tap hole.
8) Torque the elastic stud to the applicable value given in the table below:
3500
3000 400
2500
300
TORQUE [Nm]
2000
TORQUE [Nm]
1500 200
1000
100
500
0 0
10 20 30 40 50 60 70 80 90 100 110 120 10 20 30 40 50 60
Fig. 1 THREAD DIAMETER [mm] WCH03398 Fig. 2 THREAD DIAMETER [mm]

9) For the elastic studs installed in the valve cage, cylinder liner and cylinder jacket
fill the area around the elastic stud with jointing compound (see Fig. 3).
JOINTING
COMPOUND
SEALING
SURFACES
ELASTIC STUD
Fig. 3 WCH02357
2.2 Jointing Compound

Refer to the table below for the recommended manufacturers of jointing compounds
and adhesive primers:
Jointing Hardener Adhesive Manufacturer

Compound Primer
Elastosil RT 622 B G 790 Wacker-Chemie Gmbh
RT 622 A Geschäftsbereich Silicone
Hanns-Seidel-Platz 4
D-81737 München
Silcoset Silcoset Silcoset Primer AMBERSIL LTD
105 RTV Curing Agent A Wylds Rd
Bridgwater
Somerset
TA6 4DD
Uk-Great Britain
Use only the data in the related 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 than 24 hours (refer to the
data in the ISO standard reference conditions).
D Materials must flow easily to fill the area around the sealing surface (i.e. no air
pockets).
D The materials must have good adhesion qualities on primed metal surfaces.
D The materials must be easy to prepare and mix.
D The surface shrinkage must be very small, or none.
D The jointing compound must stay in an elastic condition. This will help you if it
becomes necessary to remove the elastic studs.

Intentionally blank
Masses (Weights)
Component Weight − Each Piece (kg)

Group Component Design kg
1
1115 Main bearing cover (1st) 556 (410)
1134 Main bearing shell 171
1224 Thrust bearing pad 104
1717 Casing (top part) free end 877

Casing (top part) driving end 1420
1720 Oil baffle, top part 316

Oil baffle, bottom part 187
1903 Tie rod 550

Tie rod nut 26
Intermediate ring for tie rod nut 14.7
2
2106 Elastic bolt in cylinder jacket 74.6
2124 Cylinder liner 6064
2130 Water guide jacket (top part) 175

Water guide jacket (bottom part) 210
2140 Gas admission valve 69.8
2303 Piston rod gland All related parts 135
2708 Elastic bolt for valve cage 40

Cylinder cover without accessories 2870
Cylinder cover with exhaust valve unit, All related parts 4900
all valves and top water guide jacket
2722 Injection valve All related parts 20.7
2728 Starting valve All related parts 34
2751 Exhaust valve housing with spindle All related parts 952
2754 Exhaust valve spindle 102
2790 Pilot injection valve All related parts 34.2

3
3122 Flywheel 5950 to 12790
3140 Axial damper cylinder 2-part 1142
3206 Turning gear with planetary gear 2058

Individual Components per Piece in kg
3303 Connecting rod 3932

Elastic stud and nut for bottom end
bearing 40
Elastic stud and nut for top end
bearing 10
3306 Connecting rod shaft All related parts 4105
3306 Bearing cover for bottom end All related parts 511 to 705
bearing with elastic studs
3310 Bearing shell for bottom end bearing 60
3312 Bearing cover for top end bearing 705
3315 Bearing shell for top end bearing 122
3326 Crosshead 2694

Crosshead and guide shoes All related parts 3268
Guide shoe 574
3403 Piston and piston rod All related parts 2631

Piston heag 700
Piston skirt 112
Piston rod 1702
Spray plate and oil pipe 102
Piston rings 17.3
3603 Toggle lever for piston cooling and All related parts 113
crosshead lubrication
4 All related parts
4106 Crankshaft gear wheel 2-part 2880
4325 Starting air shut-off valve 246

5
5555 Supply unit, pilot fuel 373
5591 Servo oil pump (Hawe) 235
5556 Fuel pump All related parts 427
5564 Flow limiting valve 38.8
5580 Fuel pump unit with pumps, casing, 3 fuel pumps. All 4566
and camshaft related parts
5581 Camshaft and gear wheel 3 fuel pumps. Approx. 700
5591 Servo pump unit with pumps, gear 2 servo oil pumps 472
wheels
Gear wheel pair 14

Individual Components per Piece in kg
5612 Exhaust valve control unit complete 35

6
6506 Turbocharger (ABB) A165−L 2300
A170−L 3300
A175−L 5600
A180−L 7500
A185−L 10500
A190−L 12000
A265−L 2700
A270−L 3800
A280−L 8600
6545 Auxiliary blower with electric motor All related parts 1898
Electric motor 891 to 946
6606 Scavenge air cooler A74−SD 4700
6509 Expansion piece between exhaust 125

manifolds and upstream of the
turbocharger
6708 Water separator, scavenge air SAC− A11−SF 544
Water separator, scavenge air SAC− A7−SF 413

7
7758 Electric balancer compensating shaft 2170
(gear wheel, counterweight, and
bearing pin)
415
Electric motor
8
8103 Expansion piece downstream of the DN 500 95
exhaust valve

Intentionally blank
Maintenance Schedule
Inspection and Overhaul Intervals
Group Component Work to be Done Intervals and Service
Life (Operation Hours)
0
Lubricating oil − Laboratory analysis 3000
Main fuel and − Do a check of the filter elements − specially for 3000
lubricating oil white metal particles (clean or replace filter as
filters necessary). Do the procedure in the
manufacturer’s instructions
Cooling water − Calculate quality, concentration of inhibitor and weekly

pH value. Do the procedure in the
manufacturer’s instructions
1
1112−1 Bedplate − Do a check of the pre−tension of foundation 12000
bolts, initially after 1500 Op. H
− Do a check of the condition of rubber gasket in 30000 (a replacement

the vertical oil drain to sump tank (see SPC is recommended)
9722), first time as soon as possible after ship
is supplied.
− Estimated service life: Bedplate foundation service life of engine

bolts
Crankcase − Visual examination, 100 Operation hours after 1500 to 3000

overhaul: look for white metal particles from
bearings and for defects.
− Estimated service life: crankcase service life of engine
1132−2 Main bearing − Bearing shell inspection is only necessary if at indications of too
bearing clearance, crankshaft deflection, oil much damage or worn
analysis check or crankcase inspection shows parts
too much damage or worn parts
− Do a bearing edge check with wire 6000
− Do a bearing clearance check, refer to 6000

0330−1, Group 1132
− Estimated service life: Main bearing shell 90000 (replace if

necessary)
1203−1 Thrust bearing − Do a check of the axial and vertical clearances 6000 to 8000
− Make sure that the bottom drain is not blocked 6000 to 8000
1224−1 − Thrust bearing pads inspection is only at indications of too

necessary if bearing clearance, oil analysis or much damage or worn
crankcase inspection shows too much damage parts
or worn parts
− Estimated service life: Thrust bearing 90000 (replace if

necessary)

Inspection and Overhaul Intervals (Guidelines)

1715−1 Engine stays − Friction type: do a check of the pre−tension of 6000 to 8000
screws. Remove corrosion marks from friction
elements. First time after sea trial
− Hydraulic type: do a check of the oil pressure monthly

at the gauge
1903−1 Tie rod − Do a check of the pre−tension. If necessary 24000 to 30000

apply tension again. First time one year after
ship is supplied.
− Estimated service life: Tie rod service life of engine

2
2124−1 Cylinder liner − Measure the liner wear (in installed condition) at each piston removal
2124−2 − Remove the cylinder liner as necessary
− Replace O−rings at each liner removal
− Replace the soft iron joint ring between the at each piston removal
cylinder liner and cylinder cover
− Replace O−rings of water guide jacket and at each liner removal

transition tubes
− Do a check of the condition of the antipolishing at each piston removal

ring
2124−3 − Grind off unwanted material in the bore at each piston removal
− Dress the lubricating grooves as necessary
− Clean scavenge ports and dress their edges as necessary
− Estimated service: Cylinder liner Up to 90000
2138−1 Lubricating quill − Do a check for function and tightness at each piston removal
(pulse
lubrication)
− Make sure that the non-return valves operate at each piston removal
2140−1 Gas admission − Do a check of the function and tightness of the 6000
valve (GAV) GAV
− Do an overhaul of the GAV valve seat 18000
− Do a visual check of the compensator at the at each GAV removal

gas inlet pipe
− Estimated service life: Valve spindle, includes 36000

the guide, stroke sensor and rail valve
− Estimated service life: Housing and servo drive service life of engine
2303−1 Piston rod gland − Clean the piston rings, calculate worn areas at each piston removal
− Estimated service life: Piston rod gland 36000 (refers to rings)


2708−1 Cylinder cover − Do a check of the combustion space for at each piston removal
damage and worn areas
− Estimated service life: Cylinder cover Service life of engine

(re-manufacturing as
necessary)
2722−1 Injection valve − Do an external check for tightness before starting the
(main fuel engine after longer
injector) engine stop
− Do a check of the function (nozzle tip 8000

inspection, opening pressure).
− Replace the nozzle tip (FAST type) 8000
− Replace the O-rings 8000
− Replace the injection valve 24000
− Estimated service life: Injection valve 24000
− Estimated service life: Nozzle spare parts set 8000

(e.g. coupling nut and nozzle body with
needle)
2728−1 Starting air − Do a check of the pipes upstream of the valve weekly
valve during operation. If the pipes are too hot,
disassemble the starting valve
− Remove and disassemble one starting valve, 12000

calculate the time of overhaul for the remaining
valves
− Make sure that the nut on the solenoid is tight monthly

if necessary tighten the nut.
− Solenoid valve: Do a random check of the 6000

function
− Solenoid valve: do an overhaul 18000
− Estimated service life: Starting valve service life of engine
2745−1 Relief valve on − Do a check of the blow-off pressure as necessary

cylinder cover


2751−1 Exhaust valve − General inspection of valve housing, valve at each piston removal
to spindle and valve seat (exhaust valve is not
disassembled)
2751−4 − Do a check of the condition of the valve 36000 (initial

spindle (if necessary grind the valve seat) inspection at 18000)
− Valve Drive: do a check of piston sealing ring / 36000 (initial

air spring and rod seal ring / guide bush inspection at 18000)
− Do a check of the condition of the valve seat 36000 (initial

inspection 18000)
− Do a random check of the valve drive, outer 18000

and inner pistons, damper, thrust piece
− Estimated service life: Exhaust valve spindle 108000

necessary)
− Exhaust valve seat 72000

necessary)
2790−1 Pilot injection − Do an external check for tightness before engine start
valve after a long engine
stop
− Do a check of the opening pressure 8000
− Replace the nozzle spare parts set 8000
− Replace the O-rings 8000
− Replace the pilot injection valve 24000
− Replace the pre-chamber 18000
− Estimated service life: Nozzle spare parts set 8000

3
3103−1 Crankshaft − Measure the crank deflection, always after the 6000
ship touches the sea bed and after each dock
in port
3130−1 Torsional − Get a silicon oil sample from the viscous first time after 15000 to
vibration vibration damper (use the results of the first 18000
damper sample. Refer to the manufacturer’s
documentation for the intervals to get more
samples)
3130−2 − Disassemble and do an inspection of the Refer to the

vibration damper instructions of the
damper manufacturer
3140−1 Axial damper − Disassemble and do an inspection 36000 to 48000


3206−1 Turning gear − Inspection of turning gear Refer to the

instructions of the
turning gear
manufacturer
− Lubrication of tooth flanks of pinion and 2000

flywheel, related to visual inspections, but
latest each 2000 Operation hours of main
engine
− Do a check of the screwed connections. First 12000

time after one year
3303−2 Connecting rod − Do a check of the bearing clearances (refer to 6000

bearings 0330−1, Group 3303)
− Do a check of the bearing edges with wire 6000
− Bottom end bearing inspection is only at indications of too

necessary if the bearing clearance, wire check, much damage or worn
oil analysis or crankcase inspection shows too parts
much damage or worn parts.
3303−3 − Top end bearing inspection is only necessary if at indications of too

bearing clearance, wire check, oil analysis or much damage or worn
crankcase inspection shows too much damage parts
or worn parts.
− Do a random inspection of the connecting rod 70000

top end bearing and bottom end bearing
− Estimated service life: Connecting rod bottom 90000 replace if

end bearings necessary
− Estimated service life: Connecting rod top end 90000 replace if

bearings necessary
3326−1 Guide shoe, − Do a check of the clearances 6000 to 8000

crosshead pin
3403−1 Piston − Remove and clean 18000 to 36000

(related to condition)
− Do a check of the tightness on the piston in after installation

installed position and with running oil pump.
Do a visual check through the scavenge ports
3403−3 − Disassemble and assemble (open and clean as necessary

the cooling area, minimum one piston each
three years)
3403−4 − Do a check of the condition of the piston top at each piston removal
surface
− Do a visual check through the scavenge ports 500 to 1000

of the piston, piston rings and cylinder liner


3403−4 − Measure the ring grooves. Do an inspection of 18000 to 36000

the chromium plating. Add the chromium again (related to condition)
as necessary
− Estimated service life: Piston head ring 18000 to 36000

grooves
− Piston head surface, full re-manufacturing 72000
Piston − Do a check of the condition of the piston 1500 to 3000

underside underside. Clean as necessary
− Make sure that the drains and holes are not 1500 to 3000
blocked
3425−1 Piston rings − Measure the thickness of the chrome-ceramic 1500 to 2000
layer
− Replace the piston rings (related to remaining 18000 to 36000

thickness of the layer) (related to condition)
− Estimated service life: Piston rings 18000 to 36000

4
Start interlock − Do a check of the electric and pneumatic quarterly
interlocks (refer to the Operation Manual
4003−1)
4103−1 Driving wheels − Do a check of the tooth condition 6000 to 8000
− Do a check of the running clearance and 6000 to 8000

backlash of teeth
− Estimated service life: driving wheels service life of engine
Starting air − Release pressure / vent starting air inlet after each
shut-off valve (manifold) pipe maneuvering period
4325−1 − Disassemble, clean and do a check (important 30000 to 36000

parts are: seat, springs and sealing rings)
− Do an overhaul of the common start valve 18000

(SPC: Control Valve Complete, Group 4325−2)
− Estimated service life: Starting air shut−off service life of engine

valve
Control air filter − Drain the filter weekly
− Clean the filter 6000

5
5551−1 Servo oil pump − Replace servo oil pump with new one or a 36000 (Hawe)
pump that had an overhaul in a WinGD
workshop


5552−1 Servo oil pump − Do a check of the pinion and driving wheels to 3000
drive the servo oil pump drive
− Do a check of the bearing bushes to pinion 24000
− Do a check for particles in the filter below the 2000

plug in the compensator
− Estimated service life: supply unit pinion 90000

bearing bushes
5552−2 Fuel pump drive − Camshaft: do a check of the running surface of 3000
cams, rollers and roller guides (first time after
500 Operation hours)
− Camshaft: do a check of the bearing 12000

clearances at random positions
− Camshaft: do a check of the thrust bearing 36000

clearances
− Estimated service life: supply unit camshaft 90000

bearings
5555−1 Pilot fuel supply − Lubricate the flexible coupling of the pilot fuel 1500 to 3000 (at all
unit pump operation modes)
− Replace the pilot fuel pump 24000 (at all operation

modes)
− Replace the pilot fuel filter cartridges. (the 1000 (at all operation
cartridges must be replaced earlier if the modes)
pressure difference indicator shows a high
pressure increase
− Clean the wire gauze and filter housing. 1000
− Estimated service life: Pilot fuel pump 24000
5556−1 Fuel pump − Do a random flow check of the lubricating oil 6000
− Do an overhaul of the fuel pump 18000
− Estimated service life: Fuel Pump 18000
5562−1 Fuel pressure − Do a check of the shut-down function (refer to 3000

control valve the Operation Manual 4003−1)
(PCV)
− Do a check of the function (refer to the 6000

Operation Manual 5562−1)
− General overhaul only necessary if PCV

becomes defective
− Estimated service life: Fuel pressure control service life of engine

valve (PCV)


5562−2 Fuel − Do a check of the function on the test bench 24000 to 36000
overpressure
safety valve /
Relief Valve
5564−1 Flow limiting − Do an inspection, clean the piston rod and 12000
Valve (FLV) piston running surface
− Do an overhaul of the FLV, or replace with a 24000

new item or an FLV that had a overhaul in a
WinGD workshop.
− Estimated service life: FLV 24000
Servo oil rail − Replace hoses (a minimum of each 5 years) 30000
5612−1 Exhaust valve − Do a check of the piston and slide rod 36000
control unit
− Do a check of the oil filter 18000
− Replace the 4/2-way solenoid valve 24000 to 36000
− Estimated service life: Exhaust valve control Service life of engine

unit
5583−1 Fuel pump − Make sure that the regulating linkage moves 3000
or Actuator freely. Lubricate movable parts
5556−1
6
6420−1 Scavenge air − Do a check of the flaps. Clean the flaps. 4000 to 6000
receiver
− Clean the receiver 4000 to 6000
− Make sure that the water drain pipes and holes 1500 to 3000
are not blocked
Turbocharger − Wet-clean the compressor during operation Refer to the

manufacturer’s
documentation
− Wet-clean or dry cleaning the turbine during Refer to the

operation manufacturer’s
documentation
Air filter − Do a check of the filter half yearly
− Clean the filter at an np increase of 50% as necessary

compared to the shop test value at the same
engine load (refer to the Operation Manual
6510−1)
6545−1 Auxiliary blower − Clean the impeller and casing 24000 to 36000
− Replace the ball bearing 24000 to 36000


6606−1 Scavenge air − Clean the SAC (air side) during operation, as necessary
cooler (SAC) initially each week, later if np (pressure
decrease through SAC) increases compared to
the shop test value at same engine load (refer
to the Operation Manual 6606−1)
− Do a check of the condensate collector daily

through the sight glass (refer to the Operation
Manual 8345−1)
− Make sure that the condensate collector is not 1500 to 3000

blocked (refer to the Operation Manual
8345−1)
− Do a check of the SAC sealing quarterly
− Bleed the system daily
− Remove the SAC for general overhaul as necessary
6708−1 Water separator − Do a check of the condensate collector daily

scavenge air through the sight glass (refer to the Operation
Manual 8345−1)
− Make sure that the condensate collector is not 1500 to 3000

blocked (refer to the Operation Manual
8345−1)
− Do a check of the water separator elements (if 1500 to 3000

necessary clean them)
− Remove the water separator for general as necessary

overhaul
7
7218−1 Lubricating − Replace the lubricating pump with new item, or as necessary
pump a pump that had a overhaul in a WinGD
workshop.
− Re-manufacture 30000
− Estimated service life: Cylinder lubricating 30000

pump
Filter − Replace the filter element upstream of the as necessary

replacement cylinder lubricating system
7758−1 Electric − Do a check of the bearing clearance, refer to 6000

Balancer iElba 0330−1, Group 7758
8
8135−1 Exhaust waste − General Inspection. During a longer operation in accordance with
gate (LLT) period at low engine load, manually open the instructions of valve
butterfly valve (refer to the Operation Manual manufacturer
8135−1)
Servo oil service − Do a check of the flow rate and maximum in accordance with
pump (engine pressure instructions of valve
mounted) manufacturer


Starting air − Drain (remove water) before and after each

pipes on and maneuvering period
upstream of the
engine
8135−1 Pressure − Calibrate and compare with the master 6000 to 8000
gauges and instruments
pyrometers
Pipe holders − Do a check of the pipe holders if necessary. half yearly

Tighten the screws (first time after 100
operation hours)
8447−1 Servo oil pipes − Grind the sealing faces as necessary
Non−return − Do a random check 18000

valve
8460−1 Hydraulic pipe − Grind the sealing faces as necessary

for exhaust
valve drive
8733−1 HP pipe to − Grind the sealing faces as necessary

injection valve
(on cylinder
cover)
8744−1 Supply unit fuel − Make sure that the pipes are not blocked 6000
drain pipes
8752−1 HP fuel pipe − Grind the sealing faces as necessary
8903 Gas supply pipe − Shut off and vent valves: do a check of the 6000
tightness of ball valves. Do a check of the shaft
sealing
− Do a visual check of the compensators 6000
− Estimated service life service life of engine

9
9223−1 Crank angle − Replace the proximity sensor as necessary
sensor (CAS)
unit
9308−1 Cylinder cover − − Do a check of the blow-off pressure as necessary

Relief valve
− Replace the relief valve when blown off
Oil mist detector − Do the procedure in the manufacturer’s half yearly

instructions
ECS − Replace the modules: CCM−20, MCM−11 and 48000 to 50000

LDU−20, refer to the Operation Manual
4002−4
− Do a visual check of the cables quarterly

The indicated maintenance intervals are a guide only and can be different.
The intervals are estimates only. It is possible that these intervals can be less than or
more than the recommended intervals.
Different conditions can have an effect on the service life such as the conditions given
below:
D Environmental and operating conditions
D Heavy fuel oil, gas fuel and lubricating oil qualities (refer to the Operation Manual
0300−1, 0340−1 and 0320−1)
D Engine load
D Fuel, lubricating oil and cooling water (refer to the Operation Manual 0300−1,
0340−1 and 0330−1)
D Do overhauls in accordance with the Maintenance Manual
D Original spare parts used
D Continuous engine monitoring
D Engines in accordance with the specifications of WinGD.
Note: The group numbers and their locations are shown in 0803−1 Engine
Cross Section and Longitudinal Section.

Intentionally blank
Engine Cross Section and Longitudinal Section

1. Cross section
2728−1
2722−1
8460−1
8733−1
5562−1
5612−1
6420−1
4325−1
8447−1
6606−1
3326−1 6545−1
3326−2
6708−1
3301−1
3206−1
4103−1
4103−2
1112−1
WCH03714
Fig. 1: Cross Section

Engine Cross Section and Longitudinal Section
2. Longitudinal section
2751−1
2708−1 to
to 2751−4
2708−3
2124−1
to 1903−1
2124−3 5555−1
2138−1 3403−1
to
3403−4
3425−1
8752−1
2303−1
5556−1
9223−1
3326−1
5591−1
3326−2
3303−2
to
5581−1 3303−4
3140−1
4103−1
1132−1
1132−2
3103−1
1203−1
1224−1
3130−1
3130−2
WCH03714
Fig. 2: Longitudinal Section

Maintenance Group1
Bedplate and Tie Rod Group 1
Work Cards
Bedplate: Foundation Bolts − Pre-tension Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1112−1/A1
Crankcase: Visually Examine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1112−1.1/A1
Bedplate: Rubber Gasket on the Sump Tank − Do a Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1112−1.2/A1
Bedplate: Foundation Bolts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112−1/A1
Work Cards
Main Bearing: Bearing Edge and Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1132−2/A1
Main Bearing Shell: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1132−2.1/A1
Main Bearing
Elastic Studs − Loosen and Apply Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−1/A1
Main Bearing − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−2/A1
Work Cards
Thrust Bearing: Axial and Vertical Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1203−1/A1
Thrust Bearing: Bottom Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1203−1.1/A1
Thrust Bearing Pads: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1224−1.1/A1
Thrust Bearing
Axial Clearance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203−1/A1
Thrust Bearing Pads − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224−1/A1
Work Cards
Engine Stays (Friction Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1715−1/A1
Engine Stays (Hydraulic Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1715−1.1/A1
Engine Stays with Friction Shims: Pre-tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A1
Hydraulic Engine Stays: Oil Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A2
Work Cards
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC1903−1/A1
Tie Rod: Pre-tension Check and Tie Rods Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1903−1/A1

Intentionally blank
Maintenance WC1112−1/A1
Work Card
Bedplate: Foundation Bolts − Pre-tension Checks
Necessary Conditions Necessary Spare Parts
− Engine stopped
− Starting air supply shut off
− Cooling water shut off Not applicable
− Servo oil shut off
−
−
Preparation Tools and Consumables
Not applicable Pre-tensioning jack 94145 Qty 1

HP hose 94935 Qty 1
HP oil pump 94931 Qty 1
Hydraulic distributors 94934A Qty 2
Time and Personnel necessary for Primary Task

Primary Task (estimate), without Necessary Conditions and
Preparation
Foundation Bolts − Pre-tension Checks Service Engineer 2.5 hours Qty 2

refer to the Maintenance Manual 1112−1/A1
Related Data
Overhaul intervals 0380−1/A1
Related Procedures
Pre-tensioning jacks − connect 9403−2/A1

Pre-tensioning jacks − attach 9403−4/A1

Intentionally blank
Maintenance WC1112−1.1/A1
Work Card
Crankcase: Visually Examine
− Engine stopped
Not applicable
Not applicable Not applicable

Preparation)
Visually examine the crankcase Ship Engineer 2.5 hours Qty 1
Related Data
Related Procedures

Intentionally blank
Work Card
Bedplate: Rubber Gasket on the Sump Tank − Do a Check
− Engine stopped Rubber gasket EX 97221 Qty 1
Not applicable
Not applicable
Time and Personnel Necessary for Primary Task

Preparation
Do a check of the rubber gasket Crew 0.5 hours Qty 1
Related Data
Related Procedures

Intentionally blank
Bedplate
Foundation Bolts − Checks

Tools:
1 Feeler gauge 94122 2 Hydraulic distributors 94934A
1 Pre-tensioning jack 94145 1 HP hose 94935
1 HP oil pump 94931
1. General
You must do a check of the tension of the foundation bolts (hold-down studs) at
longer intervals e.g. during overhauls. Refer to 0380−1, Bedplate.
In the area of the thrust bearing, the bedplate (7, Fig.1) and the foundation must be
attached with foundation bolts (2) and the long bushes (3).
The remaining area is attached with the foundation bolts (2, Fig.2) and the short
bush (8).
1.1 Foundation Bolts − Loosen or Apply Tension

You start the procedure to apply tension to the foundation bolt at the driving end, and
from one side to the other. The procedure is completed at the free end.
1) To loosen and apply tension to the foundation bolts (2), use the pre-tensioning
jack (94145, Fig.1).
2) Connect the pre-tensioning jacks (94145) to the hydraulic pump (94931, Fig.3),
refer to 9403−2.
3) Do the Version 1 procedure as given in 9403−4.
4) Apply tension in two steps as follows:
a) Step 1 − For metal chocks or epoxy resin chocks, first apply tension to all
foundation bolts to 1000 bar.
b) Step 2 − Apply tension to 1500 bar.
94145
1
2
2
3 8
7
9
10
4
5
6
Fig. 1 Fig. 2
WCH03620

Foundation Bolts − Check
2. Tension Check
1) Clean the threads of the foundation bolts (5, Fig.3) and the seating surfaces.
2) Attach the pre-tensioning jack (94145) to the foundation bolt (5).
3) Open the vent screw (9).
4) Turn the foundation bolt (5) fully down until there is a small clearance, or no
clearance between the foundation bolt and the round nut (7).
5) Connect the pre-tensioning jack (94145) to the HP oil pump (94931), refer to
9403−2.
6) Close the relief valve (10).
7) Operate the HP oil pump (94931) until oil that has no air flows from the vent
screw (9).
8) Close the vent screw (9).
9) Torque the foundation bolt (5) to 1500 bar and keep the pressure constant.
10) Do not move the piston (1) of the pre-tensioning jack (94145) to more than the
red limit groove (2).
11) Put the feeler gauge (94122) through the slot (4). Do a check for clearance
between the round nut (7) and the bush (6). If you find a clearance do step a) and
step b).
a) Keep the pressure of 1500 bar.
b) Use the round bar (8) to fully tighten round nut (7).
12) Decrease the pressure to zero.
13) Remove the pre-tensioning jack (94145).
9
1
2
94145
3
7 4
6 5
012.949/05
016.704/08 10 94931
016.704/08
Fig. 3

Main Bearing
Elastic Studs − Loosen and Apply Tension

Tools:
2 Double pre-tensioning jacks 94114 4 Coupling elements 94934G
1 Feeler gauge 94122 3 HP hose 94935
1 Pressure gauge 94934A 1 Hydraulic unit 94942
1 Distributing piece 94934C
Note: Always use the hydraulic double pre-tensioning jacks (94114, Fig.1) to
loosen and apply tension to:
D The main bearing elastic studs (1)
D The 1st main bearing cover (2) that has two elastic studs (1).
1) Connect only the jack that is in use to the hydraulic unit.
2) Do the general preparation for hydraulic jacks (94114), refer to 9403−4,
paragraph 1.
3) Make sure that there is oil on the threads of the elastic studs (1).
4) To loosen, do the procedure in 9403−4, paragraph 2.2 and 2.3.
5) To apply tension, do the procedure in 9403−4, paragraph 3, 3.2 and 3.3.
Note: The value for the pre-tensioning jacks (94114) is 1500 bar in one step.
6) Use the feeler gauge (94122) to do the check of the horizontal and vertical
clearance of the main bearing, refer to 0330−1, Crankshaft and Main Bearing.
All main bearing clearance values are applicable only with tightened elastic studs and
tie rods.
94114
Fig. 1 WCH02321

Intentionally blank
Work Card
Main Bearing: Bearing Edge and Bearing Clearance
− Engine stopped Not applicable
More time and personnel necessary for preparation. Feeler gauge 94123 Qty 1
Do a check of applicable work cards.

Preparation
Do check of the bearing edge and bearing clearance Service Engineer 3.0 hours Qty 2
Related Data

Tolerances and Clearances, refer to 0330−1/A1
Component weights, refer to 0360−1/A1
Related Procedures

Intentionally blank
Work Card
Main Bearing Shell: Removal and Installation
− Engine stopped Main bearing shell EX 11344 Qty 1

− Crank turned to exhaust side approximately 90_ Main bearing shell EX 11354 Qty 1
− Main oil supply: set to off
− Main bearing lubrication: set to off
More time and personnel necessary for preparation. Manual ratchet 94016-009 Qty 1
Do a check of applicable work cards. Spur-geared chain block 94017-006 Qty 2
Chain (asymmetric / symmetric) 94019A/B Qty 1
Bracket 94141 Qty 1
Eye bolt 94045-M48 Qty 1
Thrust device 94110 Qty 1
Lifting tool (narrow bearing shell) 94116A/B Qty 1
Lifting plate 94119 Qty 1
Lifting lug 94116C Qty 1
Roller support 94117 Qty 1
Turning-out device 94118A/B Qty 1
Connection block 94934 Qty 1
Pressure gauge 94934A Qty 2
HP hoses 94935 Qty 3
Hydraulic ram (100t) 94936 Qty 2
Shackle 4750 kg 94018B Qty 2
Work platform 94143 Qty 1
Molykote paste G
Preparation
Removal and Installation of Main Bearing Service Engineer 8.0 hours Qty 2
refer to the Maintenance Manual 1132−2/A1 Crew 8.0 hours Qty 1
Related Data

Related Procedures
Remove / Install elastic studs, refer to 1132−1

Measure crank deflection, refer to 3103−1
Measure bearing clearance, refer to 0330−1

Intentionally blank
Main Bearing
Main Bearing − Removal and Installation

Tools:
1 Manual ratchet (H1) 94016-009 1 Turning-out device 94118B
2 Spur-geared chain block (H2, H3) 94017-006 (wide bearing shell)
1 Chain (asymmetric) 94019A 1 Lifting plate 94119
1 Chain (symmetric) 94019B 1 Feeler gauge 94123
1 Eye bolt 94045-M48 1 Bracket 94141
1 Thrust device 94110 1 Work platform 94143
1 Lifting tool (narrow bearing shell) 94116A 1 HP oil pump 94931
1 Lifting tool (wide bearing shell) 94116B 1 Connection block 94934
1 Lifting lug 94116C 2 Pressure gauge 94934A
1 Roller support 94117 3 HP hoses 94935
1 Deviation pipe 94117B 2 Hydraulic ram (100t) 94936
1 Turning-out device 94118A 2 Shackle 4750 kg 94018B
(narrow bearing shell)
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Main Bearing Covers No. 2 to No. 8 − Removal . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Tools − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Main Bearing Cover − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Main Bearing Cover No. 1 − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Main Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Hydraulic Jacks − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Crankshaft − Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Bearing Shell No.1 (narrow) − Removal . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Bearing Shell No. 2 to No. 8 − Removal . . . . . . . . . . . . . . . . . . . . . . . 9
5. Main Bearing Shell − Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. Main Bearing Shell and Bearing Cover − Installation . . . . . . . . . . . . . . . . . . 12
6.1 Bearing Shell − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Main Bearing Cover − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7. Main Bearing − Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1. Preparation
WARNING
Injury and Damage Hazard: Do not turn the crankshaft when the
platforms, tools and/or supports, are installed. This will cause
injury to personnel and damage to equipment.
WARNING
no personnel are near the flywheel.
1) Read the data in 0012−1 General Guidelines for Lifting Tools.

2) Read the data in 3301−1 Work Platform.
3) Operate the turning gear to turn the crank to the exhaust side approximately 90_
after TDC.
4) Set to off the main oil supply pumps.
5) Close the lubrication to the main bearing.

1
2. Main Bearing Covers
No. 2 to No. 8 −
Removal
2
2.1 Tools − Installation
Fig. 1 1) Remove the oil pipe (1, Fig. 1) from the

main bearing cover (2).
94018C
H3
H1
94045−M48
94018B H2 2) Attach the work platform (94143,
94117B Fig. 2).
3) Use the feeler gauge (94123) to do a
94143 check of the bearing clearance, refer to
0330−1, Top and Bottom End Bearings.
4) Apply tension to the elastic studs (1)
and remove their nuts, refer to 1132−1.
5) Install the chain block (H2, Fig. 3) and
1 the eye bolt (94045−M48) near the
gland box.
6) Attach the manual ratchet (H1, Fig. 2)
and the shackle (94018B) to the
column above the door.
7) Attach the chain block (H3) and the
shackle (94018C) to the column roof.
Fig. 2
H2
8) Attach the roller support (94117, Fig. 3)
to the column (3) with the pin (1).
1 9) Lock the pin (1) with the double spring
2 clip (2).
10) Attach the deviation pipe (94117B,
Fig. 2) to the column.
94117
Fig. 3

Removal and Fitting of a Main Bearing
11) Install the lug (94116C, Fig. 4) to the

94116C
1
Fig. 4 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
removal of the main bearing
covers No.2 to No.8.
Note: Use the lifting plate (4) only for the

movement and installation of the
94110 thrust device (94110). If the lifting
2 plate is not in use, attach it as
4 1 shown in Fig. 5.
12) Make sure that the thrust device
(94110) is clean.
13) Apply copper paste to the thread and
3 the surface of the screw (1).
14) Open the vent screw (2) and make sure
that the piston (4) is fully engaged.
15) Put the thrust device (94110) in position
on the main bearing cover (3).
16) Make sure that the tappet (5) and the
piston (4) are in the cut-out of the main
94017−005
bearing cover (3).
1 17) Connect the thrust device (94110) to
the HP oil pump (94931), refer to
9403−2.
18) Operate the HP oil pump.
5 4 19) Close the vent screw (2) when oil that
has no air flows out.
3 20) Slowly increase the pressure to
1500 bar.
21) Tighten the screw (1).
22) On the HP oil pump, release the
pressure to zero.
23) Disconnect the HP hose.
WCH02326
Fig. 5

2.2 Main Bearing Cover −

Removal
FUEL SIDE
1) Operate the manual ratchet (H1, Fig. 6)

to lift the main bearing cover (4).
H1
CAUTION
94117
4 Damage Hazard: Use the
94116C roller support 94117 only
as shown with a maximum
angle of the manual ratchet
chain at 45° and a force of
12000 N.
2) Attach the chain block (H2) to the

bearing cover. Apply tension to the
chain block.
H2
3) Remove the roller support (94117) and
manual ratchet (H1).
4) Attach the chain block (H3, Fig. 7) to
the column.
H1
5) Move the bearing cover to the fuel side
until it hangs vertically on the chain
block (H3).
6) Remove the chain block (H2).
7) Attach the chain (94019A/B, Fig. 8) to
the chain block H2. Continue to move
the bearing cover to the fuel side.
Fig. 6
8) Lower the bearing cover on to a
wooden underlay on the bottom plate.
9) Apply protection to the bearing shell.
94018C
H3 H2
I I
94019A/B H3
94019A
H2
94019B
94117B
Fig. 7
Fig. 8

3. Main Bearing Cover

No. 1 − Removal
1) Remove the covers (2 and 3, Fig. 9).
Fig. 9
4
2) Remove oil pipe (4, Fig. 10) from the
1 3) Do a check of the bearing clearance for
comparison, refer to 0330−1, Top and
Bottom End Bearings.
Fig. 10
94116C 4) Loosen the elastic studs (5, Fig. 11)

94018C
and remove their nuts, refer to 1132−1.
H2
5) Attach the lug (94116C) to the main
1 bearing cover (1).
5 6) Attach the shackle (94018C) to the
column.
shackle (94018C) and the bearing
cover (1).
8) Operate the chain block (H2) to lift the
bearing cover (1).
9) Attach the engine room crane to the
bearing cover (1).
Fig. 11 1
10) Remove the chain block (H2).
11) Operate the engine room crane to
move the bearing cover (1) to an
applicable area.

4. Main Bearing Shell − Removal

4.1 Hydraulic Jacks − Installation
WARNING
no personnel are near the flywheel or in the engine.
CAUTION
Damage Hazard: Do not remove two adjacent main bearing shells at
the same time. Damage can occur to the bearing shells.
1) Remove the work platform (94143).

2) If necessary, operate the turning gear
to turn the crank to approximately 90_
1 after TDC.
94936 3) Put the bracket (94141A, Fig.12) on the
two main bearing girders (1) as shown.
4) Make sure that the bracket is a
minimum of 43 mm from the thrust
94141A bearing side.
5) Put the hydraulic rams (94936) on the
bracket (94141A).
WCH02332
6) Connect the hydraulic rams (94936) to
the HP oil pump (94931), refer to
Minimum 9403−2.
43 mm
4.2 Crankshaft − Lift
Fig. 12
1) Record the values of the lateral
clearances (y1 and y2, Fig.13) between
the crankshaft (2) and the bottom main
1 bearing shell (3,4) at approximately
50 mm below the bearing.
2) Install the dial gauge (1) above the
crankshaft (2) as shown
3) Set the dial gauge (1) to zero.
50 mm 4) Operate the HP oil pump (94931) to lift
the crankshaft (2) to 0.3 mm.
5) Make sure that the value on the dial
0.3mm gauge is 0.3 mm.
6) Make sure that there is no clearance
between the adjacent bearing cover
and the crankshaft.
009.810/02
3,4 2 7) Keep the pressure constant.
8) Measure the lateral bearing clearances
Fig. 13 y1 and y2. Compare these values with
the values recorded in step 1).

9) If the value of the lateral bearing clearance is more than 0.1 mm, lower the
crankshaft and do step a) to step b):
a) Install the hydraulic rams (94936, Fig.13) in a position where the lateral bearing
clearance is smaller.
b) Operate the HP oil pump (94931). To lift the crankshaft (1) to 0.3 mm.
4.3 Bearing Shell No.1 (narrow)

− Removal
CAUTION
Damage Hazard: During
this procedure, use only the
H2 applicable tools. Do not
attach external
installations. Do not use the
thrust device (94110) for
removal. Damage to
equipment can occur.
Note: The bearing cover and the top

I main bearing shell are removed.
Note: The crank is at the exhaust side at
TDC.
1) Make sure that the crankshaft is lifted
to 0.3 mm, refer to paragraph 4.1 and
94936 4.2.
94141
the eye bolt on the platform.
3) Remove the Allen screws (1) from the
Protection bearing girder.
Note: Some parts can look
1 different 4) Attach the chain block (H2) to the
middle hole of the lifting plate (94119).
5) Attach the tool (94118A) to the bottom
main bearing shell (3).
I 6) Put the ropes (2) along the lateral
edges of the main bearing shell (3) to
the other side and attach them to the
H2 lifting plate (94119) as shown.
1 94119
EXHAUST SIDE
2
FUEL SIDE
94118A
Fig. 14

7) Operate the chain block (H2, Fig. 15) to

turn the bearing shell (1) as shown in
Fig. 18 and Fig. 19.
H2 Note: If the bearing shell (1) does not
move, the lifting plate (94119,
Fig. 16) must be attached to the
1 other side of the dismantling tool
(94118A). The bearing shell must
be moved back to its initial
condition and you must do the
removal procedure done again.
1
Fig. 15
8) Remove the bearing shell (1, Fig. 16)

H2 94116B out as shown in Fig. 17.
9) Remove the device (94118A).
10) Install the lifting tool (94116B) to the
bearing shell (1).
11) Remove the chain block (H2) from the
lifting plate (94119).
1 12) Attach the chain block (H2) to the lifting
tool (94116B).
13) Remove the lifting plate (94119).
Fig. 16

bearing shell (1).
15) Move the bearing shell (1) to an area
H2 where you can operate the engine
room crane.
94116B 16) Attach the engine room crane to the
bearing shell.
17) Remove the spur-geared chain
block (H2).
move the bearing shell to a safe area.
Fig. 17

4.4 Bearing Shell No. 2 to No. 8

94143
94117 − Removal
CAUTION
this procedure, use only the
applicable tools. Do not
attach external
installations. Do not use the
thrust device 94110 for
removal. Damage to
2 equipment can occur.
I
94118B Note: The bearing cover and the top
main bearing shell are removed.
1 Note: The crank is at the exhaust side.
1) Attach the work platform (94143,
Fig. 18).
94119
to 0.3 mm, refer to paragraph 4.1 and
4.2.
I
up to approximately 0.3 mm.
Note: The two Allen screws from the top
H1 bearing shell must be removed.
4) Attach the manual ratchet (H1) to the
94119 shackle (94018B).
5) Attach the tool (94118B) to the bottom
main bearing shell (1).
6) Put the ropes (2) along the lateral
1
edges of the main bearing shell (1) to
the other side and attach them to the
7) Attach the roller support (94117) to the
column and secure it with its dowel pin.
8) Attach the chain of the manual ratchet
(H1) through the roller support (94117)
to the lifting plate (94119).
9) Make sure the the chain of the manual
ratchet (H1) is in the middle of the
FUEL SIDE
94018B 94117
H1
94118B
Fig. 18

10) Operate the manual ratchet (H1,

Fig. 19) to move the bottom bearing
shell until the chain hook is adjacent to
the roller support (94117).
94117
94016−009
Fig. 19
11) Attach the lifting tool (94116A) to the

bearing shell (1, Fig. 20).
94116A
1 middle of the lifting tool (94116A).
13) Remove the tool (94118B) and the
Fig. 20
14) Operate the manual ratchet (H1,

Fig. 21) and the lifting tool (94116A) to
lift the bearing shell (1).
15) Attach the chain block (H2) to the lifting
tool (94116A).
H2 16) Remove the roller support (94117) and
the manual ratchet (H1).
94117
FUEL SIDE
H1 94116A
1
Fig. 21

H2 H3 17) Attach the chain block (H3, Fig. 22) to

the gallery and the lifting tool (94116A)
18) Operate the chain blocks (H2, H3) to
move the bearing shell to the fuel side
as shown.
94116A
Fig. 22
19) Install the deviation pipe (94117A,

I 20) Attach the chains (94019A/B) to the
gallery as shown.
21) Attach the chains (94019B) to the chain
94019A/B
block (H2) to move the bearing shell to
H2 the fuel side as shown.
22) Put the bearing shell on to wooden
underlay on the bottom plate.
94117A
94019A
94019B
Fig. 23

5. Main Bearing Shell − Inspection

CAUTION
Damage Hazard: Do not use a scraper in the running area of the
bearing shell. Damage to the bearing shell will occur.
1) Use a soft cloth to clean the bearing shell.

2) Do a check of the bearing shell for damage e.g. 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 send a
message to WinGD.
5) Replace the bearing shells if necessary.
6) Do an inspection of the surface of the bearing pin. If necessary, repair the
surfaces that have scratches.
6. Main Bearing Shell and Bearing Cover − Installation
CAUTION
Damage Hazard: Use only the applicable tools for installation. The
sizes of the bearing shells are different (narrow and wide).
The bearing cover and bearing shell have the marks DRIVING END and must be
installed in the bearing girder in their initial positions.
Before installation, make sure that the items that follow are clean and in good
condition:
D All tools
D The crankshaft pin
D The girder bore for the bearing shell
D Bearing shells.
6.1 Bearing Shell − Installation

1) Apply a very thin layer of Molykote paste G to the rear face of the bottom bearing
shell, before each installation.
2) Make sure that the crankshaft pin and the running surface of the bearing shell are
clean and fully lubricated with clean engine oil.
Note: The bearing shells have different dimensions. For bearing shell No. 1, use
the tool (94118B) and the lifting plate (94119). For bearing shells No. 2 to
No 8 use the tool (94119C) and the lifting plate (94119A).
3) Attach the dismantling device (94118A/B) to the front face of the bottom bearing
shell.
4) Attach the lifting tool (94116A/B) to the bearing shell.
5) Use the applicable equipment as follows:
D For the bearing shell No.1, use the engine room crane and the spur-geared
chain block to lower the bearing shell in position on to the crankshaft.
D For the bearing shells No.2 to No. 8, use the chain blocks (H2, H3), the roller
support (94117A) and the manual ratchet (H1) to lower the the bearing shell
in position on to the crankshaft.
6) Put the ropes of the device (94118A/B) below the crankshaft pin and connect
them to the lifting plate (94119).
7) Remove the lifting tool (94116A/B).

Note: To prevent bearing shell movement into the bearing girder, hold the
bearing shell and move it slowly into the bearing girder (on fuel side) at
the rope ends.
8) Carefully move the bearing shell into the bearing girder (on the fuel side).
9) Carefully put the Allen screws into the bearing shell.
10) Release the pressure of the HP oil pump (94931) to fully lower the crankshaft.
11) Remove the hydraulic rams (94936) and the HP oil pump (94931).
6.2 Main Bearing Cover −
Installation
1 2
1) Make sure that the work area and all
tools and equipment are clean and in
good condition.
2) Remove all plugs from the oil
bore (OB).
OB 6 3 4 3) Use the applicable equipment to get

7 the bearing cover in the correct position
above the crankshaft as follows:
D For bearing covers No. 2 to No. 8
refer to paragraph 2.
D For bearing cover No. 1, refer to
paragraph 3).
5
Note: The top bearing shell is attached
to the cover with two Allen screws
(2, Fig. 24). The spring dowel pins
WCH02321 (1) help to get the bearing cover (3)
Fig. 24 in position during the installation.
4) Clean all surfaces on the the bearing
cover (3) and the bearing girder (5).
5) Lower the bearing cover (3) on to the
bearing girder (5). Make sure that the
two spring dowel pins engage correctly.
6) Apply tension to the elastic studs (4),
refer to 1132−1.
7) Tighten the round nuts (7).
5 6 1 8) Clean the pipes (1, Fig. 25).
9) Install the pipes (1), their gaskets and
3, 4 new tab washers (4).
10) Tighten the screws (3).
2
11) Lock the screws (3) with the new tab
washers (4).
12) Remove all tools and equipment from
the work area.
WCH02325
Fig. 25 13) Measure the bearing clearance and
compare the value measured in
paragraph 2, with the value given in the
Clearance Table 0330−1, Group 3303.
Note: If the clearance is in the limits
given, the bearing can be removed
and installed again.

14) After each installation of a new bearing shell, measure the crank deflection, refer to
3103−1.
15) Do a check of the oil supply to the main bearing.
7. Main Bearing − Lubrication

After an overhaul of the bearing shells, more lubricant can be added to prevent
damage to the surface of the bearing shells.
1) To fill the bearing shell with the lubricant do the procedure that follows:
a) Remove the blank flange (6, Fig. 25).
b) Remove the screw plug (5).
c) Fill the bearing shell with the applicable lubricant.
d) Attach the blank flange (6) with the screw plug (5).

Work Card
Thrust Bearing: Axial and Vertical Clearance
Not applicable Inside micrometer 94101 Qty 1

Preparation
Do a check of the axial and vertical clearances Service Engineer 2.0 hours Qty 1
Ship Engineer 2.0 hours Qty 1
Related Data

Related Procedures
Not applicable

Intentionally blank
Work Card
Thrust Bearing: Bottom Drain
Not applicable Inside micrometer 94101 Qty 1

Preparation
Do a check of the bottom drain Ship Engineer 1.0 hours Qty 1
Related Data

Related Procedures
Thrust Bearing − Axial Clearance Check

1203−1

Intentionally blank
Thrust Bearing

Tools:
1 Inside micrometer 94101
1
1. Procedure One
9
1) Start the engine in the direction AHEAD
8 2 to move the crankshaft fully forward.
2) Stop the engine.
3) Put the dial gauge (8, Fig. 1) in position
on the oil baffle (top part) (9) and
record the value.
4) Remove the dial gauge (8).
5) Start the engine in the direction
3 REVERSE to move the crankshaft fully
7 rearward.
6) Stop the engine.
7) Put the dial gauge (8) in position on the
6 oil baffle (top part) (9) and record the
11 value.
8) Remove the dial gauge (8).
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).
If the measured values are more than the
WCH02338
nominal values given, the thrust pads are
worn.
10) After maintenance on the area of the
thrust bearing, do as follows:
4 11) Remove the cover (4).
12) Do a check of the thrust bearing
housing.
13) If necessary, remove particles from the
area (11).
14) Install the cover (4).
15) Each 6000 to 8000 operation hours,
5
make sure that the opening (5) is clear.
Fig. 1

Checking the Axial Clearance
2. Procedure Two
1) Start the engine in the direction AHEAD
to move the crankshaft fully forward.
The crankshaft must touch the thrust
pads (3, Fig. 1).
2) Stop the engine.
3) Make sure that the crankshaft does not
move.
4) Use the micrometer (94101) to
measure the distance between the
crankshaft flange (10, Fig. 2) and the
oil baffle (top part) (9).
5) Record the value.
6) Remove the micrometer (94101).
7) Compare the value with those given in
the engine documents on the Check
9 Dimensions page (refer also to 0330−1
Thrust Bearing).
10
The difference between the distance X and
WCH02338 the value given in the engine documents is
related to the worn 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.
9
10) Make sure that the crankshaft does not
move.
11) Use the micrometer (94101) to
measure the distance between the
crankshaft flange (10, Fig. 2) and the
oil baffle (top part) (9).
12) Record the value.
13) Remove the micrometer (94101).
10 14) Compare the value with those given in
X the engine documents on the Check
Dimensions page (refer also to 0330−1
Thrust Bearing).
The difference between the distance X and
the value given in the engine documents is
related to the wear of the thrust pads (7,
Fig. 2 94101 Fig. 1).

Work Card
Thrust Bearing Pads: Replace
− Engine stopped Thrust pads ES 12240 Qty 11

Thrust pads ES 12241 Qty 1
Not applicable Manual ratchet 94016-009 Qty 1

Spur-geared chain block 94017-006 Qty 2
Shackle 94018A Qty 2
Carrier 94155 Qty 1
Link 94321 Qty 1
Lockwire

Preparation
Replace the thrust bearing pads Service Engineer 4.0 hours Qty 2
Related Data

Related Procedures
Thrust Bearing Pads − Removal and Installation,

refer to the Maintenance Manual 1224−1/A1
1203−1

Intentionally blank
Thrust Bearing
Thrust Bearing Pads − Removal and Installation

Tools:
1 Manual ratchet 94016-009 (H3) 1 Eye bolt 94045-M16
2 Spur-geared chain block 94017-006 (H1, H2) 1 Carrier 94155
2 Shackle 94018A 1 Link 94321
1 Eye bolt 94045-M12
1. Preparation
2) Remove the cover (2, Fig. 1).
3) Attach the shackles (94018A) and chain blocks (H1, H2) to the gallery.
4) Record the positions of the thrust bearing pads (thrust pads).
I I
1 2
3 3
7
6
ENGINE SIDE
DRIVING END
WCH02338
5 4
I-I
WCH02338
7 9
8
3
3 7
WCH02338
Fig. 1

2. Removal
1) Remove and discard the lockwire from the three bolts (9, Fig. 2) on the arbor
supports (3, 7) of the applicable thrust pads (5).
2) Remove the bolts (9) from the arbor support (3 or 7) of the applicable thrust pads.
3) Attach the eye bolt (94045-M12) to the arbor support (3 or 7).
4) Attach the the shackle (94018A) and chain blocks (H1, H2) to the gallery (16).
5) Remove the applicable arbor support (3 or 7).
6) Attach the chain blocks (H1, H2) to the lifting plate (94321).
7) Attach the link (94321) to the chain blocks (H1, H2).
H1 7
3
94045−M12
WCH02340
94045−M16 16
12 H2
5 94018A 94321
94155
H1
H3
11
WCH02340
Fig. 2 WCH02340

8) Install the carrier (94155) on the gear wheel (12) as shown.

9) Remove the temperature sensors (8, Fig. 1)
10) Attach the eye bolt (94045−M12) to the thrust pad (5, Fig. 2).
WARNING
no personnel are near the flywheel, or inside the engine.
11) Operate the turning gear to turn the crankshaft in the applicable direction.
Note: While the gear wheel turns, the carrier (94155) moves the thrust pads. The
first thrust pad will come out.
12) Keep a light tension on the chain blocks (H1, H2) while the thrust pad moves up.
13) Remove the thrust pad (1).
14) Move the thrust pad (1) to the exhaust side.
15) Lower the thrust pad on to a stable area.
16) Do step 10) to step 15) above for the remaining thrust pads that you must
remove.
Note: If some of the thrust pads are removed, the remaining thrust 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.
17) 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 oil to the thrust pads.
Note: You must install thrust pads that you removed before in the same
positions. Use your recorded notes for the correct positions.
3) Attach the eye bolt (94045−M12) to the thrust pad (5).
4) Attach the manual ratchet (H3) to the eye bolt (94045−M12).
5) Operate the manual ratchet (H3) to lift the thrust pad (5).
6) Move the thrust pad into position above the gear wheel.
7) Lower the thrust pad. Make sure that the thrust pad touches the carrier (94155).
WARNING
8) Operate the turning gear to turn the crankshaft in the applicable direction.
9) Put the subsequent thrust bearing pad in position.
10) Do the step 3) to step 9) for each thrust bearing pad.
11) When all thrust pads are in position, make sure that the top, outer thrust pads are at
equal height.
12) Remove the carrier (94155).
13) Install the arbor supports (3, 7) as follows:
a) Attach the eye bolt (94045-M16) to the applicable arbor support.
b) Attach the chain block (H1) to the eye bolt (94045-M16).
c) Lift the arbor support (3) lower it into position.

14) Remove the chain block and eye bolt.

15) Install the three bolts (9, Fig. Fig. 2) to the arbor support (3).
16) Lock the bolts (9, Fig. 3) with lockwire as shown.
WCH02338
Lockwire
Fig. 3
17) Install the temperature sensors (8, Fig. 1).

18) Do a check of the clearances between the arbor supports and the thrust pads
(refer to 0330−1, Crankshaft and Thrust Bearing).
Note: When you replace new thrust pads (or thrust pads that have new metal),
you must make sure that the dimensions are the same as the adjacent
pad(s).
When you replace a full set of thrust pads (or a full set of thrust pads that have new
metal), you must adjust the clearances to the original values (refer to 0330−1,
Crankshaft and Thrust Bearing and 1203−1 Axial Clearance Check).
19) For the configuration of the thrust pads, refer to Fig. 4.
CONFIGURATION OF THRUST PADS WITH FIXED PITCH PROPELLER

ENGINES WITH CLOCKWISE ROTATION
ASTERN AHEAD
SUPPORT SURFACE
VIEW FROM DRIVING END TO PADS
VIEW FROM DRIVING END TO PADS
AT DRIVING END
ON ENGINE SIDE
DRIVING END ENGINE SIDE
PROPELLER THRUST PROPELLER THRUST

ASTERN AHEAD
Fig. 4

4. Completion
1) Install the cover (2, Fig. 1).
2) Remove all tools and equipment from the work area.

Intentionally blank
Work Card
Engine Stays (Friction Type)
− Engine stopped
Not applicable Feeler gauge 94122 Qty 1

Pre-tensioning jack 94145 Qty 1
Hydraulic distributors 94934A Qty 2
HP hose 94935 Qty 1

Preparation
Do the pre-tension checks on the engine stays Service Engineer 2.0 hours Qty 1
Related Data

Related Procedures
Pre-tension Jack − Attach 9403−2

Pre-tension Jack − General Instructions
9403−4

Intentionally blank
Work Card
Engine Stays (Hydraulic Type)
Not applicable Nitrogen (N2)

Preparation
Do the pre-tensionn checks on the engine stays Ship Engineer 0.5 hours Qty 1
Related Data

Related Procedures
Manufacturer’s documentation

Intentionally blank
Engine Stays with Friction Shims
Pre-tension Checks
Tools:
1 Feeler gauge 94122 2 Hydraulic distributors 94934A
1 Pre-tensioning jack 94145 1 HP hose 94935
1 HP oil pump 94931
1. General
The engine stays (see Fig.1) are related to the design of the ship. The engine stays
are installed as follows:
D Four engine stays are installed on the exhaust side, or the fuel side.
D Two engine stays are installed at the free end.
D Two engine stays are installed at the driving end.
The engine stays have friction shims.
You must do a pre-tension check of the bolts (2) at the specified intervals (refer to
0380−1, Engine stays with friction shims.
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. The pre-tension value for the engine stays is 170 bar only
I
1
2
3
SHIP SIDE
1 6 5 4 015.731/07
Fig. 1

Engine Stays with Friction Shims: Pre-tension Checks
2. Pre-tension Checks
1) Clean the threads of the bolts (2, Fig.1) and the seating surfaces.
2) Apply Molykote paste G to the threads of the bolts (2).
3) Refer to 9403−2 and 9403−4. Attach the pre-tensioning jack and the applicable
equipment as shown in Fig. 2.
4) Apply a tension of 170 bar to the bolt (2).
5) Put the feeler gauge (94122) through the slot (7) to do a check for clearance between
the nut and its seating. If there is no clearance, the bolt tension has not changed and
you can do steps a) and b). If there is a clearance, do step 6).
a) Operate the vent screw (1) to release the pressure to zero.
b) Remove the tools and equipment.
6) If there is clearance, the tension of the bolt has changed since the last check and you
must do steps a) to d) below:
a) Use a round bar (4) to tighten the nut (3).
b) Use the feeler gauge to make sure there is no clearance.
c) Operate the vent screw (1) to release the pressure to zero.
d) Remove the tools and equipment.
Note: The data to loosen the bolts is given in 9403−4.
94934A
1
2
94935
3
Note: Disc springs
7 must be compressed
94931 94934A
016.704/08
5
2 6
017.672/08
Fig. 2

Hydraulic Engine Stays
Oil Pressure Checks
1. General
Two hydraulic engine stays (1, Fig. 1) are installed on the exhaust side and two on the
fuel side of the engine.
Nitrogen gas in a bladder in the accumulator causes the vibration damping. The usual
oil and gas pressure is 80 bar during operation.
You must do regular checks of the two opposite engine stays at the pressure
gauges (3) to compare their values. The values must be the same if the vessel is
level.
The faults that can cause a pressure decrease in a hydraulic cylinder are as follows:
D Defective O-rings
D Valves that have leaks
D Defective pipe connections
D Gas that goes out of the bladder accumulator.
2. Procedure
1) Do a check of the distance (X) to make sure that the engine is not tilted. The
distance (X) must be zero before you do a check of the pressure gauges (7).
2) Do a check of the oil pressure values at the gauges (3). If the values of two
opposite engines stays added together are less then 120 bar, do as follows:
a) Refer to the documentation of the manufacturer, then do step b) to step e).
b) Decrease fully the oil pressure.
c) Fill the accumulator with nitrogen to a pressure of 40 bar.
d) Make sure that the pressure stays constant. If not, there is a leak in the gas
system.
e) Increase the oil pressure to 80 bar.
f) Make sure that the pressure stays constant. If the pressure does not stay
constant, change piston seals.
g) Make sure that the values on the pressure gauges are the same as the
opposite engine stay.

Oil Pressure Checks
1 1
3
8 4
X WCH02339
ENGINE SIDE
WCH00915
7
Fig. 1 6
Fig. 1 Key
1 Hydraulic engine stays 5 Rod
2 Accumulator body (internal bladder) 6 Plug ⅜ inch NPT
3 Pressure gauge 7 Ball valve
4 Damping control valve 8 Hydraulic cylinder

Work Card
Tie Rods
Not applicable Feeler gauge 94122 Qty 1

Pre-tensioning jacks 94180 Qty 2
Connection block 94934 Qty 1
Hydraulic unit 94942 Qty 1
Molykote paste G

Preparation
Do the pre-tension checks on the tie rods Ship Engineer 1.5 hours Qty 2
Related Data

Hydraulic Pre-tensioning Jacks 9403−4/A1
Related Procedures

Intentionally blank
Tie Rod
Pre-tension Checks and Tie Rod Replacement

Tools:
1 Feeler gauge 94122 1 Pressure gauge 94934A
2 Pre-tensioning jacks 94180 3 HP hoses 94935
1 Connection block 94934 1 Hydraulic unit 94942
1. General
We recommend that you do a check of the tension of all the tie rods one year after
commissioning. If necessary, apply tension to the tie rods to the specified value. Do
the pre-tension checks at the intervals given in 0380−1 Maintenance Schedule,
Group 1903−1.
2. Pre-tension Check
1) Remove the protection cover (1, Fig. 1)
1 from all tie rods (2).
2) Clean the surfaces of the intermediate
rings (4).
2
Note: Start with the tie rods in the middle
of the engine a−a, then b−b etc).
3) Attach the two pre-tensioning jacks
(94180) to the two tie rods (2, a−a)
refer to 9403−4.
4) Apply 1500 bar to the tie rods (2).
3 5) Tighten the round nuts (3) if possible.
4 6) If the round nut (3) will not move, do as

follows:
5 a) Put a brass or copper bar through
the slot in the jack and into a hole
in the round nut.
WCH03699
b) Use a hammer to loosen, then
tighten the nut. Make sure that the
edge of the hole has no
deformation.
7) Remove the pre-tensioning jacks, refer
to 9304−4.
DRIVING END
FREE END
8) Apply a layer of Molykote paste G to

the threads of the tie rod (2) to prevent
corrosion.
9) Install the protection cover (1).
10) Do step 1) to step 9) for the remaining
tie rods.
WCH03699
Fig. 1

3. Tie Rods − Replacement

1 3.1 Preparation
2 1) Remove protection cover (1, Fig. 2)
from all tie rods.
3
2) Clean the surface of the intermediate
ring (3).
4 3) Refer to 9403−4, then attach the two
6
pre-tensioning jacks (94180) to two tie
5 7 rods (4) that are opposite each other
(e.g. a−a), see Fig. 1.
4) Loosen the round nuts (2), refer to
9403−4.
3.2 Removal
1) Remove the set screws (7).
2) Use two round nuts screwed together
to loosen the tie rod (4).
3) Attach the eye bolt (M20) to the tie
rod (4).
CAUTION
Injury Hazard: The weight
of the tie rod is
approximately 550 kg. Use
the correct equipment for
removal.
4) Attach the hook of the engine room
crane to the eye bolt.
5) Lift the tie rod (4) fully from the cylinder
jacket (11).
3.3 Install
1) Remove the two holders (10).
2) Make sure the nut (8) is correctly
attached.
3) Apply Molykote G paste to the bottom
8
thread of the tie rod (4).
4) Attach the eye bolt (M20) to the tie
WCH03699 rod (4).
5) Attach the hook of the engine room
crane to the eye bolt (M20).
I 6) Make sure that the bush (6) is installed.
I-I 7) Lower the tie rod (4) into the cylinder
jacket (11).
9 8) Turn the tie rod (4) until the bottom is
flush with the nut (9).
11 9) Clean the top surfaces of the cylinder
10 10
block (5).
I
10) Install intermediate ring (3).
11) Apply Molykote paste G to the top
WCH03699 thread of the tie rod and the top surface
of intermediate ring (3).
Fig. 2
12) Attach the round nut (2) to the tie rod (4).
13) Lift the tie rod (4), then fully tighten the round nut (2).
14) Make sure that the nut (8) is fully up, then install the holders (10).
Note: The tie rod at the first cylinder (driving end) has only one holder (10).
15) Apply tension to the tie rods (4), refer to paragraph 3.4.

3.4 Tensioning
Note: Start with the tie rods in the middle
of the engine a−a, then b−b etc).
1500 bar 1) Put the two pre-tensioning jacks
100 bar (94180, Fig. 3) on the tie rods (1).
2) Apply a tension of 100 bar, refer to
9403−4.
94180 3) Record the length of the tie rods (1) at
1 L.
4) Apply a tension of 1500 bar.
5) Record the extension of the tie rod (1)
at L1.
Note: The extension DL of the tie rod (1)
DRIVING END
FREE END must be 14 mm to 16 mm (L1 − L).

tie rods.
7) Tighten the set screws (7, Fig. 2)
8) Apply a layer of Molykote paste G to
prevent corrosion.
WCH03699
Fig. 3 9) Install the protection covers (1) to the
tie rods.

Intentionally blank
Maintenance Group2
Work Cards
Cylinder Liner: Measure the Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2124−1/A1
Cylinder Liner − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2124−1.1/A1
Antipolishing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2124−1.5/A1
Cylinder Liner: Remove Unwanted Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2124−3/A1
Cylinder Liner
Measure the Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−1/A1
Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports . . . . . . . . . . . . . . 2124−3/A1
Work Cards
Cylinder Lubricating Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2138−1/A1
Lubricating Quill: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A1
Work Cards
Gas Admission Valve: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2140−1/A1
Gas Admission Valve: Do an Overhaul of the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2140−1.1/A1
Gas Admission Valve: Check of the Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2140−1.2/A1
Gas Admission Valve: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2140−1.3/A1
Gas Admission Valve (GAV): Removal, Disassemble, Assemble and Installation . . . . . . . . . . . . . 2140−1/A1
Work Cards
Piston Rod Gland: Clean the Rings and Measure Worn Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2303−1/A1
Piston Rod Gland: Replace the Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2303−1.1/A1
Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation . . . . . . 2303−1/A1
Work Cards
Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2708−1/A1
Cylinder Cover
Cylinder Cover and Top Water Guide Jacket − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 2708−1/A1
Injection Valve: Grind Sealing Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−3/A1
Pilot Injection Valve: Grind Sealing Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−4/A1
Prechamber: Grind Sealing Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−5/A1
Work Cards
Injection Valve: Replace the Nozzle Body and Nozzle Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2722−1/A1
Injection Valve: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2722−1.1/A1
Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722−1/A1
Injection Valve: Disassemble, Checks, Assemble (Injection Valve with FAST) . . . . . . . . . . . . . 2722−2/A1
Work Cards
Starting Air Valve: Remove and Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2728−1.1/A1
Starting Air Valve: Check of the function of the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . WC2728−1.3/A1
Winterthur Gas & Diesel Ltd. 1/ 1 X72DF / MM / 2018−10

Group2 Maintenance
Starting Air Valve: Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2728−1.4/A1
Starting Valve: Removal, Disassemble, Grinding, Assemble, Installation . . . . . . . . . . . . . . . . . . . . 2728−1/A1
Work Cards
Exhaust Valve: General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1/A1
Exhaust Valve Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1.1/A1
Exhaust Valve: Valve Drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1.2/A1
Exhaust Valve: Check the Condition of the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1.3/A1
Exhaust Valve: Random Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2751−1.4/A1
Exhaust Valve
Exhaust Valve − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−1/A1
Valve Seat − Removal, Grind and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−3/A1
Valve Head − Seating Surface − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−4/A1
Work Cards
Pilot Injection Valve: Replace the Nozzle Spare Parts Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2790−1/A1
Pilot Injection Valve: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2790−1.1/A1
Pilot Injection Valve: Replace the Pre-chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC2790−1.2/A1
Pilot Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2790−1/A1
X72DF / MM / 2016 2/ 1 Winterthur

Winterthur Gas
Gas && Diesel
Diesel Ltd.
Ltd.
Work Card
Cylinder Liner: Measure the Bore
Necessary Conditions Necessary Spare Parts (each cylinder)

− Cooling water shut off
− Fuel shut off
− Cooling water drained
Remove the cylinder cover, refer to 2708−1/A1 Inside micrometer 94101 Qty 1
Ladder 94224 Qty 1
Gauge 94225 Qty 1
Safety harness

Preparation
Measure the bore in the cylinder liner Service Engineer 1.0 hours Qty 1
Crew 1.0 hours Qty 1
Related Data
Tolerances and Clearances 0330−1/A1

Related Procedures
Cylinder liner removal

WC2124−1.1/A1

Intentionally blank
Work Card
Cylinder Liner − Removal and Installation
− Engine stopped Cylinder liner EX 21240 Qty 1

− Starting air supply shut off O-ring: gas distributor pipe EX 89091 Qty 2
− Cooling water supply shut off O-ring: water pipe connection EX 21310 Qty 1
− Servo oil shut off O-ring: bottom water guide jacket EX 21251 Qty 1
− Fuel supply shut off O-ring: bottom water guide jacket EX 21252 Qty 1
− Gas line purged with inert gas O-ring: for gas nozzle EX 21256 Qty 2
− Lube oil supply stopped O-ring: gas admission valve EX 21435 Qty 2
− Cooling water drained O-ring: gas admission valve EX 21434 Qty 2
More spare parts, time and personnel necessary for Manual ratchets 94016-009 Qty 1
preparation. Do a check of applicable work cards. Manual ratchets 94016-031 Qty 2
Lifting tool 94210 Qty 1
Cylinder Cover Removal, refer to WC2708/A1 Sling 94202K Qty 1
Piston Removal, refer to WC3403/A1 Lifting tool 94215 Qty 1
Assembly tool 94345E Qty 1
Oil
Never Seez High Temperature
Stainless

Preparation
Cylinder Liner − Removal and Installation Superintendent 7 hrs Qty 1

refer to the Maintenance Manual 2124−2/A1 Service Engineer 7 hrs Qty 2
Related Data

Overhaul intervals, refer to 0380−1/A1
Related Procedures
Cylinder Liner − Measure the Bore 2124−1/A1

Gas Admission Valve − Disassemble 2140−1/A1

Intentionally blank
Work Card
Antipolishing Ring

− Cooling water supply shut off
− Fuel supply shut off
− Gas line purged with inert gas
− Lube oil supply stopped
− Cooling water drained
More spare parts, time and personnel necessary for Not applicable
preparation. Do a check of applicable work cards.
Cylinder Cover Removal, refer to WC2708/A1

Piston Removal, refer to WC3403/A1

Preparation
Do a check of the antipolishing ring Service Engineer 0.5 hrs Qty 1
Related Data

Overhaul intervals, refer to 0380−1/A1
Related Procedures
Cylinder Liner − Measure the Bore 2124−1/A1

Gas Admission Valve − Disassemble 2140−1/A1

Intentionally blank
Work Card
Cylinder Liner: Remove Unwanted Material

− Cylinder cover removed
More spare parts, time and personnel necessary for Not applicable
preparation. Do a check of applicable work cards.

Preparation
Remove unwanted material from the cylinder liner Service Engineer 2.0 hours Qty 1
bore Crew 2.0 hours Qty 1
Related Data

Component weights 0360−1/A1
Related Procedures
Remove piston WC3403/A1

Exhaust valve replacement 2751−1/A1

Intentionally blank
Cylinder Liner
Measure the Bore

Tools:
1 Inside micrometer 94101
1 Ladder 94224
1 Gauge 94225
WARNING
Danger: Gas Hazard.
94224 1 2 Poisonous gas can stay in
the cylinder liner. There is a
SS risk of suffocation. You
must make sure that
A
poisonous gas is removed
B before you go into the
cylinder liner. You must put
on a harness attached to a
safety person before you
RIDGE OF
do work in cylinders where
MATERIAL
gas can stay.
3
WARNING
Injury Hazard: Before you
operate the turning gear,
make sure that no
94225 personnel are near the
flywheel, or in the engine.
94101
CAUTION
Injury Hazard: Hot parts can
cause injury to personnel.
Be careful when you do
work in areas where there
are hot parts.
Note: Do not go into the combustion
chamber without removing the
cylinder cover.
F Note: Measure the the cylinder liner
before you remove a piston.
1) Remove the cylinder cover, (refer to
2708−1).
2) Operate the turning gear to move the
piston to BDC.
3) Put on a harness that is attached to a
safety person. If necessary, the safety
person can pull you out of the cylinder
liner if there is an emergency.
4) Lock the lever of the cooling water
valve in the closed position. This
makes sure that no cooling water can
go into the cylinder liner.
5) Clean the area (1) above the running
surface (2).
6) Remove the bottom part of the
Fig. 1 016.682/08 gauge (94225).

Measure the Bore
7) Put the gauge (94225) in position on the top face of the cylinder liner (3, Fig. 1) in
line with the longitudinal axis of the engine.
8) Make sure that the top hole (A) is above the ridge in the non-running surface of
the cylinder liner (3).
9) Read the values from when the bore was measured before. You compare these
values with the new values.
10) Put the micrometer (94101) in the top hole (A) to measure the distance. Record
the value.
11) Put the micrometer in position in the subsequent hole (B) in the gauge (94225),
then record the value.
12) Do the step above for the remaining holes below (A and B).
13) Move the gauge 90_ (in line with the transverse axis of the engine).
14) Do the steps above again to measure the bore in the positions (F up to A).
15) Use the formula below to calculate the rate of wear:
WR = (D1−D2) x 1000
T1
Where:
WR = the rate of wear (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)
16) For the maximum permitted inner diameter, refer to 0330−1 Clearance Table,
Cylinder liner.
17) Remove all waste particles from the cylinder liner bore.
18) Clean the bore of the cylinder liner.

Cylinder Liner
Removal and Installation

Tools:
1 Manual ratchets 94016−009 1 Chain 94202L
2 Manual ratchets 94016−031 1 Assembly tool 94233
1 Lifting tool 94201
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Cylinder Liner − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Lifting Tool − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Lifting Tool − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Cylinder Liner − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Water Guide Jacket − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 GAV − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Insulation Bandage − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7. Insulation Bandage − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8. Water Guide Jacket − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.1 GAV − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9. Cylinder Liner − Safe Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10. Cylinder Liner − Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1. General
1) Read the data in the:
D 0012−1 General Guidelines for Lifting Tools.
D Operation Manual, 0100−1, specially for natural gas.
D Operation Manual, 2140−1, Gas Admission Valve (GAV)
D Operation Manual, 8014−1, Gas Fuel System
D Operation Manual, 4003−12, Diagram Gas Fuel.
2) For the inspection intervals, refer to the Maintenance Schedule 0380−1, Group
2140.
2. Preparation
WARNING
Danger: Some gas can leak during the removal of the GAV. Do not
use equipment that can cause a spark. Make sure that all equipment
that can case a spark is not in the work area. This will prevent an
explosion, or a fire.
1) Stop the engine.

2) Set to off the main bearing oil pumps.
3) Make sure that the pressure in the servo oil supply pipes is zero.
4) Release the pressure in the gas fuel system.
5) Replace the remaining gas with inert gas. Refer to the Operation Manual 4002−2,
paragraph 3.12 to purge the gas fuel system.

Cylinder Liner: Removal and Installation
6) Remove the applicable cylinder cover,

refer to 2708−1.
6 7
7) Remove the piston together with the
piston rod gland, refer to 3403−1 and
2303−1.
8) Put an oil tray below the GAV (3,
1 Fig. 1).
9) Remove the oil pipe (7). Do not
damage sealing surface.
10) Disconnect the return pipe (2) and
lubrication pipe (1) from the GAV (3).
2 11) Disconnect the electrical connections
5 4 3 from the rail valve (6) and the valve
stroke sensor
FUEL SIDE WCH03629
12) Remove the six screws (4).
Fig. 1
13) Push the gas supply pipe (5) back a
small distance.
14) Put protection on the pipe openings.
15) Do step 8) to step 14) on the GAV at
exhaust side.
I 16) Make sure that all pipes and platforms
do not prevent the removal of the
cylinder liner together with each GAV.
3. Cylinder Liner −
1
Removal
1) Remove the screws (6, Fig. 2).
2
2) Remove the pipe connection (5) and
the transition tubes (8) from the water
WCH02341
guide jacket (3).
Note: The transition tubes (8) are a
I push-fit into the connection
tubes (5).
9
Fig. 2 4 3
WCH02341

94201
3.1 Lifting Tool − Install
CAUTION
Damage Hazard: The
cylinder liner and gas
admission valves weigh
only the correct lifting
equipment to lift and move
the cylinder liner to prevent
1 damage to equipment.
4
1) Put the two flange couplings (2, Fig. 3)
3 in position on the cylinder liner.
I
2) Tighten the five screws (4) in each
flange coupling.
2 WCH02342
3) Put the lifting tool (94201) in position on
top of the cylinder liner.
4) Apply copper paste to the threads of
the special screws (3).
I 5) Attach the two holders (1) to the flange
couplings (2) with the special screws
2 (3).
4 6) Torque the special screws (3) to
3 230 Nm.
Fig. 3
7) Connect the crane hook to the shackle
on the lifting tool (94201).
8) Carefully lift the cylinder liner (2,
Fig. 4). If necessary, turn the cylinder
liner to prevent damage to the gas
admission valves (GAV).
9) Move the cylinder liner (2) over the rail
unit as shown.
94201
10) Lower the cylinder liner (1) on to an
1 applicable wooden underlay.
3.2 Lifting Tool − Removal

1) Remove the two special screws (3,
Fig. 3).
2) Remove the lifting tool (94201) from the
cylinder liner.
3) Remove the special screws (3), then
remove the two flange couplings (2).
4) Remove the crane hook from the
shackle.
WCH02342
Fig. 4

1
I 4. Cylinder Liner −
2 Installation
1) Install the lifting tool (94201), refer to
the procedure in paragraph 3.1.
2) Clean the seating surfaces (6, Fig. 5)
II on the cylinder liner (1) and cylinder
jacket (3).
3 3) Carefully lower the cylinder liner (1)
almost on to the cylinder jacket (3). If
necessary, turn the cylinder liner to
prevent damage to the two GAV.
FUEL SIDE
4) Align the hole in the holder (4) with the
pin (5) on the cylinder jacket (3).
5) Fully lower cylinder liner (1).
6) Attach the connection pieces (8) and
the transition tubes (11) to the water
guide jacket (3) with the screws (9).
WCH02344
II 4
6
5
3
I
12
11
10
7 1
WCH02341
Fig. 5

7) Replace the O-ring in the flange of the

gas supply pipe (2, Fig 6).
8) Attach the gas supply pipe (2) to the
GAV (4) with six M12x35 screws (3).
1
2 9) Tighten equally the six M12x35
3 screws (3).
9
10) Attach the return pipe (7) and the
8 4 lubrication pipe (5) to the GAV (4).
11) Connect the electrical connection to the
rail valve (8).
5
12) Make sure that the sealing face of the
oil pipe (1) has no damage. If there is
damage, grind the sealing faces (refer
7
to 8460 paragraph 3).
13) Adjust the claw (11) with an open-end
wrench until there is a distance of
5.5 mm between the claw and the end
6 of the pipe (1) .
Fig. 6 14) Apply oil to the eight screws (9).
WCH03350
9 15) Carefully install the oil pipe (1).

16) Torque symmetrically the eight
I-I 1 screws (9) to 40 Nm.
1 17) Use the assembly tool (94023A, Fig. 8)
I I to attach the electrical connection (12)
to the valve stroke sensor (13).
18) Do step 7) to step 17) for the other
GAV.
10 19) Do a stroke signal test of a the GAV,
9
refer to the Operation Manual 4002−2,
11 paragraph 3.14 GAV Manual Valve
Test.
20) Do a leak test of the Gas System, refer
5.5 mm to Operation Manual, 4002−2, 3.13 Gas
WCH03378 Leak Test.
Fig. 7 21) Do a test of the GAV, see Operation
94023A Manual, 4002−2, 3.14 GAV Manual
Test.
12
13
Fig. 8 WCH03362

3
2
1 5. Water Guide Jacket −
Removal
5.1 GAV − Removal

CAUTION
Damage Hazard: The GAV
weighs approximately
WCH03632
70 kg. Use only the correct
lifting equipment to lift and
move the GAV to prevent
damage to equipment.
Fig. 9 1) Remove the cylinder liner, refer to
paragraph 3.
2) Remove all lubricating quills (refer to
2138−1 paragraph 1).
3) Install the M10 eye bolt (3, Fig. 9) to
gas admission valve (1).
4) Attach an applicable lifting tool (e.g.
chain block to the crane hook) to the
eye bolt.
5) Apply a light tension to the chain block
to hold the weight of the GAV.
6) Remove the four screws (2).
7) Remove the GAV.
8) Put the GAV in a clean dry area.

9) Remove the flanges of the lifting tool

(94201, Fig. 10) from the cylinder
liner (6).
94201 10) Attach the eye bolts (4) to the water
guide jacket (5).
11) Attach the three manual ratchets
(94016−031, 94016−009) to the three
eye bolts (4) and the shackles
(94018A) on the lifting tool (94201).
94018A Note: Make sure that you do not cause
damage the top of the cylinder
liner.
I
94016−031
6
I 94201
94016−009
1
3
5 2 WCH02342
Fig. 10 WCH02913
12) Remove the holder (4, Fig.11)

13) Loosen the three screws (1).
14) If the water guide jacket (3) does not
come away from the cylinder liner, do
as follows:
1 a) Put the three screws (1) in the
threaded holes of the holder (2).
b) Turn equally the three screws (1)
2 to push down the water guide
jacket.
3
Note: During step 18), make sure that
you keep the water guide jacket
level.
15) Operate the manual ratchets to lower
the water guide jacket on to the bottom
plates.
4
16) Attach the lifting tool (94201) to the
cylinder liner (refer to paragraph 2.1).
Fig. 11 WCH02344
17) Carefully lift then move the cylinder
liner to a different position on the
bottom plates.

6. Insulation Bandage −
94210
Removal
1) Remove the cylinder liner (refer to
paragraph 3).
2) Remove the water guide jacket (see
paragraph 5).
3) Use the tool (94233) to remove all the
tension springs (1, Fig. 13).
4) Remove the plate (3).
5) Remove insulation bandage (2).
7. Insulation Bandage −
Installation
1) Put the insulation bandage (2) in
position on the cylinder liner.
2) Put the plate (3) in position.
3) Use the assembly tool (94233) to
WCH02343 attach all the tension springs (1).
4) Install the water guide jacket (refer to
paragraph 8).
1
I 10 mm
II
WCH02348
3 2
II
Approx. 30 mm
Fig. 12

8. Water Guide Jacket −

Installation
94201 1) Install the insulation bandage, refer to
paragraph 7.
2) Replace all O-rings.
3) Apply oil to the O-rings.
94018A cylinder liner (refer to paragraph 3.1).
5) Lift, move and lower the cylinder liner
I into the water guide jacket (5, Fig. 13).
6) Remove special screw (1) and the
94016−009 flange (3) from the lifting tool (94201).
7) Attach the three manual ratchets
6
94201 (94016−031, 94016−009) and the
I shackles (94018A) to:
D The lifting tool (94201)
1
3 D The three eye bolts (4) on the water
guide jacket (3).
2
5 WCH02342
Note: During step 8), make sure that you
keep the water guide jacket level.
4 8) Operate the manual ratchets
(94016−031, 94016−009) to lift the
water guide jacket (5) to the applicable
WCH02913
position on the cylinder liner.
Fig. 13
1
9) Attach the water guide jacket (3,
Fig. 14) to the cylinder liner with the
2 three screws (1).
10) Attach the holder (4).
3
11) Remove the manual ratchets
(94016−031, 94016−009) and the lifting
tool (94201).
12) Install all lubricating quills, refer to
2138−1 paragraph 2.
4
WCH02344
Fig. 14

8.1 GAV − Installation

1) Clean all surfaces of the GAV (1,
Fig. 15) and the cylinder liner (3) that
touch.
2) Install new O−rings (2), to the GAV (1).
3
2 1
4
3
WCH03637
3) Attach the M10 eye bolt (5) to the
GAV (1).
4) Attach the applicable lifting equipment
to the M10 eye bolt (5).
5
5) Use the applicable lifting equipment to
1 move the GAV in position against the
6 cylinder liner (3). Make sure that the
two spring dowel pins (4) engage with
the related holes in the GAV (1).
6) Apply Never Seez High Temperature
Stainless to the thread and head of the
four bolts (6).
7) Torque the four bolts (6) to 170 Nm.
WCH03632
Fig. 15

94202L 9. Cylinder Liner − Safe

Storage
1) Make sure that the water guide jacket
is removed (refer to paragraph 5).
1
A B 2) Make sure that the insulation bandage
is removed (refer to paragraph 6).
3) Install the lifting tool (94210) to the
cylinder liner (see paragraph 3.1).
4) Attach the shackle (1, Fig. 16) to the
lifting tool (94210) in the position shown
in step A.
5) Attach the sling (94202L) to the shackle
2 (1) and the crane hook.
6) Operate the crane to put a light tension
on the sling (94202L).
7) Put the wooden underlay (2) in position
as shown in step B.
8) Carefully push the cylinder liner in the
direction shown and at the same time
lower the cylinder liner.
9) Put the wooden chocks (3) in position
C to prevent movement of the cylinder
liner (see step C).
10) Fully lower the cylinder liner (step D).
11) Remove the sling (94202L) from the
lifting tool.
D 12) Put more wooden underlays in position
(see E).
13) Remove the wooden chocks (3).
14) Carefully turn the cylinder liner 90_.
15) Put the two wooden chocks (3) in the
position shown to prevent movement.
3
cylinder liner.
10. Cylinder Liner −

Preparation
cylinder liner (refer to paragraph 3.1).
E 2) Make sure that shackle (1) is in the
position shown in step A.
3
3) Put more wooden underlays (2) in
3 position (see step E).
4) Remove the wooden chocks (3).
5) Carefully turn the cylinder liner 90_.
6) Attach the sling (94202L) to the lifting
WCH02349 tool.
Fig. 16 7) Carefully lift the cylinder liner to the
vertical position.

Intentionally blank
Cylinder Liner
Remove Unwanted Material, Dress the Lubricating

Grooves and Scavenge Ports
Tools:
1 Grinding device (opt.) 94299
1. General
During operation, the cylinder liner becomes worn and an edge of unwanted material
collects immediately above the location where the top piston ring movement stops.
Also, the lubricating grooves decrease in depth and the corner radii of the scavenge
ports become smaller.
Before each piston removal, you must first measure the bore of the cylinder liner (for
more data see 2124−1).
2. Preparation
1) Remove the cylinder cover, refer to 2708−1, paragraph 1 and paragraph 2.
2) Remove all lubricating quills, refer to 2138−1, paragraph 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 cylinder liner (1, Fig. 1), refer to the
Instruction Manual.
3) Connect the grinding tool (94299) to an applicable air supply.
4) Make sure that the milling cutter (2) has a diameter of 16 mm.
5) Align the middle of the milling cutter (2) to the edge of the unwanted material, refer
to A.
6) Operate the grinding tool (94299) to carefully remove the unwanted material from
the cylinder liner (1).
7) Make sure that you get a maximum angle of 40° at the cylinder liner (1).
Note: With a cutter of 16 mm diameter, you can remove a maximum of 1.9 mm
of material horizontally to stay below the maximum angle of 40° .

Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports
94299
WCH02352
A B C
Unwanted
Material max. 1.9 mm
2 3
Fig. 1 WCH03634

4. Lubricating Grooves
CAUTION
Damage Hazard: Make sure that you keep the initial shape of the
lubricating grooves when you remove sharp edges.
1) If the depth of the lubricating grooves (1, Fig. 2) has decreased to less than
1.5 mm, do as follows:
a) Use emery cloth or an oil stone to get the the lubricating grooves back to their
initial depth.
I 1
I-I
I
R1
I 1
R2−3
1 II
II
I 1
2.0 mm
WCH02350 I
Fig. 2

5. Scavenge Ports
CAUTION
Damage Hazard: When you polish the scavenge ports, make sure
that you do not cause damage to the running surface of the cylinder
liner.
Note: The scavenge ports (1, Fig.3) are as seen in new cylinder liners.
1) Use emery cloth to polish the surfaces of the scavenge ports. Make sure that you
keep the shape of the scavenge ports the same as those shown.
II II - II
III
1
II ROUNDED III
EDGES
WCH02350
WCH02350
WCH02350
Fig. 3
2) After the repair is completed, clean fully the lubricating grooves and the bore of
the cylinder liner.
3) Remove unwanted particles that could have passed into the scavenge space
through the ports.
4) Manually operate the cylinder lubrication until oil flows from all the lubricating
points. This will flush unwanted metal dust.

Work Card
Cylinder Lubricating Quill

− Lubricating quill removed

Hydraulic distributor 94934H Qty 1
Connection nipple (G¼ inch) 94934I Qty 1
HP hose 94935 Qty 1
Cylinder lubricating oil:

SAE 50 at 40_C (200 cSt)
SAE 30 at 25_C (190 cSt)

Preparation
Do a check of the tightness of the and function of Service Engineer 2.0 hours Qty 1
the lubricating quill and the NRV
Related Data

Bleed oil pipes 7218−1/A1
Bleed flex lube pump 7218−1/A1
Related Procedures
Bleed oil pipes 7218−1/A1

Bleed flex lube pump 7218−1/A1

Intentionally blank
Lubricating Quill

Tools:
1 HP oil pump 94931 1 Connection nipple (G¼ inch) 94934I
1 Hydraulic distributor 94934H 1 HP hose 94935
(with pressure gauge 1 Dismantling tool 94213
0 bar to 25 bar)
11
10
3 9
8
7
1
2
6 5
4 3
WCH03641
Fig. 1
1. Removal Procedure
Note: If it is not necessary to remove the cylinder liner (1, Fig. 1), do not drain
the cylinder cooling water.
1) Loosen the nuts of the lubrication quill unions (3).
Note: Make sure that you do not cause damage to the oil pipe (5).
2) Remove the oil pipe (5) from the lubricating quill (4) and the pipe union (6).
3) Seal the oil pipe (5) with an applicable plug to prevent contamination.
4) Remove the two bolts (2).
5) Remove the lubricating quill (4).
6) If necessary, do a function check of the lubricating quills (see paragraph 3).
Note: Steps 7) to 10) are only necessary if the cylinder liner (2) must be
removed.
7) Remove all holders (7) on the cylinder liner (1).
8) Remove the eight pipes (8, 10) from the pipes (9, 11).
9) Seal the pipes (8, 10) from the pipes (9, 11) with applicable seals to prevent
contamination.
10) Remove the cylinder liner (1), refer to 2124−2, paragraphs 1, 2 and 3.

Lubricating Quill
2. Nozzle Tip − Replace

1) Remove the two bolts (2, Fig. 2) and the plate (1) from the distance sleeve (3).
2) Put the distance sleeve (3) on (5) of the lubricating quill.
3) Attach the plate (1) to the nozzle tip (4). Engage the collar on the plate with the
recess on the lubricating quill (5).
4) Turn equally the two bolts (2) to remove the nozzle tip (4) from the holder (5).
5) Remove the distance sleeve (3).
6) Attach a new new nozzle tip (4) to the holder (5).
7) Make sure that the nozzle tip (4) is correctly attached to the holder (5).
8) Do the procedure in paragraph 3.
94213
3
1
5 2
I 1
4
A
WCH03863
3 I
Fig. 2
2018−02 2/ 5 Winterthur Gas & Diesel Ltd.

Lubricating Quill
3. Lubricating Quill − Function Check
3.1 General
Note: During the function check, keep the lubricating quill (2, Fig. 3) in a
horizontal position.
You do a function check to make sure that the non-return valve (3) operates correctly.
The pressure that opens the non-return valve is 5.0 bar.
For the function check, use an oil with a viscosity as given in the specifications that
follow:
D SAE 50 at 40_C (approx. 200 cSt)
D SAE 30 at 25_C (approx. 190 cSt).
3.2 Procedure
1) If necessary, remove the union (1) on the lubricating quill (2).
2) Connect the HP hose (94935) to the nipple (94934I).
3) Attach the nipple (94934I) to the lubricating quill (2).
4) Hold the lubricating quill (2) up and operate the pump until oil that flows has no
air.
5) Open the relief valve (RV) and decrease the pressure to 2.0 bar.
6) Close the relief valve (RV).
7) Hold the lubricating quill (2) in a horizontal position.
8) Operate the pump and increase the pressure in steps of 1.0 bar until the
non-return valve (3) opens.
9) Record the pressure shown on the pressure gauge (94934H).
Note: The minimum permitted pressure to open the non-return valve is 4.25 bar.
If necessary, replace a defective lubricating quill (2).
94934I
1 2 3
WCH00112
94931 RV 94934H 94935

Fig. 3

Lubricating Quill
4. Installation
CAUTION
Damage Hazard: The surfaces of the cylinder liner and the nozzle
tip make a metallic seal. The seat angles in the cylinder liner and on
the nozzle tip are different. Do not use a gasket between the
cylinder liner and the nozzle tip. Damage to the equipment can
occur.
Note: When you install the lubricating quill, replace all components.
1) Make sure that the sealing surfaces (1, Fig. 4) are clean and have no damage.
WCH03216
Fig. 4

Lubricating Quill
2) Apply oil to the threads of the two screws (3, Fig. 5).
3) Put the lubricating quills (5) in position.
4) Torque the two screws (3) to 10 Nm.
5) Step a) to step f) is only necessary if the cylinder liner was removed.
a) Install the cylinder liner (2), refer to 2124−2, paragraph 4.
b) Remove the protection from the eight pipes (9, 11.
c) Install the eight pipes (9,11).
d) Attach the holders (8) to the cylinder liner (2).
e) Remove the plugs from the oil pipes (10, 12).
f) Connect the oil pipes (9, 11) to the oil pipes (10, 12).
6) Connect the oil pipe (6) to the pipe union (4) and the pipe union (7).
7) Tighten the nuts of the pipe unions (4, 7).
8) Bleed the oil pipes (6) (refer to 7218−1, paragraph 3.2).
9) If necessary, bleed the flex lube pump (1), refer to 7218−1, paragraph 3.1.
10) Do a function check of the cylinder lubricating system, refer to 7218−1,
paragraph 1.2.
1
12
11 1
3 10
9
8
2
3
7 6
5 4
WCH03641
Fig. 5

Intentionally blank
Work Card
Gas Admission Valve: Check
− Engine stopped O-ring EX 21418 Qty 2

− Gas admission valve removed, 2140−1/A1 O-ring EX 21429 Qty 2
O-ring EX 21430 Qty 2
Pressure reducing valve 94241B Qty 1

Bush 94214E Qty 1
Bracket 94241D Qty 1
Spring press 94214C Qty 1
Oil tray
Plugs etc for pipe protection
Nitrogen supply
WD 40
Molykote G Rapid Plus
Preparation
Do a check of the tightness and function of the GAV Service Engineer 4.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Work Card
Gas Admission Valve: Do an Overhaul of the Valve Seat

− Gas admission valve removed, 2140−1/A1
Knurled nut 94214A Qty 1
Lube oil
Lapping paste
(0.5 to 4.0 microns

Preparation
Do an overhaul of the valve seat Service Engineer 2.0 hours Qty 1

Related Data

Related Procedures
Gas Admission Valve − Pressure Test 2140−1/A1

Intentionally blank
Work Card
Gas Admission Valve: Check of the Compensator

− Gas admission valve removed, 2140−1/A1
Not applicable

Preparation
Do a check of the compensator Service Engineer 0.5 hours Qty 1

Related Data

Related Procedures

Intentionally blank
Work Card
Gas Admission Valve: Replace
− Engine stopped Gas admission valve EX 21404 Qty 2

− Gas admission valve removed, 2140−1/A1 Rail valve EX 21415 Qty 2
− Disassemble the gas admission valve 2140−1/A1 Valve stroke sensor EX 21417 Qty 2
Not applicable

Preparation
Replace the Valve Spindle, Guide, Valve Stroke Service Engineer 0.5 hours Qty 1
Sensor and Rail Valve
Related Data

Related Procedures

Intentionally blank
Gas Admission Valve

Removal, Disassemble, Assemble and Installation
Tools:
1 Eye bolt 94045−M10 1 Assembly tool 94023A
1 Dismantling tool 94214 2 Screw M10 94214L
1 Handle 94214A 2 Hexagon nut M10 94214M
1 Pressure reducing valve 94214B
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1 Valve Assembly − Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Valve Seat − Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. General
1) Read the data in the:
D Operation Manual, 0210−1 Safety Precautions and Warnings
D Operation Manual, 2140 Gas Admission Valve (GAV)
D Operation Manual, 8014−1, Gas Fuel System
D Operation Manual, 4003−12, Diagram Gas Fuel.
D Operation Manual, 4002−2, 3.14 GAV Manual Test
2) For the inspection intervals, refer to the Maintenance Schedule 0380−1, Group
2140.
Note: Because removal of the gas admission valve (GAV, 1 Fig. 1) cannot be
done easily, it is recommended that you disassemble the GAV in the
installed position. The housing and the gas supply pipe (2) can stay on
the cylinder liner.
2 1
2
EXHAUST SIDE FUEL SIDE
Fig. 1

Gas Admission Valve: Removal, Disassemble, Assemble and Installation
2. Preparation
1) Stop the engine.
2) Set to off the main bearing oil pumps (use the service pump for tests).
3) Make sure that the pressure in the servo oil supply pipes is zero.
4) Make sure that the pressure in the gas pipe, high pressure pipe and lubricating
oil pipe is zero.
5) Make sure that the drain from the gas control valve is open.
WARNING
Danger: Some gas can leak during the removal of the GAV. Do not
use equipment that can cause a spark. Make sure that all equipment
that can case a spark is not in the work area. This will prevent an
explosion, or a fire.
3. Removal
1) Put an oil tray below the GAV (2,
Fig. 2).
1
1) Remove the oil pipe (1). Do not
damage sealing surface.
6 2) Remove the return pipe (5) and
2 lubrication pipe (3) from the GAV (2).
3) Put protection on the pipe openings.
3 4) Disconnect the electrical connection

from the rail valve (6).
4
Fig. 2
WCH03350
94023A
5) Use the tool (94023A, Fig. 3) to
disconnect the electrical connection (1)
from the valve stroke sensor (2).
1
Fig. 3

1
2 4. Disassemble
3 1) Remove four bolts (3, Fig 4).
2) Carefully remove the cover (4) together
with the rail valve (5). Make sure that
4 the piston (8) does not go into the
cover (7).
3) Remove the coupling nut (1) on the
5 valve stroke sensor (2).
4) Remove the valve stroke sensor (2)
and its distance sleeve.
3 5) Remove symmetrically the six bolts (6).
7 6 WCH03350 6) Carefully remove cover (7).
4 3
WCH03361
Fig. 4 8
7) Remove the six screws (1, Fig. 5).
WCH03648
Fig. 5

8) Put the two M10 screws 94214L (1,

Fig. 6) in position in the M10 threads.
1
9) Turn equally the two M10 94214L
screws to remove the valve
2 assembly (2).
4.1 Valve Assembly −

Disassemble
1) Attach the steel plate (94214F, Fig. 7)
to the bush (94214E) with the five
screws.
3 2) Put the steel plate (94214F) and the
attached bush (94214E) horizontally
into a vice.
3) Make sure that the sealing faces (SF1)
are clean.
4) Put the soft metal gasket (94214I)
between the sealing faces (SF1).
Fig. 6 WCH03361 5) Put the valve assembly (7) into the
bush (94214E).
6) Apply Molykote G-Rapid plus to the
rods of the spring press (94214C).
7) Attach the spring press (94214C) and
the valve assembly (7) to the bush
(94214E) with the six M10x45
94214C 1 screws (4).
8) Torque the six screws (4) to 40 Nm.
11 9) Attach the bracket (94241D) to the
other side of the bush (94214E) with
the two M6x75 screws (10).
2 10) Turn the special screw (9) fully in.
3
11) Turn the T-handle (1) clockwise to
94214C
compress the spring (5). This pushes
4 the valve cotter (2) out of the spring
carrier (3).
12) Remove the valve cotter (2).
5
13) Turn the T-handle (1) counterclockwise
6 to release the tension in the spring (5).
94214F 14) Remove the bracket (94214D).
7 15) Remove the valve spindle (8).
8 16) Clean the valve spindle (8) and do a
check for damage, specially the sealing
94214E surface (SF2).
94214I 17) Carefully put the valve spindle (8) into
SF1
SF2 the valve guide (6).
18) Move the valve (8) spindle fully in and
94214D out. The friction must be the same
10 9 during the stroke, e.g. the valve spindle
WCH03362 must not slip, or stay in position. The
Fig. 7 valve spindle must move down
smoothly.

5. Pressure Test
1) Apply lube oil to the valve spindle (6,
1
Fig. 8).
2) Put the valve spindle (6) into the valve
guide (5).
3) Install the bracket (94241D) to the bush
(94214E) with the two M6x75
2
screws (8).
3
94214C 4) Turn the special screw (7) fully in.
5) Turn the T-handle (1) in to compress
the spring (4).
6) Install the valve cotter (2) on the valve
4 spindle (6).
94214B 5 7) Turn the T-handle (1) back to release
the tension in the spring (4). Make sure
that the valve cotter (2) is fully in the
spring carrier (3).
8) Attach the pressure reducing valve
6
(94241B) to the bush (94214E).
94214E
9) Attach a pressurized nitrogen supply to
94214I the pressure reducing valve (94241B).
SF1
SF2 10) Set the pressure reducing valve to
10 bar.
94214D 11) Apply a thin layer of WD40 (or an
8 7 approved alternative) as a spray to the
Fig. 8 WCH03362 area of the valve seat SF2.
12) The test is satisfactory if:
a) Up to five bubbles each second
come from the valve seat.
b) No bubbles come from the soft
metal seal.
13) If the test results are different than
1 94214A those given, do the procedure given in
2 paragraph 6.
6. Valve Seat − Lap

1) Remove the spring (5, Fig. 7), refer to
paragraph 4.1.
2) Attach the knurled nut( 94214A, Fig. 9)
to the valve spindle as shown.
3) Apply lube oil to the valve spindle (1).
4) Put the valve spindle (1) into the valve
94214E guide (2).
5) Use oil-based lapping paste with a
grain size of 0.5 to 4.0 microns to lap
Fig. 9 WCH03362 the valve seat.
6) Do the pressure test again (refer to
paragraph 5). If the leakage is is
unsatisfactory, replace valve spindle
and the valve guide.

7. Assemble
94214C 1 1) Insert the valve assembly (valve guide
(7, Fig. 10), valve spindle (8), spring (5)
11 and spring carrier (3)) into the bush
(94214E).
2) Attach the spring press (94214C) and
2 the valve assembly to the bush
3 (94214E) with the six M10x45
94214C screws (4).
4 3) Tighten the screws (4).
4) Attach the bracket (94241D) on the
5 other side of the bush (94214E) with
the two M6x75 screws (10) .
6 5) Turn the special screw (4) fully in.
94214F 6) Turn the T-handle (1) clockwise to
7 compress the spring (5).
8 7) Put the valve cotter (2) on the spring
94214E carrier (3) in the groove of the valve
spindle (8).
94214I
SF1 8) Slowly turn the T-handle (1)
SF2 counterclockwise. Make sure the valve
cotter (2) stays in the correct position.
94214D
9) Remove the spring press (94214C) and
10 9 remove the valve assembly from the
bush (94214E).
WCH03362
10) Clean all surfaces and bores of the

housing (12).
11) Replace the O-rings (14) with new
ones.
12) Apply oil to the O-rings (14).
13) Replace the gasket (13).
14
12
Fig. 10 13 WCH03361

1 14) Make sure the spring dowel pin (2,

2 Fig. 11) is installed in the housing (1).
3 15) Put the valve assembly (valve guide
(3), spring (15), spring carrier (6), valve
spindle (4)) in the correct position in the
housing (1) in the cylinder liner.
Stainless to the six M10x50 screws (7).
17) Torque the six M10x50 screws (7) to
40 Nm.
18) Make sure the spring dowel pin (2) is
7 6 5 4 installed in the housing (1).
19) Replace the O-ring (13) in the
cover (14).
Stainless to the six M10x80 bolts (11).
4 8 9 21) Make sure the surfaces of the
15 6 cover (14) that touch are clean.
10 11
22) Install the cover (14) with the six
14 M10x80 bolts (11).
12
23) Torque the six bolts (11) to 40 Nm.
CL 24) Replace the O-ring (12) on the distance
sleeve (8) (the distance sleeve is
bonded on).
25) Put the valve stroke sensor (9) into the
cover (14). Turn the valve stroke
sensor clockwise until it touches the
spring carrier (6).
WCH03361 26) Turn the valve stroke sensor (8)
13 counterclockwise one turn. This gives a
clearance (CL) of 1.5 mm.
Fig. 11 27) Apply Never Seez High Temperature
Stainless to the thread of sleeve (10).
28) Hold the sensor (9) and torque the
sleeve (10) to 90 Nm.
29) Replace the O-ring (1, Fig. 12) and

O-ring (2).
WCH03649 2
Fig. 12

30) Measure the distance (PT, Fig. 13) of

2 the valve spindle to the cover (11).
1
31) Clean the piston hole in the cover (1).
32) Apply lubricating oil to the piston (3).
3
33) Put the piston (3) fully into the hole.
34) Measure the piston stroke (ST).
35) Calculate the valve clearance ST − PT.
ST
Note: The valve clearance ST − PT must

4 5 be 0.20 to 1.37 mm. If the valve
clearance is too low, the valve
PT
6
12 7 cannot fully close.
8
36) Clean the surfaces of the cover (11)
11 and the cover (1).
9
CL Stainless to the threads of the four
bolts (2).
38) Attach the cover (1) with the four
bolts (2).
WCH03361
10
Fig. 13

8. Installation
1) Attach the return pipe (5, Fig. 14) and
1 the lubrication pipe (3) to the GAV (2).
7 rail valve (6).
6
3) Make sure that the sealing face of the
2
oil pipe (1) has no damage. If there is
damage, grind the sealing faces (refer
to 8460−1, paragraph 3).
3
4) Adjust the claw (9) with an open end
wrench until there is a distance of
5 5.5 mm between the claw and the end
of the pipe (1) .
5) Apply oil to the eight screws (7).
6) Carefully attach the oil pipe (1) to the
4 GAV (2) with the eight screws (7).
7) Torque symmetrically the eight
WCH03350 screws (7) to 40 Nm.
8) Use the assembly tool (94023A) to
attach the electrical connection (10) to
the valve stroke sensor (11).
1
9) Do a stroke signal test of the GAV, refer
I-I to the Operation Manual 4002−2,
I I paragraph 3.14 GAV Manual Valve
1
Test.
10) Do a leak test of the Gas System, refer
to the Operation Manual, 4002−2, 3.14
Gas Leak Test.
7
11) Do a test of the GAV, refer to the
8 Operation Manual, 4002−2, 3.14 GAV
Manual Test.
9
5.5 mm
WCH03378 94023A
10
11
Fig. 14 WCH03362

Intentionally blank
Work Card
Piston Rod Gland: Clean the Rings and Measure Worn Parts

− Piston rod gland disassembled
Remove the piston rod gland, refer to 2303−1/A1 Not applicable
Note: There are two procedures to remove and

install the piston rod gland.

Preparation
Clean the rings and measure worn parts Service Engineer 5.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Work Card
Piston Rod Gland: Replace the Rings
− Engine stopped Extension spring EX 23111 Qty 4

− Piston rod gland disassembled Extension spring EX 23112 Qty 4
O-ring set and locking plates EX 23145 Qty 1
Scraper ring set EX 23200 Qty 1
Remove the piston rod gland, refer to 2303−1/A1 Not applicable
Note: There are two procedures to remove and

install the piston rod gland.

Preparation
Replace the rings Service Engineer 5.0 hours Qty 1

Related Data

Related Procedures
Assemble the Piston Rod Gland, 2303−1/A1

Intentionally blank
Piston Rod Gland
Removal, Disassemble, Measure Worn Parts, Assemble,

Installation,
Tools:
2 Work platforms 94142 1 Distance piece (11 mm) 94231C
2 Work supports 94143 1 Distance piece (9 mm) 94231D
2 Distance holders 94230 2 Spring assembly tool 94233
1 Clamp ring (2-parts) 94231A 1 Piston support device 94350
1 Distance piece (12 mm) 94231B 1 Platform 94234
1 Template 94231E 2 Manual ratchets (H1, H2) 94016−009
1 Lifting tool 94235
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Procedure One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Piston Rod Gland − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Piston Rod Gland − Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Worn Parts − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Piston Rod Gland − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Piston Rod Gland − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Procedure Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Piston Rod Gland − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Piston Rod Gland − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1. General
CAUTION
Damage Hazard: Do not turn the crankshaft when the work
platforms (94142) or the work supports (94143) are installed in the
crankcase. Damage to the equipment can occur.
For safety, always use the work platform (94142) and the work supports (94143) for
all maintenance work in the crankcase. Make sure that the grids and working supports
are correctly attached. For more data, see 3301-1.
Examine the piston rod gland for damage and worn parts on each overhaul of the
piston (refer to 0380−1, Group 2303−1). If necessary, replace the unserviceable parts.
When you assemble the piston rod gland, make sure that all parts are in a serviceable
condition.
D Procedure One: The piston with the piston rod gland is removed from the engine.
The piston rod gland is disassembled and assembled in the external piston
support device (94350). For more data, refer to paragraph 2.1.
D Procedure Two: The piston stays in position. The piston rod gland is
disassembled and assembled in the crankcase. For more data, refer to
paragraph 3.

Removal, Disassemble, Measure Worn Parts, Assemble, Installation,
2. Procedure One
2.1 Piston Rod Gland − Removal

WARNING

piston to BDC.
2) Lock the turning gear to prevent
movement of the crankshaft.
1
3) Attach the two distance holders (94230,
Fig. 1) to the piston rod (3).
4) Remove the four inner bolts (1) from
2
the support (2).
3 5) Remove the piston and the piston rod
gland, refer to 3403−1, paragraph 1,
and paragraph 2.
6) Make sure that the piston rod gland (2,
Fig. 2) is in the correct position on the
two hinged covers (1).
2
1
94230
94350
WCH02398
Fig. 1 94230
Fig. 2 WCH02398

I 2.2 Piston Rod Gland −

Disassemble
5 1) Remove the four screws (4, Fig. 3)
from the piston rod gland (3).
2) Remove the O-Rings (1).
4 3) Push the two parts of the housing (5)
1 away from the piston rod.
4) Remove the two parts of the
housing (5).
5) Remove the spring dowel pin (2).
WCH02376
3 6) Remove the parts that follow:
I 2
D Tension springs (6, 10)
D Scraper rings (15, 13, 11)
D Gaskets (13, 8, 9)
I-I D Spring dowel pins (7, 14)
D Ring supports (12).
15 6
7
14 2.3 Worn Parts − Measure
13 Note: You can find the maximum
14 permitted dimensions of worn
8 parts in 0330−1, Piston Rod Gland.
13 If necessary, replace the worn
9 parts.
10 1) Compare the dimension of the worn

parts that follow:
D Scraper rings (15, 13, 11)
D Gaskets (14, 8, 9).
12
2) Make sure that the tension springs (6,
11 10) and O-ring (1) are serviceable. If
Fig. 3 necessary, replace the unserviceable
WCH02292
parts.

II - II
II
3
II 4
2
5
1
WCH02292
I I
1
4 I-I
6
10
9 8 8 7
Fig. 4: Piston Rod Gland − Key to Parts
1 Bolt M12x55 6 Dowel Pins

2 Cylinder Block 7 Inner Bolt M16x100
3 Spring dowel pin 8 Lock-plate
4 Housing, 2-part 9 Outer Bolt M16x100
5 Support 10 O-Rings

10
2.4 Piston Rod Gland −
9
1 Assemble
2 1) Attach the two parts of the clamp ring
(94231A, Fig. 5) to the piston rod.
94231B
8 2) Put the three parts of the ring support
(6) and the scraper rings (5) on the
3
8 clamp ring (94231A).
94231C
3) Use the assembly tool 94233 to attach
the tension spring (7) to the ring
support (6).
7
4) Put the two parts of the distance piece
94231D (9.0 mm height) on the ring
6 support (6).
94231D
5 Note: The height of the distance piece
(4231C) is the same as the
distance between the ring grooves
in the housing.
4
94231A 5) Put the next three parts of the ring
support (6) and the scraper rings (5) on
3 the distance piece. Make sure that
WCH02292
there is an equal distance between the
three parts.
attach the tension spring (7) to the ring
support (6).
7) Remove the distance piece (94231D).
8) Do the step 4) to step 7) above again
10 1 until the four ring supports (6) are
12 attached to the piston rod (4).
11
9) Put the two parts of the distance piece
8
(94231C) (11.00 mm height) on the top
11
ring support (6).
2
8 Note: One segment of the gaskets (8, 2,
3 3) has two holes for the horizontal
spring dowel pins (11). The other
7 three segments have only one
hole. On the top of one segment of
the gasket (2) there is one hole for
a vertical spring dowel pin (12).
6 10) Put the four parts of the gaskets (8, 3)

5 on the distance piece (94231C).
11) Make sure that all horizontal spring
WCH02292
dowel pins (8) are installed.
Fig. 5 12) Use the assembly tool (94233) to
attach the tension spring (1) to the
gaskets (8,3).
13) Remove the distance piece (94231C).

14) Put the two parts of the distance piece (94231B, Fig. 5) (12 mm height) on the
gaskets (8, 3).
15) Put the four parts of the gaskets (8, 2) on the distance piece (94231B). Make
sure that there is an equal distance between the four parts.
16) Make sure that all horizontal spring dowel pins (8) and the vertical spring dowel
pin (12) are installed.
Note: On top of the scraper rings (9) there is one hole for a vertical spring
dowel pin.
17) Put the scraper ring (9) on the gaskets (8, 12). Make sure that there is an equal
distance between the four parts.
18) Make sure that the vertical spring dowel pins (12) are installed.
19) Use the assembly tool (94233) to attach the tension spring (1) to the scraper
ring (9).
Note: There is no hole for a vertical spring dowel pin on the top of the scraper
ring (10).
20) Put the scraper ring (10) on the top of the scraper ring (11). Make sure that there
is an equal distance between the four parts.
21) Make sure that the vertical spring dowel pins (12) between the scraper ring (10)
and the scraper ring (11) is correctly installed.
I attach the tension spring (1) to the
scraper ring (10).
5
23) Remove the distance piece (94231B).
24) Remove the clamp ring (94231A,
Fig. 6).
4
25) Put the template (94231E) over the
1 assembled rings. Make sure that all
parts are in the correct position. If
necessary, correct their positions.
26) Apply bearing oil to the piston rod and
WCH02376 the assembled rings.
3
2 27) Push the two parts of the housing (5)
I
over the assembled rings. Make sure
that the dowel pins (2) are installed.
I-I
28) Torque the two screws (4) to the value
given in 0352-2 Torque Values for
5 Standard Screws, paragraph 1.
29) Apply oil to the new O-rings (1).
94231B 30) Attach the O-rings (1) to the two parts
of the housing (5).
94231C 31) Put the dowel pin (2) in position.
94231D
Fig. 6 94231E
94231A

2.5 Piston Rod Gland − Installation

To install the piston rod gland (1, Fig. 7), do the steps that follow:
1) Apply lubricating oil to the opening in
the cylinder jacket (3) and to the area
1
of the O-rings (2) on the housing (1).
2) Make sure that the distance holders
2 94230 are attached to the piston rod
(see Fig. 2).
3) Make sure that the support (4) is
installed on the cylinder jacket (3). If
necessary, torque the outer bolts 7 to
150 Nm.
4) Install the piston and the piston rod
gland, refer to 3403−1, paragraph 3.
3
the area.
2
WCH02292
Fig. 7 4

3. Procedure Two

Removal
WARNING
I Injury Hazard: Before you
make sure that no
personnel are near the
1 flywheel, or in the engine.
1) Disconnect the toggle lever (1, Fig. 8)

from crosshead (2).
94143 2 2) Use a chain block to lift and hold the
toggle lever (1) in the position shown.
3) Operate the turning gear to turn the
3
crankshaft (3) 90° counterclockwise
from TDC.
4) Install the work support (94143).
5) Lock the turning gear to prevent
movement.
6) Remove four bolts (4) together with the

lock-plates.
4 4
WCH03570
Fig. 8

7) Install the lifting tool (94235, Fig. 9)

5 1 below the piston rod gland (5). Make
sure that the piston rod gland touches
the lifting tool.
8) Lightly tighten the four bolts (3).
4 10) Remove the eight bolts (4) together
94235 with the lock-plates.
3
WCH03570
Fig. 9
94018B 94018B
H1 11) Remove the work support (94143,
H2 Fig. 10).
3 94045-M12 crosshead (1) to BDC.
14) Attach the shackles (94018B) to each
side of the column.
I 1
2 15) Attach the manual ratchets (H1, H2) to
94143 the shackles (94018B).
16) Install the two eye bolts (94045-M12) to
the piston rod gland (3).
17) Attach the manual ratchets (H1, H2) to
the eye bolts (94045-M12) on the
piston rod gland (3).
18) Operate the manual ratchets (H1, H2)
I to apply a light tension to the chains.
7 19) Make a mark as shown on the piston

rod (7) to record the position of the
MARK 94045-M12
20) Remove the four bolts (4) from the
3
21) Slowly loosen the four bolts (5) on the
tool (94235), sufficiently to pull down
6 the tool together with the support (6).
94235
22) Pull the tool (94235) down to the piston
5 4 rod foot (2).
Fig. 10 WCH03570

CAUTION
Equipment Hazard. Do not
get on the support (94344).
The maximum permitted
weight is 140 kg. Damage to
23) Install the assembly platform (94234,

Fig. 11) through the support plate (2)
on the studs of the piston rod foot (3).
1 24) Operate the manual ratchets (H1, H2)
94234 to lower the piston rod gland on to the
assembly platform (94234).
2
3
WCH03570
Fig. 11
To disassemble the piston rod gland, do the procedure given in paragraph 2.2.
To measure worn parts, do the procedure given in paragraph 2.3.
To assemble the piston rod gland, do the procedure given in paragraph 2.4.

H1
H2 Installation
MARK
1) Operate the manual ratchets (H1 and
H2, Fig. 12) to lift the piston rod gland
(1) to the mark you made before.
2) Remove the assembly platform
(94234).
3) Lift the tool (94235) together with the
1 support plate (2) up to the piston rod
gland (1).
94234
4) Attach the tool (94235) to the piston rod
gland (1) with the four bolts (4).
2 94235 Note: Make sure the dowel pin in the
piston rod gland (1) is at the same
position as the hole in the support
plate (2).
WCH03570 6) Remove the work support (94143).
piston rod gland (1) into the cylinder
block (to TDC). Make sure that the
5 dowel pin in the piston rod gland
engages with hole in the support
MARK plate (2).
94045-M12
1
2
94235
4 3
WCH03570
Fig. 12

9) Apply oil to the eight bolts (4, Fig. 13).

5 1
10) Install the eight new lock-plates and
bolts.
11) Torque the eight bolts to 150 Nm.
Note: Make sure that the spring dowel
pin in the piston rod gland goes
4 into the hole in the support
94235 plate (5).
3 12) Bend the lock-plates to lock the eight
bolts (4).
13) Remove the four bolts (3).
2 14) Loosen the four bolts (1).

15) Remove tool (94235).
16) Apply oil to the four bolts (6).
WCH03655
17) Install the four new lock-plates and

bolts (6).
19) Bend the lock-plates to lock the four
bolts (6).
6 6
Fig. 13 WCH03570
1
20) Attach the toggle lever (1, Fig. 14) to
the crosshead.
21) Tighten the five M20x70 bolts (3).
22) Lock the five bolts (2) with wire as
shown.
2
the work area.
WCH03654
Fig. 14

Work Card
Cylinder Cover

− Cylinder cover removed
Remove the cylinder cover, refer to 2708−1/A1 Not applicable

Preparation
Do a check of the combustion space Service Engineer 1.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Cylinder Cover and Top Water Guide Jacket

Tools:
1 Lifting tool (option) 94215 1 Adapter 94934
8 Pre-tensioner 94215A 1 Pressure gauge 94934A
1 Suspension device 94265 3 HP hose 94935
1 Hydraulic unit 94942 7 Flexible hose 94935A
1. Preparation
WARNING
9
8 1 Injury Hazard: You must put
on safety goggles and
7 gloves when you do work
2 on hot components. Oil can
3 come out as a spray and
6
4 cause injury.
1) Stop the engine.
2) Let the engine temperature decrease.
5
3) Make sure that all tools and equipment
3 are clean.
4) Close manually the starting air supply
valves 930-V03 and 930-V04, refer to
the Operation Manual 4003−2, Control
Diagram.
5) Close the cylinder inlet butterfly valves
to the cooling water system.
6) Open the drain valve to the cylinder
cooling water from the applicable
cylinder, refer to the Operation Manual
in 8017-1.
Fig. 1 WCH03657
7) Close the valves from the gas supply. Make sure that there is no pressure in the
gas pipes.
8) Close the valves from the fuel supply and pilot fuel supply. Make sure that there
is no pressure in HP fuel pipes (7, Fig. 1) and pilot fuel pipe (8).
9) Remove the hydraulic pipe (6), refer to 8460−1.
10) Remove the three HP fuel pipes (7), refer to 8733−1.
11) Remove the applicable HP pilot fuel pipes, refer to 8790−1.
12) Make sure that there is no pressure in the cooling water pipe (2).
13) Remove the cooling water pipe (2).
14) Remove the expansion piece (1), refer to 2751−1, paragraph 2, step 3) to step 9).
15) Close the starting air valve. Disconnect the air pipe (5) from the cylinder cover.
16) Remove the oil leakage pipe (9) and the pilot fuel pipe (8).
17) Disconnect the air pipe from the exhaust valve housing.
18) Record the positions of the connections to the injectors.
19) Disconnect all connections from the injectors.
20) Disconnect all other connections from the cylinder cover and the exhaust valve.

Cylinder Cover and Top Water Guide Jacket: Removal and Installation
2. Removal
1) Operate the engine room crane to put
the lifting tool (94215, Fig. 2) in position
94215 above the cylinder cover.
2) Lower the lifting tool (94215) to get the
eight pre-tensioning jacks (94215A)
directly above the elastic studs (1).
2
3) Attach the pre-tensioning jacks
(94215A) and the distance sleeves (2)
94215A on the elastic studs (1).
4) Connect the jacks to the hydraulic
1 pump, refer to 9403−2.
5) Apply tension to the elastic bolts, refer
to 9403−4.
6) Remove the six round nuts from elastic
studs (1).
7) Remove the tool (94215).
CAUTION
WCH03658 Injury Hazard: The weight
of the cylinder cover, the
Fig. 2 top water guide jacket and
the exhaust valve is
approximately 3700 kg. To
prevent injury, use the
correct equipment for
removal.
2
eye bolt (1, Fig. 3) on the exhaust
valve (2).
9) Carefully lift the cylinder cover (3)
together with the exhaust valve (2) and
the top water guide jacket (5).
I 3 I-I 10) Lower the cylinder cover on to wooden
4 supports.
11) Remove the three screws (4) from the
4 cylinder cover (3).
Note: During step 12) make sure that the
top water guide jacket stays on the
wooden supports. If this does not
I 6 occur, use a mallet to move the top
6 5 water guide jacket.
WCH03660
Fig. 3 12) Use the engine room crane to lift the
WCH03659 exhaust valve assembly approximately
10 mm. Make sure that the top water
guide jacket stays on the wooden
supports.

13) Lift, then lower the cylinder cover (4,

Fig. 4) and the exhaust valve
assembly (3) on to wooden supports.
1 14) Apply tension to the elastic studs (1),
2 refer to 9403−4
3 15) Remove the round nuts (2).
16) Operate the engine room crane to lift
the exhaust valve assembly (3)
approximately 10 mm. Make sure that
the cylinder cover stays on the wooden
4 supports.
17) Fully lift the exhaust valve assembly (3)
from the cylinder cover.
18) Carefully lower the exhaust valve
assembly (3) on to wooden supports.
Wooden Support
Fig. 4 WCH03660
1
3
94265
19) Attach the tool (94265, Fig. 5) to the
cylinder cover as shown.
20) Attach the round nuts (3) to the elastic
2 studs. Tighten the round nuts.
21) Attach the the engine room crane to
tool (94265).
move the cylinder cover (2) to an
applicable area.
WCH02640
Fig. 5 23) Remove the tool (942656).
24) Remove and discard all O-rings.
25) Remove and discard the soft iron joint
ring.

1 3. Installation
1) Clean the O-ring grooves.
2) Clean the sealing surfaces of the
cylinder cover.
2 3) Put oil on the new O-rings (7 and 8,
3 Fig. 6).
I 4 4) Install new O-rings (7, 8).
5) Put a new soft iron joint ring (9) in
position in the cylinder liner.
5 6) Put oil on the new O-ring (13).
7) Put the O-ring (13) in position on the
transition tube (12).
8) Clean the threads of all elastic
I studs (2).
6 I-I 9) Put oil on the threads of all elastic
5 studs (2).
eye bolt (1).
11) Lift the exhaust valve assembly (4).
12) Carefully lower the exhaust valve (4)
assembly on to the cylinder cover (5).
13) Attach the round nuts (3) to the elastic
7 studs (2).
10
8
14) Apply tension to the elastic studs (2),
6 refer to 9403−4.
15) Tighten the round nuts (3).
WCH03659
9 16) Lift the exhaust valve assembly (4)
together with the cylinder cover (5).
17)
assembly (4) and the cylinder cover (5)
on to the top water guide jacket (6).
19) Tighten the screws (10).
20) Lift the exhaust valve assembly (4),
cylinder cover (5) and top water guide
jacket (6).
6 Note: During step 19), make sure that the
tube (12) goes into the bore in the
13 top water guide jacket (6).
12 assembly (4), cylinder cover (5) and top
water guide jacket (6) on to the cylinder
liner (11).
22) Remove the engine room crane from
the eye bolt (1).
11 to 9403−4.
24) Remove the six round nuts from elastic
WCH03659 studs (1).
Fig. 6

26) Attach the eight round nuts (2, Fig. 7)

to the elastic studs (1).
27) Use the lifting tool (94215) to move the
eight pre-tensioning jacks (94215A) on
28) Attach the pre-tensioning jacks
94215
(94215A) and the distance sleeves (2)
on the elastic studs (1).
29) Connect the jacks to the hydraulic
2 pump, refer to 9403−2.
to 9403−4.
94215A
31) Tighten the eight round nuts (2).
1 32) Remove the tool (94215).

2
WCH03658
Fig. 7

3.1 Completion
1) Install the expansion piece (2), refer to
2751−1, paragraph 3.
9 2) Install the hydraulic pipe (6), refer to
8 1 8460−1.
7 3) Install the three HP fuel pipes (7), refer

2 to 8733−1.
3 4) Install the applicable HP pilot fuel
6
4 pipes, refer to 8790−1.
5) Install the cooling water pipe (2).
6) Install the expansion piece (1), refer to
5 2751−1, paragraph 2, step 14) to
step 21).
3
7) Connect the air pipe (5) to the cylinder
cover.
8) Install the oil leakage pipe (9) and the
pilot fuel pipe (8).
9) Connect the air pipe to the exhaust
valve housing.
10) Connect all connections from the
injectors. Use your recorded notes for
the correct connections.
W
11) Connect all other connections to the
cylinder cover and the exhaust valve.
Fig. 7
12) Open the valves you closed before
(one valve each time) and do a check
for leaks.
13) Set to on the cooling water pump.
14) Make sure that the cooling water is at
the usual operation pressure and
temperature.
15) Do a check for leaks.
the work area.

Cylinder Cover
Injection Valve − Grind Sealing Face

Tools:
1 Grinding device 94270−01
1 Stencil 94270−1D
4. Sealing Face − Grind

1) Make sure that the stop sleeve (7) is attached to the spindle (8) of the device
(94270−01, Fig. 1).
2) Make sure that the O−rings (2) are serviceable.
3) Use the applicable grade of emery cloth related to the quantity of metal you want
to remove.
4) Put the stencil (94270−1D) on the emery cloth.
5) Use a pencil or a ball pen to make the inner shape.
6) Cut out accurately the shape.
7) Attach the shape (3) to the device (94270−01) with the clamp (4) and the Allen
screw (5).
8) Torque the Allen screw (5) to 4.0 Nm.
9) Apply a thin layer of oil to the O−rings (2).
10) Attach the device (94270−01) to the cylinder cover (9) with the two stud bolts (1).
11) Attach an electric drill to the spindle (2).
12) Operate the electric drill at a maximum of 500 rpm.
13) Apply a light pressure and start grinding.
14) Regularly remove the unwanted material from the device (94270−01) and the
bore (6).
15) Make sure that the circular marks around the sealing face are concentric.
16) Change the emery cloth for a smoother grade, then do step 3) to step 15) again
until you get a smooth finish.
17) Clean the bore (6).

94270−02
WCH03882
I
8
94270−02
3
94270−1D
5 4
Fig. 1
2/ 2 Winterthur Gas & Diesel Ltd.

Cylinder Cover
Pilot injection Valve − Grind Sealing Face

Tools:
1 Grinding device 94270−02 2 Stud bolts 94270F

1) Make sure that the stop sleeve (2) is attached to the spindle (1) of the grinding
device (94270−02, Fig. 1).
2) Make sure that the two O−rings (7) are serviceable.
to remove.
6) Cut out accurately the shape (4).
screw (5).
8) Torque the Allen screw (5) to 8.0 Nm.
9) Apply a thin layer of oil to the O−rings (7).
10) Attach the device (94270−02) to the cylinder cover with the two stud bolts
(94270F).
bore (3).

94270−02 94270F
I 94270−02
WCH03882
7
2
94270−2D
94270−02
3 94270F
6 5 4
Fig. 1

Cylinder Cover
Prechamber − Grind Sealing Face

Tools:
1 Grinding device 94270−03

1) Make sure that the stop sleeve (2) is attached to the spindle (1) of the grinding
device (94270−03, Fig. 1).
to remove.
5) Cut out accurately the shape (4).
screw (5).
7) Attach the device (94270−03) with the two M12x30 Allen screws (3) as shown.
bore (7).

94270−03
94270−3D
6 5 4
Fig. 1

Work Card
Injection Valve: Replace the Nozzle Body and Nozzle Tip
− Engine stopped Nozzle tip EX 27244 Qty 2

− Injection valve removed Nozzle body EX 96144 Qty 2
Spare kit − seals EX 96146 Qty 2
Remove the injection valve, refer to 2722−1/A1 Nozzle removal tool 94278A Qty 1
Nozzle installation tool 94278B Qty 1

Preparation
Replace the nozzle body and nozzle tip Service Engineer 3.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Work Card
Injection Valve: Replace
− Engine stopped Injection valve EX 27200 Qty 2

Nozzle tip EX 27244 Qty 2
Remove the applicable HP fuel pipe, refer to Nozzle removal tool 94278A Qty 1
8733−1/A1 Nozzle installation tool 94278B Qty 1

Preparation
Replace the injection valve Ship Engineer 2.0 hours Qty 1
Related Data

Related Procedures
Injection Valve, Removal and Installation, refer to

the Maintenance Manual 2722−1/A1

Intentionally blank
Injection Valve

Tools:
2 Hexagon head bolt 94270C 2 Stud bolts 94270D
1. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I
1. Removal
1 CAUTION
2
3 of the injection valve is
4 approximately 20 kg. Use
the correct equipment to lift
5 and move the injury. This
will prevent injury to
personnel.
1) Remove the applicable HP fuel pipe,

refer to 8733−1.
2) Disconnect the cable (2, Fig. 1) from
I terminal box 95.4.
WCH03708
3) Make sure that the injection valve
cooling is stopped. Refer to the
I-I Operation Manual 8016-1.
4) Remove the two screws (1) and the
spring cages (3) from the injection
valve (4).
94270C
5) Put the two bolts (94270C) in the
positions as shown.
4
6) Turn equally the two bolts (94270C)
50 mm fully into the valve bush (5) (until the
shoulder of the bolt touches the bush).
7
7) Turn equally the two bolts (94270C) to
5 lift the injection valve (4) for a minimum
of 50 mm.
8) Remove the injection valve (4).
9) Remove and discard the five
O-rings (7).
10) Put protection on the nozzle tip (6).
11) Put the injection valve (4) in the correct
package.
6
12) Put the injection valve (4) in a clean,
dry storage area.
Fig. 1
WCH02390

2. Installation
94270D
WARNING
5
Injury and Damage Hazard:
4 Do not use copper paste in
this procedure. Copper
Approximately paste can be a conductor
7.0 mm
of electricity. Injury to
personnel and damage to
3
CAUTION
Injury Hazard: When you do
work with white spirit,
2 always put on gloves and
safety goggles that have a
closed side frame. White
spirit can cause damage to
your skin and eyes.
WCH02390
1) If applicable, remove the new injection
valve from the package.
Fig. 2 2) Use white spirit e.g. Shellsol TD,
Shellsol T or Solvent FP68 to clean and
remove grease from the injection valve.
3) Do a check of the condition of the
sealing face in the cylinder cover (2,
Fig. 2). If necessary, do the procedure
given in 2708−3.
4) Put oil on the five new O-rings (1).
Note: The five O-rings (1) are included in
the spare parts set for the injection
valve.
5) Put the five O-rings (1) in their correct
positions on the injection valve (4).
6) Carefully put the injection valve (4) into the valve bush (3).
7) Turn the two stud bolts (94270D) into the valve bush (3) as shown.
8) Turn equally the two nuts (5) to push the injection valve into the valve bush (3).
Note: A high force is necessary to install the five O-rings.
Note: The injection valve is fully in when the nozzle body (3) of the injector
makes a seal with the cylinder cover (2). The distance between the bush
and the nozzle body will be approx. 7 mm.
9) Remove the two stud bolts (94270D).

10) If the spring cage (3, Fig. 3) was

6 disassembled, make sure that the cup
5 springs (1) are installed as shown (four
sets of six cup springs).
4
Note: A correctly assembled spring cage
3 1.8 mm has a distance of 1.8 mm between
the spring guide (4) and the spring
1 cage (3).
11) Put the spring cages (3) in position on
the injection valve (2).
12) Apply Never-Seez NSBT to the threads
2 and the seating surface of the two
screws (5).
13) Tighten equally the two screws (5) until
the spring guide (4) is flush with the
spring cage (3).
14) Connect the cable (6) to terminal box
95.4.
15) Install the applicable HP fuel pipe, refer
to 8733−1.
WCH02401
Fig. 3
3. Storage Area
You must make sure that the storage area is clean, dry and has no contamination in
the air.

Intentionally blank
Injection Valve
Disassemble, Checks, Assemble

(Injection Valve with FAST)
Tools:
1 Torque spanner 94011−03 1 Valve holder 94273
1 Slugging wrench 94269A−65 1 HP hose 94275
1 Hydraulic cylinder 94269B 1 Leakage oil hose 94275B
1 Torque wrench extension 94269C−41 1 Nozzle removal tool 94278A
1 Torque wrench extension 94269C−70 1 Nozzle installation tool 94278B
Injector test bench 94272 1 T-handle 94289A
1 Connecting piece 94272B 1 Bush 94289B
1 Bush 94289C
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Pilot Valve − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Nozzle Tip − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 Pilot Valve − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2 Injection Valve − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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
Calibration Fluid 1487) are as follows:
D The density at 15_C is 827 kg/m3 (ISO 12185)
D The kinematic viscosity at 40_C is 2.6 mm2/s (ASTM D445)
D The pour point is −27_C (ISO 3016).
If calibration fluid is not available, you can use clean diesel oil (gas oil). If clean diesel
oil (gas oil) is used, install the injection valve immediately after you complete the
checks.
Note: It is not recommended that diesel oil (gas oil) is used if the injection valve
is put into storage after these checks. Diesel oil (gas oil) can cause
corrosion of the injection valve.
On some injection valves, the quantity of leakage flow can be more than others. If the
test bench flow is not sufficient to open the needle, you can use a clean additive-type
crankcase (system) oil of SAE 30 viscosity. For more data see the Operation Manual
0750, paragraph 2 System Oil).

Injection Valve: Disassemble, Checks, Assemble Injection Valve with FAST
94272 2. Preparation
WARNING
94275
Fire Hazard. Do not use
94275B
welding or grinding
equipment near the work
area.
I
WARNING
Health Hazard. Calibration
fluid is harmful to your
health.
1
1) Read and obey the data in the
instruction manual of the test bench
94273 manufacturer.
2 2) Make sure that the work station is
clean.
3) Make sure that the support (3) is
removed from the valve holder (94273,
Fig. 1).
4) Use a brass wire brush to remove
combustion particles from the external
WCH02260 parts of the nozzle.
3 5) Put the injection valve in position in the

valve holder (94273). Make sure that
4 the injection valve points down.
5 6) Attach the injection valve (1) to the
2 valve holder with the spring cages (5)
and Allen screws (4).
WCH02419
7) Attach the HP hose (94275) to the
connecting piece (94272B).
1
8) Connect the leakage oil hose (94275B)
to the injection valve.
94273
3. Procedure
3.1 Checks
2
I DANGER
Injury Hazard: Do not put
94275B 94272B
your fingers near the holes
in the nozzle tip. Fuel can
go through your skin and
4 WCH02419 cause dangerous injury.
5 1) Start the test bench.
2) At regular intervals, use a master
WCH02260 pressure gauge to do checks of the
pressure gauges on the test bench. If
Fig. 1 necessary, adjust the pressure gauges.

3) Read the data in the manufacturer’s instructions to set the pressure of the test
bench to 600 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 approximately 400 bar.
b) Monitor the injection valve for 30 seconds. Look to see if calibration fluid comes
out of the nozzle.
6) Do a check of the opening pressure as follows:
a) Set the pressure to 350 bar, then push the INJECT button.
b) Make sure that no calibration fluid comes out of the nozzle.
c) Set the pressure to 450 bar, then push the INJECT button.
d) Make sure that calibration fluid comes out of the nozzle as a spray.
3.2 Results
1) For the correct function and to use an injection valve again, read the data below:
D The opening pressure is between 350 and 450 bar, refer to the test above.
The opening pressure for new injection valves is approximately 400 bar.
D For used injection valves, a pressure decrease of 30 bar is permitted.
D Most of the calibration fluid will come out as a spray from the top set of holes
in the nozzle tip at the specified opening pressure.
D At the end of an injection, no calibration fluid must come out of the nozzle.
2) If the injection valve does not operate satisfactorily, disassemble as given in
paragraph 4.
You must replace nozzle tips that have worn holes. It is possible, but not
recommended, to replace 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.

1 4. Disassemble
94011A
4.1 Injection Valve

1) Make sure that the test bench has no
pressure.
94269C−41 2) Remove the receiver (2, Fig. 1) from
the valve holder (94273).
3) Make sure that the HP hose (94275) is
disconnected from the connecting
piece (94272B).
4) Make sure that the leakage oil hose
(94275B) is disconnected from the
2 injection valve.
5) Turn the valve holder through 180_ into
the vertical position (see Fig. 2).
94269A-70 6) Use the torque spanner (94011A) and
adapter (94269C-41) to carefully
94273 loosen the locknut (1).
3
7) Remove the locknut (1).
8) Use the wrench (94269A-70) and the
hydraulic cylinder (94269B) to loosen
the coupling nut (2).
WCH02422
9) Remove the coupling nut (2).
10) Remove the nozzle body (8) together
with the:
6
D Intermediate plate (11)
4
D Compression spring (10).
5
12 D Tappet (9)
7
D Needle (7)
D Nozzle tip (6).
8
Note: The needle (7) and nozzle body (8)
9 are machined together so that their
sealing surfaces have the same
contours. You must keep these
10
items together. If it is necessary to
replace the needle or the nozzle
body, you must replace the two
items. Do not replace only one
11
item.
WCH02401 11) If it is necessary to remove the nozzle
tip (6) from the nozzle body (8), do the
procedure in paragraph 5.
12) Remove the intermediate plate (11).
13) Remove the compression spring (10),
Fig. 2 the tappet (9) and the needle (7).

94289A 4.2 Pilot Valve − Removal

94289C 1) Remove the pilot valve (3, Fig. 3) from
the injection valve (2) as follows:
1
Note: When you do the step blow, it is
not necessary to torque the
coupling nut (1).
3
2) Attach the coupling nut (1) to the
2 injection valve (2).
3) Attach the bush (94289C) to the
coupling nut (1).
4) Put the T-handle (94289A) in position
as shown.
5) Engage the T-handle (94289A) with the
pilot valve (3).
6) Turn the T−handle (94289A) to remove
the pilot valve (3).
7) Examine all parts for damage and
WCH02427 corrosion. Replace parts that have
damage or corrosion.
Fig. 3 5. Nozzle Tip − Replace
5.1 Removal
Note: It is possible, but not
recommended, to replace the
nozzle tip with the needle installed.
Remove only the locknut.
1
2 D2 1) Do the procedure given in paragraph 4,
step 1) to step 7).
3 94278A
2) Make sure that the needle (1, Fig. 4),
D1 compression spring (4) and tappet (3)
4 are removed from the nozzle body (2).
WCH02740
3) Attach the nozzle body (2) with
WCH02428
coupling nut (6) to the injection valve
5 (7) on the test bench.
4) Attach the hexagonal nut (D1, 94278A)
D2 to the nozzle body (2).
D1 5) Put the plate (D2) in the clearance
between the nozzle body (2) and the
nozzle tip (5).
6) Carefully turn the hexagonal nut (D1)
6 up to remove the nozzle tip (5).
7) Remove the nozzle tip (5) from the
nozzle body (2).
8) Remove the tool (94278A) from the
7 nozzle tip (5).
Fig. 4 WCH02741

A1 5.2 Installation
94278B 1) Attach the nozzle body (1, Fig. 5) and
A2 coupling nut (2) with the injection
A1
A3 valve (4) on the test bench.
6
2) Make sure that the dowel pin (5) is
A2 installed.
A3
3) Attach the guide bush( A2, 94278B) to
5 the nozzle body (1).
2 4) Put the nozzle tip (6) into the cylinder

1 (A1, 94278B). Align the recess in the
nozzle tip with the dowel pin (A3).
2 5) Put the cylinder (A1) and the nozzle
tip (6) into the guide bush (A2).
WCH02742
6) Turn the cylinder (A1) until the recess
in the nozzle tip aligns with the dowel
3
pin (5).
Note: The cylinder (A1) moves down a
4 small distance and cannot be
moved more with your hand.
7) Use a copper or rubber mallet to tap
WCH02742 the cylinder (A1) fully down.
Fig. 5 8) Turn the guide bush (A2)
counterclockwise to remove the nozzle
assembly tool (94278B).
9) Remove the coupling nut (2) and the
nozzle body (1).
10) Use clean diesel oil, or clean kerosene
to clean the needle, (5, Fig. 6),
7 1
compression spring (6), and tappet (5).
11) Use a clean, low-pressure air supply to
6 dry the needle, (5) compression spring
(6), and tappet (5).
5
12) Put the needle (5) into the nozzle tip
2
(3). Make sure that the the needle
moves freely.
13) Put the tappet (5) and compression
spring (6) into the nozzle body (2).
4
14) Attach the intermediate plate (7) to the
3 nozzle body (2). Make sure that dowel
WCH02401
pin (1) engages in the hole in the
nozzle body.
15) Do the procedure in paragraph 6 to
Fig. 6
assemble the injection valve.

6. Assemble
94289A
6.1 Pilot Valve − Install
1) Install the pilot valve (1, Fig. 7) in the
injection valve (2) as follows:
1
1 Note: When you do the step below, it is
94289B not necessary to torque the
3 coupling nut (3).
2 2) Attach the coupling nut (3) to the
injection valve (2).
3) Attach the bush (94289B) to the
coupling nut (3).
4) Engage the T-handle with the pilot
valve (1).
5) Put the T-handle (94289A) through the
bush as shown.
6) Turn the T-handle to install the pilot
valve (1).
WCH02427
Fig. 7

6.2 Injection Valve − Assemble

1
7 WARNING
8 Injury and Damage Hazard:
Do not use copper paste in
7 this procedure. Copper
2
paste can be a conductor of
electricity. Injury to
9 personnel and damage to
10
4 1) Make sure that the sealing faces of the
intermediate plate (6, Fig. 8) and the
related faces in the injection valve (10):
5
D Are clean and dry
D Are in a satisfactory condition
6 D Have no lubricant.
Note: When you do the step below, make
WCH02401 sure that the dowel pin (9)
engages with the hole in the
intermediate plate (6).
TS = TT x D1 2) Put the nozzle body (3) together with

the intermediate plate (6) in position on
D2 + D1
the injection valve (10).
3) Apply a thin layer of Never-Seez
TS for coupling nut 6: 100 x 530 NBST-8 to the thread and seating face
= 88 Nm
75 + 530 of the coupling nut (8).
4) Attach the coupling nut (8) to the
TS for locknut 7: 190 x 530 nozzle body (3) with your hand.
= 169 Nm
65 + 530 5) Refer to the formula shown where:
D TS = the applicable torque setting
for the torque spanner.
D2 D1
D TT = the specified torque setting for
the coupling nut and locknut.
D D1 = the distance from the center of
the square drive to the center of the
hand grip.
D D2 = the distance from the center of
94269C−41 94011A the square drive to the center of the
94269C−65 adapter.
Fig. 8 6) Use the torque spanner (94011A) and the adapter (94269−65) to torque the
coupling nut (8) to 88 Nm.
7) Use the wrench (94269A−65) and the cylinder on the test bench to add 35°- 40°
to the position of the coupling nut (8).
8) Apply a thin layer of Never-Seez NBST to the thread and seating face of the
locknut (7).
9) Attach the locknut (7) to the nozzle body (3) with your hand.
10) Use the torque spanner (94011A) and the adapter (94269−41) to torque the
locknut (7) to 169 Nm.
11) Do a check of the injection valve, refer to paragraphs 3.1 and 3.2.

Work Card
Starting Air Valve: Remove and Disassemble
− Engine stopped O-ring EX 27294 Qty 1

− No pressure in the starting air system O-ring EX 27301 Qty 1
− Shut-off valves to starting air bottles closed O-ring EX27295 Qty 1
− Handwheel set to the position CLOSED
− Open the ball valves 30-8605_E0_6 and
30-8605_E0_7
− Control air pipe removed

Preparation
Remove and disassemble the Starting Air Valve, Service Engineer 3.0 hours Qty 1
refer to the Maintenance Manual 2728−1/A1 Crew 3.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Work Card
Starting Air Valve: Check of the function of the solenoid valve
− Engine stopped 3/2-way solenoid valve EX 27298 Qty 1

Preparation
Do a check of the function of the solenoid valve Ship Engineer 1.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Work Card
Starting Air Valve: Overhaul
− Engine stopped Parts set − starting air valve EX 27350 Qty 1

− No pressure in the starting air system
− Shut-off valves to starting air bottles closed
− Handwheel set to the position CLOSED
− Open the ball valves 30-8605_E0_6 and
30-8605_E0_7
− Control air pipe removed
Remove the Starting Air Valve, refer to 2728−1/A1 Not applicable

Preparation
Do an overhaul of the starting air valve Service Engineer 3.0 hours Qty 1
Related Data

Related Procedures
Work Card WC2728−1.1

Remove and Install the Starting Air Valve, refer to
the Maintenance Manual 2728−1/A1

Intentionally blank
Starting Air Valve
Removal, Disassemble, Grinding, Assemble, Installation

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. General
You must remove and disassemble the starting air valve for maintenance if:
D The starting air valve does not operate correctly during the engine start
procedure
D The starting air pipe becomes hotter than on adjacent cylinders during operation.
Read the data in the Maintenance Manual 0380−1, Group 2728−1, for the applicable
intervals to do checks on the starting air valve.
2. Preparation
1) Stop the engine.
2) Release the pressure in the starting air system as follows:
3) Close the shut-off valves on the starting air bottles.
4) Turn the handwheel of the starting air shut-off valve (30-4325_E0_1) to the
position CLOSED.
5) Open the ball valves (30-8605_E0_6 and 30-8605_E0_7) to release the pressure
(refer to the Operation Manual, 4003−2, Control Diagram and 4003−2 Air
Systems).
6) Remove the control air pipe from the starting air valve.

Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation
I
3. Removal
from the 3/2-way solenoid valve (15,
1 Fig. 1).
14
13 2) Remove the four screws (16).
2
12 Note: When you do the step below, make
sure that you do not damage the
11 pipe (3).
3 3) Carefully remove the starting air
10
2 valve (1) from the cylinder cover (4).
9 4) Remove and discard the gasket (5).
8 5) Put applicable protection over the

4 opening in the cylinder cover (4).
7
6) Remove the pipe (3) from the cover (1).
6
4. Disassemble
1) Put the starting air valve in a vice.
Make sure that the vice jaws do not
damage the starting air valve.
5
2) Remove the two screws (17).
3) Remove the cover (1) together with the
3/2-way solenoid valve (15).
WCH03709 4) Remove the self-locking nut (14).
5) Remove the piston (13) from the valve
I spindle (6).
16 6) Remove the compression spring (9)
from the housing (10).
7) Remove the valve spindle (6) from the
housing (2).
8) Remove and discard the O-rings (2, 8
15 and 12).
II II
II - II
15
17
Fig. 1

5. Grinding
1
1) If the seating faces of the housing (1,
Fig. 2) and the valve spindle (2) have
minimum damage, do as follows:
2) Manually grind the seat faces of the
housing (1) and the valve spindle (2).
3) Make sure that you keep the radius to
the values given.
4) If the seating faces of the housing (1)
and the valve spindle (2) have more
than minimum damage, do as follows:
a) Use a machine tool to grind the
seating face of the housing (1)
and valve spindle (2).
b) Manually grind the seating faces
WCH02388 of the housing (1) and the valve
spindle (2) to get a good finish.
c) Make sure that you keep the
radius to the values given.
90°
WCH02389
91°
Fig. 2

I 6. Assemble
1) Clean all the parts of the starting air
15 valve (1, Fig. 3).
2) Put a small quantity of oil on all the
1 parts and the new O-rings (2, 8, 12).
14
3) Put two new O-rings (2) on the pipe (3).
13
2 4) Put the new O-rings (8, 12) in the
12
housing (2).
11 5) Put the valve spindle (6) into the
3 housing (2).
10
6) Put the compression spring (9) into the
2 housing (2).
9
7) Put the piston (13) in position on the
8 valve spindle (6).
4
Note: Do not get Molykote paste G on
7
the thread of the valve spindle (6)
where the insert of the self-locking
nut (14) will go.
6 8) Apply a thin layer of Molykote paste G
to the thread of the valve spindle.
9) Attach the self-locking nut (14) to the
valve spindle (6).
5
10) Torque the self-locking nut to 300 Nm.
11) Tap the top of the valve spindle (6) with
a hammer. The valve spindle must
spring back to its initial position.
I WCH01215
12) Attach the cover (1), together with the
16 solenoid valve (15), to the housing (2)
with the two screws (17).
13) Torque the two screws (17) to 70 Nm.
14) Put the pipe (3) in position in the
cover (1).
15 7. Installation
1) Put a new gasket (5) in the bore in the
cylinder cover (4).
II II II - II
2) Apply a thin layer of oil to the bore of
the cylinder cover (4).
3) Carefully put the starting air valve in the
cylinder cover (4). Make sure that the
15 pipe (3) goes into the bore of the
cylinder cover (4) correctly.
1 4) Apply a thin layer of oil to the threads of
the four screws (16).
5) Put the four screws (16) in position in
17 the cover (1).
6) Torque the four screws to 350 Nm.
7) Attach the control air pipe to the
Fig. 3 starting air valve.

Work Card
Exhaust Valve: General Inspection
Remove the exhaust valve, refer to 2751−1/A1, Not applicable

paragraphs 1 and 2

Preparation
Do a general inspection of the exhaust valve: valve Service Engineer 0.5 hours Qty 1
housing, valve spindle and valve seat (exhaust
valve is not disassembled)
Related Data

Related Procedures

Intentionally blank
Work Card
Exhaust Valve Spindle

paragraphs 1 and 2

Preparation
Do a check of the condition of the valve spindle (if Service Engineer 1.0 hours Qty 1
necessary grind the valve seat)
Related Data

Related Procedures
Valve Seat − Removal, Grind, Installation, refer to

2751−3/A1

Intentionally blank
Work Card
Exhaust Valve: Valve Drive Check

paragraphs 1 and 2

Preparation
Valve Drive: do a check of the piston sealing ring / Service Engineer 1.0 hours Qty 1
air spring and rod seal ring / guide bush
Related Data

Related Procedures

Intentionally blank
Work Card
Exhaust Valve: Check the Condition of the Valve Seat

paragraphs 1 and 2

Preparation
Do a check of the condition of the valve seat Service Engineer 1.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Work Card
Exhaust Valve: Random Checks

paragraphs 1 and 2

Preparation
Do a random check of the exhaust valve drive, outer Service Engineer 2.0 hours Qty 2
and inner pistons, damper, thrust piece
Related Data

Related Procedures

Intentionally blank
Exhaust Valve
Exhaust Valve − Removal and Installation
Tools:
2 Sling 94049A
1. Preparation
1) Drain the cylinder cooling water from the related cylinder, refer to the Operation
Manual 8017−1, paragraph 3.1 step 1).
2) Close the air inlet to the air spring at the control air supply.
3) Remove the hydraulic pipe (1, Fig. 1) from the related exhaust valve, refer to
8460−1, paragraph 1 and paragraph 2.
4) Disconnect the the cooling water pipe (2).
5) Disconnect the the oil drain pipe (6).
6) Disconnect the air supply pipe (5) from the air spring.
7) Close the valves from the pilot fuel supply. Make sure that there is no pressure in
the pilot fuel pipes (4).
8) Remove the three HP pilot fuel pipes (4), refer to 8790−1.
2. Removal
1) Remove the two round nuts (3), refer to the procedure given in 9403−4,
paragraph 1 and paragraph 2.
2) Disconnect the electrical connection (7) from the valve stroke sensor.
Note: Some parts can

look different.
7
2
6
5
4 3
WCH03380
Fig. 1

3) Put the slings (94049A, Fig. 2) in

I position on the expansion piece (4) as
94049A shown.
6 4) Attach the slings (94049A) to the hook

on the crane.
1 5) Operate the crane to put a light tension
on the slings (94049A).
6) Remove the 16 screws (5).
2 7) Remove the 16 nuts (3) and the
bolts (2).
8) Move the expansion piece (4) to one
side.
9) Lower the expansion piece (4) on to an
applicable surface.
10) Attach the crane hook to the eye
5 bolt (6).
4
3
WCH03710
11) Operate the crane to lift the exhaust

valve (7) from the cylinder cover.
12) Carefully lower the exhaust valve (7) on
6 to a wooden underlay.
13) Remove and discard the O-rings (9, 10)
from the valve cage (8)
10
8
9
016.885/08
Fig. 2

3. Installation
1) Clean all the sealing surfaces of the
exhaust valve and the cylinder cover.
2) Examine the sealing surfaces of the
exhaust valve and cylinder cover for
1
damage.
3) Remove the 2.0 mm metal gasket (1,
Fig. 3) from the cylinder cover.
4) Clean the the 2.0 mm metal gasket (1).
5) Examine the 2.0 mm metal gasket (1)
for damage. Make sure that the
Cylinder Cover
dimension of the metal gasket is
WCH02355 correct.
Fig. 3 6) If the 2.0 mm metal gasket (1) has
damage, or the dimension is not
correct, replace the gasket.
7) Put the 2.0 mm gasket (1) in position in
the cylinder cover.
2 8) Put a thin layer of oil on the new

O-rings (1 and 2, Fig. 4).
1
9) Put the new O-rings on the valve cage.
Fig. 4 10) Attach the lifting tool (94209) to the eye
016.885/08 bolt (13, Fig. 2).
11) Operate the crane to lift the exhaust
valve.
2
Note: When you do the step 12), make
sure that you do not damage the
threads of the elastic studs (1,
Fig. 5).
12) Carefully lower the exhaust valve into
the correct position in the cylinder
cover. The cylindrical pin (2) in the
cylinder cover will help you get the
correct position.
WCH02354
Fig. 5 13) Install the round nuts, refer to the
procedure given in 9403−4,

14) Clean the sealing surfaces of the

1 expansion piece (2, Fig. 6) and the
related faces on the valve cage and
I exhaust pipe (1).
15) Apply a thin layer of lubricant, that is
I resistant to heat, to the sealing faces
and the screws (5, 7).
16) Put the slings (94049A) in position on
the expansion piece (2).
2
17) Connect the slings (94049A) to the
hook on the crane.
WCH02353
18) Operate the crane to lift the expansion
piece (2).
19) Put the expansion piece (2) in the
I-I correct position between the valve cage
2 (6) and the exhaust pipe (1). Make sure
that the direction of flow is correct (see
view I-I).
20) Attach the expansion piece (2) with the
WCH02353 16 screws (5, 7) and the 16 nuts (4).
Direction of Flow 3 21) Remove the slings (94049A).
94049A
7 1
5 2 4
WCH02353
Fig. 6
2015 6
4. Completion
1) Connect the electrical connector to the valve stroke sensor (7, Fig. 7).
2) Open the air inlet to the air spring at the control air supply.
3) Install the applicable hydraulic pipe to the exhaust valve, refer to 8460−1,
paragraph 5.
4) Connect the air inlet pipe (5) to the air spring supply.
5) Install the three HP pilot fuel pipes (4), refer to 8790−1.
6) Connect the oil supply pipe (6) to the valve guide.
7) Connect the cooling water pipe (2).
8) On the applicable cylinder, fill the cylinder cooling water.
9) Open the valves you closed before (one valve each time) and do a check for
leaks.

look different.
7
2
6
5
4 3
WCH03380
Fig. 7

Intentionally blank
Exhaust Valve
Disassemble and Assemble

Tools:
1 Thrust pin 94259 1 Depth gauge 94126
2 Jack screws 94263 2 Eye bolts 94045−M20
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Exhaust Valve − Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Valve Drive − Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Valve Spindle − Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Guide Bush − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Exhaust Valve − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Guide Bush − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Valve Spindle − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Valve Drive − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Damper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Valve Stroke Sensor − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Non-return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.8 Oil Supply to Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. General
The International Association of Classification Societies (IACS) recommends that
there are two exhaust valves on board.
Only qualified personnel, or a WinGD 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 not weld or grind materials in the area. The sparks from
welding equipment and grinding tools can cause a fire.
CAUTION
Injury Hazard: The weight of the valve cage is approximately
830 kg. Always use the correct equipment to lift and move the valve
cage. This will prevent injury to personnel.
Note: Make sure that the work area is clean.

Exhaust Valve: Disassemble and Assemble
19
23
24
25
26
40
3
5 25
21 4
13
2
20
34
1
9 2
10
33
6
17
15 16
35
12
10
11
36
37
Turned through 90 degrees
7
1
38
39
Fig. 1 WCH03711

19
2. Exhaust Valve −
25
Disassemble
3
21 2.1 Valve Drive − Disassemble

2 crane and the eye bolt (19, Fig. 2).
42 2) Remove the six nuts (21).

3) Operate the crane to remove the top
1
housing (3).
4) Disconnect the electrical connection
from the valve stroke sensor (28).
6) Remove the transmitter housing (27).
7) Remove the valve stroke sensor (28).
8) Remove the six cap screws (42).
9) Remove the bottom housing (2).
2.2 Valve Spindle − Remove

1) Remove the circlip (33).
2) Push the piston (16) up, then remove
the valve cotters (15).
3) Remove the piston (16) from the valve
spindle (7).
4) Remove the cup springs (18).
5) Use the lifting tool (94209) and the
7 crane to lift the valve cage (1) to the top
27
of the valve spindle (7). Make sure that
29 the valve spindle does not move.
33
28 6) Lower the valve cage (1) on to its side.
15
16
18
WCH03711
Fig. 2

12
2.3 Guide Bush − Removal
1) Remove the four screws (12, Fig. 3).
2) Remove the spacer (10).
3) Remove and discard the rod seal (11).
4) Put the jack screws (94263) into the
flange of the guide bush (9).
WCH03711
5) Turn the jack screws (94263) to lift the
guide bush from the valve spindle (7).
12 11 10 6) Remove and discard the O-ring (37).

7) Measure the inner diameter of the
guide bush (9).
8) Compare the dimension with the values
1 given in 0330−1, Exhaust Valve.
37
3. Exhaust Valve −
Assemble
3.1 Guide Bush − Installation

WCH03711
94263 1) Clean the bore in the valve cage (1).
2) Clean the bore in the guide bush (9).
3) Make sure that the oil bores (OB) in the
guide bush (9) are clear.
4) Install a new O-ring (37).
5) Put oil on the guide bush (9).
6) Put the guide bush (9) in position in the
valve cage (1).
7 9
7) Use the jack screws (94263) to push
the guide bush fully into the valve
WCH03711 cage (1).
94263
OB 37
Fig. 3 WCH03711

3.2 Valve Spindle − Installation

1) Measure the dimensions of the valve
spindle (7, Fig. 4).
2) Compare the values with those given in
0330−1, Exhaust Valve.
7
27 3) Do a check of the piston seal ring (17)
for damage. If you find damage,
29
33 replace the piston seal ring.
28
4) Replace all O-rings.
15
17 5) Put oil on the valve spindle (7).
6) Use the two M20 eye bolts and two
16 ropes or the lifting tool (94209) to to lift
the valve cage to the top of the valve
spindle (7). Make sure that the valve
spindle does not move.
7) Carefully lower the valve cage over the
18 valve spindle. Make sure that you do
not damage the guide bush.
8) Put oil on the new rod seal (11).
WCH03711
9) Put the new rod seal (11) in position on
the valve spindle (7, Fig. 3).
10) Before you install a new piston seal
ring (17, Fig. 4), do as follows:
a) Put the new piston seal ring in
very hot water for some minutes.
6
b) Carefully put the piston seal ring
in the correct position on the
piston (16).
7
3.3 Valve Drive − Assemble

1) Push the valve spindle (7) against the
1 valve seat (8).
2) Install the cup springs (18).
3) Put the piston (16) in position on the
valve spindle (7).
4) Attach the valve cotters (15) to the
valve spindle (7) with the circlip (33).
valve cage (1) and the crane.
6) Operate the crane to lift the valve
cage (1) to the vertical position.
WCH03711 7) Lower the valve cage (1) on to a
8 suitable wooden underlay (30).
30 8) Remove the lifting tool (94209) from the

valve cage (1).
Fig. 4
9) Fill the oil bath (6) with system oil.


housing (2, Fig. 5) and the crane.
2
11) Lift, then lower the bottom housing (2)
on to the valve cage (1).
12) Install the six screws (42).
13) Attach the lifting tool to the eye bolt (19,
1 Fig. 6).
42
14) Lift, then carefully lower the top
WCH03711
housing (3) on to the housing (2).
top housing (3) and the crane.
16) Put oil on to the threads of the elastic
19 studs (20).
Fig. 5
25 17) Put the six nuts (21) on to the elastic

26 studs (20).
18) Torque symmetrically the six nuts (21)
3 to 290 Nm.
25
21
3.4 Damper Setting
4
2 20 You set the damper (25) only after you replace
a valve spindle or valve seat, or after one of
the seating faces is ground.
1) Remove the damper (25).
2) Make sure that the bores (4) in the
damper are clear.
WCH03711
3) Make sure that the exhaust valve is
closed.
4) Use a feeler gauge to make sure that
there is no clearance between the
valve plate and valve seat.
94126
5) Use the depth gauge (94126) to
measure the height H from the edge of
3 Shim the top housing (3) to the bottom of the
damper bore.
6) Install the damper (25) and the
H
applicable shims (26) to get the total
thickness.
Note: The distance H must be a total of
165.2±0.5 mm. For example, if the
5 measured distance H is 163 mm,
you must install two shims. Each
shim has a thickness of 1.0 mm.
7) Install the correct quantity of shims to
make sure that the distance is
165.2±0.5 mm.
Fig. 6

3
3.5 Valve Stroke Sensor −
Installation
1) Clean the parts that follow:
D The valve stroke sensor (28,
27 Fig. 7).
2
29 D The transmitter housing (27).
D The bore and collar in the
28
housing (3).
2) Attach the transmitter housing (27) to
the bottom housing (2)with the two
Fig. 7 WCH02355
screws (29).
valve stroke sensor (28).
3.6 Throttle
1) Do a check of the throttle as follows:
23 a) Remove the screw plug (24,
Fig. 8).
24
b) Remove the throttle (23).
c) Make sure that the throttle (23) is
3 clear.
d) Put oil on the threads of the
throttle (23).
2) Put the throttle (23) in position.
Fig. 8 WCH02355
3) Torque the throttle (23) to 4.0 Nm.
32
3.7 Non-return Valve
1) Do a check of the non-return valve (32,
Fig. 9) as follows:
2 a) Remove the non-return valve (32)
13 b) Make sure that the non-return

valve operates correctly.
Fig. 9
WCH02355 2) Install the non-return valve (32) to the
housing (2).
3.8 Oil Supply to Valve Guide

1) Make sure that the oil bore to the valve
guide (22, Fig. 10) is clear.
22
1
WCH02355
Fig. 10

Intentionally blank
Exhaust Valve
Valve Seat − Removal, Grind and Installation
Tools:
1 Feeler gauge 94122
1 Valve seat dismantling device 94261
1 Template 94279
1 Tool, grinding 94291
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Valve Seat − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Recommended Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 Alternative Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Valve Seat − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Valve Seat − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Valve Seat − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
You must replace the valve seat when:
D The sealing surface has too much damage, or
D Frequent grinding has worn the valve seat to more than the specified limit.
2. Preparation
1) Disassemble the exhaust valve and remove the valve spindle, refer to 2751−2,
paragraphs 2.1 and 2.2.
2016
5
Winterthur Gas & Diesel Ltd. 1/ 5

3. Valve Seat − Removal

1
1) If a valve seat is removed e.g. to
replace an unserviceable O-ring, you
2 must:
a) Grind the valve seat before
installation (paragraph 4), or:
b) Record the position of the valve
seat in the valve cage before you
start the removal procedure.
Fig. 1 3.1 Recommended Procedure

WCH02362
1) Turn the valve cage (2, Fig. 1) until the
valve seat (1) points up.
3 2) Carefully put the valve cage on to an
4 applicable wooden underlay (5).
1 3) Install the top two halves of the device
(94261) into the groove of the valve
5 seat (1).
94261 4) Install the bottom two halves of the
device (94261) into the groove of the
valve cage (2).
2 5) Turn the three jack-screws (5) equally
WCH03386 to push out the valve seat (1) from the
valve cage (2).
6) Remove and discard the O-ring (4).
7) Remove the device (94261).
3.2 Alternative Procedure

If it is necessary to remove the valve seat
when the valve cage must stay in the usual
position (i.e. the top of the valve cage points
up), do the procedure that follows:
1) Use the crane and an applicable lifting
tool to hold the valve cage immediately
2
above an applicable wooden underlay
(3, Fig. 2).
1
WCH02362 2) Use applicable wooden chocks to keep
the valve cage in position and prevent
5 movement.
3) Install the top two halves of the tool
cage (2).
4 4) Install the bottom two halves of the tool
2 (94261) into the groove of the valve
seat (1).
Note: The valve seat weighs 100 kg. Be
94261 careful when you do step 5).
5 5) Carefully turn the three jack screws (5)
equally until the valve seat (1) falls out
WCH03386
1 of the valve cage (2).
6) Lift and move the valve cage (2) away
Fig. 2 3 from the valve seat (1).

7) Remove and discard the O-ring (4,

Fig. 2).
I 8) Remove the tool (94261).
1
4. Valve Seat − Grind
Use only the tool (94291, Fig. 3) to grind the
valve seats.
1) Read the data in the manufacturer’s
manual for the tool (94291).
2) Put the valve seat (1) in the correct
94291 position on the tool (94291).
3) Put the template (94279, Fig 4) on the
valve seat.
Note: The data on the template (94279)
shows the maximum permitted
WCH02361 limits for the valve seat (1).
4) Use the feeler gauge (94122) to
measure the values.
I Between: 5) If the measured values are more than
30°0' and 30°2’ the limits given on the gauge (94122),
you must replace the valve seat (1).
6) If the values are less than the limits
1 given, do the procedure that follows:
a) Operate the tool (94291) to grind
the sealing face of the valve
Fig. 3 seat (1). Make sure that you get a
smooth and flat surface.
b) Keep the valve seat angle to
between 30°0' and 30° 2’.
94279
WCH02361
Fig. 4

2 5. Valve Seat − Check

You do this procedure to make sure that the
sealing face of the valve spindle correctly
5
touches the sealing face of the valve seat.
3 1) Put a thin layer of engineer’s blue paste

on the sealing face of the valve spindle
(5), see Fig. 5.
4
2) Put the valve spindle (5) in position in
the valve guide bush.
3) Put the wooden block (3) on the valve
003.457/00 spindle (5).
Note: During the step below, do not turn
the valve spindle (5) because this
can cause the sealing faces to
catch.
5 4) Tap the wooden block (3) with the
S = 0.054 mm to 0.070 mm hammer (2) three or four times.
5) Use the feeler gauge (94122) to do a
check of the clearance between the
sealing faces of the valve spindle (5)
and valve seat (4).
4 Note: The clearance between the valve
spindle (4) must be as shown,
I (S = 0.054 mm to 0.070 mm).
6) Remove the valve spindle (5) from the
003.455/00 guide bush.
7) Do a check of the engineer’s blue
paste. The blue paste must only show
on the inner part of the full
circumference of the valve spindle (see
I View I).
8) Remove the valve seat from the tool
(94291).
Engineer’s blue
paste mark
Fig. 5

4 6. Valve Seat − Installation

1
1) Clean the bores and the sealing faces
2
of the valve cage (2, Fig. 6) and the
valve seat (1).
9426
2) Apply oil (or lubricants e.g. Never-Seez
NBST, or Loctite anti-seize compound)
3
WCH03386 to the bores and sealing faces of the
valve seat (1) and the valve cage (3).
3) Put the same lubricant on the new
O-ring (4).
4) Put the new O-ring (4) on to the valve
seat (1).
5) If the valve seat (1) was removed to
replace the O-ring, do the step below:
I a) Align the marks on the valve
1 seat (1) with the marks on the
valve cage (3).
6) Push the valve seat (1) into the bore of
the valve cage (3).
94122
7) Install the top two halves of the tool
seat (1).
8) Install the bottom two halves of the tool
cage (3).
3 9) Turn the three jack screws (2) equally

to fully push the valve seat (1) into the
Sealing Faces valve cage (3).
10) Use the feeler gauge (94122) to make
sure that there is no clearance between
the sealing faces.
Fig. 6
7. Completion
1) Assemble the exhaust valve and install
the valve spindle, refer to 2751−2,
paragraphs 3.2 and 3.3.

Intentionally blank
Exhaust Valve
Valve Head: Seating Surface − Grind

Tools:
1 Tool, valve grinding device 94291
1 Template 94292
1. General
1 Use only the tool (94291, Fig. 1) to grind the
valve head.
a = between: You must grind valve heads that have

30°16' and 30°18' a damage or corrosion on the seating surface.
If the rotation wing is missing from the valve
spindle, do not grind the valve head.
2. Valve Head − Grind

1) Read the data in the manufacturer’s
manual for the grinding tool (94291).
2) Put the grinding tool (94291) in an
area where there is no vibration.
Note: If necessary, put the tool on a
rubber mat. This will help to
prevent rough surfaces during the
grinding procedure.
3) Put the valve spindle in position in the
Fig. 1 WCH03263 tool (94291).
4) Put the gauge (94292) on the valve
head (1, Fig. 2).
Note: The data shown on the
gauge (94292) shows the
maximum limits for the valve head.
measure the values.
6) If the values are less than the limits
Max. 3.0 mm given, do step a) to step c):
a) Use the tool (94291) to grind the
surface of the valve head (1).
Remove only the minimum
material necessary to get a
1 smooth, flat surface.
b) Use an applicable coolant to keep
the valve head (1) cool.
WCH03263
c) Keep the angle of the valve
head (1) to between 30°16' and
30°18'.
Note: You can grind off a maximum of
Max. 9.0 mm 3.0 mm from the seating surface.
7) Do a check of the valve seat and valve
Fig. 2
spindle, refer to 2751−3, paragraph 5.

Valve Head: Seating Surface − Grind
8) If the measured values are more than the limits given on the gauge (94122), you
can repair the valve spindle (refer to the data below).
9) If more than 3.0 mm is ground off, do step a) and step b) below:
a) Use a build-up welding procedure to repair the surface of the valve seat.
b) Grind the seating surface of the valve spindle again (refer to paragraph 2).
3. Corrosion
Corrosion can occur at the bottom of the valve plate when engines operate for a long
period (e.g. in rough weather conditions).
If the corrosion is less than or equal to 9.0 mm (see Fig. 2), the valve spindle can be
repaired.
Note: The repair procedure can only be done in a WinGD authorized repair
workshop.
Valve spindles cannot be repaired when the corrosion is more 9.0 mm, but can
continue to operate until the corrosion has a depth of 21 mm.

Work Card
Pilot Injection Valve: Replace the Nozzle Spare Parts Set

− Pilot injection valve removed
Remove the pilot injection valve, refer to 2790−1/A1 Wrench 94269A-55 Qty 1
Socket wrench insert 94269C−55 Qty 1
Obel test bench 94272 Qty 1
Hydraulic cylinder 94269B Qty 1
Molykote paste G−n

Preparation
Replace the nozzle spare parts set Service Engineer 2.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Work Card
Pilot Injection Valve: Replace
− Engine stopped Pilot injection valve with seals EX 27915 Qty 2

− Engine temperature must be at ambient (without the tension washer
− Fuel supply and pilot fuel supply valves closed cage)
− Fuel supply set to off
− Lube oil supply set to off
− Applicable pilot fuel pipe removed
Pilot Valve, Removal and Installation, refer to Socket wrench insert 94269C−55 Qty 1
2790−1/A1 Obel test bench 94272 Qty 1
Support plate 94270F Qty 1
Screw for support plate 94270G Qty 2
Stud bolts 94270E Qty 2
Eye bolts 94045−M12 Qty 2
Molykote paste G−n

White spirit
Brass wire brush
Never Seez NSBT

Preparation
Replace the pilot injection valve Service Engineer 2.0 hours Qty 1
Related Data

Related Procedures
Replace the nozzle body, refer to WC2790−1/A1

Replace the pre-chamber, refer to WC2790−1.2/A1

Intentionally blank
Work Card
Pilot Injection Valve: Replace the Pre-chamber
− Engine stopped Conical seal EX 27905 Qty 2

− Pilot injection valve removed O-ring EX 27909 Qty 2
− All pipes and connectors removed from the holder Pre-chamber EX 27903 Qty 2
Pilot injector valve with seals EX 96235 Qty 2
Remove the pilot injection valve, refer to 2790−1/A1 M12 eye bolts 94045−M12 Qty 2
Never Seez NSBT

Preparation
Replace the pre-chamber Service Engineer 5.0 hours Qty 1
Related Data

Related Procedures
Replace the nozzle body, refer to WC2790−1/A1

Replace the pilot injection valve WC2790−1.1/A1

Intentionally blank
Pilot Injection Valve

Tools:
1 Obel test bench 94272 1 Socket wrench insert 94269C−55
1 Support plate 94270F 2 Stud bolts 94270E
2 Screw for support plate 94270G 2 Eye bolts 94045−M12
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Replace Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Pre-chamber − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8. Install Pre Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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
Calibration Fluid 1487) are as follows:
D The density at 15° C is 827 kg/m3 (ISO 12185)
D The kinematic viscosity at 40_C is 2.6 mm2/s (ASTM D445)
D The pour point is −27° C (ISO 3016).
If calibration fluid is not available, you can use clean diesel oil (gas oil). If clean diesel
oil (gas oil) is used, install the injection valve immediately after you complete the
checks.
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.
On some pilot injection valves the quantity of leakage flow can be more than others. If
the test bench flow is not sufficient to open the needle, you can use a clean
additive-type crankcase (system) oil of SAE 30 viscosity. For more data see the
Operation Manual 0750, paragraph 2 System Oil).
On some injection valves the quantity of leakage flow can be more than others. If the
test bench flow is not sufficient to open the needle, you can use a clean additive-type
crankcase (system) oil of SAE 30 viscosity. For more data, refer to the Operation
Manual 0320, paragraph 2 System Oil).

3
2. Preparation
2
1) Stop the engine, refer to the procedure
in the Operation Manual 4002−2.
2) Let the engine temperature decrease
before you start the removal procedure.
3) Close the valves from the fuel supply
and pilot fuel supply. Make sure that
1 there is no pressure in the pilot fuel
pipe (1, 2 or 3, Fig. 1).
4) Set to off the fuel supply.
5) Set to off the lube oil supply.
6) Make sure that the drain from the pilot
injection valve to the sludge tank is
open.
7) Remove the applicable pilot fuel pipe
(1, 2 or (2), refer to 8790 paragraph 1
and paragraph 2.
WCH03401
8) Make sure that the pipes attached to

the holder (6) of the pilot injection valve
have no pressure:
a) Lube oil return (10)
4 b) Lube oil inlet (8)

c) Leakage fuel/lube oil (10)
d) Control fuel return (9).
9) Disconnect the connection (5)
12
11 3. Removal
5 1) Remove the two bolts (4) together with
the spring cages (12) and flange (11).
10
6
7
8
9
Fig.1

I
2) Attach the support plate (94270F) with
the screws (94270G) to the pilot
94270F
I injection valve (1, Fig. 2).
94270G
3) Turn equally the two screws (94270G)
clockwise to lift the pilot injection valve
44 mm.
4) Remove the pilot injection valve from
44 mm the holder (2).
5) Do a check of the pilot injection valve,
1 refer to paragraph 4.
CAUTION
2
Injury Hazard: Always put
on gloves and safety
goggles that have a closed
side frame when you do
work with white spirit.
White spirit can cause
damage to your skin and
eyes.
6) To clean the injection valve, use white

spirit, e.g. Shellsol TD, Shellsol T or
Solvent FP68.
7) If necessary, keep the pilot injection
Fig. 2 valve in a clean and dry storage area.
WCH03445
The storage area must not have air that
can cause corrosion.
94272F
1 4. Check
1) Read the data in the instruction manual
94273
of the test bench manufacturer.
2) Make sure that the work station is
clean.
3) Put the injection valve (1, Fig. 3) in
position in the valve holder (94273).
Make sure that the injection valve
points down.
4) Make sure the surfaces that touch on
connection piece (94272F) and the pilot
injector (1) are clean.
5) Attach the connection piece (94272F)
to the pilot injector (1).
6) Use a brass wire brush to remove
Fig. 3 combustion particles from the external
parts of the nozzle.

7) Attach the HP hose to the connecting

piece (94272F, Fig. 3).
8) Connect the injector cable (2, Fig. 4) to
the socket for the pilot injector.
4.1 Procedure
1
WARNING
Fire Hazard. Do not use
welding or grinding
equipment near the work
area. Fuel and solvents are
2
flammable.
94273 WARNING
Injury Hazard. Calibration
fluid is a harmful
substance. Always read the
manufacturer’s safety
instructions before you use
PILOT INJECTOR calibration fluid.
DANGER
Injury Hazard. Do not put
Fig. 4 your fingers near the holes
in the nozzle tip. Fuel can
go through your skin and
cause injury or kill you.
1) Start the test bench.

2) At regular intervals, use a master
pressure gauge to do checks of the
pressure gauges on the test bench. If
necessary, adjust the pressure gauges.
3) Read the data in the manufacturer’s instruction.
4) Set the pressure of the test bench to 600 bar.
5) Push the inject button. The injection valve must operate correctly.
6) Do a check of the seating surface between the needle seat and nozzle as
follows:
a) Keep the pressure in the test bench constant at approximately 400 bar.
b) Monitor the injection valve for 30 seconds. No fuel must come out of the nozzle.
7) Do a check of the pressure as follows:
a) Set the pressure to 250 bar, then push the INJECT button. No fuel must come
out of the nozzle.
b) Set the pressure to 400 bar, then push the INJECT button. Fuel must come out
of the nozzle as a spray.

4.2 Results
1) For the correct function and to use an injection valve again, read the data below:
D The pressure to operate the pilot injection valve is between 300 bar and 400 bar,
refer to the test above. The pressure to operate a new injection valve is
approximately 350 bar.
D For used injection valves, a minimum opening pressure of 250 bar and a
maximum opening pressure of 500 bar is permitted.
D Most of the fuel will come out as a spray.
D At the end of an injection, no fuel must come out of the nozzle.
2) If the injection valve does not function satisfactorily, replace the nozzle body as
given in paragraph 5.
Only the injection valve manufacturer, or an authorized company can repair or replace
nozzle bodies that operates unsatisfactorily.
5. Replace Nozzle Body

1) Attach the injection valve (1) to the
1 valve holder (94273) as shown in
Fig. 5.
2) Make sure that the test bench has no
pressure.
3) Use the wrench (94269A-55) and the
94269A−55 hydraulic cylinder (94269B) to loosen
94269B the coupling nut (1) of the pilot injection
2 valve (2).
4) Remove the coupling nut (1) and
replace nozzle body if necessary
94273
(Spare Parts Code FX96236).
WCH03448 5) Apply Molykote paste G−n to the
contact surfaces and thread of the
coupling nut (1).
Fig. 5 6) Use the torque wrench and socket
wrench insert (94269C−55) to torque
the coupling nut (1) to between
800 Nm and 830 Nm. Refer to 2722−2 ,
paragraph 6.2.
7) Replace the O−rings on the pilot
injector (Spare Parts Code FX96237).

94270E 1 6. Installation
1) Apply oil to the O−rings of the pilot
3 injection valve (3, Fig. 6).
41 mm
2) Put the injection valve (3) into the
holder (2).
2
3) Put the stud bolts (94270E) into the
holder (2) as shown.
4) Turn equally the two nuts (1) equally
down until there is a distance of 41 mm
as shown.
5) Remove the stud bolts (94270E).
6) If the spring cage (5) was
disassembled, make sure the cup
springs (CS) are installed correctly,
(four packs with six cup springs each.
7) Apply Never Seez NSBT to the threads
and surfaces that touch of the bolts (4).
8) Install the bolts (4) together with the
spring cage (5) as shown.
WCH03455
9) Tighten equally the bolts (4) until the
top of the spring guide is flush with the
top of the spring cage (5).
10) Install the applicable pilot fuel pipe (1 or
2, Fig. 1), refer to 8790−1, paragraph 3.
FLUSH 11) Connect the injector cable (7) to

terminal box E95.4.
4 12) Set to on the fuel supply.
7 13) Set to on the lube oil supply.
5
6x CS
6x CS
CS
6x CS
6x CS
6
WCH03456
Fig. 6

7. Pre-chamber − Removal
1) Remove the pilot injection valve, refer
3 to paragraph 1 , paragraph 2 and
4 paragraph 3.
2
2) Remove all pipes and connectors from
the holder (4, Fig. 7)
1
3) Loosen the two bolts (3) one turn.
4) Remove the four bolts (1).
5) Attach two M12 eye bolts to the
threads (3).
CAUTION
of the pre-chamber is
the correct equipment, or
two persons to lift and
move the pre-chamber. This
WCH03667 personnel.
6) Carefully lift the holder (4) together with

the pre-chamber from the cylinder
cover.
7) Remove the two bolts (2) and the
pre-chamber (5).
WCH03668
Fig. 7

3
8. Install Pre Chamber
1) Make sure that the pre-chamber (2,
Fig. 8) is internally and externally clean.
2) Install the 8x20 dowel pin (3).
1
3) Attach a new O-ring (1) to the
pre-chamber (2).
Fig. 8 WCH03669
4) Attach the new seal (3, Fig. 9) to the

pre-chamber (2).
5) Put the pre-chamber (2) in the correct
position on the holder (1) with the two
M12x200 bolts.
6) Torque the two M12x200 bolts to the
value given in 0352−2, paragraph 1.
3
WCH03669
Fig. 9

1) Put the holder (1) together with the

pre-chamber (2) into the cylinder cover.
2) Apply Never Seez NSBT to the four
1 bolts (3).
3
4) Connect all pipes to the holder (1).
5) Install the pilot injection valve, refer to
paragraph 6.
Fig. 10
WCH03667
9. Completion
1) Install the applicable pilot fuel pipe (1 or
2, Fig. 11), refer to 8790 paragraph 3.
2) Open the valves from the fuel supply
1 and pilot fuel supply.
3) Set to on the lube oil supply.
4) Set to on the fuel supply.
WCH03401
Fig. 11

Intentionally blank
Maintenance Group3
Crankshaft, Connecting Rod and Piston Group 3
Work Cards
Crankshaft: Crank Deflection − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3103−1/A1
Crankshaft: Crank Deflection − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103−1/A1
Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−1/A1
Vibration Damper
Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−2/A1
Axial Damper: Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3140−1/A1
Turning Gear: Teeth and Screwed Connections − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3206−1/A1
Crankcase: Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−1/A1
Work Cards
Connecting Rod: Check the Bearing Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3303−2/A1
Connecting Rod
Bottom End Bearing − Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−2/A1
Top End Bearing − Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−3/A1
Top End Bearing Cover − Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−5/A1
Work Cards
Crosshead and Guide Shoe: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3326−1/A1
Crosshead
Clearance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−1/A1
Crosshead Pin − Removal ad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−2/A1
Crosshead Pin − Removal and Installation (Engines with Integrated ELBA) . . . . . . . . . . . . . . . . . . . 3326−2/A2
Work Cards
Piston: Remove and Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−1/A1
Piston: Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−3/A1
Piston: Check the Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−4/A1
Piston: Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−4.1/A1
Piston: Fully Re-manufacture the Piston Head Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3403−4.2/A1
Piston Underside: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3404−1/A1
Piston
Top Surface − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403−4/A1
Work Cards
Piston Rings: Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3425−1/A1
Piston Rings: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC3425−1.1/A1
Piston Rings: Piston Rings and Ring Grooves − Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425−1/A1

Intentionally blank
Work Card
Crankshaft
The indicator valves must be open Crankshaft equipment (dial 94305 Qty 1
The ship must float freely in the water as horizontal gauge)
as possible.
The crankshaft must be in position on all the main
bearings

Preparation
Measure the crank deflection, refer to 3103−1/A1 Ship Engineer 0.5 hours Qty 1
Service Engineer 0.5 hours Qty 1
Related Data

Related Procedures
Not applicable

Intentionally blank
Crankshaft
Crank Deflection − Measure
Tools:
1 Crankshaft equipment (dial gauge) 94305
1. General
It is sufficient to measure the crank-web deflection in accordance with the intervals
specified in the class rules. It can be necessary to measure the crank-web deflection
in unusual conditions, for example:
D Important change of crank-web deflection results compared to the data before.
D Bearing temperature alarms, or bearing damage.
D After the primary bearing shells were replaced, and again after approximately
100 service hours.
D If the ship has touched the sea bed.
For the examples given above, it is recommended that you speak to WinGD for
support.
2. Preparation
Make sure that:
D The indicator valves are open.
D The ship floats freely in the water as horizontal as possible.
D The crankshaft is in position on all the main bearings.
The data that follow have an effect when
you measure the crank-web:
D The engine is cold, or has service
2
temperature.
D The temperature difference between the
lubricating oil sump and the seawater.
D The loaded condition of the ship (the
draught).
1
D Strong sunshine.
It is recommended that you include these
data in the records.
WCH03666
Fig. 1
3. Measure
WARNING
Note: Make sure that you turn the flywheel (1, Fig. 1) and pinion (2) in the
correct direction (The arrows show the correct direction.)

Measuring Crank Deflection
Note: Step 1) is applicable only for a cold engine. If the engine has usual
operation temperature, continue from step 2).
1) Make sure that the tank heater and lubricating oil separator are set to off for a
minimum of eight hours.
2) Operate the turning gear to move the crank to the BDC 1st position (see Fig. 2).
3) Attach the dial gauge (94305) to the connecting rod. Make sure that the dial
gauge goes into the center punch marks.
4) Turn the rod of the dial gauge to apply tension.
5) Set the dial gauge to zero. The dial gauge must not have a difference of more
than 0.01 mm.
6) Use the turning gear to move the crank to each position shown. At each position,
record the indications on the dial gauge.
Note: You can read from the dial gauge the change in the distance between the
crank webs. The smaller the difference, the better the crankshaft is
aligned.
7) If the difference between the two BDC positions is more than 0.05 mm, you must
do the check again.
VIEW FROM
DRIVING END
CLOCKWISE
DIRECTION
FUEL SIDE TDC EXHAUST SIDE
BDC 1st Position BDC 2nd Position
CRANK DEFLECTION
SIGN ON DIAL GAUGE
94305
+ −
OR
− +
Approximately.
18 mm
Center Punch Mark for

Fig. 2 Dial Gauge 94305

Measuring Crank Deflection
4. Data Analysis
STROKE
94305
nB.D.C
D
nT.D.C
Fig. 3
The difference between the indicated values shows the crank deflection during one
full turn (Fig. 2).
Where values are measured, which are above the maximum permitted limits, you
must find the cause (e.g. defective main bearing, engine stay changed because hull
deformation, loose hold-down bolts, defective propeller shaft bearings, equipment
94305 etc).
The limits are applicable for all conditions of ship operation after delivery i.e.:
D The draught and trim of the ship are in the limits for usual operation.
D The engine is hot or cold.
Table 1: Deflection Limits
Usual Ship Operation: Crank-web Deflection Limits (mm)
Vertical Horizontal
Cylinder No. 1 Cylinder No. 2 Last Cylinder All Cylinders

(Driving End) to the Last but (Free End)
One cylinder
Note 1) Note 2)
0.56 0.40 0.40 0.40 0.18

−0.56 −0.40 −0.40 −0.56 −0.18
1) For engines without a torsional vibration damper, front disc or free end Power
Take Off.
2) For engine with a torsional vibration damper, front disc or free end Power Take
Off.
Speak to WinGD, if the last data is more than the limits given in the table above.

Intentionally blank
Vibration Damper
Silicone Fluid Sample
1. General
Viscous vibration dampers that Hasse & Wrede, Metaldyne International UK, STE
Schwingungstechnik and Geislinger manufacture can be installed at the free end of
the crankshaft.
The service life of a vibration damper is related to the speed range in which the
engine operates.
The effect of the vibration damper can decrease when changes to the properties of
the silicone oil occur, and when the internal parts become worn.
Initially, the silicone oil must be examined between approximately 15000 operation
hours and 18000 operation hours. Regular examinations of the silicone oil will show
the manufacturers the condition of the vibration damper. Subsequent examinations
are related to the results of the initial examinations.
Special sample containers are available from the vibration damper manufacturer.
2. Silicone Oil Sample −

Preparation
1 WARNING
2 2 operate the turning gear,
make sure that no
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)
crankshaft (1) until a screw plug (2) is
horizontally opposite the other screw
plug. If this is not possible, a vertically
opposite position is satisfactory.
3) Carefully clean the area around the
2 2 screw plugs (2).
4) Leave the vibration damper (1) in
009.739/02
position for a minimum of two hours.
Note: The same conditions apply for a
vibration damper that is removed
Fig. 1 from the engine.
5) Use applicable tools to remove the
sealing material from the screw
plugs (2).
Note: When you do step 6), make sure
that the screw plug (2) still makes
a seal.
6) Carefully loosen the screw plug (2).

Taking a Silicone Fluid Sample
3. Silicone Oil Samples
3.1 Metaldyne and STE

Metaldyne
and STE Note: Two different threads are used for
the sample bores of the Metaldyne
International and STE vibration
1 1 dampers.
SC
Note: The sample container lets you get
a specified quantity of silicone oil
from the damper. The total number
of samples must not be more
3/ ”
than 10.
8 BSF (M16) 5/ ”
16 BSF (M10)
1) Remove the two cap nuts (1, Fig. 2).
2) Examine the bore in the sample
CP
2 container (SC). Make sure that the bore
is clean.
3 3) Remove the screw plug (2) loosened
before.
4) Remove and discard the O-ring (3).
007.964/97 5) Put a new O-ring (3) in the screw plug
Fig. 2 (2).
6) Put the the sample container (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 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) STE: Torque the screw plug (3) to 15 Nm (M10) or 45 Nm (M16).
11) Use a center punch to lock the screw plug (3) in position.
12) Attach a label to the sample container. The label must have the data that follows:
D Engine type and engine number
D Number of operation hours of the vibration damper
D Name of vessel
D Shipyard and hull number
D Manufacturer’s serial number (data plate or stamped marks)
D Damper location (crankshaft or camshaft).

13) Send the sample to:

Metaldyne International UK Ltd
131 Parkinson Lane
Halifax HX1 3RD
United Kingdom
Tel: +44 1422 357 234
Fax: +44 1422 354 432
Note: For STE Schwingungstechnik manufactured vibration dampers, send the
samples to Hasse & Wrede (see paragraph 3.2, step 13)).
3.2 Hasse and Wrede

SAMPLE CONTAINERS
Note: The sample container lets you get
Hasse & Wrede a specified quantity of silicone oil
from the damper. The total number
of samples must not be more
M10x1 SC M10x1 than 10.
1) Remove the two cap nuts (1, Fig. 3).
2) Examine the bore in the sample
container (SC). Make sure that the bore
is clean.
1 1 3) Remove the screw plug (2) loosened
before.
4) Remove and discard the sealing
2 ring (3).
3 CP 5) Put a new sealing ring (3) in the screw

plug (2).
6) Put the the sample container (SC) fully
into the vibration damper housing, then
turn the sample container back one
Fig. 3 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) Attach the other cap nut (1) to the sample container (SC).
10) Torque the screw plug (2) to 20 Nm.
11) Use a center punch to lock the screw plug (3) in position.
12) Attach a label to the sample container. The label must have the data that follows:
D Number of operation hours of the vibration damper
D Name of vessel
D Manufacturer’s serial number of damper (data plate or stamped marks)

13) Send the sample to:

Hasse & Wrede
Georg-Knorr-Strasse 4
D-12681 Berlin
Germany
Tel: +49 30 93 92 3135
Fax: +49 30 70 09 0835
If you cannot get a sample as given in paragraphs 3.1 and 3.2, do the procedure that
follows:
1) Leave sample container (SC) in position.
1) Remove the opposite screw plug.
Note: Before you do step 2), make sure that the connections are clean.
2) Connect a clean, dry compressed air supply of approximately 3.5 bar to the
screw plug.
3) When silicone oil flows to the open end of the sample container, stop the
compressed air supply.
4) Attach a cap nut to the sample container.
5) Disconnect the compressed air supply.
6) Remove the sample container and attach the other cap nut.
7) Attach the related 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 samples must not be more than 10.
For vibration dampers manufactured at Geislinger, send to samples to:
Geislinger GmbH
Hallwanger Landesstrasse 3
A-5300 Hallwang / Salzburg
Austria
Tel: +43 662 66 999 0
Fax: +43 662 66 999 40
The label must contain the following information:

D Number of operating hours of the vibration damper
D Ship name
D Manufacturer’s serial number of damper (data plate or stamped marks)

Vibration Damper
Inspection (GEISLINGER Vibration Damper)
1. General
Some engine designs can have a Geislinger manufactured vibration damper installed
at the free end of 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.
WCH02478
For View I − I, see Fig. 2
Fig. 1: Vibration Damper (front view)

1 Vibration damper monitor 3 Monitor pipe
2 Damper casing 4 Oil supply pipe

2. Checks
2.1 Engine Filters

You must do regular checks of the engine filters for steel or bronze particles. If
particles are found in the housing, you must speak to, or send a message to the
supplier immediately.
Note: The vibration damper must not be operated until the cause is found and
the problem is repaired.
If the oil pressure decreases to less than 1.0 bar, do not use the adjustable throttle in
the supply pipe (4, Fig. 1 and Fig. 2). You must investigate the cause of the pressure
decrease
CAUTION
Damage Hazard: If the oil supply to the damper is stopped, the
engine must be stopped immediately. Damage to the vibration
damper can occur. The oil supply must flow correctly before the
engine is started again.
If damage occurs to engine bearings because of water contamination in the

lubricating oil, you must examine the vibration damper for damage as soon as
possible.
2.2 Inner Spring Tips and Groove Flanks

Note: You must only disassemble the vibration damper if you think there is
damage, or the parts have become worn to more than the specified limits.
You must speak to the manufacturer for instructions.
Note: Only specialists can make adjustments of the vibration damper. The
torsional vibrations and these adjustments must be done at the same
time.
To do a check of the inner spring tips and groove flanks, do the procedure that
follows:
1) Stop the engine.
2) Remove the inspection cover from the vibration damper casing.
3) Examine the inner spring tips and groove flanks. Refer to the manufacturer’s
manual for the limits.
4) Attach the inspection cover to the vibration damper casing.
5) Start the engine.
Before you remove a vibration damper and balance weight, record their positions with
reference to the crankshaft position.
For the torque values of the coupling bolts (6), refer to 0352−1.
For the test run after the first commissioning, the usual checks and servicing intervals,
refer to the manual of the vibration damper manufacturer.
The address for GEISLINGER vibration dampers is given below:
Geislinger GmbH
A-5300 Hallwang / Salzburg
Austria
Tel: +43 662 66 999 0
Fax: +43 662 66 999 40

I-I
1
6
2 3
4
5 1
OIL
FREE SUPPLY
END
WCH02478
000.940/93
Note: Some parts can look different.
Fig. 2: Vibration Damper (section view)

1 Vibration damper 4 Oil supply pipe
2 Damper casing 5 Crankshaft
3 Vent nozzle 6 Coupling bolt

Intentionally blank
Axial Detuner

Tools:
2 Spur-geared chain block 94017-006 2 Eye bolt 94045-M36
2 Shackle 94018A 1 Lifting plate / link 94321
1 Chain 94019C
1. Removal
When the 2-part gasket (9 or 10, Fig. 1) must be removed from the axial damper, do
the procedure that follows:
2) Remove the pipes (7, 8).
3) Remove the top housing (1).
4) Remove the oil supply pipe (6).
5) Remove the six bolts (5) and the four screws (4) from the top housing (1).
6) Remove the 2-part gaskets (9, 10).
Note: Engine operation does not usually cause the 2-part gaskets to become
worn. The 2-part gaskets must be replaced if they do become worn, or if
contamination causes damage.
7) Examine the 2-part gaskets (9, 10) for damage and contamination. If necessary,
replace the 2-part gaskets.
For more data about the Axial Damper, refer to the Operation Manual 3140−1.
I-I
8 1
I 2
3 9
4 10
10
WCH01218
Fig. 1 I

Axial Detuner: Disassembly and Assembly
8) Attach the two eye bolts (94045-M36, Fig. 2) to the axial detuner.
9) Attach the chain (94019C) to the eye bolts (94045-M36).
10) Attach the plate (94321) to the chain (94019C).
11) Install the two shackles (94018A, Fig. 3) to the column.
12) Attach the spur-geared chain blocks (94017-006) to the shackles in the column.
13) Operate the spur-geared chain blocks (94017−006) to lift and move the axial
detuner to a position below the engine room crane.
14) Attach the hook of the engine room crane to the plate (94321).
15) Remove the spur-geared chain blocks (94017−006) from the plate (94321).
16) Operate the engine room crane to lower the axial detuner on to an applicable
surface.
94017-006 94018A
94321
94017-006
94321
13
94019C
WCH02417
94045-M36
Fig. 2 Fig. 3

Axial Detuner: Disassembly and Assembly
2. Installation
1) Apply clean engine oil to the 2-part gaskets (9, 10, Fig. 1).
2) Install the 2-part gaskets (9, 10). Make sure that the 2-part gaskets can move
freely.
3) Attach the plate (94321, Fig. 3) to the axial damper.
4) Attach a spur-geared chain block (94017−006) and the engine room crane to the
plate (94321).
5) Operate the engine room crane and spur-geared chain block (94017−006) to lift
and move the axial damper into position.
6) Attach the other spur-geared chain block (94017−006) to the axial damper.
7) Remove the hook of the engine room crane from the plate (94321).
8) Operate the two spur-geared chain blocks to carefully lower the axial damper on
to the bottom housing. Make sure that you do not cause damage to the 2-part
gaskets.
9) Apply Molykote paste G−n to the threads of the six bolts (5, Fig. 1).
10) Torque the six bolts (5) to 900 Nm (refer to 0352−1.
11) Install the four screws (4).
12) Install the pipes (7, 8) and the oil supply pipe (6).
13) Remove all tools and equipment from the work area.

Intentionally blank
Turning Gear
Teeth and Screwed Connections − Check

Tools:
1 Pre-tensioning jack 94320
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Pinion and Flywheel Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Recommended Suppliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Elastic Bolts − Apply Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. General
Before you operate 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 0750−1.
For maintenance of the turning gear (1), refer to the manufacturer’s instructions.
You must do a check of the tension of the elastic bolts (4). The intervals for the
checks are given in the 0380.1, Maintenance Schedule, Inspection and Overhaul
Intervals Turning Gear. The procedure to do a check of the tension is given in
paragraph 3.
3
I
WCH02320
Fig. 1

Turning Gear: Teeth and Screwed Connections − Check
2. Pinion and Flywheel Teeth

2.1 Procedure
Note: Make sure that only a thin layer of lubricant is applied to the tooth flanks
of the pinion (2) and the flywheel (3). This makes sure that the lubricant
stays on the tooth surfaces during engine operation.
Table 1: Instructions − Pyroshield

Manufacturer Location Instruction
LE 5182 Apply a thin layer of the
Pyroshield lubricant to the teeth as shown
in the photograph.
Table 2: Instructions − Klüberfluid

Manufacturer Location Instruction
Klüberfluid Increase the temperature of
C−F 3 Ultra the Klüberfluid.
Put an applicable quantity of
Klüberfluid into a container.
Put the container into warm
water until the Klüberfluid is
approximately 35_C.
Apply the Klüberfluid as shown
in the photograph.
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 Recommended Suppliers

Lubrication Engineers Inc.
300 Bailey Avenue
Forth Worth, TX
USA
http://www.lelubricants.com/
Email: [email protected]
Klüber Lubrication München KG

Geisenhausenerstrasse 7
81379 München
Germany
http://www.klueber.com
Email: [email protected]

Turning Gear: Teeth and Screwed Connections − Check
3. Elastic Bolts − Apply

Tension
94320
1) Clean the round nuts, the threads of
the elastic bolts and the seating
surfaces.
2) Read the data in 9403−4.
3) Put the pre-tensioning jack (94320,
Fig. 2) in position on the applicable
elastic bolt (1, Fig. 3).
4) Apply tension to the elastic bolts (1) in
the specified sequence shown and in
accordance with the values given in
9403−4, Turning Gear..
Fig. 2 5) Apply a protection agent e.g. Valvoline

Tectyl 132 to the bolt threads, round
nuts and the seating surfaces to give
protection against corrosion
SEQUENCE
I
Fig. 3

Intentionally blank
Crankcase
Work Platform
Tools:
2 Platform, each platform includes three grids 94142
2 Support 94143
1. General
WARNING
Injury and Damage Hazard: Do not turn the crankshaft when the
platforms and/or supports are installed. This will cause injury to
personnel and damage to equipment.
You use the platform (94142, Fig. 1) and support (94143) when you do work in the
crank area and between the columns. The platforms help to prevent accidents in
these areas.
You install the platform (94142) on the longitudinal beam (2) and the crank (1).
You install the support (94142) at the applicable height on the steps (3) between the
columns. This support is adjustable between 725 mm and 902 mm.
To prevent accidents, the platform (94142) and supports (94143) must be used for
inspections or work in the crankcase.
94143
Maximum Load
250 kg/m2
1
EXHAUST SIDE
3
FUEL SIDE
94142
Maximum Load
300 kg/m2
WCH03210
Fig. 1

Intentionally blank
Work Card
Connecting Rod: Check the Bearing Clearances

− Crankshaft at TDC
Feeler gauge 94122 Qty 1

Preparation
Do a check of the bearing clearances, refer to Service Engineer 1.0 hours Qty 1
0330−1, Group 3303
Related Data

Related Procedures

Intentionally blank
Connecting Rod
Bottom End Bearing − Removal, Inspection and

Installation
Tools:
2 Manual ratchet H1/H5 1000 kg 94016-009 4 Eye bolt M8 94045-M8
2 Manual ratchet H2/H3, 1000 kg 94016-011 1 Deviation pipe 94117B
1 Manual ratchet H4, 1500 kg 94016-017 1 Pre-tensioning jack 94252
4 Shackle, 4750 kg 94018B 1 Chain 94327
2 Shackle, 8500 kg 94018C 1 Console Frame 94326
1 Chain, 5300kg 94019B 1 Support 94322
1 Support (for iELBA) 94322A
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Bearing Cover − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Top Bearing Shell − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Top Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Top Bearing Shell − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Bottom Bearing Shell − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8. Bearing Cover − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Preparation
WARNING
make sure that no
EXHAUST SIDE
crankshaft until the applicable crank (2,

Fig. 1) is at TDC.
2) Lock the turning gear.
3) Attach the eye bolts (94045-M8) to the
bearing cover (3).
94018B 1 4) Attach the shackles (94018B) to the
H3 H2 column.
2 the shackles (9418B) and the eye bolts
94018B on the bearing cover (3).
94045-M8 6) Apply a light tension the manual
3 ratchets (H2, H3).
2. Bearing Cover −
Removal
1) Loosen the round nuts (1), refer to
9304−4 paragraph 2.
2) Remove the round nuts (1).
3) Carefully lower the bearing cover (3).
4
4) Examine the bearing shell (4).
WCH02423
Fig. 1 Note: If the bearing shell is in good
condition, lower the bearing cover
on to the bottom of the crankcase.

Bottom End Bearing − Removal, Inspection and Installation
5) Attach the chain (94019B) to the

gallery.
94019B 6) Attach the manual ratchet (H4) to the
chain (94019B).
7) Install the deviation pipe (94117B) to
H4
the column.
FUEL SIDE
to move the bearing cover (1) to the

fuel side.
EXHAUST SIDE
H3 9) Remove the manual ratchet (H2) from
1 H2 the eye bolt on the bearing cover.
eye bolt on the bearing cover (1).
to remove the bearing cover (1) from
the crankcase.
12) Lower the bearing cover (1) on to an
94117B applicable surface.
WCH02423
Fig. 2
94327
1
3. Bearing Shell −
Removal
1 1) Remove the two screws (1, Fig. 3).
94045-M8 2) Install the four eye bolts (94045-M8).
3 3) Attach the chain (94327) to the four eye
bolts (94045-M8).
2
chain (94327).
WCH02423
Fig. 3 5) Operate the engine room crane to lift
bearing shell (3) from the bearing cover
(2).

4
4. Top Bearing Shell −
Check
160 mm
1 WARNING
3 Injury Hazard: Before you
2
make sure that no
94322A 94322 flywheel, or in the engine.
1) Unlock the turning gear.

WCH03208
iELBA Installed 2) Operate the turning gear to move the
crank to the fuel side. Continue to
operate the turning gear until the
crosshead is approximately 300 mm
4 above the plug bore center (Fig. 4).
3) Apply a small quantity of clean oil to the
four bolts(1, 4).
160 mm
4) Attach the supports as follows:
1
a) For an engine with an iELBA
3 installed, attach one support
2 (94322A) and one support
WCH03208 (94322) with the four bolts (1, 4).
94322 94322 b) For an engine with no iELBA
Fig. 4 iELBA Not Installed
installed, attach two supports
(94322) with the four bolts (1, 4).
5) Torque the four bolts (1, 4) to 300 Nm.
6) Operate the turning gear to lower
crosshead to 160 mm above plug bore
center.
H3 7) Tighten the special screws (2, 3) on

each support.
8) Put the chain of the manual ratchet
(H3, Fig. 5) around the connecting
rod (3).
3 1
crank (2) to the fuel side. Keep the
tension on the manual ratchet (H3).
X 10) Make sure that there is no load on the
X corners (X) of the bearing shell (1).
11) Operate the turning tear to turn the
2
crank (2) to 100° after TDC.
12) Do a check of the bearing shell (1).
WCH02423
Fig. 5

H1 5. Top Bearing Shell −

94018C Removal
H5 1) Attach the two shackles (94018C,
the shackles (94018C).
3) Attach the console frame (94326,
Fig. 7) to the bearing shell (4) with the
four screws (2).
4) Connect the manual ratchets (H1, H5)
to the console frame (94326).
5) Apply a light tension to the manual
ratchets (H1 and H5, Fig. 6).
94326
6) Remove the two screws (3, Fig. 7).
Fig. 6 WCH02423
4
1
3
94326
Fig. 7 WCH02423
94019B
H5/H1 to lower the console frame (94326,
H4 Fig. 8) together with the bearing shell.
H3 eyelet in the console frame (94326).
10
9) Operate the manual ratchets (H4, H1,
H5) to move the console frame (94326)
and bearing shell out of the column.
94326
10) Remove the manual ratchets (H1, H5).
Fig. 8 WCH02423

6. Top Bearing Shell −

Installation
4
1) Clean the seating surface of the
1
connecting rod (1, Fig. 9) and the
3 bearing shell (4).
94326 2) Put the bearing shell (4) on the console
frame (94326)
3) Tighten the four screws (2).
2 4) Clean the seating surface of the
connecting rod (1) and the bearing
shell (4).
Fig. 9 WCH02423 5) Attach the manual ratchet (H4, Fig. 10)
to the console frame (94326).
6) Operate the manual ratchet (H4) to lift
the console frame (94326) into position.
the console frame (94326).
8) Remove the manual ratchet (H4).
9) Put oil on the surface of the bearing
shell.
94019B 10) Operate the manual ratchets (H1, H5)

to move the console frame (94326) and
H5/H1 bearing shell into position.
H4 Note: Make sure that the distance
between each end of the bearing
H3 shell and the connecting rod rod is
the same.
11) Attach the bearing shell (4, Fig. 9) to
94326 the connecting rod (1) with the two
screws (3).
12) Remove the console frame (94326).
1 13) Make sure that the surface of the crank
pin (1, Fig. 10) is in a satisfactory
condition.
14) Put oil on the crank pin.
WARNING
WCH02423 Injury Hazard: Before you
make sure that no
Fig. 10 flywheel.

crank to TDC. Make sure that there is
no load at the points (X, Fig. 5).
16) Remove the supports (94322, 94322A).

7. Bottom Bearing Shell −

Installation
94327 1) Attach the four eye bolts (94045-M8,
Fig. 11) to the bearing shell (3).
2) Attach the chain (94327) to the four eye
bolts (94045-M8).
1
chain (94327).
4) Operate the manual ratchet (H4)to lift
1 the bottom bearing shell (3).
94045-M8 5) Clean the seating surface of the
bearing cover (2) and the bearing
3
shell (3).
2
6) Apply a small quantity of clean oil to the
surface of the bearing shell (3).
WCH02423 7) Attach the bearing shell (3) to the
bearing cover (2) with the four screws
(1).
Note: Make sure that the distance
Fig. 11 between each end of the bearing
shell and the connecting rod rod is
the same.
8) Remove the chain (94327) and the four
eye bolts (94045-M8).
8. Bearing Cover −
94019B Installation
1) Attach the chain (94019B, Fig. 12) to
the gallery.
H4
2) Attach the manual ratchets (H4) to the
chain (94019B) and the eye bolt on the
FUEL SIDE
bearing cover (1).

EXHAUST SIDE
eye bolt on the bearing cover (1).

1 H3
H2 4) Operate the manual ratchets (H3,H4) to
move the bearing cover (1) into the
crankcase.
column and the bearing cover (1).
7) Operate the manual ratchets (H2 H3) to
lift the bearing cover (1) into position.
WCH02423
Fig. 12

8) Make sure that the bearing shell is

clean.
9) Put oil on the bearing shell as follows:
a) If you start the engine immediately
after completion of this procedure,
use only bearing oil.
b) If the engine has stopped for
some days, use a mixture of
1 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
x2 1000/1500 high viscosity oils is
x1
given in Table 1.
10) Put the round nuts (1, Fig. 13) on the
elastic studs.
11) Tighten the round nuts (1) equally with
a round bar.
12) Measure the distance (X1, X2) between
WCH02447
Fig. 13 the edges of the bearing shells and the
bearing cover.
13) For new bearing shells, the dimensions
X1 plus X2 must be between 1.18 mm
and 1.34 mm.
14) Apply tension to the elastic studs, refer
to 9403−4, paragraph 3.
the work area.
Table 1: ISO G 1000/1500 Suppliers
Supplier Type Viscosity at Viscosity at Weight at

40° C mm2/s 100° C mm2/s 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 SUPER Cylinder Oil 680 39.0 0.905
SHEEL FIONA Oil 1500 1500 37.0 0.958
SHEEL VALVATA OIL 1000 1000 45.4 0.924
TEXACO 650T MINERAL Cylinder Oil 985 44.0 0.919

Intentionally blank
Work Card
Connecting Rod
− Engine stopped Bearing shell (bottom end EX 33100 Qty 1

bearing, top half)
Bearing shell, (bottom end EX 33101 Qty 1

bearing, bottom half)
Bearing shell (top end bearing) EX 33150 Qty 1
Attach applicable equipment, refer to 3303−2/A1 Manual ratchet 94016-009 Qty 2

and 3303−3/A1 Manual ratchet 94016-011 Qty 2
Manual ratchet 94016-017 Qty 1
Manual ratchet 94016-031 Qty 2
Shackle 94018B Qty 4
Shackle 94018C Qty 2
Chain 94019B Qty 1
Chain 94019A Qty 1
Chain, 4-Sling 94327 Qty 1
Deviation pipe 94117B Qty 1
Chain 94327 Qty 1
Console Frame 94326 Qty 1
Support 94322 Qty 1
Support (for iELBA) 94322A Qty 1
Platform 94143 Qty 1
Lifting tool 94324 Qty 1
Stop plate 94335 Qty 1
Steam engine cylinder oil, ISO
VG 1000/1500
Bearing oil

Preparation
Replace the connecting rod bearings, refer to Superintendent 10.0 hours Qty 1
3303−2/A1 and 3303−3/A1 Service Engineer 10.0 hours Qty 2

WC3303−3/A1 Maintenance
Related Data

Related Procedures

Connecting Rod
Top End Bearing − Removal, Inspection and Installation

Tools:
2 Manual ratchet, 1000kg, H1,H2 94016-011 1 Deviation pipe 94117B
1 Manual ratchet, 1500kg, H3 94016-017 1 Platform 94143
2 Manual ratchet, 3000kg, H6,H7 94016-031 1 Support 94322
1 Chain block, 500kg, H5 94017-006 1 Support (for iELBA) 94322A
1 Chain block, 2000kg, H4 94017-021 1 Lifting tool 94324
4 Eye bolt 94045-M8 1 Chain, 4-Sling, 1120kg 94327
2 Eye bolt 94045-M24 1 Stop plate 94335
1 Eye bolt 94045-M48 1 Lifting tool 94337
2 Shackle, 4750 94018B 2 Pre-tensioning jack 94315
2 Shackle, 8500kg 94018C 2 Pre-tensioning jack 94340
1 Chain symmetrical 94019A
1 Chain asymmetrical 94019B
1. Piston − Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Crosshead − Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Bearing Shell − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Piston − Hold
4 1 WARNING
2
make sure that no
1) Read the data in 0012−1 General

Guidelines for Lifting Tools.
WCH02434 2) Operate the turning gear to turn the

crank to BDC.
3) Apply tension to the elastic studs (1,
3 Fig. 1) of the piston rod foot (3), refer to
Fig. 1 9403−4.
4) Remove the round nuts (2).
crank to TDC.

Top End Bearing − Removal, Inspection Installation
6) If necessary, put oil on the two bolts (1,

Fig. 2)
7) Install the two holders (94333) with the
four bolts (2) to the piston rod foot.
1
9) Tighten the two bolts (2).
94333
2 crank to BDC. The connecting rod
moves down away from the piston rod
WCH02435
foot.
Fig. 2 11) Lock the turning gear to prevent
movement of the crankshaft.
2. Preparation
1) Install the platform (94143, Fig. 3).
2) Install one eye bolt (94045-M48) near
EXHAUST SIDE
the gland box.

94045-M48 3) Install one eye bolt (94045-M48) on the
guide shoe below the eye bolt near the
94117B gland box.
4) Install the deviation pipe (94117B) to
the column opening.
5) Use the pre-tensioning jack (94315) to
apply tension to the elastic stud (3),
1 refer to 9403−4.
94045-M48
2 94324
7 6) Remove the four round nuts (4).
3 7) Attach the lifting tool (94324) to the
4 elastic studs (3) with the round nuts (4)
8) Tighten the round nuts (4) with the
94335
round bar (94005).
9) Install the stop plate (94335) to the
94337 bearing cover (7).
10) Install the lifting tool (94337) to each
5 side of the connecting rod.
94143 6 11) Torque the four bolts of the lifting tool
(94337) to 150 Nm.
12) Disconnect the toggle lever (1, Fig. 4)
from the connecting rod.
WCH02433
Fig. 3

94018C 3. Crosshead − Lift

94019B
1) Attach the shackles (94018B, Fig. 4) to
H3 1
each side of the column.
I 2) Attach a manual ratchet (H1, H2) to the

shackles (94018B) and the the two
lifting tools (94337).
94018B H1
94045-M48 3) Apply a light tension to the manual
H2 ratchets (H1, H2).
Note: If the cylinder cover and piston are
removed you can use the engine
94337 room crane and chain block (H4) to
I lift the crosshead.
4) Attach the chain (94019B) to the two
94143 H3 shackles (94018C).
H4 5) Attach the manual ratchet (94016-017,
H3) to the chain (94019B).
94324
6) Attach the manual ratchet (94017-21,
(H4) to the eye bolt (94045-M48) at the
top of the column and the eye bolt on
the bearing cover, see View I.
Fig. 4 WCH02433 94322 7) Operate the manual ratchet (H3) to lift
the crosshead approximately 300 mm
above the plug bore center (Fig. 5) in
the column.
4 8) Keep the tension on the chain
block (H4).
160 mm 9) Apply a small quantity of clean oil to the
1
four bolts(1, 4).
3 10) Attach the supports as follows:
2 a) For an engine with an iELBA
installed, attach one support
94322 (94322A) and one support
94322A
WCH03209
b) For an engine with no iELBA
iELBA Installed installed, attach two supports
11) Torque the four bolts (1, 4) to 300 Nm.
4 12) Operate the turning gear to lower
crosshead to 160 mm above plug bore
center.
160 mm 13) Tighten the special screws (2, 3) on
1 each support.
14) Examine the bearing shell.
3
2 15) If it is necessary to replace the bearing
WCH03208 shell, refer to paragraph 4, step 1) to
94322 94322 step 11).
Fig. 5 iELBA Not Installed 16) Remove the platform (94143, Fig. 4).

FUEL 4. Bearing Shell −

SIDE
Removal
94019A 1) Attach the chain (94019A, Fig. 6) to the
94019B
gallery.
H5
2) Attach the chain block (94017-006, H5)
to the chain (94019A).
H1 3) Operate the manual ratchets (H1, H2)

94327 H2 to move the connecting rod to the fuel
side.
I 4) Install the four eye bolts (94045-M8)
into the bearing shell (2).
5) Attach the chain (94327) to the manual
ratchet (H5) and the four eye bolts in
the bearing shell (2).
6) Remove manual ratchet (H2) from the
connecting rod.
WCH02433
chain (94327).
I 8) Remove the two screws (1).
9) Operate carefully the manual ratchet
1 (H2) and the chain block (H5) to lift the
bearing shell (2) from the connecting
rod.
94045-M8
10) Continue to operate the manual ratchet
(H2) and the chain block (H5) to
2 remove the bearing shell (2) from the
engine.
11) Lower the bearing shell (2) on to an
applicable surface.
12) Remove the chain (94327), the manual
WCH02433 ratchets (H2) and the chain block (H5).
Fig. 6 13) Use the chains (94019A and 94019B,
Fig. 7) and the two chain blocks (H6,
H7) to move the bearing cover (1) to an
applicable area.
14) Remove the four eye bolts (94045−M8)
from the bearing cover (2).
94019A
94019B
H6
H7
2
WCH02433
Fig. 7

5. Bearing Shell − Installation

1) Clean the seating surface of the bearing shell (2, Fig. 6).
2) Put oil on the surface of the bearing shell as follows:
a) If you start the engine immediately after completion of this procedure, use only
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.
3) Clean the seating surface of the connecting rod and make sure that there is no
damage.
4) Make sure that the surface of crosshead pin is in a satisfactory condition.
5) Install the four eye bolts (94045−M8) to the bearing shell (2).
6) Attach the chain block (H5) to the chain (94327).
7) Attach the chain block (H5) to the eye bolts (9405−M8).
8) Carefully operate the the chain block (H5) to lift then lower the bearing shell (2)
on to the connecting rod.
9) Install the two screws (1) to the bearing shell (2).
94018C 10) Remove the chain block (H5).

11) Remove the four eye bolts
(940545−M8).
94019B 1 12) Attach the manual ratchet (H2, Fig. 8)
to the lifting tool (94337).
H3
I to move the connecting rod to the
center position below the crosshead.
94018B H1 14) Install the platform (94143).
94045-M48
H2 15) Make sure that there is tension on the
chain blocks (H3, H4).
16) Remove the two supports (94322,
94337 94322A).
I 17) Operate carefully the chain blocks (H3,
H4) to lower the crosshead into the
94143 H3 connecting rod.
H4 18) Remove the tools (94337).
94324 19) Connect the toggle lever (1) to the

connection piece.
Fig. 8 WCH02433 94322

1
20) Put the round nuts (3, Fig. 9) on the
2 elastic studs (2).
3 21) Use the round bar (94005) to tighten
equally the round nuts (3).
x1 22) Measure the distances (X1, X2)

between the edges of the bearing
shells and the connecting rod (5).
x2 23) For new bearing shells, the dimensions
X1 plus X2 must be between 0.41 mm
and 0.49 mm.
24) Apply tension to the elastic studs, refer
4 to 9403−4, paragraph 3.
Note: During step 24), do not remove the
holders (94333).
5
the work area.
Fig. 9 WCH02447
Table 1: ISO G 1000/1500 Suppliers
Supplier Type Viscosity at Viscosity at Weight at

40° C mm2/s 100° C mm2/s 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 SUPER Cylinder Oil 680 39.0 0.905
SHELL FIONA Oil 1500 1500 37.0 0.958
SHELL VALVATA OIL 1000 1000 45.4 0.924
TEXACO 650T MINERAL Cylinder Oil 985 44.0 0.919

6. Bearing Lubrication
To decrease the risk of dry-running on new bearing shells, it is necessary to apply a
mixture of high-viscosity oil (steam engine cylinder oil, ISO VG 1000/1500) and
bearing oil.
1) Remove the oil inlet pipe (2, Fig. 10).
2) Attach the flange (94336) to the support (1).
3) Connect the hose (3) to the flange (94336).
4) Fill the lubricating pump (4) with steam-engine cylinder oil (refer to Table 1).
5) Operate the lubricating pump (4) until oil flows from the sides of the bearing.
Note: Do step 1) to step 5) weekly if the 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 (2) to the support (1).
Note: The steam-engine cylinder oil can stay in the oil system.
1 94336
WCH02448
Fig. 10

7. Completion
WARNING
make sure that no
94333 personnel are near the
flywheel, the propeller shaft
or inside the engine.
WCH02435 1) Make sure that the piston rod foot

(1, Fig. 11) is clean and has no
damage.
1 2) Make sure that the compression shim
(4) is clean and has no damage.
3) Remove the platform (94143).
2
4) Unlock the turning gear.
4
3 5) Operate the turning gear to move the
crankshaft to TDC. Make sure that the
crosshead touches the piston rod
foot (1).
6) Remove the holders (94333).
7) Operate the turning gear to lower the
piston to BDC. Make sure that the
piston rod foot (1) and the crosshead
WCH02434 stay together.
8) Put the four round nuts (3) on the
elastic studs (2)
Fig. 11
tighten the four round nuts (3) refer to
the area.

Connecting Rod

Tools:
4 Manual ratchet, 1000kg, H1, H2 94016-009 1 Chain asymmetrical 94019B
2 Chain block, 2000kg, H3,H4 94017-021 1 Bracket 94334
1 Shackle, 8500kg 94018C 1 Connecting element 94334A
1 Chain symmetrical 94019A 1 Shackle 3250 kg 94018A
2 Manual ratchet, 3000kg, H5, H6 94016−031
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Connecting Rod − Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Preparation
1 1) Read the data in 0012−1 General
2
Note: During step 2), do not move the
crosshead to BDC.
94018A 2) Prepare the piston, refer to 3303−3,
paragraph 1.
H1
H2 3) Remove or lower the bottom end
bearing cover of the connecting rod,
refer to 3303−2, paragraph 2.
94018A
4) Attach the two shackles (94018B,
Fig. 1) and the two manual ratchets
94335 (H1, H2) to the column.
5) Attach the two shackles (94018B) to
the bracket (94335).
to the shackles on the bracket (94335).
017.679/08 7) Apply copper paste to the thread of the

pin screw (4).
look different. 8) Put the rods (3) into the connecting rod.
to lift the bracket (94335) into position
on the the rods (3).
94018B 10) Tighten the nuts and bolts (5).

11) Torque the rods (3) to 90 Nm.
3 3 12) Lift the crosshead, refer to 3303−3,
paragraph 2 and 3.
4
13) Remove the the manual ratchets (H1,
H2) from the plate (94335).
5 14) Remove the toggle lever (1) from the
5 connecting rod (2).
Fig. 1 94335

94018C H3
2. Removal
WARNING
Injury Hazard: The
H1 connecting rod weighs
approximately 3900 kg. To
H2 prevent injury, be careful
FUEL SIDE
when you move the

94337 connecting rod.
WARNING
make sure that no
flywheel.
Fig. 2 WCH02449
1) Use the manual ratchets (H1, H2,
Fig. 2) to move the connecting rod (1)
to the fuel side.
I 2) Attach the shackle (94018C) and the

chain block (H3) to the top of the
column.
H4 H3 bottom shackle of the lifting
tool (94337).
4) Apply a light tension to the chain of the
94337 chain block (H3).
the gallery.
6) Remove the manual ratchet (H2) from
the top shackle of the lifting tool
(94337).
2
1 7) Operate the turning gear and the chain
block (H3) to move the connecting
rod (1) counterclockwise to the position
shown.
WCH02449 8) Attach the applicable chain (94019A or
94019B) to the gallery.
I applicable chain (94019A or 94019B).
94019B 10) Attach the manual ratchet (H4) to the
94019A
H4 top shackle of the lifting tool (94337).
11) Apply tension to the manual
ratchet (H4).
1 12) Remove the manual ratchets (H1, H2)
bottom shackle of the lifting tool
(94337).
Fig. 3

14) Operate the turning gear and chain

block (H4, Fig. 4) to move the crank
anticlockwise to the position shown.
H4 lug (5) on top of the rod (4)
16) Apply a light tension to the chain of the
H3 manual ratchet (H1).
17) Connect the chain block (H3) to the
bracket (94334).
18) Apply a light tension to the chain
FUEL SIDE
block (H3).
5 Note: When you do step 19), hold the
bracket (94334) in position.
H1
19) Carefully remove the bottom nut and
4 bolt (2) from the bracket (94334).
1 20) Lower the bracket (94334) to the floor.
94018A
21) Remove the chain block (H3) and the
shackle from the bracket (94334).
22) Attach the connecting element
(94334A) to the bottom of the rod (3)
94334A
3 with the nut and bolt (2).
2 23) Attach the shackle (94018A) and the
chain block (H3) to the connecting
94334 WCH02449 element (94334A).
Fig. 4
the lug (3) on top of the rod (2).
H4
25) Operate the turning gear and the chain

H3 block (H3 and H4, Fig. 5) to carefully
move the connecting rod out of the
column.
shackle (94018A) on the connecting
element (94334A).
FUEL SIDE
Fig. 5 WCH02449

3. Connecting Rod − Move

If it is necessary to move the connecting
rod (1, Fig. 6) away from the area, do step
1) to step 12).
H2 1) Read the applicable safety precautions.
H1
2) Put on the applicable personal
protective equipment.
3) Lower the connecting rod (1) to the
floor.
1 4) Remove the chain (94019 or 94019B).
5) Attach the two manual ratchets
Fig. 6 (94016-009, ) to the connecting rod and
the eyelets in the gallery as shown.
6) Read and obey the data given in Fig. 7.
Load Condition 1 Load Condition 2

Permitted Load on Gallery Eyelets
Column Side
a = maximum 35°
b = maximum 20°
F = WLL = 15000 N F = WLL = 10300 N
Load Condition 3 Load Condition 4
Note: only one load is permitted
Column Side
on each eyelet.
F = WLL = 24600 N F = WLL = 10300 N

Load Condition 5: Application with 2-leg chain (94019A or 94019B)
Column Side
F = WLL = 10300 N
Load Condition 6: Application with 2-leg chain (94019A or 94019B)
Column Side
F = WLL = 15000 N WCH02669
Fig. 7: Load Condition Data
7) Lift the connecting rod (5, Fig. 8) a small distance.

8) Attach the manual ratchets (H5, H6) to the connecting rod as shown in step B.
9) Loosen the tension on the manual ratchets (1, 2). At the same time, operate the
manual ratchets (3, 4) to move the connecting rod.
10) Remove and attach the manual ratchets (1 to 4) as given in step 9) to continue to
move the connecting rod a sufficient distance (step C).
11) Lower the connecting rod to the floor.
12) Attach the engine room crane, then remove the manual ratchets.

3 4
1 2
Fig. 8 A B C
4. Installation
WARNING
94019A or
94019B Injury Hazard: The
connecting rod weighs
3900 kg. To prevent injury,
H4
be careful when you move
the connecting rod.
H3
WARNING
H1
make sure that no
4 flywheel.
94018A
1) Clean the bearing shell (4, Fig. 9) and
3 the crank pin (1).
2) Put oil on the bearing shell (4) and the
crank pin (1).
94334A 3) Attach the chain block (H3) to the
2 shackle (94018A) on the connecting
1 element (94334A).
shackle (94018A) on the top rod (3).
WCH02449
Fig. 9

5) Operate the turning gear, the chain

blocks (H4, H3) and manual ratchet
(H1), Fig. 10) to move the connecting
rod and the crankshaft as shown.
H4
shackle (94018A).
H3
7) Remove the shackle (94018A) and the
connecting piece (94334A).
8) Attach the chain block (H3) to the top
eyelet on the plate (94334).
FUEL SIDE

plate (94334) into position on the crank
3
pin.
H1
10) Attach the plate (94334) to the bottom
2 of the rod (2) with the nut and bolt (1).
3 11) Remove the chain block (H3) from the
top eyelet of the plate (94334).
2 12) Attach the chain block (H3) to the
bottom eyelet on the plate (94334).
1 13) Operate the chain block (H3) to lift the
plate (94334).
94334 WCH02449
14) Attach the bottom end of the

plate (94334) to the bottom rod (2) with
the nut and bolt (1).
bottom eyelet of the plate (94334).
the lug on the top rod.
H4
1
94334
WCH02669
Fig. 10

17) Operate the turning gear and the chain

block (H4, Fig. 11) to move the
connecting rod (1) and crankshaft (2)
clockwise into the position shown.
H4 18) Attach the chain block (H3) to the

H3
bottom shackle on the lifting
tool (94337).
19) Remove the chain block (H4) and the
94337
chain (94019A or 94019B).
2
1
WCH02449
Fig. 11
94018C H3 20) Operate the turning gear and the chain

block (H3, Fig. 12) to move the
connecting rod (1) and crankshaft (2)
clockwise into the position shown.
H1 top shackle of the lifting tool (94337).
H2 22) Remove the chain block (H3) from the
FUEL SIDE
bottom shackle of the lifting

94337 tool (94337) and the top of the column.
23) Use the turning gear and the chain
block (H3) to move the connecting rod
1 (1) and crankshaft clockwise into the
position shown.
WCH02449
Fig. 12

24) Operate the turning gear and the

manual ratchets (H1 and H2, Fig. 13) to
94018C move the connecting rod and
crankshaft clockwise into the position
shown.
94019B 25) Make sure that there is tension on the
chain block (H4).
H3 26) Remove the two supports (94332).
I
CAUTION
H1 step 27), make sure that the
94045-M48
H2 elastic studs are aligned
with the related holes in the
crosshead. This will
prevent damage to
94337 equipment.
I
Note: During step 27), keep the tension
H3 on the chain block (H4).
H4 27) Operate the chain blocks (H3, H4) to
lower the crosshead on to the
94324 connecting rod.
28) Attach the four round nuts (2) to the
elastic studs (1).
29) Remove the chain blocks (H3, H4).
WCH02433 94322 30) Remove the tool (94324).
31) Remove the manual ratchets (H1, H2)
from the lifting tool (94337).
32) Remove the lifting tool (94324).
33) Remove the eye bolt (94045−M36).
34) Remove the stop plate (94355).
94045-M36 1
from the lifting tools (94337).
2
94335
94337
WCH02433
Fig. 13


connecting rod (1, Fig. 14) clockwise to
TDC.
the eyelets on the the bracket (94334).
38) Apply a light tension to the chains of
the manual ratchets (H1, H2).
1 39) Remove the two nuts and bolts (2) from

the plate (94334).
H2
H1
94334

different. Data from W-X62 WCH02669
40) Operate the manual ratchets (H1 and

Fig. 14 H2, Fig. 15) to lower the plate (94334).
the eyelet on the plate (94334).
42) Use the manual ratchet (H1) to remove
1 the plate (94334) from the crankcase.
3
2 43) Connect the toggle lever (1) to the
3 connection piece on the connecting
rod (2).
44) Remove the rods (3) from the
connecting rod (2).
H1 H2
5. Completion
1) Install the bearing cover, refer to 3302,
94334 paragraph 8.
2) Install the platform (94334).
3) Attach the crosshead to the piston rod
foot, refer to 3303, paragraph 7.
4) Make sure that all tools and equipment
are removed from the area.
different. Data from W-X62
Fig. 15

Intentionally blank
Connecting Rod
Top End Bearing Cover − Removal, Inspection and

Installation
Tools:
2 Manual ratchet 1000 kg (H1, H2) 94016-009 1 Chain 5300 kg 94019A
1 Manual ratchet 1500kg H3 94016-017 1 Chain 5300 kg 94019B
2 Eye bolt 94045-M20 1 Deviation pipe 94117B
2 Shackle, 4750 kg 94018B 1 Platform 94143
2 Shackle, 8500 kg 94018C 2 Pre-tensioning jack 94315
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Preparation
2) Prepare the piston, refer to 3303−3, paragraph 1.
3) Install the platform (94143, Fig. 1).
4) Install the deviation pipe (94117B) to the top of column opening.
5) Make sure that the turning gear is locked to prevent movement of the crankshaft.
94117B
94143
WCH02662
Fig. 1

Top End Bearing Cover − Removal, Inspection and Installation
94019C 2. Removal
3 1) Use the pre-tensioning jack (94315) to
94045−M20
2 loosen the four round nuts (3, Fig. 2),
refer to 9403−4.
2) Remove the four round nuts (3) from
the elastic bolts (2).
3) Attach the two eye bolts (94045-M20)
to the bearing cover (1).
1
4) Attach the chain (94019C) to the two
eye bolts (94045-M20).
WCH02662
Fig. 2
5) Attach the two shackles (94018C,

Fig. 3) to the attachment points on the
frame.
6) Attach the two manual ratchets (H1,
94018C 94018C H2) to the shackles (94018C).
H1 H2
H2) to the shackle (94018B). Make
sure that the chain lengths of the
94018B manual ratchets are equal.
94019A
8) Attach the chain (94019A) to the
1 shackle (94018B).
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
WCH02662 prevent damage to the
Fig. 3 elastic bolts.
9) Operate carefully the two manual

ratchets (H1, H2) to lift the bearing
cover (1).

10) Attach the chain (94019B, Fig. 4) to the

gallery.
chain (94019B).
94019B H1 H2 12) Operate the two manual ratchets (H1,
H2) to move the bearing cover to the
H3 fuel side.
13) Lower the bearing cover a small
distance.
94018A
shackle (94018B).
15) Remove carefully the manual
ratchet (H1).
1 to move the bearing cover (1) to the
fuel side.
17) Lower the bearing cover (1) on an
applicable surface.
18) If necessary, remove the chain
WCH02662 (94019A) from the bearing cover (1).
Fig. 4
19) Do an inspection of the bearing
cover (1). If necessary, replace the
bearing cover.
3. Installation
H1 H2
1) Make sure that the bearing cover
(1, Fig. 5) has no damage.
94018B 2) If necessary, attach the chain (94019A)
94019A
to the bearing cover (1).
1 3) Attach the manual ratchets (H2, H3) to
I the chain (94019A).
to move the bearing cover (1) to a
position above the crosshead.
chain 94019A).
6) Carefully remove the manual
WCH02662
ratchet (H3) from the shackle (94018B).
I to move the bearing cover (1) to a
position directly above the elastic bolts.
Note: During step 8), make sure that you
3 do not cause damage to the elastic
bolts (2).
2 8) Lower carefully the bearing cover (1)
on to the crosshead pin.
9) Make sure that the holes in the bearing
cover (1) engage with the four dowel
pins (2).
Fig. 5 WCH02664

10) Attach the round nuts (3, Fig. 6) to the

elastic bolts (2).
tighten the four round nuts (3) refer to
3 9403−4.
2
WCH02662
Fig. 6
4. Completion
1) Attach the piston to the crosshead, refer to 3303−3, paragraph 7.
2) Remove all tools and equipment from the area.

Work Card
Crosshead and Guide Shoe: Check

− During overhaul or installation of the crosshead
None Feeler gauge 94238 Qty 1
Hardwood wedge (or an item that Qty 2

is almost the same)

Preparation
Do a check of the guide shoe and crosshead pin Service Engineer 1.0 hours Qty 2
clearances, refer to 3326−1/A1
Related Data

Related Procedures
Clearance checks, 0330−1, Group 3326

Intentionally blank
Crosshead
Clearance Checks
Tools:
1. General
During an overhaul or after the installation of
the crosshead, you must do as follows:
D Measure and record the clearances
shown in Fig. 1 and Fig. 2.
8 D Compare the clearances with those
given in 0330−1, Group 3326.
7
2. Clearance Checks
6 3
2.1 Guide Shoe and Guide Way
1) Make sure that the related crank pin is
4 in a position so that the guide shoes (6)
touch the guide ways (3) on the fuel
5 side (or exhaust side).
4 2) Measure the clearance j between the

guide shoe (6) and the guide way (3).
Note: The clearance j is applicable for
the full length of the guide way (3)
Fig. 1 WCH03670 and measured at the position
shown in Fig. 2.
3 2 1 2 1
2.2 Crosshead
1) Measure the lateral clearance k at
each position of the crosshead as
follows:
a) Use an applicable hardwood
wedge (or an item that is almost
1 the same) to push the crosshead
90° BEFORE OR axially to one side. Make sure that
AFTER TDC you apply the pressure only to the
guide shoe.
2.3 Guide Shoe and Top End

Bearing
1) Measure the full lateral clearance l
between the top end bearing (8) and
the the guide shoes (6).
2.4 Radial Clearance

013.784/06
1) Measure the radial clearance m
between the guide shoe (6) and
crosshead pin at all positions of the
Fig. 2
crosshead.

Intentionally blank
Crosshead
Crosshead Pin − Removal and Installation

Tools:
1 Deviation pipe 94117B 2 Eye bolt M20 94045−M20
1 Platform 94142 2 Eye bolt M30 94045−M30
1 Lifting tool 94324 4 Eye bolt M48 94045−M48
2 Chain block 2000 kg (H1, H2) 94017−021 1 Chain 94325
2 Manual ratchet 1500 kg (H6, H7) 94016−017 1 Chain 94019B
2 Manual ratchet 1000 kg (H4, H5) 94016−011 1 Link 94321
1 Manual ratchet 1000 kg (H8) 94016−009 2 Lifting tools 94337
2 Manual ratchet 3000 kg (H3, H9) 94016−031 2 Supports 94322
4 Shackle 4750 kg 94018B 1 Feeler gauge
4 Shackle 8500 kg 94018C
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Crosshead Pin − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Guide Shoes − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Guide Shoes − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Crosshead Pin − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Clearance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Preparation
WARNING

2) Operate the turning gear to turn the crank of the related cylinder to BDC.
3) Keep the turning gear engaged to prevent an accidental engine start.
4) Install the platform (94142), refer to 3301−1.
5) Disconnect the toggle lever (9, Fig. 1) from the crosshead pin (2). Let the toggle
lever hang in the column.
6) Remove the round nuts from the elastic studs on the connecting rod, refer to
9403−4.
7) Remove the top bearing cover, refer to 3303−5, paragraph 2.
8) Put protection on the oil inlets of the crosshead pin to prevent damage and
contamination.

H1 94018C
2. Crosshead Pin −
H2
I 1 Removal
H3
1) Attach the lifting tool (94324, Fig. 1) to
the crosshead.
2) Attach the two eye bolts (94045−M48)
94018B II to the bottom of the cylinder jacket.
H5
H4 3) Attach the two shackles (94018C) to
2 the top of the column.
4) Attach the two chain blocks (H1, H2) to
5) Attach the link (94321) to the chain
blocks (H1, H2).
WCH02437 6) Attach the manual ratchet (H3) to the
link (94321) and the eye
94045−M48
I bolt (94045−M48) on the lifting tool.
3 to the guide shoes (6, 7).
8) Attach the two lifting tools (94337) to
the connecting rod (2).
H2
94018C H5) to the shackles (94018B). Operate
H1 WCH02437 the manual ratchets to apply a light
tension to the chains.
94321
II 10) Operate the manual ratchet (H3) to lift
94018B
above the center of the pin hole (4).
4
94142
WCH02437
94045−M48
94324
7 6
94337
WCH02437
Fig. 1

Note: The two supports (94322, Fig 2)

Turned hold the weight of the crosshead
94045−M48 through while you move the connecting
H3 90° rod (4).
H3 11) Attach the two supports (94322) to the

H4 94045−M48 guide way with the four bolts (1) as
shown.
12) Torque the bolts (1) to 300 Nm.
13) Tighten the two set screws (2).
14) Put a wooden block (3) in position as
FUEL SIDE
shown.
Note: During the step 15), slowly move
1 the connecting rod to the exhaust
side.
15) On the fuel side, gradually loosen the
manual ratchet (H4). At the same time,
keep tension on the chain of the
4 3 manual ratchet (H5).
WCH02437
2 16) Continue with step 15) until the

connecting rod (4) touches the wooden
94322 block (3).
17) Loosen the two set screws (2).
18) Lift the crosshead a small distance.
19) Remove the two supports (94322).
21) Lower the crosshead to the same
height as the column door frame.
the eye bolts (94045−M48) on the
guide shoes (5) and (6).
the manual ratchets (H6, H7). Make
3 sure that the primary load stays on the
WCH02437 4
chain of the manual ratchet (H3).
94045−M48 94045−M48
H3
H6 H7
94045−M48 94045−M48
6 5
WCH02437
Fig. 2

24) Remove the two bolts, tab washers and

holding plates (1, Fig. 3) from the
1 guide shoe (4).
4 2 25) Attach the two eye bolts (94045−M20)
and the chain (94325) to the crosshead
pin (4).
26) Attach the shackle (94018B) to an
applicable position on the column.
eye bolts and the shackle (94018B).
28) Operate the manual ratchet (H8) to pull
the crosshead pin (4) until the guide
shoe (3) is clear.
94045−M20 29) Operate the manual ratchet (H6) to lift
the guide shoe (3).
3 WCH02437
94325 30) Remove the chain (94325), manual
ratchet (H8), shackle (94018B) and eye
H6 H7 bolts.
32) Attach the eye bolts and chain (94325)
and manual ratchet (H8) to the other
side of the crosshead pin.
H8 3 2 shoe (2) is clear.
the guide shoe (2).
35) When the crosshead (4) is in the first or
last cylinder position,do step 36) to
step 43)
36) Attach the eye bolt (94045−M30, Fig. 4)
to the hole in the column.
WCH02437 eye bolt (94045−M30) and the eye bolt
(94045−M48).
Fig. 3 38) Operate the manual ratchet to pull the
crosshead (4) from the guide shoe (2,
or 3).
94045−M30 39) Operate the manual ratchet (H6 or H7)
to lift the guide shoe (2, or 3).
40) Remove the manual ratchet (H8) and
H8
the eye bolt (94045−M30).
94045−M48 41) Attach the eye bolt (94045−M30) to the
2 or 3 other side of the column.
eye bolt (94045−M30) and the eye bolt
(94045−M48).
43) Operate the manual ratchet H6 or H7)
Fig. 4 WCH02437
to pull the crosshead (4) from the guide
shoe (2 or 3).

44) Operate the manual ratchet

(94016−009, Fig. 4) to lift the guide
94019B
shoe (2 or 3).
94321
46) Attach the protection tool (94117B,
H9 Fig. 5) to the door frame.
H3
I attachment point on the gallery.
1 48) Attach the chain (94019B) to the

manual ratchet (H9) and the eye bolt
on the crosshead pin (2).
49) Turn the crosshead pin (2) 90°.
Note: When you step 50), keep the
tension on the two manual
WCH02437 ratchets (H3, H9).
50) Move the crosshead pin (1) through the
door frame as follows:
a) Tighten the manual ratchet (H9).
I At the same time, carefully loosen
Door Frame b) Lower the crosshead on to an
applicable wooden underlay.
94117B
WCH02247
c) Remove the manual ratchets (H3,
H9) from the eye bolt on the
94117B crosshead pin (1).
3. Guide Shoes − Removal

1) Record the positions of the guide
shoes (2, 3). The shims of the guide
shoes can have different dimensions.
This will help you during the installation
procedure.
2) Operate the manual ratchet (H6, Fig 3)
to lower the guide shoe (3) to the level
of the door frame.
94321 H9) to the eye bolt on the guide shoe
H9 (3, Fig. 5).
H3 4) Apply a light tension to the chains of
2, 3 the guide shoe (3).
Note: When you do step 6) and step 7),
keep the tension on the two
manual ratchets (H3, H9).
WCH02437
Fig. 5

6) Tighten the manual ratchet (H9). At the

same time, carefully loosen the manual
ratchet (H3, Fig. 6).
7) Lower the guide shoe (2) on to an
8) Do the procedure in this paragraph
(step 1) to step 7)) to remove the guide
shoe (3).
94321 4. Guide Shoes −

H9
H3
Installation
Note: When you do step 1) to step 8)
below, make sure that you install
the guide shoes in their original
2, 3 positions.
H9) to the eye bolt on the guide
shoe (2).
Fig. 6 WCH02437 the manual ratchets (H3, H9).
Note: When you do step 3) and step 4)
below, keep the tension on the two
3) Move the guide shoe (2) through the
ratchet (H9).
5) Attach the applicable manual ratchet
(H6 or H7, Fig. 3) to the applicable
guide shoe (2, 3).
6) Remove the two manual ratchets (H3,
H9) from the guide shoe (2 or 3).
7) Operate the applicable manual ratchet
(H6 or H7) to lift the guide shoe (2 or
3).
8) Do step 1) to step 7) in this paragraph
to install the other guide shoe.
94321
H9 5. Crosshead Pin −
H3
Installation
1) Clean the crosshead pin, the guide and
bearing surfaces.
1
2) Make sure that the surfaces of the
crosshead pin are clean and have no
damage.
3) Apply bearing oil to the crosshead pin
and all guide and bearing surfaces.
Fig. 7 4) Attach the two manual ratchets (H3,
WCH02437
H9, Fig. 7) to the eye bolt on the
crosshead (1).


H6 H7 below, keep the tension on the two
manual ratchets .
5) Tighten the manual ratchet (H3, Fig. 7).
At the same time, carefully loosen the
manual ratchet (H9) to move the
crosshead pin (1) into the engine.
1 ratchet (H9).
2
7) Turn the crosshead pin (3, Fig. 8) 90° .
8) Operate the manual ratchet (H7) to
lower and align the guide shoe (2) with
3 the crosshead pin (3).
pin (3).
WCH02437
4 the crosshead pin (3) into the guide
1 shoe (2).
3
13) Remove the chain (94325), eye bolts,
shackle (94018B) and manual
ratchet (H8).
14) Attach the eye bolts and chain (94325),
to the other side of the crosshead
pin (3).
94045−M20
2 WCH02437 the crosshead pin (3).
94325
H8
94045−M30 the crosshead pin (3) into the guide
shoe (1).
94016−031 shackle (94018B) and manual
ratchet (H8).
94045−M48
1 or 2
WCH02437
Fig. 8

20) When the crosshead pin is in the first or

1 last cylinder position, do step 21) to
2 step 29).
4 21) Attach the eye bolt (94045−M30, Fig. 8)
1 to the hole in the column.
eye bolts (94045−M30, 94045−M48).
3
4 23) Operate the manual ratchet (H8) to pull
the crosshead into the guide shoe (1 or
2).
24) Operate the manual ratchet (H6 or H7)
to lower the guide shoe (1 or 2).
25) Remove the manual ratchet (H6 or H7)
and eye bolt (94045−M30).
NO CLEARANCE
WCH02437 26) Attach the eye bolt (94045−M30) to the
other side of the column.
27) Attach the manual ratchet (H6 or H7) to
the eye bolt (94045−M30) and the eye
bolt (94045−M48).
Turned 28) Operate the manual ratchet (H8) to pull
through the crosshead into the guide shoe (1 or
H3 94045−M48 90°
H3 2).
94045−M48 and the eye bolt (94045−M30).
H4 30) Attach the two holding plates (1, Fig. 9)
to the guide shoe (2) with the tab
washers and bolts.
between the holding plates (1) and
FUEL SIDE
crosshead pin (4).

5 the crosshead approximately 160 mm
94337
33) Attach the two supports (94322) to the
guide way.
WCH02437
8 7 35) Tighten the two set screws (6).
6 36) Attach the two manual ratchets (H4,
H5) to the shackles (94018B) and tools
94322
(94337) on the connecting rod (8).
H3
Apply a light tension to the chains.
H4
37) Gradually tighten the manual ratchet
94045−M48 (H4) to slowly move the connecting rod.
94324 At the same time, keep tension on the
2 38) Continue with step 37) above until the
9 H5
connecting rod (8) aligns with the
crosshead.
39) Remove the wooden block (7).
94337 40) If necessary, lift the crosshead a small
distance.
Fig. 9 WCH02437


Fig. 9).
Note: During step 43), make sure that the
elastic bolts on the connecting rod
(8) align with the holes in the
crosshead pin (4).
43) Lower carefully the crosshead on to the
connecting rod (8).
44) Remove the lifting tools (94337).
1 45) Remove all manual ratchets, eye bolts
2
and chain blocks.
46) Remove the deviation pipe (94117B).
NOTE: THE 47) Remove the protection from the
CRANK IS AT BDC
crosshead pin (4).
Fig. 10 WCH02438
CAUTION
Damage Hazard: Damage
will occur to an incorrectly
connected toggle lever.
Make sure that you connect
the toggle lever correctly.
48) Connect the toggle lever (1, Fig. 10) to

the crosshead pin (2). make sure that
the toggle lever is in the position
shown.
6. Clearance Checks
1) Do the clearance checks given in 3326−1.
2) Compare the clearances with those given in 0330−1 Clearance Table, Crosshead
Guide.
7. 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) Make sure that all tools and equipment are removed from the work area.
4) Disengage the turning gear.
5) Set the lubricating oil pump to on.
6) Make sure that the crosshead and the bottom end bearings of the connecting rod
have sufficient lubrication.

Intentionally blank
Crosshead

Tools:
1 Deviation pipe 94117B 2 Eye bolt M20 94045−M20
1 Platform 94142 2 Eye bolt M30 94045−M30
1 Lifting tool 94324 4 Eye bolt M48 94045−M48
2 Chain block 2000 kg (H1, H2) 94017−021 1 Chain 94325
2 Manual ratchet 1500 kg (H6, H7) 94016−017 1 Chain 94019B
2 Manual ratchet 1000 kg (H4, H5) 94016−011 1 Link 94321
1 Manual ratchet 1000 kg (H8) 94016−009 2 Lifting tools 94337
2 Manual ratchet 3000 kg (H3, H9) 94016−031 1 Support 94322
4 Shackle 4750 kg 94018B 1 Support 94322A
4 Shackle 8500 kg 94018C 1 Feeler gauge
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Crosshead Pin − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Guide Shoes − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Guide Shoes − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Crosshead Pin − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Clearance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Preparation
WARNING

2) Operate the turning gear to turn the crank of the related cylinder to BDC.
3) Keep the turning gear engaged to prevent an accidental engine start.
4) Install the platform (94142), refer to 3301−1.
5) Disconnect the toggle lever (9, Fig. 1) from the crosshead pin (2). Let the toggle
lever hang in the column.
6) Remove the round nuts from the elastic studs on the connecting rod, refer to
9403−4.
7) Remove the top bearing cover, refer to 3303−5, paragraph 2.
8) Put protection on the oil inlets of the crosshead pin to prevent damage and
contamination.

H1 94018C
2. Crosshead Pin −
H2
I 1 Removal
H3
the crosshead.
94018B II to the bottom of the cylinder jacket.
H5
H4 3) Attach the two shackles (94018C) to
2 the top of the column.
4) Attach the two chain blocks (H1, H2) to
5) Attach the link (94321) to the chain
blocks (H1, H2).
WCH02437 6) Attach the manual ratchet (H3) to the
link (94321) and the eye
94045−M48
I bolt (94045−M48) on the lifting tool.
3 to the guide shoes (6, 7).
8) Attach the two lifting tools (94337) to
the connecting rod (2).
H2
94018C H5) to the shackles (94018B). Operate
H1 WCH02437 the manual ratchets to apply a light
tension to the chains.
94321
II 10) Operate the manual ratchet (H3) to lift
94018B
4
94142
WCH02437
94045−M48
94324
7 6
94337
WCH02437
Fig. 1

Note: The two supports (94322, Fig 2)

Turned hold the weight of the crosshead
94045−M48 through while you move the connecting
H3 90° rod (4).
H3 11) Attach the two supports (94322,

H4 94045−M48 94332A) to the guide way with the four
bolts (4) as shown.
12) Torque the bolts (4) to 300 Nm.
13) Tighten the two set screws (1).
4 14) Put a wooden block (2) in position as
FUEL SIDE
shown.
Note: During the step 15), slowly move
1 the connecting rod to the exhaust
side.
94322A 94322
15) On the fuel side, gradually loosen the
manual ratchet (H4). At the same time,
keep tension on the chain of the
3 2 manual ratchet (H5).
WCH02437
16) Continue with step 15) until the
connecting rod (3) touches the wooden
block (2).
18) Lift the crosshead a small distance.
94322A).
21) Lower the crosshead to the same
height as the column door frame.
the eye bolts (94045−M48) on the
guide shoes (5) and (6).
2 the manual ratchets (H6, H7). Make
WCH02437 3
sure that the primary load stays on the
chain of the manual ratchet (H3).
94045−M48 94045−M48
H3
H6 H7
94045−M48 94045−M48
6 5
WCH02437
Fig. 2

24) Remove the two bolts, tab washers and

holding plates (1, Fig. 3) from the
1 guide shoe (4).
4 2 25) Attach the two eye bolts (94045−M20)
pin (4).
shoe (3) is clear.
94045−M20 29) Operate the manual ratchet (H6) to lift
the guide shoe (3).
3 WCH02437
94325 30) Remove the chain (94325), manual
ratchet (H8), shackle (94018B) and eye
H6 H7 bolts.
32) Attach the eye bolts and chain (94325)
and manual ratchet (H8) to the other
side of the crosshead pin.
H8 3 2 shoe (2) is clear.
the guide shoe (2).
35) When the crosshead (4) is in the first or
last cylinder position,do step 36) to
step 43)
36) Attach the eye bolt (94045−M30, Fig. 4)
to the hole in the column.
WCH02437 eye bolt (94045−M30) and the eye bolt
(94045−M48).
Fig. 3 38) Operate the manual ratchet to pull the
crosshead (4) from the guide shoe (2,
or 3).
94045−M30 39) Operate the manual ratchet (H6 or H7)
to lift the guide shoe (2, or 3).
H8
94045−M48 41) Attach the eye bolt (94045−M30) to the
2 or 3 other side of the column.
eye bolt (94045−M30) and the eye bolt
(94045−M48).
43) Operate the manual ratchet H6 or H7)
Fig. 4 WCH02437
to pull the crosshead (4) from the guide
shoe (2 or 3).

44) Operate the manual ratchet

(94016−009, Fig. 4) to lift the guide
94019B
shoe (2 or 3).
94321
46) Attach the protection tool (94117B,
H9 Fig. 5) to the door frame.
H3
I attachment point on the gallery.
1 48) Attach the chain (94019B) to the

manual ratchet (H9) and the eye bolt
on the crosshead pin (2).
49) Turn the crosshead pin (2) 90°.
Note: When you step 50), keep the
tension on the two manual
WCH02437 ratchets (H3, H9).
50) Move the crosshead pin (1) through the
a) Tighten the manual ratchet (H9).
I At the same time, carefully loosen
Door Frame b) Lower the crosshead on to an
94117B
WCH02247
c) Remove the manual ratchets (H3,
H9) from the eye bolt on the
94117B crosshead pin (1).
3. Guide Shoes − Removal

1) Record the positions of the guide
shoes (2, 3). The shims of the guide
shoes can have different dimensions.
This will help you during the installation
procedure.
2) Operate the manual ratchet (H6, Fig 3)
to lower the guide shoe (3) to the level
of the door frame.
94321 H9) to the eye bolt on the guide shoe
H9 (3, Fig. 5).
H3 4) Apply a light tension to the chains of
2, 3 the guide shoe (3).
Note: When you do step 6) and step 7),
keep the tension on the two
WCH02437
Fig. 5


ratchet (H3, Fig. 6).
7) Lower the guide shoe (2) on to an
8) Do the procedure in this paragraph
(step 1) to step 7)) to remove the guide
shoe (3).
94321 4. Guide Shoes −

H9
H3
Installation
Note: When you do step 1) to step 8)
below, make sure that you install
the guide shoes in their original
2, 3 positions.
H9) to the eye bolt on the guide
shoe (2).
Fig. 6 WCH02437 the manual ratchets (H3, H9).
below, keep the tension on the two
3) Move the guide shoe (2) through the
ratchet (H9).
5) Attach the applicable manual ratchet
(H6 or H7, Fig. 3) to the applicable
guide shoe (2, 3).
6) Remove the two manual ratchets (H3,
H9) from the guide shoe (2 or 3).
7) Operate the applicable manual ratchet
(H6 or H7) to lift the guide shoe (2 or
3).
8) Do step 1) to step 7) in this paragraph
to install the other guide shoe.
94321
H9 5. Crosshead Pin −
H3
Installation
1) Clean the crosshead pin, the guide and
bearing surfaces.
1
2) Make sure that the surfaces of the
crosshead pin are clean and have no
damage.
3) Apply bearing oil to the crosshead pin
and all guide and bearing surfaces.
Fig. 7 4) Attach the two manual ratchets (H3,
WCH02437
H9, Fig. 7) to the eye bolt on the
crosshead (1).


H6 H7 below, keep the tension on the two
manual ratchets .
5) Tighten the manual ratchet (H3, Fig. 7).
At the same time, carefully loosen the
manual ratchet (H9) to move the
crosshead pin (1) into the engine.
1 ratchet (H9).
2
7) Turn the crosshead pin (3, Fig. 8) 90° .
3 the crosshead pin (3).
pin (3).
WCH02437
4 the crosshead pin (3) into the guide
1 shoe (2).
3
shackle (94018B) and manual
ratchet (H8).
14) Attach the eye bolts and chain (94325),
to the other side of the crosshead
pin (3).
94045−M20
2 WCH02437 the crosshead pin (3).
94325
H8
94045−M30 the crosshead pin (3) into the guide
shoe (1).
94016−031 shackle (94018B) and manual
ratchet (H8).
94045−M48
1 or 2
WCH02437
Fig. 8

20) When the crosshead pin is in the first or

1 last cylinder position, do step 21) to
2 step 29).
4 21) Attach the eye bolt (94045−M30, Fig. 8)
1 to the hole in the column.
eye bolts (94045−M30, 94045−M48).
3
the crosshead into the guide shoe (1 or
2).
24) Operate the manual ratchet (H6 or H7)
to lower the guide shoe (1 or 2).
and eye bolt (94045−M30).
NO CLEARANCE
WCH02437 26) Attach the eye bolt (94045−M30) to the
other side of the column.
27) Attach the manual ratchet (H6 or H7) to
the eye bolt (94045−M30) and the eye
bolt (94045−M48).
Turned 28) Operate the manual ratchet (H8) to pull
through the crosshead into the guide shoe (1 or
H3 94045−M48
H3 90° 2).
94045−M48 and the eye bolt (94045−M30).
H4 30) Attach the two holding plates (1, Fig. 9)
to the guide shoe (2) with the tab
washers and bolts.
6 31) Make sure that there is no clearance
between the holding plates (1) and
FUEL SIDE
crosshead pin (4).

5 the crosshead approximately 160 mm
94322A above the center of the pin hole (3).
94337 94322
33) Attach the two supports (94322,
94322A) to the guide way.
WCH02437
8 7 35) Tighten the two set screws (5).
H5) to the shackles (94018B) and tools
(94337) on the connecting rod (8).
H3
Apply a light tension to the chains.
H4
37) Gradually tighten the manual ratchet
94045−M48 (H4) to slowly move the connecting rod.
94324 At the same time, keep tension on the
2 38) Continue with step 37) above until the
9 H5
connecting rod (8) aligns with the
crosshead.
39) Remove the wooden block (7).
94337 40) If necessary, lift the crosshead a small
distance.
Fig. 9 WCH02437

42) Remove the two supports (94322 and

94322A Fig. 9).
Note: During step 43), make sure that the
elastic bolts on the connecting rod
(8) align with the holes in the
crosshead pin (4).
43) Lower carefully the crosshead on to the
connecting rod (8).
44) Remove the lifting tools (94337).
1 45) Remove all manual ratchets, eye bolts
2
and chain blocks.
46) Remove the deviation pipe (94117B).
NOTE: THE 47) Remove the protection from the
CRANK IS AT BDC
crosshead pin (4).
Fig. 10 WCH02438
CAUTION
Damage Hazard: Damage
will occur to an incorrectly
connected toggle lever.
Make sure that you connect
the toggle lever correctly.
48) Connect the toggle lever (1, Fig. 10) to

the crosshead pin (2). make sure that
the toggle lever is in the position
shown.
6. Clearance Checks
1) Do the clearance checks given in 3326−1.
2) Compare the clearances with those given in 0330−1 Clearance Table, Crosshead
Guide.
7. 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) Make sure that all tools and equipment are removed from the work area.
4) Disengage the turning gear.
5) Set the lubricating oil pump to on.
6) Make sure that the crosshead and the bottom end bearings of the connecting rod
have sufficient lubrication.

Intentionally blank
Work Card
Piston: Remove and Clean

− Engine temperature must be at ambient
Remove the cylinder cover, refer to 2708−1 4-leg sling 94209 Qty 1
Remove the piston, refer to 3403−1/A1 Distance piece 94344A Qty 1
If the piston ring stroke has unwanted material, refer Disassembly/assembly device 94344 Qty 1
to 2124−3 Antipolishing ring removal tool 94208 Qty 1
Clean the top part of the cylinder liner Piston lifting tool 94341 Qty 1
Attach the applicable equipment Lifting tool 94333 Qty 1
Remove the antipolishing ring Eye bolt 94045−M36 Qty 4
Disassembly/assembly tool 94342 Qty 1
Platform 94143 Qty 1
Distance piece 94230 Qty 2
Piston support tool 94350 Qty 1
Piston ring tensioner 94338 Qty 1
Oil
Drip trays

Preparation
Remove and clean the piston Superintendent 2.0 hours Qty 1

Service Engineer 2.0 hours Qty 2
Related Data

Related Procedures
Install the piston, refer to 3403−1/A1.

Do a tightness check of the piston in the installed
position. Do a visual check through the scavenge
ports.
Do a check of the condition of the piston top
surface.

Intentionally blank
Piston
Tools:
1 4-leg sling 94209 1 Disassembly/assembly tool 94342
1 Distance piece 94344A 1 Platform 94143
1 Disassembly/assembly device 94344 1 Support 94142
1 Antipolishing ring removal tool 94208 2 Distance piece 94230
1 Piston lifting tool 94341 1 Piston support tool 94350
1 Lifting tool 94333 1 Piston ring tensioner 94338
4 Eye bolt 94045−M36
1. Preparation
WARNING
94350 make sure that no
1) Read the data in 0012−1, Guidelines

for Lifting Tools.
2) Stop the engine, refer to the procedure
in the Operation Manual 4002−2.
3) Let the engine temperature decrease
before you start the removal procedure.
94143 4) Make sure that all tools and equipment
are clean.
5) Remove the cylinder cover, refer to
2708−1.
94142
6) Look at the area of the piston ring
Fig. 1 WCH03413
stroke. If there is unwanted material,
refer to the procedure in 2124−3.
7) Clean the top part of the cylinder liner.
8) Put the support tool (94350, Fig. 1) in
position as shown.
9) Put the platform (94143) and support
94209 (94142) in position as shown.
antipolishing ring (1) with the three
screws.
11) Attach the sling (94209) to the
1 tool (94208) and the engine room
94208 crane.
remove the antipolishing ring (1).
WCH03413
Fig. 2

Piston: Removal and Installation
2 2. Removal
1) Remove the platform (94143) and
support (94142).
crank (1, Fig.3) approximately 90° to
the exhaust side.
3) Remove the four round nuts (2) from
the piston rod foot, refer to the
1 procedure in 9403−4.
WCH03413
Fig. 3
3
4) Remove the four inner bolts (3, Fig. 4)
from the support (4).
94045−M36
5) Remove two applicable outer bolts from
the support (4).
to the support (4).
WCH03413 7) Attach the lifting tool (94333) to the
94344B piston rod foot.
94333B
94045−M36 to the lifting tool (94333).
9) Attach the two chains (94333B) to the
94333 four eye bolts (94045−M36).
that the bolts of the piston rod foot
do not catch.
crank to BDC until the chains are tight.
WCH03413
Fig. 4
2016 6
11) Put the spacer (94344A, Fig. 5) on the

crosshead pin.
94230
crosshead pin up sufficiently so there is
no tension on the chains (94333B,
94344A Fig. 4).
13) Remove the chains (94333B) and the
four eye bolts (94045−M36). Keep the
spacer (94344A) in position on the
crosshead pin.
WCH03413
Fig. 5
94230 14) Attach the two distance pieces (94230,

Fig. 6) to the piston rod foot.
15) Make sure that:
D The four inner bolts (3,Fig. 4) are
removed
D The distance pieces (94230,
WCH03413 Fig. 6) are in line with the gland
box.
Fig. 6
Note: When you do step 16), the piston
moves up and the distance pieces
(94230) move the gland box up.
piston (1, Fig. 7) to TDC.
17) Clean the three holes (2) and the top
2 1 part of the piston crown (1).
WCH03413
Fig. 7

1 18) Make sure that the tool (94341, Fig. 8)

is clean.
94341 19) Remove the six bolts (1). and the three
brackets (2).
20) Apply Molykote past G−n to the threads
2 of the six bolts (1).
WCH03671
Fig. 8
21) Put the tool (94341, Fig. 9) in position

on the piston crown. Make sure that the
4 grooves for the brackets (2) align with
94341 the holes in the piston crown (3).
Note: To help you align the brackets (2),
I first attach one bracket to the tool
3 (94341).
2 22) Attach the three brackets (2) to the tool
(94341) with the six bolts. Make sure
that the brackets fully engage in the
holes in the piston crown (3).
WCH03413 23) Torque the six bolts (1) to 170 Nm.
24) Attach the hook (4) of the engine room
crane to the tool (94341).
I
1 94341
Fig. 9
WCH03671

94350 25) Make sure that the piston support

tool (94350, Fig. 10) is in the correct
1 position on the top platform.
3
26) Loosen the four screws (3).
27) Move fully out the two supports (1).
2 28) Lift and lock the plates (2) in the
vertical position.
that the piston rod foot does not
touch the support of the piston rod
gland box.
Fig. 10 WCH03413
the piston fully out of the cylinder liner.
94341 30) Lower and align the piston between the

supports (1, Fig. 11) until the piston rod
foot is below the plates (2).
31) Close the plates (2).
32) Push fully in the two supports (1).
33) Tighten the four screws (3).
34) Lower the piston on to the supports (1).
35) Remove the crane hook from the
1 tool (94341).
36) Remove the distance holders (94230)
94350 from the piston rod foot.
38) To disassemble the piston, refer to
3043−3 paragraph 1 and paragraph 2.
2
WCH03413 39) Do a check of the top surface of the
piston, refer to 3403−4.
40) Do a check of the piston rings and
grooves, refer to 3425−1.
41) Refer to the Maintenance Schedule for
1 other work on each piston 0380−1.
Select the related data.
94230
Fig. 11

3. Installation
1) Make sure that the items that follow are
clean and in a satisfactory condition:
1
D All parts of the piston rod gland
D The piston ring grooves and the
piston rings
D All surfaces of the piston.
94209 2) Make sure that the O-rings in the piston
rod gland are in a satisfactory
condition.
94342
3) Apply oil to the bore and O-rings of the
piston rod gland.
4) Apply oil to the piston rings, piston skirt,
2
3 piston rod and running surface of the
cylinder liner.
5) Install the piston rings, refer to 3425−1,
WCH03413
paragraph 3.4 (Used Piston Rings), or
Fig. 12 3.5 (New Piston Rings).
6) Put oil on the surfaces of the positioner
tool (94342, Fig. 12).
7) Make sure that the piston rod gland is
correctly installed on the piston rod.
8) Attach the sling (94209) to the
positioner tool (94342).
9) Attach the sling to the engine room
crane.
94341 10) Operate the crane to put the positioner
tool (94342) in position on the cylinder
1 liner (3). Lock the tool in position with
the three bolts (2).
11) Make sure that the spacer (94344A,
Fig. 13) is in position on the crosshead
2 pin.
12) Attach the tool (94341) to the piston
crown, refer to paragraph 2, step 18) to
23).
94344A tool (94341).
14) Attach the the distance holders (94230,
(Fig. 5) to the piston rod foot.
crosshead to TDC.
16) Loosen the screws (3, Fig. 10) on the
piston support tool (94350) and push
the supports (1) fully out.
17) Turn and lock the two plates (2) up
before the piston rod foot touches
them.
WCH03413
18) Operate the engine room crane to Lift
Fig. 13 the piston together with the piston rod
gland box from the support (94350).

19) Move the piston (1, Fig.13) into position

above the cylinder liner (2).
4
20) Make sure that each clearance in the
3 piston rings is opposite the clearance in
the piston ring above/below.
94045−M36 that you do not damage the
cylinder liner (2) or the support for
the piston rod gland.
21) Carefully lower the piston into the
cylinder liner (2) until the piston rod foot
WCH03413 touches the spacer (94344A).
94344B
23) Remove the distance pieces (94230)
94045−M36 from the piston rod.
94333B
1 the piston rod foot (1).
94333 94344A to the support ring (3).
2 27) Attach the two chains (94333B) to the

four eye bolts (94045−M36).
crosshead to BDC until the two chains
(94333B) have tension.
29) Continue to operate the turning gear to
move the crank to BDC until you can
remove the spacer (94344A).
30) Remove the spacer (94344A).
WCH03413
that the bolts on the crosshead
align with the holes in the piston
rod foot.
crosshead to TDC.
32) Make sure that the piston rod gland is
in the correct position for the dowel pin
I-I (5) to engage with the support (4).
I 5 33) Make sure that the chains (94333B)
have no tension.
35) Remove the two chains (94333B) and
the four eye bolts (94045−M36).
36) Attach the piston rod gland to the
I support (4) with the four bolts and (3)
WCH02292 new locking plates.
Fig. 14 38) Bend the locking plates to lock the four

bolts (3).

1
39) Put oil on the four elastic studs (2,
2
Fig. 15).
3
40) Attach the four round nuts (3) to the
elastic studs (2).
41) Tighten the four round nuts (3), refer to
9403−4.
tool (94209, Fig. 16).
43) Remove the three bolts (2).
WCH03413 remove the tool (94209) from the
Fig. 15 cylinder liner (3).
94209 45) Make sure that the cylinder liner and

the anti-polishing ring (1, Fig.17) are
clean and in a satisfactory condition.
94342
46) Put oil on the surfaces of anti-polishing
ring (1).
47) Connect the crane to the lifting tool
2
3 (94209).
48) Attach the tool (94209) to the loops on
the tool (94208).
Fig. 16 WCH03413
49) Operate the crane to install the
anti-polishing ring (1) into the cylinder
liner.
50) Remove the lifting tool (94209) and the
tool (94208).
94209 4. Completion
WARNING
Injury Hazard: You must put
on safety goggles and
gloves when you do work
1 on hot components. Oil can
94208 come out as a spray and
cause injury.
1) Do a function check of the cylinder
lubricating system, refer to 7218−1,
WCH03413
paragraph 1.2.
Fig. 17
the work area.

Work Card
Piston: Disassemble and Assemble
− Engine stopped O-ring for spray plate EX 34016

− Piston removed O-ring for piston rod EX 34018
O-rings − set EX 34260
Remove the piston, refer to 3403−1/A1 Pre-tensioner 94340 Qty 3

Attach the applicable equipment Lifting tool 94341 Qty 1
Jacking screws (see Note) 94364A Qty 3
Jacking screws (see Note) 94364B Qty 2
Jacking screws (see Note) 94364C Qty 3
Note: Use the available screws

from the piston assembly
Loctite No. 0270

Preparation
Disassemble and assemble the piston, refer to Superintendent 4.0 hours Qty 1
3403−3/A1 Service Engineer 4.0 hours Qty 1
Related Data

Related Procedures
Do a check of the piston top surface, refer to

3403−4/A1.
Install the piston, refer to 3403−1/A1.

Intentionally blank
Piston
Disassemble and Assemble
Tools:
3 Pre-tensioner 94340 3* Jacking screws 94364A
1 Lifting tool 94341 2* Jacking screws 94364B
3* Jacking screws 94364C
* Use available screws from

piston assembly
1. Preparation
2) Remove the piston, refer to 3403−1, paragraph 1 and paragraph 2.
Note: You disassemble a piston to clean the chamber in the piston head, do an
overhaul of the ring grooves etc.
Note: When you do step 3), apply tension to the elastic bolts in the sequence
given in Fig. 1.
3) Apply tension to the elastic bolts (1) to loosen the nine round nuts, refer to
9403−4.
4) Remove the nine round nuts.
1
b c
a
a
b
c
b c
a
Fig. 1: Sequence to Apply Tension to the Elastic Bolts

2. Disassemble
Note: Some parts can look different.
CAUTION
Damage Hazard: When you
3 disassemble the piston,
make sure that you do not
damage the pipes or
nozzles on the spray plate.
1 1) Put the two jacking screws (94364A,

Fig. 2) fully into the two tap holes in the
top of the piston rod (1). Make sure that
the jacking screws touch the piston
head (3).
2) Tighten equally the two jacking screws
until there is a clearance between the
piston head (3) and the piston rod (2).
lifting tool (94341, Fig 3).
2 94364A
4) Install the lifting tool, refer to 3403−1,
paragraph 2, step 17) to step 24).
WCH02674
the piston head.
6) Move the piston head to an applicable
area.
7) Remove the jacking screws (94364A)
from the top of the piston rod (2).
94341
WCH03345
Fig. 2

CAUTION
1 Damage Hazard: If it
becomes necessary to
2 remove the the elastic
bolts, do not use a pipe
3 wrench. This could cause
8
damage to the bolt shank.
8) Remove the piston skirt (4, Fig. 3) from

7 the piston rod (5) as given in step a) to
4 step c):
6 a) Remove the two bolts (6).
b) Use the jacking screws (94364C)
to remove the piston skirt (4) from
the piston rod (5).
5 WCH02675 Note: When you lift the piston skirt
(4), make sure that the spring
dowel pin (8) does not catch.
c) Lift the piston skirt (4) away from
Fig. 3 7 the piston rod (5).
9) Remove the ten nuts (7).
10) Use the two jacking screws (94364B) to
remove the spray plate (3) from the
piston rod (5).
11) If necessary, remove the pipes (2) and
nozzles (1).
12) Do a check of the top surface of the
piston head, refer to 3403−4.

1
3. Assemble
2
Note: Do not install pipes or nozzles that
have damage.
1) Apply Loctite No. 0270 to the thread of
the pipe (2, Fig. 4).
3 2) Use the applicable tool to install the
pipe (2) to the spray plate (3).
4
3) Use a center punch to lock the pipe (2)
in position.
4) Apply Loctite No. 0270 to the thread of
Center 4 the nozzle (1).
WCH03410
Punch
here 5) Use the applicable tool to install the
nozzle (1) to the pipe (2).
6) Put oil on the new O-rings (4).
7) Install two new O-rings (4) on the spray
94341 plate (3).
8) Install a new O-ring to the piston rod.
9) Attach the spray plate (9) to the piston
rod (11) with the ten nuts (13).
5 10) Torque the ten nuts (13) as follows:

a) Symmetrically torque the ten nuts
to 20 Nm.
6
b) Symmetrically torque the eight
WCH03345 screws to 75 Nm.
that the dowel pin (13) engages in
the related hole in the piston
skirt (10).
7 11) Attach the piston skirt (10) to the piston

rod (11) with the two screws (12).
8 12) Operate the engine room crane to
lower the piston head (5) on the piston
9
14 skirt (10). Make sure that the dowel pin
(14) engages with the hole in the piston
head.
13 13) Attach the nine round nuts to the elastic

10 bolts.
12 14) Apply tension to the elastic bolts. Refer
to Fig. 1 for the sequence to apply
tension.
15) Tighten the round nuts on the elastic
bolts.
11 WCH02675
16) Install the piston, refer to 3403−1,

paragraph 3.
Fig. 4

Work Card
Piston: Check the Top Surface

If necessary, remove the piston, refer to 3403−1/A1 Feeler gauge 94122 Qty 1
Template 94366 Qty 1
Template 94366A Qty 1
Emery paper
Applicable grinding tool

Preparation
Do a check of the top surface of the piston, refer to Service Engineer 3.0 hours Qty 1
3403−4/A1. Crew 3.0 hours Qty 1
Note: This task can be done when the piston is

installed, or removed.
Related Data

Related Procedures
Visual check of the piston and piston rings through

the scavenge ports, refer to WC3403−4.1/A1

Intentionally blank
Work Card
Piston: Visual Check

None Not applicable

Preparation
Do a visual check through the scavenge ports of the Service Engineer 1.0 hours Qty 1
piston, piston rings and cylinder liner.
Related Data

Related Procedures
Do a check of the piston top surface, refer to

3403−4/A1.

Intentionally blank
Work Card
Piston: Fully Re-manufacture the Piston Head Surface
− Engine stopped Piston head EX 34060 Qty 1

Remove the piston, refer to 3403−1/A1 Applicable surface welding

Remove the piston head, refer to 3403−3/A1 equipment
Emery paper

Preparation
Fully re-manufacture the piston head surface Service Engineer 1.0 hours Qty 1
Related Data

Related Procedures
Top surface check of the piston, 3403−4/A1

Intentionally blank
Work Card
Piston Underside: Check

None Not applicable

Preparation
Do a check of the condition of the piston underside. Crew 1.0 hours Qty 2
Clean as necessary
Make sure that the drains and holes are not blocked
Related Data

Related Procedures
None

Intentionally blank
Piston
Top Surface − Check
Tools:
1 Template 94366
1 Template 94366A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Procedure − Piston Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Procedure − Piston Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. General
Each time you remove a piston, you must do a check of the top surface of the piston
head for damage (burn scars).
The causes of burn scars are as follows:
D Poor combustion
D Worn nozzles
D Heavy local carbon particles on top of the piston head etc.
Note: You can also do this check with the piston installed.
2. Procedure − Piston
Removed
1) Put the template (94366, Fig. 1) in
position on the top piston ring (1).
2) Turn the template (94366) around the
10 mm axis of the piston head.
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).
94366 5) If the burn scars are less than 10 mm,
do step a) and step b):
a) Use an applicable tool to grind the
burn scars.
b) Use emery paper to make sharp
edges smooth.
6) If the burn scars are more than 10 mm
deep, do step a) to step c):
WCH03411 1 a) Remove the piston head (refer to
3403−3, paragraph 1 and
paragraph 2).
b) Use surface welding to repair the
piston head to its original
thickness.
c) Assemble the piston (refer to
Fig. 1 3403−3, paragraph 3).
Note: Before you start the engine, find
the cause of the burn scars.

Piston
3. Procedure − Piston
Installed
WARNING
make sure that no
1 flywheel, or inside the
engine.

piston to BDC.
2) Look at the piston head through the
scavenge ports (1, Fig. 2) to find burn
scars.
10 mm 3) Put the template (94366A) through the

related scavenge port (1).
measure the depth of the burn scar(s).
Note: You can also use a depth gauge to
94366A measure the depth of the 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 10 mm,
WCH03411 do step a) and step b):
a) Use an applicable tool to grind the
burn scars.
Fig. 2 b) Use emery paper to make sharp

edges smooth.
8) If the burn scars are more than 10 mm,
do step a) to step d).
a) Remove the piston, refer to
paragraph 2.
b) Remove the piston head, refer to
paragraph 2.
c) Use surface welding to repair the
piston head to its original
thickness.
d) Assemble the piston, refer to
Note: Before you start the engine, find
the cause of the burn scars.

Work Card
Piston Rings: Measure

− Applicable piston at BDC
Calibrate the Permascope MP0 Inside micrometer 94101 Qty 1

Feeler gauge 94122 Qty 1
Permascope MP0 (with 94356 Qty 1
instruments to measure
chrome-ceramic layers)
Calliper gauge
Piston ring piece (for alternative

procedure to measure the
thickness of the chrome-ceramic
layer)

Preparation
Measure the thickness of the chrome-ceramic layer, Service Engineer 0.5 hours Qty 1
refer to 3425−1/A1 Ship Engineer 0.5 hours Qty 1
Related Data

Operation Manual 0750−1 Lubricating Oils.
Related Procedures
Compare the measured data with the limits given in

0330−1, Clearance Table, Piston and Piston Rings

Intentionally blank
Work Card
Piston Rings: Replace
− Engine stopped Piston ring GTP1CC22 EX 34250 Qty 1

− Engine temperature must be at ambient Piston ring GTP1CC13 EX 34251 Qty 1
Remove the piston, refer to 3403−1/A1 Piston ring tool 94338 Qty 1
Piston ring tool 94338A Qty 1

Preparation
Replace the piston rings, refer to 3425−1/A1 Service Engineer 6.0 hours Qty 1
Related Data

Related Procedures
Install the piston, refer to 3403−1/A1

Intentionally blank
Piston Rings
Piston Rings and Ring Grooves − Rate of Wear

Tools:
1 Inside micrometer 94101 1 Permascope MP0 94356
1 Feeler gauge 94122 (with instruments to
1 Piston ring tool 94338 measure chrome-ceramic layers)
1 Piston ring tool 94338A 1 Calliper gauge
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Piston Ring − Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Chrome-ceramic Layer − Measure (Piston Installed) . . . . . . . . . . . . 2
2.2 Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Service Life − Calculate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Piston Ring Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Piston Ring Clearance (Piston Installed) . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Piston Rings − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Piston Ring 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 condition
of the cylinder liner, piston and piston rings.
The rates of wear are related to the type of fuel used, the engine load profile, ambient
conditions etc, during engine operation.
Visual inspections show very important conditions of cylinder liners and piston rings
after a short time. For more data to monitor the cylinder liner and piston ring
conditions, refer to the Operation Manual 0750−1 Lubricating Oils.
When you measure and record the piston ring grooves, the data is used to calculate
the wear.
Refer to 0380, Piston Rings for the scheduled intervals.

Piston Rings: Wear of Piston Rings and Ring Grooves
2. Piston Ring − Rate of Wear
2.1 Chrome-ceramic Layer − Measure (Piston Installed)

WARNING
1) Read the data in the suppler documentation for the Permascope MP0 (94356).
2) Calibrate the Permascope MP0 (94356). Use the calibration foils and the top
flank of a spare top piston ring to get a correct setting.
3) Operate the turning gear 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. If the recorded data is not in the limits given, you must
do an overhaul of the piston head.
Locations to Measure the Thickness of the

Chrome-ceramic Layer on the Piston Ring
Minimum Recommended
P9 P1 P9 P1
1 94356
P7 P3
WCH01216
P5 P5
Fig. 1

2.2 Rate of Wear

The rate at which the the chrome-ceramic layer becomes worn is related to the
operation conditions. If you find a piston ring that has some wear of the
chrome-ceramic layer (see Fig. 2), do an overhaul of the unit as soon as possible.
Chrome-ceramic
Layer is Worn
Fig. 2 Chrome-ceramic Layer

With regular procedures to measure the chrome-ceramic layer, you can calculate the
rate of wear for each piston ring.
You can continue to use the piston rings if the remaining chrome-ceramic layer is
more than the limits that follow:
D Top piston ring, more than 0.05 mm
D Middle and bottom piston rings, more than 0.02 mm
If the thickness of the chrome-ceramic layer is less than the limits given, you must
replace the applicable piston ring.

2.3 Service Life − Calculate

Use the formula below to calculate the rate of wear of a piston ring:
(D1−D2) x 1000
WR =
T2−T1
Where:
D WR = Rate of Wear (mm/1000 hrs)
D T2 = Time (hrs)
D T1 = First recorded operation hours (hrs)
D D1 = First recorded thickness of the chrome-ceramic layer (mm)
D D2 = Second recorded thickness of the chrome-ceramic layer (mm).
See Table 1 for examples of results.
Table 1: Rate of Wear − Examples
D1 D2 T1 T2 WR
0.382 0.367 0 (new) 1500 0.01
0.351 0.340 3500 5000 0.0073
Use the formula below to calculate the remaining piston ring service life:
(D2−Dmin) x 1000
LT =
WR
Where:
D LT = Remaining in-service time (hrs)
D D2 = second recorded thickness of chrome-ceramic layer (mm)
D Dmin = Minimum thickness of the chrome-ceramic layer (mm) (see paragraph
2.2)
D WR = Calculated rate of wear (mm/1000 hrs)
Table 2: Example for Remaining Service Life
D1 D2 Dmin T1 T2 WR LT
0.382 0.367 0.05 0 (new) 1500 0.01 31700
0.351 0.340 0.05 3500 5000 0.007333 39545

3. Piston Ring Grooves

Do a check of all dimensions and record them (refer to 0330−1 Pistons and Piston
Rings). These records are important for an analysis of the running gear and must
include the data that follow:
D All dimensions
D The date of the overhaul
D The operation hours of the different components
D The operation hours of the engine.
2 X2 3.1 Piston Ring Clearance

(Piston Installed)
1 WARNING
Possible Shape make sure that no
On Piston Groove personnel are near the
X2 flywheel, or in the engine.
1) Use the turning gear to move the piston

(2, Fig. 3) down.
2 Note: Push the feeler gauge fully into the
groove in the piston head. Make
1 sure that the feeler gauge touches
the inner diameter of the groove.
2) Measure the clearance X1 at Point A. If
there is unwanted material on the
chrome-ceramic layer, you can push
the feeler gauge only to that point.
94122
X1 3) Measure the clearance at X2.
4) Do step 2) and step 3) at between two
and four different locations around the
2 piston (2).
X1
The sum of each value from X1and X2 will
give the total piston ring clearance.
1 A
The maximum clearance is at point A. For
the maximum wear data, refer to 0330−1,
Pistons and Piston Rings.
Unwanted Material On 5) If the clearance at point A is more than
Chrome-ceramic Layer the permitted value, do step a) and
2 step b)
a) Replace the piston rings.
1 WCH02244
b) Repair the piston head.
Fig. 3 Note: For the repair of piston heads,
speak to the nearest WinGD
Service Center.

3.2 Piston Rings − Removal

CAUTION
Damage Hazard: Do not open the piston rings too far. This will
cause damage to the piston rings.
Note: If the same piston rings must be installed again, record their positions.
1) Use the tool (94338, Fig. 4) to remove the top piston ring. Make sure that you do
not cause damage to the chrome-ceramic surface.
2) Use the tool (94338A) to remove the middle and bottom piston rings. Make sure
that you do not cause damage to the chrome-ceramic surface.
3) Clean the grooves in the piston head.
WCH02274
Fig. 4 94338 and

94338A
3.3 Piston Ring Clearance (Piston Removed)

Note: You can use a calliper gauge, an inside micrometer set (94101, paragraph
3.3.1), or a piece of piston ring (paragraph 3.3.2) to measure the grooves
in the piston head.
3.3.1 Procedure with Calliper Gauge or Inside Micrometer Set

1) Use the calliper gauge (1, Fig. 5) or inside micrometer set (94101) to measure
the height of the groove at point A and point B. Measure the height of the groove
at a minimum of four locations around the circumference of the piston head.
2) Record the value from the calliper gauge (1) or inside micrometer set (94101).
3) If the clearance at point A or point B is more than the permitted value, you must
repair the piston head.
B
A
WCH02244
1
Possible Shape On
Worn Piston Groove
Fig. 5
Note: If the clearance at point A and, or point B is more than the permitted
value, you must repair the piston head. For the maximum values, refer to
0330−1, Piston and Piston Rings.

3.3.2 Alternative Procedure with Piston Ring Piece

1) Measure the thickness of the piece of piston ring (1, Fig. 6).
X1
2
1
94122
WCH02244
Fig. 6
2) Put the piece of piston ring (1) into the piston ring groove.
3) Use the feeler gauge (94122) to measure the clearance X1 between the face of
piston ring and the groove.
Note: You must measure the height of the groove at a minimum of four
locations around the circumference of the piston head (2).
4) Use the data that follow to calculate the piston ring clearance:
C = GH − RT
Where:
D C = Clearance (mm)
D GH = the measured height of the piston ring groove (mm)
D RT = the nominal piston ring thickness (mm).
Note: If the clearance at X1 is more than the permitted value, you must repair
the piston head. For the maximum values, refer to 0330−1, Piston and
Piston Rings. For the repair of piston heads, speak to the nearest WinGD
Service Center.
Do not install a piston head that has clearances near the maximum value, because
the service life will be too short.

3.4 Used Piston Rings − Installation

For the ring types and their locations, see Table 3.
Table 3: Standard Piston Ring Locations
Ring Type Material Application
Top Piston Ring

1 x GTP1CC22 (gas tight) chrome-ceramic layer For new and fully
honed cylinder liners
Middle Piston Ring and used cylinder
1 x SCP2CC13 (straight cut) chrome-ceramic layer liners in good
condition
Bottom Piston Ring
1 x SCP2CC13 (straight cut) chrome-ceramic layer
CAUTION
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 tool (94338) to install the piston rings.
1) Use the tool (94338A) to install the bottom piston ring (4, Fig. 7) to the piston
head.
2) Use the tool (94338A) to install the middle piston ring (3) to the piston head.
3) Use the tool (94338) to install the top piston ring (1) to the piston head. Make
sure that the ring clearance (5) is opposite the ring clearance (2) of the middle
piston ring (3).
5
1
WCH02274
94338 and
94338A 2
4
WCH02682
3
Fig. 7

3.5 New Piston Rings − Installation

CAUTION
Note: Make sure that the mark TOP, on the piston ring, points up.
Note: For the ring types and their locations, refer to Table 3.
1) Measure and record the thickness of the chrome-ceramic layer on each piston
ring. This will help you monitor the rate of wear during operation.
2) Use the tool (94338A, Fig. 8) to install the bottom piston ring (4) to the piston
head.
5
1
WCH02274
94338 and
94338A
2
4
WCH02682
3
Fig. 8
3) Use the tool (94338A) to install the middle piston ring (3) to the piston head.
4) Use the tool (94338) to install the top piston ring (1) to the piston head. Make
sure that the ring clearance (5) is opposite the ring clearance (2) of the middle
piston ring (3).
5) Refer to the Operation Manual, 0410−1 for the running-in procedure for new
piston rings.
4. Piston Rings − Storage

Keep the piston rings in their original packages in a dry area. Make sure that the
piston rings are in a horizontal position on a flat surface.
To prevent damage, be careful when you prepare the piston rings for installation and
during movement.

Intentionally blank
Maintenance Group4
Driving Wheels and Shut-off Valve for Starting Air Group 4
Work Cards
Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC4003−1/A1
Driving Wheels
Running and Backlash Clearances and Tooth Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−1/A1
Crankshaft Gear Wheel − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−2/A1
Work Cards
Starting Air Shut-off Valve: Remove and Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC4325−1/A1
Starting Air Shut-off Valve: Remove the Common Start Valve . . . . . . . . . . . . . . . . . . . . . . . . . . WC4325−1.1/A1
Starting Air Shut-off Valve: Cleaning and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325−1/A1

Intentionally blank
Work Card
Start Interlock
None Magnet tester

Screwdriver

Preparation
Do a check of the electric and pneumatic interlocks Ship Engineer 1.0 hours Qty 1
(refer to the Operation Manual 4003−1, paragraph
4.10).
Related Data

Related Procedures
None

Intentionally blank
Drive Wheels
Running and Backlash Clearances and Tooth Condition

Tools:
1 Feeler gauge 94122 1 Dial gauge
1 Micrometer 1 Lead wire 1.5 mm diameter
1. General
On new engines during the running-in period, you must do a visual check of the gear
wheels after approximately one and two operation hours. You must do the same
checks on in-service engines that have new gear wheels installed.
2. Checks
WARNING
1) Operate the turning gear to turn 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 occur during this period, repair them.
7) If you hear unusual noises in the area of the gear train, you must find the cause.
Replace defective drive wheels as soon as possible to prevent damage to
adjacent drive wheels.
8) Do the inspection given above one time each year when the drive wheels have
operated correctly for between 6000 hours and 8000 hours.
To do checks of the clearances and tooth marks, you must tighten the tie rods and
elastic studs of the main bearings.

3. Gear Tooth Backlash

Checks
Refer to 0330−1, Driving Wheels for Supply
f1 Unit (Group 4103) for data about the gear
tooth backlash values.
f2
There are three procedures to measure the
backlash.
3.1 Feeler Gauge (94122)

10 1) Measure the clearance between the
tooth flanks (10, Fig. 1). Do this
Drive Wheel procedure at a minimum of four
c
positions around the circumference of
the gear wheel.
WCH02402
Gear Wheel 3.2 Dial Gauge

1) Put the dial gauge in a position where
you can read the backlash value when
the gear wheel moves.
15 mm 2) Make sure that the drive wheel does
Equal Distances not move.
3) Operate the turning gear to carefully
15 mm move the gear wheel a sufficient
b1 distance.
b3 4) Measure the backlash when one tooth

of the gear wheel moves between the
a1 profiles of two gear wheel teeth.
7
a3 3.3 Lead Wire
b
c Note: Use a new lead wire of 1.5 mm
WCH02402 a diameter (Pb 9.99 fine) for each
measurement.
Lead Wire 1) Attach three lengths of lead wire
(approximately 200 mm) in the
positions shown with Scotcht tape.
0
1 2) Put marks (0 to 9) on the tooth profiles
as shown.
2
3 3) Operate the turning gear to turn the
gear wheel so that the lead wire goes
4 once through the teeth of the gear
5 wheel and drive wheel.
6
The lead wire (c) shows the full backlash (f).
7
The lead wires (a) and (b) show the
8 parallelity of the tooth profile.
9
The parallelity Df is the difference between
WCH02402
the values of the wires on the drive
Fig. 1 flanks (10) between e.g. a1 − b1.
4) Remove the lead wire.

5) Use the micrometer to measure the lead wire.

6) Calculate as follows:
D The full tooth backlash: f = f1 + f2
D The parallelity: Df = a1 − b1 or a3 − b3.
The permitted difference of the tooth profile parallelity is between 0.0% and 0.2%
across 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 turn the engine.
3) Do a check of the marks on the gear wheel teeth and driving wheel teeth. This is
make sure that the teeth engage correctly and are parallel.

Intentionally blank
Drive Wheels
Crankshaft Gear Wheel − Replace

Tools:
1 Ring slugging wrench 94002−60
1. General
Usually, the crankshaft gear wheel is installed as one part on the crankshaft. If it
becomes necessary to replace a damaged crankshaft gear wheel, it must be divided
into two parts and disassembled. To prevent damage, speak to the engine supplier or
to WinGD to get the applicable instructions to disassemble the crankshaft gear wheel.
The spare crankshaft gear wheel is a two-part assembly.
When you disassemble and assemble the crankshaft gear wheel, you must
disengage the intermediate wheel of the supply unit.
When you order a new two-part crankshaft gear wheel, give the data that follows:
D Engine type
D Engine number
D Engine supplier.
This data is necessary because the two-part crankshaft gear wheel is manufactured
to the specifications and dimensions of the crankshaft related to the engine.

2. Preparation
6
1
I I
9
d
4
5
3
9
5
4
Fig. 1 WCH02403
1) Make sure that the temperature of the crankshaft, the gear wheel and the tool to
measure the dimensions is the same.
2) Measure and record the inner diameter (d, Fig. 1) of the two-part gear wheel (1).
3) Measure and record the outer diameter of the crankshaft.
4) The inner diameter of the crankshaft gear wheel must be between 0.05 mm and
0.14 mm less than the outer diameter of the crankshaft.
Note: The nominal diameter of the crankshaft flange is 1670 mm.
5) If the value is not as given in step 4),
do as follows before you assemble the
gear wheel:
a) Use the applicable equipment and
DRIVING
processes (e.g. mill, or ream the
END
bore etc) to get the inner diameter
to the correct dimension.
b) Make sure that there is a mark on
2 the crankshaft flange (2, Fig. 2).
During the assembly procedure,
Remove the partition of the crankshaft gear
Grease
6 wheel must align with this mark.
Fig. 2 WCH02403

Note: When you step 6) and step 7), do not use Molykote or oil.
6) Remove all grease from the applicable area on the crankshaft flange (2, Fig. 2).
Make sure that the area is clean and in satisfactory condition.
7) Remove grease from the bore of the crankshaft gear wheel. Make sure that the
crankshaft gear wheel is clean and in satisfactory condition.
3. Assemble
WARNING
Note: Carefully assemble the crankshaft gear wheel. Small faults can have an
unsatisfactory effect on the operation of all gear wheels.
1) Measure and record the length of the
four elastic studs (3,Fig. 3).
2) Remove grease from the thread of the
castle nuts (1).
3) Apply Loctite 262 to the thread of the
1
castle nuts (1).
2
Molykote 4) Put one elastic stud (3) in opposite
3 positions in each half of the crankshaft
gear wheel.
5) Put a base (2) and castle nut (1) in
4
position on each end of the two elastic
studs (3). Make sure that there is a
distance of 7.0 mm between the top of
5 the elastic stud and the castle nut.
Loctite 262 2 6) Put a split pin in position in the elastic
1 stud (3) to hold the castle nut (1) in
7.0 mm position.
Note: The cure time for Loctite 262 is
WCH02403 between one day and two days.
Fig. 3
3.1 Procedure
crankshaft. Get the mark on the
crankshaft flange approximately
horizontal to the crankshaft centerline.
Note: When you do step 2) make sure
that the joint face of the crankshaft
gear wheel aligns with the mark on
6
the crankshaft flange.
1 2) Put one half of the crankshaft gear
wheel (with two assembled elastic
3
studs (3)) in position on the crankshaft
flange.
WCH02403 3) Make sure that the mark DRIVING
Fig. 4 END, on the front of the crankshaft
gear wheel, points to the flywheel.
4) Remove the grease from all flange
screws (6, Fig. 4) and their locknuts.

5) Put three flange screws (6, Fig. 4) in

position as shown in the wheel half (1).
Tighten the screws temporarily.
3
6) Turn the turn the crankshaft to move
the gear wheel half (1, Fig. 5) to the
1 bottom position.
6 7) Put the other half of the crankshaft gear

Fig. 5 WCH02403 wheel (1, Fig. 6) (with the other two
assembled elastic studs) in position on
the crankshaft flange. Make sure that at
one side, there is no clearance.
0.16 mm to
8) Measure the clearance between the
0.41 mm
two halves of the crankshaft gear
Clearance wheel. The clearance must be between
0.00 mm 0.16 mm to 041 mm.
Note: If the clearance is not between
0.16 mm and 0.41 mm do not
assemble the gear wheel. Refer to
paragraph 2, step 5.
Fig. 6
WCH02403 9) Adjust the top half of the crankshaft
gear wheel (1) to get an equal
clearance on each side.
6
10) Lightly tighten the castle nuts on the
1 elastic studs (3, Fig. 7).
3 11) Put a flange screw (6) in the center

position in the top half of the crankshaft
gear wheel (1). Temporarily tighten the
flange screw.
12) Remove the two outer flange screws
from the bottom half of the crankshaft
Fig. 7 gear wheel (1). Make sure that only the
top and bottom flange screws (6,
WCH02403
Fig. 8) stay in position.
13) Make sure that there is no clearance on
the seating surfaces between the
6 crankshaft gear wheel and the
crankshaft flange.
14) Apply Molykote paste the threads of the
3 four remaining castle nuts (1, Fig. 3)
1
15) Install the four remaining castle nuts (1)
Note: In step 16), tighten only the castle
Fig. 8 6 nuts that have Molykote paste on
WCH02403 the threads.
16) Use the slugging wrench (94002−60) to
symmetrically tighten the castle nuts.
Use a wrench to hold the opposite
castle nuts (that have a split pin and
Loctite 262 on the threads).

17) Measure the length of the elastic studs (3, Fig. 3)

Note: The elastic studs have the correct tension if they are extended to
1.3± 0.06 mm more than the length measured in paragraph 3, step 1).
18) Make sure that there is no clearance between the two halves of the crankshaft
gear wheel.
19) If you cannot install the split pin to lock the castle nut (1) do as follows:
a) Turn the castle nut the minimum sufficient distance to align the slots with the
hole in the elastic stud.
b) Install the split pin.
20) Apply Loctite 262 to the threads of the flange screws
21) Install all the flange screws (6, Fig. 9), distance sleeves (7) and self-locking
nuts (8) to the crankshaft gear wheel (1).
22) Symmetrically torque the flange screws (6) to 2700 Nm.
23) Do a check of the backlash and running clearances, refer to 4103−1.

I
I-I
3/4
I 2
WCH02403
MOLYKOTE 94002−60 3 LOCTITE
262
7 8
8 6
7
Fig. 9

Work Card
Starting Air Shut-off Valve: Remove and Disassemble
− Engine stopped Joint ring (for screw plug) EX 43268 Qty 1

− Stop valves closed on starting air bottles O-ring (for the housing) EX 43270 Qty 1
930−V03−V04. O-ring EX 43273 Qty 6
Joint ring (for the silencer) EX 43274 Qty 1
O-ring (for the housing) EX 43276 Qty 1
Joint ring EX 43277 Qty 1
Gasket EX 43281 Qty 1
O-ring (for the valve guide) EX 43289 Qty 2
O-ring (for the cover) EX 43290 Qty 1
Piston joint ring (for the valve) EX. 43291 Qty 1
DU bush EX 43303 Qty 1
Scraper ring EX 43305 Qty 1
Rod joint ring EX 43316 Qty 1
Spare parts for double non return EX 43322 Qty 1
valve
Remove and disassemble the starting air shut-off AF 60 swan neck spanner
valve, refer to 4325−1/A1
No consumables are necessary

Preparation
Clean and do a check of the starting air shut-off Ship Engineer 5.0 hours Qty 2
valve
Related Data

Related Procedures
Assemble and install the starting air shut-off valve,

refer to 4325−1/A1

Intentionally blank
Work Card
Starting Air Shut-off Valve: Remove the Common Start Valve

− Stop valves closed on starting air bottles
930−V03−V04.
− Turning gear engaged
Remove the common start valve, refer to 4325−1/A1 No special tools are necessary
No consumables are necessary

Preparation
Do an overhaul of the common start valve Service Engineer 2.0 hours Qty 1
Related Data

Related Procedures
Assemble and install the starting air shut-off valve,


Intentionally blank
Starting Air Shut-off Valve

Cleaning and Function Check
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Shut-off Valve − Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.1 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
necessary maintenance and intervals on the shut−off valve for starting air (shut-off
valve).
Refer to the data in the Operation Manual 4003−2, Engine Control Diagram and
4003−9, Pipe Diagram − Air Systems.
9 2. Preparation
7 1
8 1) On the starting air bottles, close the
stop valves 930−V03 and 930−V04.
2) Engage the turning gear.
3) Open the ball valves 30−8605_E0_6
and 30−8605_E0_7 to release air in the
system.
4) Disconnect the electrical connections
6 from the pressure transmitter (8, Fig. 1)
2
and the solenoid valves (1, 9).
5) Remove the pipe (5).
5 4
6) Remove the pipe (2).
3 7) Remove the eight screws (6) from the
Fig. 1 WCH02404
flange (7).
8) Remove the eight screws (4) from the
flange (3).
9) Remove the shut-off valve from the engine.
10) Do a check of the two gaskets that are installed on the flanges (3) and (7). If the
gaskets are unserviceable, replace them.

Shut-off Valve for Starting Air: Cleaning and Function Check
3. Disassemble
1) Remove the eight screws (23, Fig. 2) from the cover (6).
2) Turn the handwheel (7) fully in. This moves the cover (6) from the spindle (8).
3) Remove the handwheel (7), the cover (6) and the spring (9).
4) Use an AF 60 swan neck spanner to remove the spindle nut (11).
5) Remove the spindle (8).
6) Remove the two screws (25) from the valve guide (16).
7) Remove the valve guide (16).
8) Remove the stopper (18) together with the spring (19) and valve body (20).
9) Remove the silencer (22) and its gasket.
10) Remove the screw plug (5) together with the spring (4), valve (1) and piston (21)
from the control valve (19).
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 (8).
3) If you find corrosion on the springs (9, 19 and/or 4) you must replace them.
4) Do a check of all gaskets and O-rings that you removed for damage. If you find
damage, replace the applicable gaskets and/or O-rings.
5) Do a check of the piston joint ring (10). If you find damage, replace the piston
joint ring.
6) Do a check of the valve seats (13, 14). If necessary, grind the sealing surfaces.

21 1 2 3 4
17 18 19 20
6
7
WCH02229
16 15 14 13 12 11 10 9
To Ball Valve
35−8353_E0_2
I
28 24
22 ZV7013C ZV7014C
27
6
PS5017C
25
23
26
Fig. 2

5. Assemble
1) Make sure that all bores are clear.
2) Remove grease from the surfaces of the spindle (8, Fig. 2) and the threads of the
spindle nut (11).
3) Apply a thin layer of Molykote paste to the stopper (18), the spring (19) and the
valve body (20).
4) Put the O-ring (17) and valve body (20) into the housing (15).
5) Put the stopper (18) and spring (19) into the valve guide (16), then attach the
valve guide to the housing (15) with the two screws (25).
6) Torque the two screws (25) to the value given in 0352−1, paragraph 1.
7) Apply Molykote paste to the bore of spindle nut (11). Put the spindle nut on the
spindle (8).
8) Apply Loctite 0243 to the threads of the spindle nut (11).
9) Put the spindle (8) and spindle nut (11) into valve (12).
10) Attach the valve (12) together with spindle (8) 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 (8) in the cover (6).
13) Attach the cover (6), spring (9) and spindle (8) to the housing (5) with the eight
screws (23).
14) Torque the eight screws (23) to value given in 0352−1, paragraph 1.
15) Install the handwheel (7).
16) Attach the control valve (3) to the cover (6) with the two bolts (2).
17) Torque the two bolts (2) to the value given in 0352−1, paragraph 1.
18) Put the piston (21), valve (1), spring (4) and screw plug (5) in position in the
control valve (3), see Fig. 3.
Note: When you do step 19), look through the hole in the control valve (3).
19) Make sure that the clearance between the valve (1) and the piston (21) is
1.0 ±0.2 mm.
1.0 ±0.2 mm 2 3
3
5
21
WCH02229
4
1
Fig. 3

20) Attach the silencer (2, Fig. 4) to the

1 control valve (1).
2
21) Put the assembled shut-off valve in
position as shown in Fig. 5.
22) Attach the flange (11) to the valve
guide with the eight screws (10).
23) Torque the eight screws (10) to the
24) Attach the flange (6) to the shut-off
valve with the eight screws (7).
WCH02404 25) Torque the eight screws (7) to the value

given in 0352−1, paragraph 1.
Fig. 4
26) Connect the check-pipe (8) to the pipe
connection on the valve body.
27) Connect the control air pipe to the pipe
connection (12).
13
1 6. Shut-off Valve − Test
11 12
2
3 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.
10 4 2) Use the handwheel (3) to move the
9 shut-off valve in the position CLOSED.
8 3) Disengage the turning gear.
7
6
6.2 Test Procedure
WCH02404
5
WARNING
Fig. 5 Injury hazard. During this
test, do not select START.
Injury to personnel can
occur.
1) Close the ball valve 30−8605_E0_6.

2) Slowly open the stop valves 930−V03 and 930−V04.
3) Slowly loosen the screw plug (9). Make sure that no air flows out.
Note: If air flows out, tighten the screw plug (9). The shut off valve is not
airtight.
4) Remove the screw pug (9).
5) Slowly turn the handwheel (3) to move the shut-off valve to the position OPEN.
6) Make sure that air flows from the bore of the screw plug (9). When air flows, the
manual function of the shut-off valve operates correctly.

7) Use the handwheel (3, Fig. 5) to move the shut-off valve to the position
AUTOMAT. Make sure that the lever (4) engages with the groove in the spindle.
8) Make sure that no air flows from the bore of the screw plug (9). 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 (13), which shows that the valve body and valve operate.
2) Open the ball valve 35−8353_E0_2 to activate the control valve (13). The shut-off
valve opens automatically.
3) Make sure that air flows from the bore of the screw plug (9).
4) Close the ball valve 35−8353_E0_2.
5) Make sure that no air flows from the bore of the screw plug (9).
7. Completion
1) Use the handwheel to move the shut-off valve to the position CLOSED.
2) Install the screw plug (9).

Maintenance Group5
Supply Unit and Rail Unit Group 5
Work Cards
Servo Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5551−1/A1
Servo Oil Pump Drive: Remove the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−1/A1
Servo Oil Pump Drive: Remove the servo oil pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−1.3/A1
Fuel Pump Drive: Camshaft Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−2/A1
Fuel Pump Drive: Check Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−2.1/A1
Fuel Pump Drive: Check Thrust Bearing Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−2.2/A1
Fuel Pump Drive: Replace the Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5552−2.3/A1
Pilot Fuel Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5555−1/A1
Pilot Fuel Supply Unit − Pilot Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5555−1.1/A1
Pilot Fuel Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−1/A1
Pilot Fuel Pump: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−2/A1
Work Cards
Fuel Pump: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5556−1/A1
Fuel Pump: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5556−1.1/A1
Fuel Pump
Removal, Disassemble, Assemble, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−1/A1
Seized Pump Plunger − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−2/A1
Fuel Pressure Control Valve: Removal, Check, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A1
Fuel Pressure Control Valve: Manual Release Valve − Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A2
Work Cards
Fuel Overpressure Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5562−2/A1
Fuel Overpressure Safety Valve: Removal, Check and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−2/A1
Flow Limiting Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−3/A1
Work Cards
Flow Limiting Valve (FLV): Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5564−1/A1
Flow Limiting Valve (FLV): Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5564−1.1/A1
Exhaust Valve Control Unit (VCU): Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5612−1/A1
Exhaust Valve Control Unit (VCU): Replace the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . WC5612−1.1/A1
Exhaust Valve Control Unit (VCU): Oil Filter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5612−1.2/A1
Supply Unit
Lubrication of Supply Unit during Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−5/A1
Camshaft and Bearing Shells − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5581−1/A1
Fuel Pump Actuator
Connection to Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5583−1/A1
Work Cards
Fuel Pump Actuator: Regulating Linkage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC5801−1/A1
Servo Pump Unit
Servo Oil Pump − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5591−1/A1
Servo Oil Rail: Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation . . . . . 5612−1/A1
Winterthur Gas & Diesel Ltd. 1/ 1 X72DF / MM / 2018−02

Intentionally blank
Work Card
Servo Oil Pumps
− Engine stopped Servo oil pump EX 55400 Qty 1

− Main bearing oil pump set to off
− Applicable electrical connections disconnected
Remove the HP servo oil pipes, refer to 8447-1 Sling 94650 Qty 2
Remove the HP fuel pipes, refer to 8752−1/A1 Engine room crane
Remove the applicable drain pipes, oil pipe and inlet
pipes

Preparation
Replace the servo oil pump, refer to 5591−1/A1 Service Engineer 3.0 hours Qty 1
Related Data

Related Procedures
Remove and install the servo oil pump, refer to

5591−1/A1
Do a check for leaks

Intentionally blank
Work Card
Servo Oil Pump Drive: Remove the Cover Supply Unit Casing
Remove the cover from the supply unit casing Not applicable

Preparation
Do a check of the bearing bushes to the pinion Service Engineer 2.0 hours Qty 1
Related Data

Related Procedures
Attach the cover to the supply unit casing

Intentionally blank
Work Card
Servo Oil Pump Drive: Remove the servo oil pumps
− Engine stopped Bearing bush EX 55532 Qty 2
Remove the servo oil pumps, refer to 5591−1/A1 Oil

Drip tray

Preparation
Replace the bearing bushes Ship Engineer 2.0 hours Qty 2
Related Data

Related Procedures
Install the servo oil pumps, refer to 5591−1/A1

Intentionally blank
Work Card
Fuel Pump Drive: Camshaft Check
Remove the covers from the supply unit housing, Sealing compound

Preparation
Camshaft: Do a check of the running surface of Ship Engineer 2.0 hours Qty 1
cams, rollers and roller guides (first time after 500
Operation hours)
Related Data

Related Procedures
Attach the covers to the supply unit housing, refer to

5581−1/A1

Intentionally blank
Work Card
Fuel Pump Drive: Check Bearing Clearance
− Engine stopped Top bearing shell half EX 55462 Qty 4

Bottom bearing shell half EX 55463 Qty 4

Preparation
Camshaft: Do a check of the bearing clearances at Service Engineer 2.0 hours Qty 1
random positions Ship Engineer 2.0 hours Qty 1
Related Data

Related Procedures

5581−1/A1

Intentionally blank
Work Card
Fuel Pump Drive: Check Thrust Bearing Clearances

Preparation
Camshaft: Do a check of the thrust bearing Service Engineer 2.0 hours Qty 1
clearances Ship Engineer 2.0 hours Qty 1
Related Data

Related Procedures

5581−1/A1

Intentionally blank
Work Card
Fuel Pump Drive: Replace the Camshaft Bearing
− Engine stopped Thrust bearing ring half EX 55461 Qty 2

Top bearing shell half EX 55462 Qty 5
Bottom bearing shell half EX 55463 Qty 5
Remove the covers from the supply unit housing, Pre-tensioning jack 94557
refer to 5581−1/A1 Screwjack 94567B
Assembly template 94567
Assembly template 94567A
Holder 94566A
Holder 94566B
Sealing compound

Preparation
Replace the camshaft bearings, refer to 5581−1/A1 Service Engineer 2.0 hours Qty 1
Related Data

Related Procedures
Loosen the round nuts, refer to 9403−4

Tighten the round nuts, refer to 9403−4
Camshaft installation 5581−1/A1

Intentionally blank
Work Card
Pilot Fuel Supply Unit

− Service cover removed
None Lubricating oil

Preparation
Lubricate the flexible coupling of the pilot fuel pump, Service Engineer 1.0 hours Qty 1
Related Data

Related Procedures
Attach the service cover

Intentionally blank
Work Card
Pilot Fuel Supply Unit − Pilot Fuel Pump
− Engine stopped High pressure piston pump EX 55382 Qty 1
Refer to 5551−1/A1 No special tools necessary

Preparation
Replace the pilot fuel pump Ship Engineer 4.0 hours Qty 1
Related Data

Related Procedures
None

Intentionally blank
Supply Unit
Lubrication of Supply Unit during Maintenance

Tools:
1 Lubricating tool 94844 1 Adapter
1 Adapter
1. General
The engine has a manual lubrication system. This system prevents damage to the
bearings and bushes of the supply unit (7, Fig. 1) during dry-running of the engine.
Clean system oil is used for the lubrication.
2. Procedure
1) Clean the surface of the supply unit casing.
2) Remove the blind flange from the lubricating tool (94884).
3) Attach a flange with a G1/2” thread to the lubricating tool (94884).
4) Remove the applicable pipe from the supply unit (7).
5) Make sure that the ball valve (9) is closed.
6) Attach the adapter (1) to the flange (6) on the lubricating tool (94844).
7) Attach the flexible hose (2) to the adaptor (1) with the hose clip (5).
8) Attach the lubricating tool (94844) to an applicable position approximately 2.0 m
above the supply unit as shown.
9) Attach the flexible hose (2) to the adaptor (3) with the hose clip (4).
10) Remove the inspection covers from the supply unit (7).
11) Fill the lubricating tool (94844) with system oil.
12) Open the ball valve (9).
13) Make sure that the system oil flows on to the bearings and camshaft (8).
WARNING
14) After a period of 15 minutes, operate the turning gear.

Note: If the turning gear operates for long periods, keep the system full to make
sure that the bearings and camshaft (8) have sufficient lubrication.
15) Make sure that the bearings and camshaft (8) have sufficient lubrication.
16) Install the inspection covers to the supply unit (7) that you removed before.
17) Close the ball valve (9).
18) Remove the lubricating tool (94844), flexible hose (2) and adaptors (1, 3).
19) Install the pipe that you removed before to the supply unit (7).

Lubrication of Supply Unit during Maintenance
I-I
94844
I
9
2
I
6
II
5
1
II
2
II - II
2
3
4
7
8
WCH03860
Fig. 1

Pilot Fuel Supply Unit

1. General
If you operate the engine in gas mode continuously, it is recommended that you have
one more pilot fuel supply unit as a replacement.
The supply unit is an electric motor that has a flexible coupling to the pump and a
duplex filter.
2. Maintenance
Lubricate the flexible coupling in accordance with the maintenance schedule.
1) Remove the service cover (4).
2) Turn the flange until you see the grease nipple.
3) Lubricate the flexible coupling.
4) Install the service cover (4).
CAUTION
Injury Hazard: The weight of the pilot fuel supply unit is
approximately 367 kg. Use the correct equipment to lift and move
the pilot fuel supply unit. This will prevent injury to personnel.
Note: To get access to duplex filter (2), you must remove the cover on the pilot
fuel pump (3).
After the period given in the Maintenance Schedule, replace the pilot fuel supply unit.
WCH03121
Fig. 1 6 5 4 3 2
Key to Fig. 1
1 High pressure fuel pipe 4 Service cover for flexible coupling
2 Filter unit 5 Flexible coupling
3 Pilot fuel pump 6 Electric motor

2016
Intentionally blank
Pilot Fuel Pump

Tools:
1 HP oil pump 94931 1 HP hose 94935
1 Pressure gauge 94934A 1 Assembly tool 94573
1. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Removal
1) Stop the engine.
2) Make sure that the pilot fuel pump (5, Fig. 1) has stopped.
3) Disconnect the electrical connection from the electric motor (1).
4) Close the stop valve (3).
5) Remove the pilot fuel pressure pipe (4).
6) Remove the pilot fuel return pipe (2).
7) Remove the fuel inlet pipe (9).
8) Hold the weight of the pilot fuel pump (7).
9) Remove the four Allen screws (6).
10) Remove the pilot fuel pump (5) from the electric motor (1).

Pilot Fuel Pump: Removal and Installation
1 2 3 I
I 4
WCH03857
II
2
7 6 5
4 9
Fig. 1
11) On the assembly tool (94573, Fig. 2), turn fully back the special nut (2).
12) Apply Molykote G−Rapid Plus to the surfaces (4).
13) Attach the adapter piece (6) to the shaft of the pilot fuel pump (1).
14) Torque the adapter piece (6) to 45 Nm.
15) Turn the special nut (2) until touches the spherical disc (3). Do not tighten the
special nut.
16) Connect the HP oil pump and hose to the assembly tool (94573).
17) Operate the HP oil pump tp increase the pressure to between 1600 bar and 1800
bar. Make sure that the coupling half floats on the oil film.
18) Operate the HP oil pump to keep the pressure constant.
19) Turn back 5.0 mm the special nut (2). Make sure that the hydraulic force pushes
the coupling half against the spherical disc (3).
20) Make sure that the coupling half is loose.
21) Release the pressure from the HP oil pump.
22) Remove the gear coupling.

94573
1
2
I I
WCH03848
I-I
4
Fig. 2
2. Installation
1) Push as far as possible the special nut (2, Fig. 3) on the shaft of the pilot fuel
valve (1). Make sure that the couping is at 90° to the shaft of the pilot fuel valve.
2) Measure the distance from the special nut (2) to the end face of the pump (1).
Make sure that the distance is approximately 107.5 mm.
3) On the assembly tool (94573) turn fully back the special nut (2).
4) Apply Molykote G−Rapid Plus to the surfaces (3).
5) Attach the adapter piece (4) to the shaft of the pilot fuel pump (1).
6) Torque the adapter piece (4) to 45 Nm.
7) Turn the special nut (2) until it touches the spherical disc (7).
8) Attach the HP hose (9) to the HP oil pump (8)
9) Attach the hose (9) to the closing valve (5).
10) Operate the HP oil pump to get a pressure of between 1600 bar and 1800 bar.
11) Make sure that the coupling floats on the oil film.

12) Push the special nut (2) forward until the distance from the end face of the pilot
fuel pump is 61.5 mm.
13) Release the pressure in the HP oil pump (8).
14) Remove the hose (9) from the closing valve (5).
15) Remove the assembly tool (94573) from the pilot fuel pump (1).
1 I-I
2
3
WCH03848
I I 4 5
107.5 mm
6
7
61.5 mm
8
2
9
WCH03848
Fig. 3
16) Attach the pilot fuel pump to the electric motor temporarily with the four bolts and
nuts (8, Fig. 1).
17) Measure the distance X through the opening in the connection piece (1, Fig. 4).
18) Remove the electric motor (6) from the connection piece (1).
19) Push the flange on the motor shaft until you get a distance of X−3.0 mm.
20) Lock the hubs with an M8 screw (5).
21) Fill the coupling with grease.
22) Attach the electric motor (6) to the connection piece (1) with the bolts/nuts (7).
23) Make sure that the distance between the hubs is 3.0 mm.

Note: Some parts can look different. I-I

6 7 1
X
II
I I
WCH03848
II 4
2
III
3
II - II
X−3.0 mm 3.0 mm
5
WCH03848
III
Fig. 4
24) Attach the sleeves together with the screws and nuts (2) (Fig. 4).
25) Torque the screws (3) and nuts (2) to 36 Nm.
26) Make sure that the sleeves (1) turn freely an axial distance of ±1.5 mm.
3. Completion
1) Apply NeverSeez NSBT8 to the threads and surfaces that touch of the pilot fuel
pressure pipe (4, Fig. 5).
2) Attach the pilot fuel pressure pipe (4) as shown.
3) Torque the two coupling nuts (5) to 30 Nm.
4) Install the pilot fuel return pipe (2).
5) Install the fuel inlet pipe (10).
6) Connect the electrical connection to the electric motor (1).

1 2 3 4 I
I 5
5
9
WCH03857
II
2
8 7 6
Fig. 5
4 10

Work Card
Fuel Pump: Check
Operate the turning gear to get the roller of the Heat gun
related fuel pump to its highest position. Nylon brush
Remove the oil drain pipe from the fuel pump, refer Drill bit (small)
to 5556−1/A1.
Set to on the servo oil service pump. WD−40

Preparation
Do a random flow check of the lubricating oil, refer Service Engineer 1.0 hours Qty 1
to 5556−1/A1
Related Data

Related Procedures
Technical Bulletin RT−180

Attach the oil pipe to the fuel pump.

Intentionally blank
Work Card
Fuel Pump: Replace
− Engine stopped O-rings and rod seal ring (set) EX 55670 Qty 1
− Fuel temperature must be at ambient Fuel pump (includes the fuel EX 55600 Qty 1
− Fuel supply must be set to off pump plunger)
− Main oil supply must be set to off
− Fuel return valve must be open
− Fuel inlet valve must be closed
− Supply unit pressure must be zero
− Work area must be clean (no dust particles)
Set to off the power supply to the actuators. Lifting tool 94552 Qty 1
Make sure that the valves to the fuel pumps are Manual ratchet 94016−017 Qty 1
closed. Fuel pump rack 94592 Qty 1
Remove the applicable HP fuel pipes, refer to Oil tray 94592A Qty 1
8752−1 Impact wrench 94958 Qty 1
If necessary, attach the fuel pump rack to the top Extension 94958A Qty 1
primary platform Socket wrench insert 94958B
Oil

Preparation
Replace the fuel pump, refer to 5556−1/A1 Service Engineer 4.0 hours Qty 2
Related Data

Related Procedures
Flow check of the lubricating oil, refer to 5556−1/A1

Technical Bulletin RT−180

Intentionally blank
Fuel Pump
Removal, Disassemble, Assemble, Installation
Tools:
1 Circlip pliers 94007−A41 1 Guide bracket 94593
1 Handle 94009−M10 Which includes:
1 Manual ratchet 94016−017 1 Ring 94593A
1 2-part clamping ring 94550 2 Ring (2-part) 94593B
1 Spindle press 94551 2 Guide rods 94593C
1 Lifting tool 94552 4 Screws M12x130 94593D
1 Rod 94553 With special nuts
1 Distance piece 94555 2 Screws M30x110 94593E
1 Fuel pump rack 94592 1 Mandrel (∅ 70 mm) 94597
Which includes: 1 Pneumatic impact wrench 94598
1 Oil tray 94592A 2 Extensions 94598A
2 Limiters 94592B 1 Socket spanner insert 94598B
2 Screws 94592C
4 Screws 94592D
2 Screws 94592E
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Fuel Pump − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Guide Piston − Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Toothed Rack - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Pump Cylinder − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Non-return Valve − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Fuel Pump − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Pump Cylinder − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Non-return Valve − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Pump Cover − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Guide Piston − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.5 Top Housing − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6 Bottom Housing − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7 Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.8 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. Fuel Pump − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. Oil Flow Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fuel Pump: Disassemble, Assemble
1. Preparation
WARNING
Fire Hazard. Do not weld or grind materials in the area. Sparks can
cause a fire to occur.
WARNING
Injury Hazard. Put on gloves and eye protection. Fuel can come out
as a spray and cause injury.
CAUTION
Damage Hazard: Do not operate the engine with a fuel pump
removed. This will decrease the supply of oil, i.e. there could be a
decrease of lubrication to the other fuel pumps. Damage to
Note: Read the data in 0012−1 General Guidelines for Lifting Tools.
1) Stop the engine,refer to the Operation Manual 0310−1.
2) Set to off the fuel supply
3) Set to off the main oil supply.
4) Make sure that the fuel return valve is open, refer to the Operation Manual, Control
Diagram 4003−2 and Pipe Diagram 4003−11.
5) Close the fuel inlet valve, refer to the Operation Manual, Control Diagram 4003−2
and the Pipe Diagram 4003−11.
6) Make sure that the pressure in the supply unit decreases to zero.
7) Set to off the power supply to the fuel pump actuators.
8) Make sure that there is no pressure in the fuel system.
9) Make sure that the temperature of the fuel has decreased to ambient.
10) Clean the work area and make sure that there are no dust particles.
11) Set to off the power supply to the actuators.
12) Make sure that the valves to the fuel pumps are closed.
13) Remove the applicable HP fuel pipe(s), refer to 8752−1 paragraph 1 and
paragraph 2.
14) Attach the pump rack 94592 (Fig. 1) to the top primary platform (1) with the screws
94592D.
94592
94592D
1
Fig. 1 WCH03212

ÊÊ
2. Fuel Pump − Removal
94016−017
1) Operate the turning gear to get the
I 94552 applicable cam in the supply unit to
BDC.
6
I 1
2) Disconnect the applicable oil pipe (3,
5 Fig. 2).
2 3) Attach the lifting tool (94552) to the
4
pump cover.
3 4) Disconnect the connecting element (5)
between toothed rack (6) and the
actuator lever (4).
5) Remove the screws (2) from the fuel
pump (1).
Fig. 2 WCH03212
6) Attach the manual ratchet (94016−017)

to the engine room crane.
8) Carefully lift the fuel pump (1).
9) Attach covers to all open flanges to
prevent contamination in the pipes.
2 10) Operate the manual ratchet
1
(94016−017) to lower the fuel pump
into the rack (94592).
94592C
11) Attach the fuel pump to the fuel pump
94592B rack (94592, Fig. 3) with the screws
(94592C).
94592
94592A 12) Put the limiters (94592B) on both sides
of the rack (94592).
13) Put the oil tray (94592A) below the fuel
94592D pump.
14) Remove the manual ratchet
(94016−017).
WCH03212
15) Remove the oil inlet pipe (1) and the oil
drain pipe (2).
Fig. 3

94552
3. Disassemble
1) Remove the screws (94592E, Fig. 3),
then remove the two limiters (94592B).
2) Turn the fuel pump until the roller (1)
1 points up.
3) Attach the two limiters (94592B) to
each side of the fuel pump with the
screws (94592E) to hold the pump in
position.
4) Remove the tool (94552) and let the
fuel drain into the oil tray (94592A).
5) Loosen equally the two Allen screws (1,
Fig. 4).
1
6) Remove the two Allen screws (1).
7) Lubricate the spindle (5, Fig. 5) with
lubrication paste Molykote G−Rapid
Plus.
8) Attach the spindle press (94551) to the
94592B bottom housing (3).
94592E
9) Turn slowly clockwise the eye bolt (6)
and the spindle (5) to push the roller (1)
into the bottom housing.
10) Use the handle (94009−M10) to
remove the guide pin (4).
Fig. 3
5 94551
1
1 2
3 94009−M10
4
1 Fig. 5
Fig. 4 WCH03100

11) Turn the eye bolt (1, Fig. 6)

1 counterclockwise to move the spindle
(2) up.
12) Carefully lift the bottom housing (4)
2 together with the guide piston (3), the
bottom spring carrier (5) and pump
94551 plunger (7).
13) Remove the compression spring (6).
14) Remove the screw (8).
15) Remove the pump plunger (7) from the
bottom spring carrier (5).
3 Note: If you cannot remove the pump
plunger (7), refer to 5556−2.
16) Remove the circlip (13) and push the
4
retaining ring (12) down.
17) Hold the bottom spring carrier (5) while
you remove the two connection
5 pins (10).
18) Put the bottom housing (4) on an
6 applicable underlay.
19) Put the pump plunger (7) into a safe
storage area.
8 7
94551
WCH03053
10 11
12
13
Fig. 6
7
WCH03053

8 1 3.1 Guide Piston − Disassemble

7
2 1) Attach the two M10 eye bolts (1, Fig. 7)
6 into the guide piston (5).
3
2) Remove the guide piston (5) from the
4 housing.
5 3) Remove the circlip (6).
4) Remove the pin (7).
5) Push out the roller pin (3) then remove
the roller (4), bush (8) and the two
pressure discs (2).
6) Put the parts in a clean, safe area.
WCH03052
Fig. 7 3.2 Toothed Rack - Removal
1) Use the two M8 bolts (or handles) to
remove the top spring carrier (1, Fig. 8)
2) Turn the regulating sleeve (4) until the
guide pin (3) is in line with the cut-out.
4 3) Remove the regulating sleeve (4).

1
4) Remove the six screws (6).
3
2 5) Remove the cover (7).
6) Remove the two circlips (9).
7) Remove the ring (8).
8) Remove the three screws (11).
9) Remove the intermediate flange (10)
and the rod joint ring (5).
10) Remove the toothed rack (2).
10 11
2
WCH03052
9
8
7
6
Fig. 8

1
3.3 Pump Cylinder − Removal
2
Note: The pump cylinder (7, Fig. 9) and
3 pump plunger are not
interchangeable and must stay
together as a unit.
4 1) Turn the fuel pump until the pump
cover (2) points upward.
5 2) Remove symmetrically the twelve
screws (1).
7
6 pump cover (2).
4) Remove the pump cover (2).
Fig. 9 WCH03053
WCH03052
5) Attach the clamp ring (94550, Fig. 10)

to the valve block.
6) Use the clamp ring (94550 to remove
the valve block (4).
7) Remove the retaining screw (5) and
fluted seal ring.
94550 8) Carefully remove the pump cylinder (7)
9) Put all parts in a safe, clean storage
area.
WCH03102
Fig. 10
6 1
3.4 Non-return Valve − Removal
2
1) Remove the two screws (6, Fig. 11).
2) Remove the intermediate piece (1) and
5
the spring (5).
3
3) Remove the valve body (3) from the
valve block (2).
4) Remove the two O-rings (4)
WCH03053
Fig. 11

X
4. Fuel Pump − Assemble
1) Clean all parts of the fuel pump and
1 check their condition.
2 2) Examine all parts of the fuel pump for
damage. Replace damaged parts with
new items.
3
3) Replace all O-rings and rod seal rings.
4) Use a low-pressure air supply to make
sure that the bores in the housings and
the pump cylinder (1, Fig. 12) are clear.
5) Make sure that the top housing (3) points
up.
4.1 Pump Cylinder − Assemble

1) Carefully put the pump cylinder (1) in
WCH03053
the top housing (3).
Fig. 12
2) Align the opening in the pump
cylinder (1) with the bore in the top
housing (3).
3) Install the seal ring and screw (2).
Note: Make sure that there is a clearance
(X) between the end of the
screw (2) and the opening in the
pump cylinder (1).
4.2 Non-return Valve −

6 1 Assemble
1) Make sure that the sealing surfaces of
2 the valve block (2, Fig. 13) are clean
and have no damage.
2) Put oil on the new O-rings (4).
5
3) Put the new O-rings (4) on the valve
3
block (2).
4) Put the spring (5) in position in the
valve body (3).
5) Attach the intermediate disc (1) to the
valve body (2) with the two bolts (6).
6) Torque the two bolts (6) to 4.0 Nm.
4
WCH03053
Fig. 13

I 4.3 Pump Cover − Assemble

1 1) Put oil on the bottom part of the
2 non-return valve (3, Fig. 14.
2) Carefully put the assembled non-return
valve (3) into the top housing (5).
3) Put the pump cover (2) in position on
3 the top housing (5).
4) Apply NeverSeez NSBT to the threads
4 and the bottom faces of the 12
bolts (1).
5) Put the 12 bolts (1) in position in the
5 pump cover (2).
6
I 6) Torque the 12 bolts as follows:
1
a) Torque the 12 bolts in the
sequence shown to 100 Nm.
b) Torque the 12 bolts in the
c) Torque the 12 bolts in the
WCH03053
Fig. 14
4.4 Guide Piston − Assemble
1) Clean all parts of the guide piston (5,
Fig. 15).
2) Put oil on all parts of the guide piston.
Note: In step 3), the pin (7) is installed
from the inner surface of the guide
piston (5).
8 3) Put the pin (7) in position in the guide
1
7 piston (5).
2
6 4) Torque counterclockwise the pin to
3 60 Nm.
5) Put oil on the flanks of the roller (4).
4
6) Put the roller (4), bush (8) and the two
5
pressure discs (2) in the guide
piston (5).
7) Hold the roller pin (3) in position and
align the groove with the pin (7).
8) Push the roller pin (3) into the guide
piston (5) and the roller (4).
9) Attach the circlip (6) to hold the roller
pin (3) in position.
Fig. 15
WCH03053

4.5 Top Housing − Assemble

1) Turn the fuel pump into the position
shown in Fig. 16.
4
1 2) Put the toothed rack (2) in position.
3
2 Note: Make sure that the toothed rack (2)
moves easily.
3) Put oil on the rod seal ring (5).
4) Put the rod seal ring (5) into the
intermediate flange (8).
5) Put the intermediate flange (8) together
with the O-ring (11) into the top
housing (10).
10 6) Install the three screws (9).
8 9
2 7) Attach the rings (6) and the circlips (7).
WCH03053
7
Fig. 16 11
8) Move the toothed rack (2, Fig. 17) fully
out.
9) Put the regulating sleeve (5) in position
in the top housing (3).
10) Turn the regulating sleeve (5) until the
guide pin (4) is in line with the cut-out.
3
11) Move the toothed rack through the full
5 range of movement.
1
4 12) Put the top spring carrier (1) in position
2 in the top housing.
13) Push the top spring carrier (1) against
the top housing, then move the
regulating sleeve (5) up and down.
14) Use a dial gauge to measure the axial
clearance between the regulating
Min 0.5 mm sleeve (5) and the top spring carrier (1).
Max. 0.7 mm
15) Make sure that the axial clearance is
between 0.5 mm and 0.7 mm.
WCH03053
Fig. 17 3

1 16) Move the toothed rack (3, Fig. 18) to

the middle position.
2 17) Put the compression spring (1) in
position in the top housing (2).
4.6 Bottom Housing −

Assemble
1) Attach the spindle press (94551) to the
WCH03053
lower housing (9, Fig 19).
Fig. 18 2) Put a new O-ring on the guide pin (1).
3) Put the assembled guide piston (8) in
the bottom housing (9). Make sure that
the groove in the guide piston aligns
with the bore in the bottom housing.
4) Use the handle (94009−M10) to install
the guide pin (1).
5) Use the mandrel (94597) to install a
94551
new seal (10) to the bottom spring
carrier (7).
6) Put the bottom spring carrier (7) in
position on the guide piston (8).
9 94009−M10 7) Put new O-rings (3) on the connection
1
pins (2).
8 8) Put the two connection pins (2) through
the bores in the top spring carrier.
2 3 Make sure that the connection pins
7 engage with the groove in the guide
piston (8).
4 9) Attach the retaining rings (4) to the
94597 connection pins (2).
5
10) Attach the circlips (5) to hold the
connection pins (2) and the retaining
7 rings (4) in position.
10 11) Lift the assembly into position above
7 11 the top housing.
6 12) Attach the pump plunger (6) to the
WCH03053 bottom spring carrier (7).
13) Make sure that there is a clearance (X)
of between 0.12 mm and 0.24 mm.
X
Fig. 19
14) Apply Loctite 243 the thread of the
screw (11).
15) Torque the screw (11) to 9 Nm.

94551 4.7 Fuel Pump Assembly

1) Attach the ring (94593A, Fig. 20) to the
1 bottom housing (1).
94593A 2) Attach the two-part ring (94593B) to the

top housing (2). Make sure that the
guide rods (94593C) align with the
holes in the ring (94593A).
3 3) Attach the crane hook to the spindle
94593C press (94551).
4
94593B
WCH03053 WCH03053
Fig. 20
4) Carefully lower the lower housing (1,

Fig. 21) sufficiently to engage the rods
(94593C) with the holes in the ring
(94593A).
5) Continue to lower the bottom
1 housing (1) until the pump plunger (4)
94593A
is a small distance from the regulating
sleeve (5).
94593C
2
3
4
5
WCH03053
WCH03053
Fig. 21

6) Lower the bottom housing (1, Fig. 22)

94551 on to the top housing (3) until the
spring carrier (6) is approximately
10 mm to 20 mm above the spring (5).
7) Align the tabs(7) on the pump
1 plunger (4) with the holes in the
regulating sleeve (2).
8) Continue to lower the bottom
10 mm to housing (1) until the spring carrier (6)
6 touches the spring (5).
20 mm
5 9) Remove the crane hook from the
spindle press (94551).
I I
10) Remove the ring (94593A) and the
2 two-part ring (94593B).
3
4
I-I
7
2
WCH03053
Fig. 22
I-I 11) Make sure that there is a clearance of

50 mm between the top housing and
the bottom housing (see Fig. 23).
12) Put the two Allen screws (1) in position
as shown.
13) Tighten equally with your hand the two
II II Allen screws (1).
14) At the same time, torque the two Allen
screws to 140 Nm.
1
50 mm
I I II - II
WCH03053
Fig. 23

94551 4.8 Function Check

1) Turn the eye bolt on the spindle
1 press (94551, Fig. 24) to move the
roller (1) down 59 mm.
Note: The distance of 59 mm is equal to
a hub stroke of 55 mm.
2) Turn the eye bolt on the spindle press
(94551) back to the initial position.
94555 3) Attach a spring balance to the toothed

59 mm rack (2).
Note: During step 4), do a check of the
spring balance. If the force to
move the toothed rack is more
than 30 Nm, disassemble the fuel
pump and do a check of all
important dimensions.
2
4) Use the spring balance to pull the
toothed rack (2) fully out. Make sure
that the toothed rack (2) moves freely.
5) Make sure that you can install the
distance piece (94555).
6) Remove the the spindle press (94551).
7) Attach the cover (3) to the fuel pump
3 with the six screws (4).
8) Torque the six screws to 20 Nm.
Fig. 24
94552
1
94592C
9) Remove the limiters (94592B and
94592B 94592C).
10) Turn the fuel pump (1, Fig. 25) until the
pump cover points up.
11) Attach the lifting tool (94552) to the fuel
pump pump (1).
Fig. 25 WCH03053

5. Fuel Pump − Install

94016−017
WARNING
94552
I Injury Hazard: Before you
1 operate the turning gear,
make sure that no
For View I, 2 flywheel, or in the engine.
see Fig 27
1) Use the turning gear to turn the
3
camshaft until the applicable cam is at
BDC.
2) Do a check of all parts of the fuel
pump.
WCH03212 3) Make sure that the seating surfaces of
the fuel pump are clean and have no
damage.
4) Put new O-rings (4, Fig. 26) on the
bottom housing (5).
5) Put oil on the threads and seating
surfaces of the four bolts (2).
to the lifting tool (94552) and the
engine room crane.
7) Lift the fuel pump.
8) Put the fuel pump directly above the
applicable position of the supply unit.
2 94598
9) Carefully lower the fuel pump into
position.
5 10) Torque the four M30x220 bolts (2) to
4 94598A
1250 Nm (i.e. the value given in
WCH02790
0352−1). Use the socket wrench insert
(94598B), the extensions (94598A) and
the pneumatic impact wrench (94598).
11) Install the applicable HP fuel pipe(s),
refer to 8752−1 paragraph 4.
12) Connect the oil drain pipe (6) and the
oil inlet pipe (7).
13) Make sure that the fuel return valve
and the fuel inlet valve are open. Refer
94598B
to the Operation Manual, 4003−2 and
4003−11.
7
14) Operate the pump and do a leakage
6 check.
Fig. 26

15) Make sure that the connecting

I element (4, Fig. 27) moves freely.
4 5
3 16) Apply Molykote paste G to the
connecting element(4).
2 17) Connect the connecting element (4) to

the actuator lever (2) with the screw
and new self-locking nut (3).
1 18) Move the the toothed rack (5) to the
middle position as shown. Make sure
that there is 48 mm at each end of the
the toothed rack.
19) Make sure that the indicator (1) on the
actuator shows 50% fuel.
20) Attach the cover (7) to the fuel pump
with the six screws (6).
21) Torque the six screws (1) to 20 Nm.
48 mm
7 6
WCH03052
Fig. 27

6. Oil Flow Check

WARNING
Injury Hazard: Do not
1 operate the engine. Injury
to personnel can occur.
WARNING
make sure that no
2 flywheel, or in the engine.
Note: The oil flows through the throttle

3 (1, Fig. 27) to the bottom housing
(2) and the guide piston (3).
1) The engine must be stopped.
WCH02790
roller of the related fuel pump to its
highest position (TDC).
3) Remove the oil drain pipe (4) from the
fuel pump.
4) Set to on the servo oil service pump.
5) After one minute, make sure that you
can see the oil flow as shown.
6) If the oil does not flow as shown, read
5 4
the data in Technical Bulletin RT−180.
7) Make sure that the oil flows in the inlet
4 pipe (5).
Oil Flow Note: If the oil in the inlet pipe (5) does
not flow freely, it is possible that
there are unwanted particles in the
oil supply system. If you find
particles, remove them.
WCH02790
8) If there is incorrect oil flow or no flow
from the drain hole, do step a) to
step d):
a) If the oil cannot flow freely, flush
the holes with e.g WD−40.
Fig. 27
b) If there is no oil flow, use a heat
gun to apply heat to the clogged
drain hole.
c) Use a small drill bit to open the
hole.
d) Remove the particles with a nylon
brush.
9) Install all unions and plugs.
10) Attach the oil drain pipe (4) and oil inlet
pipe (5) to the fuel pump.

7. Storage
Do the procedure that follows to put the fuel pump into storage:
1) Make sure that the storage area is clean and dry.
2) Put oil on the fuel pump to prevent contamination.
3) Put the pump in a vertical position.
4) Put petroleum jelly (e.g. Vaselinet) in the oil inlet and oil drain holes of the fuel
pump.
5) Put the plastic stoppers into the open spaces.
6) Put a cover (material or plastic) on the fuel pump.

Fuel Pump
Seized Pump Plunger − Removal
Tools:
1 Piston reset tool 94595D 2 Screws 94595E
1 Hydraulic ram 94595 1 HP oil pump 94931
1 Short push rod 94595B 1 Pressure gauge 94934A
1 Long push rod 94595C 1 HP hose 94935
1. Fuel Pump − Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Hydraulic Ram − Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Hydraulic Ram − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Removal with Tool 94595B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Removal with Tool 94595C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Fuel Pump −
Preparation
1) Remove the fuel pump, refer to 5556−1
2) Disassemble the fuel pump (5556−1
paragraph 3) until the condition is as
shown in Fig. 1.
94595E
Fig. 1 WCH03053

Fuel Pump: Removal of a Seized Pump Plunger
I II
5 1 2. Hydraulic Ram −
94595 Preparation
1) Open the vent screw (5, Fig. 2) and
2 push the piston (2) to the top of the
cylinder of the hydraulic ram (94595).
2
94595D 2) If you cannot move the piston (2) with
your hand, do step a) to step c):
WCH02281
a) Remove the push rod (4) (94595B
4 3 or 94595C) from the piston (5).
b) Attach the piston reset tool
(94595D) to the hydraulic ram
III (94595) with two of the screws (1).
Note: The screws (1) are from the
fuel pump cover.
c) Use the spindle (3) to push the
piston (2) to the top of the
cylinder.
3) Remove the piston reset tool (94595D).
4) Put the short push rod (4) (94595B)
into the piston (5).
WCH02281
Fig. 2
3. Hydraulic Ram −
Installation
I-I 94595E CAUTION
Damage Hazard: There is
no support below the
housing. The bottom
housing can fall and cause
damage when the screws
are removed.
94595E
II WCH02365
II
1) Attach the hydraulic ram (94595) to the
fuel pump with the twelve screws (1).
6
II - II
2) Hold the bottom housing (4, Fig. 3) in
I I position, then remove the four bolts (5)
from the top housing (6).
1 3) Put the two screws (94595E) through
the bores of the flange in the top and
5 bottom housings (6, 4) in the positions
2
shown (view I−I).
10 mm to 3
15 mm 4) Put the nuts (3) on the screws
4 (94595E).
WCH02365 94595E 5) Adjust the nuts (3) to get a minimum
clearance of between 10 mm to 15 mm
(view II−II).
Fig. 3 014.181/06

4. Removal with Tool

10
94595B
9 1) Connect the hydraulic ram (94595,
94595
8 Fig. 4 to the HP oil pump (94931).
94595B 1 2) Close the relief valve (5).
2 3) Make sure that the vent screw (10) is
I
open.
7 3
4) Operate the HP oil pump until oil that
has no air flows from the vent
screw (10).
4
Note: During the step below, make sure
that you keep a clearance of
between 10 mm and 15 mm
between the nuts (3, Fig. 3 II−II)
and the bottom housing (4).
6) Operate slowly the HP oil pump
(94931, Fig. 4) until:
D The compression spring (4)
pushes the plunger (2) out of the
017.890/08
94932 cylinder (7), or
94935 D The indicator (6) is flush with the
WCH02281 housing. (This shows that the
piston is at the end of its stroke.)
5 94931
7) Open the relief valve (5) to release the
I 6 pressure in the HP oil pipe (94935).
8) Disconnect the HP oil pump from the
FLUSH hydraulic ram (94595).
9) Remove the screws (9).
10) Remove the hydraulic ram (94595).
Fig. 4
11) Remove the plunger (3).
12) Move the piston (8) to the initial
position, refer to paragraph 2.
13) Continue to disassemble the fuel pump,
14) If you cannot remove the plunger (2),
do the procedure given in paragraph 5.

5. Removal with Tool

8
94595C
7
94595 1) Remove the short push rod (94595B)
6 from the hydraulic ram (94595).
94595C 2) Put the long push rod (94595C, Fig. 5)
I 1 into the hydraulic ram (94595).
2 3) Install the hydraulic ram (94595) to the
fuel pump (refer to paragraph 3).
4) Connect the hydraulic ram (94595) to
the HP oil pump.
3
5) Close the relief valve (4).
6) Open the vent screw (8).
7) Operate the HP oil pump until oil that
has no air flows from the vent
screw (8).
Note: During the step below, make sure
that you keep a clearance of
between 10 mm and 15 mm
017.890/08 between the nuts (3, Fig. 3
94932 view II−II) and the bottom
94935
housing (4).
WCH02281
9) Operate slowly the HP oil pump until:
4 94931 D The compression spring (3, Fig. 5)
pushes the plunger (2) out of the
I 5 cylinder (1), or
D The indicator (5) is flush with the
FLUSH housing. (This shows that the
piston is at the end of its stroke.)
Fig. 5 10) Remove the screws (7).
11) Remove the hydraulic ram.
12) Remove the plunger (2).
13) Continue to disassemble the fuel pump,
2016
66
Fuel Pressure Control Valve

Removal, Check, Installation
Tools:
1 HP oil pump 94931 1 HP hose 94935
1 Pressure gauge 94934A 1 PCV test block with tube 94556
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. PCV Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Setpoint Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
To prevent failure of the pressure control valve (PCV), WinGD 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,
PCV.
To do a check the fuel overpressure safety valve (6, Fig. 1), refer to 5562−2.
2. Preparation
WARNING
WARNING
Injury Hazard. You must put on gloves and safety goggles when you
do work on hot components. Hot fuel can come out as a spray and
cause injury.
1) Stop the engine, refer to the Operation Manual, 0310−1.

2) Release the pressure in the fuel rail. Do the procedure given in the Operation
Manual 0515, paragraph 5.3.
3) Make sure that the work area is clean.

Fuel Pressure Control Valve: Removal, Check, Installation
3. Removal
1) Make sure that the fuel rail (4, Fig. 1) has no pressure.
2) Disconnect the electrical connection from the solenoid valve (2).
3) Loosen the angle union (7), then remove the fuel return pipe (5) from the
PCV (1).
5) Remove the PCV (1) from the valve block (3).
6) Put protection on the valve block (3) to prevent contamination.
1
6
2
WCH02237
5
4
3
9
5 WCH02366
Fig. 1

4. PCV Check
4.1 Preparation
1) Put protection (6, Fig. 2) around the PCV test block (94556).
2) Put the test block (94556) in a bench vice.
3) Make sure that the sealing surfaces of the PCV and the test block (94556) are
clean and have no damage.
4) Put the PCV in position on the test block (94556).
5) Put oil on the threads of the four screws (1).
6) Put the four screws (1) in position in the PCV.
7) Tighten the screws in the sequence given in 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 flexible tube (a part of the test block 94556) to the PCV outlet (2). Put
the other end of the flexible tube into an applicable container (3).
9) Connect the HP oil pump (94931), pressure gauge (94932) and HP hose (94935)
to the test block (94556).
10) Identify each of the two pressure control set screws.
11) On the setpoint adjustment valve (SAV) (7), loosen the locknut.
12) Fully loosen the SAV (7).
I 1 I
II
6 2
a c
d b
94935
94556
II
94932
WCH02281
94931
4
3 Safety Valve
Fig. 2 DO NOT ADJUST

4.2 Adjustment Procedure

CAUTION
Damage Hazard. Do not connect the solenoid valve. Damage to the
PCV can occur.
1) Operate the HP oil pump (4, Fig. 2).

2) Tighten the SAV (7) to get a value of 100 bar.
Note: If oil flows into the groove (5) the PCV has a leak, or the O-ring in the tool
(94556) has damage.
4) Continue to tighten the SAV (7) and do checks for leaks at the same time.
5) Adjust the SAV (7) until the PCV opens at 1050 bar.
6) On the SAV (7), tighten the locknut.
7) On the HP oil pump (94931), open the relief valve (4) to decrease the pressure to
zero.
4.3 Setpoint Check

1) On the HP oil pump (94931), close the relief valve (4).
2) Operate the HP oil pump (94931).
3) Make sure that the PCV opens at 1050 ± 30 bar.
4) If the PCV opens at less than 1020 bar or more than 1080 bar, do the procedure
in paragraph 4.2 again.
Note: If the PCV does not open at less than 1300 bar or opens at less than 1020
bar (when the SAV (7) is fully closed), the PCV has a malfunction. You
must find and repair the malfunction before you install the PCV.
5) On the HP oil pump, open the relief valve (4) to decrease the pressure to zero.
6) Disconnect the flexible tube from the PCV outlet (2).
7) Disconnect the HP hose (94935) from the tool (94556).
8) Remove the four screws (1) from the PCV.
9) Remove the PCV from the bench vice.

5. Installation
1) Do a check of the lip seal (9, Fig. 1). Replace the lip seal if necessary.
2) Remove the protection from the valve block (3).
3) Make sure that the sealing surfaces of the PCV and the valve block (3) are clean
and have no damage.
4) Put the PCV in position on valve block (3).
5) Put oil on the threads of the four screws (1).
6) Put the four screws (1) 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 (5, Fig. 1) to the PCV (1).
9) Tighten the angle union (7).
10) Connect the electrical connection to the solenoid valve (2).

Intentionally blank
Fuel Pressure Control Valve: Manual Release Valve −

Clean
1. General
If the pressure control valve does not close correctly, do the procedure given in
paragraph 2.
2. Procedure
2.1 Disassemble
Note: It is not necessary to remove the PCV (1, Fig. 1) from the fuel rail (2) to do
this procedure.
Note: For the full PCV overhaul instructions, speak to or send a message to
WinGD.
1) Stop the engine
2) Make sure that the PCV (1) is open.
Note: If HFO is used, the drain port will be hot when the PCV is open.
3) Operate the pressure release button more than two times to release pressure.
1
6
2
O−ring Pusher
WCH02900
Rubber Cap
DRIVING END
Pressure
Release Button
Hole
Solenoid Tube
Lever
Internal Pin
Spring Plunger
Drain Port
Fig. 1

Fuel Pressure Control Valve: Manual Release Valve − Clean
4) Carefully remove the rubber cap

(Fig. 2).
Rubber
Cap
Solenoid
Plastic
Collar 5) Record the installed position of the
plastic collar.
Nut 6) Remove the nut, plastic collar and
solenoid.
Solenoid
Tube
Hole
7) Remove the solenoid tube.
8) Use your finger to push the lever. Make

sure that you can feel two different
Lever spring tensions.
Note: If the valve closes and you can get
rail pressure, it is not necessary to
continue the procedure. Refer to
paragraph 2.3, step 5) to step 9) to
assemble the PCV.
Block
CAUTION
M6 Allen Injury Hazard: Make sure
Screws that there is no pressure in
the fuel rail or the drain side
of the system. High
pressure fuel can cause
injury to personnel.
9) Remove the four Allen screws from the

block.
10) Remove the block.
Fig. 2

Fuel Pressure Control Valve: Manual Release Valve − Clean
11) Carefully remove the pusher (Fig. 3).

Note: It is possible that the pusher will
stay on the PCV body.
12) Remove the plunger and spring from
the PCV.
Block 2.2 Clean and Apply NeverSeez

1) Remove the grease from all
components (pusher, plunger, spring
and O−ring).
2) Apply a thin layer of NeverSeez to all
components (plunger, spring and
Pusher O−ring pusher.
3) Put NeverSeez into the hole in the
solenoid tube (see Fig. 1 and Fig. 2).
4) Push the internal pin in and out with
your hand to apply the NeverSeez.
2.3 Assemble
1) Put the plunger and spring into the
pusher assembly.
2) Put the O−ring and pusher in position in
the block.
3) Attach the valve block to the PCV with
the four M6 Allen screws.
O−ring 4) Torque the for M6 Allen screws to
15 Nm.
5) Attach the solenoid tube to the valve
block.
Plunger
6) Put the solenoid in position on the
valve block.
7) Put the thick part of the collar against
the solenoid.
Spring
8) Attach the nut to the solenoid. Tighten
the nut.
Rubber
Cap
Note: During step 9), hold in the pusher

with your hand to help you attach
the rubber cap (Fig. 3).
Flat−blade 9) Use a small flat−blade screwdriver to
Screwdriver attach the rubber cap over the plastic
collar.
Fig. 3

Intentionally blank
Work Card
Fuel Overpressure Safety Valve

− The fuel rail must have no pressure
Read the data in the instructions from the HP oil pump 94931 Qty 1
manufacturer about the specifications of the test Valve holder 94272A Qty 1
bench. Hydraulic unit 94942 Qty 1
Attach / connect the applicable equipment to the fuel Adapter piece 94234F Qty 1
overpressure safety valve Adapter piece 94234A Qty 1
AF80 spanner
Calibration fluid S.9365

Preparation
Do a check of the function on the test bench, refer to Service Engineer 2.0 hours Qty 1
5562−2/A1
Related Data

Related Procedures
None

Intentionally blank
Fuel Overpressure Safety Valve

Removal, Check, Installation
Tools:
1 HP oil pump 94931 2 Pressure gauge 94934A
1 Adapter piece 94234F 2 HP hoses 94935
1 Adapter piece 94272A 1 Valve holder 94273
1 Hydraulic unit (optional) 94942
1. General
Maintenance of the relief valve (1, Fig. 1) is not usually necessary, but you must do a
function check at regular intervals. Refer to the Maintenance Schedule 0380−1 Relief
Valve for the frequency to do the function test. Unserviceable relief valves must be
sent to the manufacturer, or to a WinGD authorized repair workshop for inspection
and repair.
The International Association of Classification Societies (IACS) approval is given for:
D The type of test
D The type of certificate
D The frequency of the test.
The results of the test must be recorded on the Inspection Report.
Note: The two bores (2) identify the relief valve (1) as a new item.
I II - II
1 II
1
4
AF80
Fuel Rail
2
WCH03213
3
4
015.499/07
I
II WCH03672
Applicable pressure that

opens the relief valve
Fig. 1

PCV Relief Valve: Removal, Check, Installation
2. Removal
1) Stop the engine (refer to the Operation Manual 0310−1).
2) Make sure that the fuel rail has no pressure.
3) Use a spanner (AF80, Fig. 1) to remove the relief valve (1) from the connecting
piece (4).
3. Relief Valve Test
3.1 Test and Calibration Fluid − Physical Conditions

You use the test bench (94272) and the test and calibration fluid (e.g. Shell
Calibration Fluid S.9365) to do a test of the relief valve. Table 1 gives the mandatory
data for the test and calibration fluid.
Table 1
ASTM D445
Kinematic Viscosity at 40_C 2.6 mm2/s
Density at 15_C 827 kg/m3 ISO 12185
Pour Point −27_C ISO 3016
3.2 Preparation
Note: Read the data in the instructions from the manufacturer about the
specifications of the test bench.
1) Put the relief valve (1, Fig. 2) in the valve holder (94272A).
2) Tighten the relief valve (1).
3) Connect the valve holder (94272A) to the HP oil pump (94931) or the hydraulic unit
(94942).
4) Close the valve (3).
3.3 Sealing Pressure Check

1) Operate the HP oil pump (94931) to increase the pressure to 1150 bar.
2) Keep the pressure constant for one minute.
3) Make sure that there are no leaks.
3.4 Operation Pressure Check

1) Operate the HP oil pump to increase the pressure until the relief valve (1) opens.
2) Make sure that the relief valve opens at between 1200 bar and 1350 bar (1250 bar
+100, −50 bar).
3) Operate the valve (3) to release the pressure in the HP hoses (94935).
4) Remove the relief valve (1) from the valve holder (94272A).

PCV Relief Valve: Removal, Check, Installation
94935 94273
94934A
94934F
94931 3 94934A
94272A 94272
2
013.486/05
Fig. 2 013.484/05
4. Installation
1) Apply Never-Seez NSBT to the thread of valve housing (2, Fig. 3).
2) Install the relief valve (1) in the connecting piece (3).
3) Torque the relief valve (1) to 300 Nm.
3 1
Fuel Rail AF80
WCH03213
WCH03672
Fig. 3

Intentionally blank
Flow Limiting Valve

Tools:
No special tools
are necessary
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
It is possible to do the maintenance on a flow limiting valve (FLV) on board. Speak to,
or send a message to WinGD to get a repair kit and instructions.
Approved personnel only are permitted to do maintenance on an FLV. If there are no
approved personnel, send the FLV to a WinGD service station for overhaul.
5
6 7 1 RS
RS 4
3
WCH03228
Fig. 1 2
Fig. 3: Flow Limiting Valve
1 Piston 5 Flange
2 Lip seal 6 Piston rod
3 Cover 7 Valve block
4 O-ring RS Running surface

Flow Limiting Valve
2. Preparation
WARNING
WARNING
Injury Hazard: You must put on gloves and safety goggles when
you do work on hot components. Fuel and oil can come out as a
spray and cause injury.
WARNING
Injury Hazard: Do not operate the turning gear. Fuel can come out of
the opening in the fuel rail and cause injury.
1) Stop the engine, refer to the Operation Manual, 0310−1.

2) Cut out the injection, refer to the Operation Manual, 0510−1.
3) Let the engine temperature decrease.
4) Let the pressure in the fuel rail decrease to zero.
5) Make sure that the fuel injection system has no pressure.
6) Make sure that all tools and equipment are clean and in good condition.
7) Clean the work area adjacent to the
1 FLV (3, Fig. 2).
5
8) Remove the HP fuel pipes (1), refer to
4 8733−1, paragraph 1 and paragraph 2.
9) Remove the leakage pipes (2, 4) from
2 the flow limiting valve (3).
10) Apply protection to the openings on the
FLV.
11) Apply protection to the open ends of
the pipes (1, 2 and 4).
3
Fig. 2
WCH03227

Injection Control Unit
2
3. Removal
CAUTION
of the FLV is approximately
39 kg. Use the correct
1 equipment, or two persons,
to lift and move the FLV.
This will prevent injury to
personnel.
2 1
1) Remove the eight bolts (2, Fig. 3) from
the FLV (1).
2) Lift the FLV.
3) Remove the lip seal (3). Make sure that
you do not damage the lip seal.
Fig. 3 WCH03229
3 4) Put the lip seal (3) in a safe area.
5) Make sure that the dowel pins stay in
the fuel rail.
6) Lower the FLV (1) on to an applicable
clean surface.
4. Disassemble
1) Remove the three bolts (5, Fig. 4) and
the cover (4).
2) Remove the twelve bolts (3).
3) Carefully remove the flange (2)
1
together with the piston rod (8) and the
piston (6).
4) Remove the piston (6) together with
5 piston rod (8) from the flange (2).
4 3 2
RS
RS 5) Use ScotchBritet and a cleaning
3 solvent e.g, NeovalR, WD40R etc to
5 clean the piston rod (8) and piston (6).
6) Put the piston rod (8) and piston (6) in
the flange (2). If the piston rod does not
freely move, clean the piston and
piston rod again.
4 8 7 2 6 1
7) Examine the running surfaces (RS) of
Fig. 4
WCH03229 piston rod (8), flange (2), piston (6) and
valve block (1).
8) Speak to, or send a message to
WinGD for replacement parts and
instruction. If necessary, send the FLV
to a WinGD Service Station for an
overhaul.

Injection Control Unit: Removal and Installation
5. Assemble
1) Clean all parts and running surfaces
(RS, Fig. 5).
2) Apply lubricating oil to all running
surfaces (RS).
1 3) Put the piston rod (8) together with the

piston (6) into to flange (2). Make sure
that the piston rod moves easily.
4) Put the piston (6) together with the
5
4 3 2 flange (2) into the valve block (1).
RS
RS 5) Apply Never Seez NSBT to the threads
3 and surfaces of the twelve bolts (3).
5
6) Tighten equally the twelve bolts (3) with
your hand. Make sure that the twelve
bolts turn easily.
7) Torque symmetrically the twelve
bolts (3) to 60 Nm.
4 8 7 2 6 1
Fig. 5 WCH03229
8) Put a new O-ring (7) on the cover (4).
9) Attach the cover (4) to the flange (2)
with the three bolts (5).
6. Installation
1) Make sure that the dowel pins are in
the fuel rail.
1
2) Clean the sealing surface in the valve
block (1, Fig. 6) and the lip seal (3). It is
recommended that you install a new lip
2 1 seal.
3) Install the lip seal (3).
4) Clean the related surfaces on the fuel
rail and the valve block (1).
5) Carefully put the FLV in the correct
position on the fuel rail.
Fig. 6 WCH03229
6) Apply Never Seez NSBT to the threads
3
and surfaces of the eight bolts (2).
7) Put in the eight bolts (2) together with
distance sleeves into the valve block
8) Tighten equally the bolts (2) with your
hand.
9) Torque symmetrically the eight bolts (2)
to 60 Nm.

Injection Control Unit: Removal and Installation
1 7. Completion
5
1) Install the leakage pipes (2 and 4,
4
Fig. 7) to the FLV (3).
2) Install the HP fuel pipes (1), refer to
2 8733−1, paragraph 4.
3) Cut in the injection, refer to the
Operation Manual, 0510−1.
4) Operate the engine for a minimum of
one hour with marine diesel oil. For
3 more data, refer to the Operation
Manual 0510−1.
Fig. 7 WCH03227
8. 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 correctly the FLV.
4) Put the FLV in a plastic bag.
5) Remove as much air as possible from the plastic bag.
6) Seal the plastic bag.

Intentionally blank
Work Card
Flow Limiting Valve (FLV): Inspection

− engine temperature must be at ambient
− Fuel rail pressure must be zero
− Fuel injection system pressure must be zero
− All tools and equipment must be clean
− The work area must be clean
Cut out the injection, refer to Operation Manual, No special tools are necessary
refer to 0310−1.
Remove the applicable HP fuel pipes, refer to ScotchBritet
8733−1 Cleaning solvent
Remove the leakage pipes from the FLV O-ring
Remove the FLV, refer to 5562−3/A1 Never Seez NSBT
Lubricating oil

Preparation
Do an inspection, clean the piston rod and piston Service Engineer 4.0 hours Qty 1
running surface
Related Data

Related Procedures
Install the FLV,

Intentionally blank
Work Card
Flow Limiting Valve (FLV): Replace
− Engine stopped Flow limiting valve EX 55720 Qty 1

− engine temperature must be at ambient
− Fuel rail pressure must be zero
− Fuel injection system pressure must be zero
− All tools and equipment must be clean
− The work area must be clean
Cut out the injection, refer to Operation Manual, No special tools are necessary
refer to 0310−1.
Remove the applicable HP fuel pipes, refer to ScotchBritet
8733−1 Cleaning solvent
Remove the leakage pipes from the FLV Never Seez NSBT
Remove the FLV, refer to 5562−3/A1 Lubricating oil

Preparation
Replace the FLV, refer to 5562−3/A1 Service Engineer 4.0 hours Qty 1
Related Data

Related Procedures
None

Intentionally blank
Work Card
Exhaust Valve Control Unit (VCU): Check

− Servo oil rail pressure must be zero
Remove the applicable hydraulic pipe, refer to Not applicable

8460−1
Disassemble the VCU, refer to 5612−1/A1

Preparation
Do a check of the piston and slide rod Service Engineer 3.0 hours Qty 1
Related Data

Related Procedures
Assemble and install the VCU, refer to 5612−1/A1

Intentionally blank
Work Card
Exhaust Valve Control Unit (VCU): Replace the solenoid valve
− Engine stopped Spare kit O-rings EX 96191 Qty 1

Spare kit solenoid EX 96192 Qty 1
Spare kit solenoid connector EX 96193 Qty 1
None Not applicable

Preparation
Replace the 4/2-way solenoid valve on the exhaust Ship Engineer 1.0 hours Qty 1
valve control unit
Related Data

Related Procedures
None

Intentionally blank
Supply Unit
Camshaft and Bearing Shells − Removal and Installation
Tools:
2 Pre-tensioning jacks 94557 1 Screwjack 94567B
2 Support 94566 1 Connection block 94934
1 or 2 Holders 94566B 1 Pressure gauges 94934A
1 Holder 94566C 3 HP hoses 94935
1 Assembly template 94567 1 Hydraulic unit 94942
1 Assembly template 94567A
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Bearing Shells − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Camshaft − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Camshaft and Bearing Shells − Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Preparation
1) Remove the covers (3, 4, 5 and 6, Fig. 1) from the housing (2).
2) Remove the fuel pumps (1) refer to 5556−1, paragraph 1 and paragraph 2. As an
alternative, lift the rollers (refer to step 3) and step 4).
6
2
WCH02236
Fig. 1 4

3) Make sure that the bearing covers at positions No. 3, No 4 and No. 5 Fig. 2 and
the housing (1), have marks to identify them as a set.
Note: The bearing at position No. 2 has the two thrust bearing ring halves (3).
4) Install the holders (94566B, 94566C) to lift the rollers and guide pistons of the
fuel pumps.
94566B 94566B 94566C
1 2 3 4 5 6
3
I
WCH02385
I II
II
94566B
94566B
2 mm 94566C
WCH02383
WCH02385
II
Fig. 2
2016 5
2. Bearing Shells −
I II Removal
1) Loosen the two Allen screws (3, Fig. 3)
and remove the filling piece (1) from
bearing cover No.3.
1 2 3 4 5 6 2) Use the pre-tensioner (94557) to
loosen the round nuts (5) of the bearing
covers No.1, No.3, No.4 and No.5,
refer to 9403−4.
III 3) Remove the round nuts (5) and the

II bearing covers No.1, No.3, No.4 and
I No.5.
94567B 4) Put the screwjack (94567B) in position
1 under the last cam.
WCH02385 5) Turn the screwjack (94567B) to lift the
I-I camshaft between 0.05 mm and
0.15 mm.
5 6) Put the assembly template (94567) in
4 position on the top bearing shell (7) of
bearing No.5 (see View III).
3 7) Use the assembly template (94567) to
1 turn the top and bottom bearing shells
(6, 7) 90° (see View III).
Note: If you cannot turn the bearing
II - II shells, adjust the screwjack
(94567B) again.
2 8) Hold the top bearing shell (7), then
94557 remove the assembly template
7 (94567).
9) Put marks on the top bearing shells to
identify their positions. This will help
you when you install the bearing shells.
6
10) Remove the top bearing shell (7).
11) Do step 3) to step 10) to remove the
remaining top bearing shells at
positions No.3 and No.5.
III
94567 94566B
WCH02385
94567B 94567
Fig. 3

3. Camshaft − Removal
I 1) Put the two supports (94566) in the
II positions at No.1 and No.5 (Fig. 4).
2 3
2) On the two supports (94566), tighten
1 the nuts (4).
3) Make sure that the camshaft stays in
1 2 3 4 5 6 position before you remove the last
bearing cover.
4) Remove the remaining bearing covers
and top bearing shells at positions No.2
and No.6 (see the procedure in
paragraph 2, step 2) to step 11)).
II I
5) Remove the screwjack (94567B,
Fig. 3).
WCH02385
6) Carefully move the camshaft (3, Fig. 4)
I-I and the gear wheel (2) on to the two
supports (94566).
7) Make sure that the camshaft (3) and
4 gear wheel (2) do not move.
8) Make a mark on the remaining bottom
bearing shells to identify their positions.
This will help you when you install the
bearing shells.
9) Remove the remaining bearing shells.
94566
4. Camshaft and Bearing
Shells − Installation
1) Make sure that all items are clean and
do not have damage.
2) Apply oil to the bearing shells and the
camshaft (3).
3) Put all bottom bearing shells into the
casing in their correct positions. Refer
to the marks you made before.
94566 4) Put the camshaft (3) and gear
wheel (2) in position on the two
II - II supports (94566).
5) Carefully move the camshaft (3) and
9
5 the gear wheel (2) into the housing (1).
Make sure that the bearing shells stay
8 in position and do not fall.
6) Make sure the camshaft does not
move.
6
7
Fig. 4

7) Put the screwjack (94567B, Fig. 5) in

II I position.
8) Turn the screwjack (94567B) to lift the
camshaft between 0.05 mm and
1 2 3 4 5 6 0.15 mm.
9) Put the assembly template (94567A) on
2 the bottom elastic bolt (7).
10) Put the round nut (8) on the elastic
bolt (7). Tighten the round nut with your
1 I 94567B hand.
II 11) Put the top bearing shell (6) in position
on the camshaft.
12) Put the assembly template (94567) in
WCH02385
position on the bottom half of the top
I-I bearing shell. Use the assembly
template (94567A) to help you get the
bearing shell in the center.
II - II
13) Use the assembly template (94567) to
6
turn the bearing shells (7, 8 Fig. 4)
5 94567 90°upwards .
14) Make sure that the semicircular slots of
4 the two bearing shells (7, 8) are in a
horizontal position.
3
15) Remove the assembly templates
(94567, 94567A).
94567A 8 7
16) Remove the holder (94566A or
94566B).
94567 94566B
17) Make sure that the pin (3, Fig. 5 is in
the bearing cover (4).
18) Attach the bearing cover (4).
19) Put the round nuts (8) on the elastic
bolts (7). Tighten the round nuts with
your hand.
WCH02385 bearing shells.
94567B 21) Remove the two supports (94566).
94567
22) Put the bearing cover (4) that has the
dowel pin (5) on to position No. 3.
23) Install the tool (94557) on to the elastic
bolts (7) (refer to 9403−4).
94557
24) Tighten the round nuts (8) to the value
specified in 9403−4.
at (X).
Fig. 5

5. Completion
1) Refer to 0330−1 Clearance Table, Group 5552 for the axial clearances.
2) If the axial clearances are not in the specified range, loosen the round nuts on
one of the bearing covers (refer to paragraph 2, step 2)).
3) Put the bearing cover in position again, refer to paragraph 4, step 17) to step 19)
and step 22) to step 25).
4) Attach the filling piece (1, Fig. 3) to the bearing cover (5) with the two Allen
screws (9).
5) If the fuel pumps (1, Fig. 6) were not removed, do step a). If the fuel pumps were
removed, do step b).
a) Remove the holders (94566B and 94566C).
b) Install the fuel pumps, refer to paragraph 5.
6) Apply sealing compound to the sealing surfaces of the covers (3, 4 and 6).
7) Install the covers (3, 4, 5 and 6) to the housing (2).
8) Set to on the oil pump.
WARNING
9) Operate the turning gear to turn the engine.

10) Make sure that lubricating oil flows to all lubricating points and bearings.
6
2
WCH02236
Fig. 6
4

Fuel Pump Actuator

Connection to Fuel Pump
1. General
Maintenance of the connection between the fuel pump and the actuator is not
necessary.
1) Do a check of the connecting element (1, Fig. 1) as follows:
a) Make sure that the connecting element is lubricated with Molykote paste G.
b) Make sure that the connecting element can move freely.
WCH01192
Fig. 1

Fuel Pump Actuator: Connection to Fuel Pump
2. Actuator and Fuel Pump − Align

If there was an overhaul on the actuator, or the actuator was replaced do step 1) to
step 9):
1) Make sure that the actuator is electrically disconnected.
2) Make sure that the connecting element (1, Fig 2) is disconnected from the
lever (2).
3) Move the shaft (3) to get the indicator (5) to the 50% fuel position.
4) Remove the six screws (9), then remove the cover (10).
5) Move the toothed rack (6) to get a distance of 48 mm at each end.
6) Attach the cover (10) to the actuator (11) with the six screws (9).
7) Put the lever (2) in position on the shaft (3). Make sure that the center-line of the
lever aligns with the 50% fuel indication on the actuator (11).
8) Attach the lever (2) to the connecting element (1) with the screw (8) and the
self-locking nut (7).
9) Tighten the screw (4) on the shaft (3).
Note: For data about emergency operation with defective fuel actuators, refer to
the Operation Manual 0515−1.

Fuel Pump Actuator: Connection to Fuel Pump
48 mm
I I
WCH02410 5
11
I
48 mm
10 9 WCH02411
6
48 mm
Fig. 2

Intentionally blank
Servo Oil Rail

Exhaust Valve Control Unit: Removal, Disassemble,
Assemble, Installation
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8. Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. General
For more data, see the Operation Manual 8016−1.
2. Preparation
WARNING
1) Stop the engine, refer to 0310−1.

2) Release the pressure in the servo oil rail, refer the Operation Manual 0520−1
paragraph 2.3.
3) Remove the applicable hydraulic pipe, refer to 8460−1, paragraph 1 and
paragraph 2.

Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation
3. Removal
1 1) Make sure that the servo oil rail (1,
Fig. 1) has no pressure.
2) If the valve control unit (VCU) to be
removed is nearest the driving end of
the servo oil rail, do step a):
2 a) Remove the HP hose (3) from the
3 VCU (7).
9 4 from the 4/2-way solenoid valve (4).
4) Remove the return pipe (2) from the
VCU (7).
1 5) Remove the supply pipe (9) from the
6 VCU (7).
6) Remove the six screws (6) from the
7 VCU (7).
7) Carefully remove the VCU (7).
8) Put protection over the bore in the
holder (8) and the servo oil rail (1).
8
9) Install blanks to the ports on the
WCH02370 VCU (7).
Fig. 1
4. Disassemble
1) Remove the pan head screw (6, Fig. 2).
2) Remove the plug (7).
3) Remove and discard the O-ring (5) and
the back-up ring (4).
9 4) Make sure that the piston (8) moves
freely.
5) Remove the oil filter (1) and the screw
plug (2) from the valve control
block (9).
1 6) Make sure that the oil filter (1) is clean
8 and has no damage. If necessary,
2 replace the oil filter.
7 7) Make sure that the seal (3) has no
damage. If necessary, replace the seal.
3
6 WCH03673 5. Assemble
1) Apply oil to the thread of the oil
filter (1).
FLUSH
2) Put the oil filter (2) and the screw
plug (1) into the valve control block (9).
3) Torque the oil filter (1) to 225 Nm.
5
4) Put a new O-ring (5) and back-up
ring (4) on the plug (7).
4 5) Push the plug (7) into the valve control
Fig. 2
block (9).
6) Install the pan head screw (6).
7) Make sure that the plug (7) is flush with
the bottom of the valve control
block (9).

6. Installation
I
WARNING
Injury Hazard: You must put
1
2 on gloves and eye
protection when you use
white spirit. White spirit can
8 3 cause damage to the skin
and eyes.
1) If the VCU (1) is a new item, carefully
7 remove it from its package.
4 2) Use white spirit, e.g. Shellsol TD,
Shellsol T or Solvent FP68 to clean the
5 VCU.
3) Remove the blanks from the ports in
the VCU (5, Fig. 3).
4) Remove the protection from the
6
holder (6) and the servo oil rail (7).
WCH02370 5) Clean the seating surfaces of the VCU
(5) and the holder (6).
6) Make sure that the seating surfaces of
the holder (6) and the VCU (5) have no
damage.
I 7) Carefully put the VCU (5) in position on
the holder (6).
8) Apply oil to the threads of the six
screws (4).
9) Tighten with your hand the six
screws (4).
10) In the sequence given, torque the six
c a screws to 350 Nm.
11) Install the supply pipe (8) to the
VCU (5).
12) Install the return pipe (1) to the
f e VCU (5).
13) If the VCU (5) installed is nearest the
b d driving end of the servo oil rail (7), do
step a):
a) Install the HP hose (2) to the
VCU (5).
4/2-way solenoid valve (3).
Fig. 3
WCH03673
7. Completion
1) Install the hydraulic pipe, refer to
8460−1, paragraph 4 and paragraph 5.
2) Put the replaced VCU in its original
package.
3) Put the replaced VCU in an applicable
dry storage area. The storage area
must not be contaminated (e.g. with
exhaust gases or air that has
corrosion).

8. Relief Valve
Maintenance of the relief valve (1, Fig. 4) is not necessary.
The relief valve has 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 setpoint can be adjusted.
WCH02301
Symbol
B
Out B
In A A
Fig. 4

Servo Pump Unit

Servo Oil Pump − Removal and Installation
Tools:
2 Sling 94650
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Servo Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Pinions and Camshaft Gear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Servo Oil Pump − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Bearing Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Servo Oil Pump − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. General
Data about operation, maintenance and
servicing of the servo oil pumps are given in
the related documentation of the servo oil
pump manufacturer.
Do the related maintenance in 0380−1
Maintenance Schedule, Servo Oil Pump
and Servo Oil Pump Drive.
For more data, refer to the Operation
Manual 5551-1 Servo Oil Pump.
2. Checks
WCH02395
2.1 Servo Oil Pump

1
1) While the servo oil pumps (1 and 4,
2, 3 Fig. 1) operate, listen for unusual
noises. If you hear unusual noises, you
4 must find the cause and correct the
malfunction immediately.
2) Compare the temperatures of the two
servo oil pumps (1, 4). If there is a
temperature difference, you must find
the cause and correct the malfunction
immediately.
Note: The filter (3) is installed in the
pipe (2).
3) Each time the ship is in port, do a
check of the filter as follows:
a) Make sure that the servo oil
pumps do not operate.
b) Remove the pipe (2).
c) Do a check of the filter (3) for dirt
or particles.
Fig. 1
d) If necessary, clean the filter (3).
e) Install the pipe (2)

2.2 Pinions and Camshaft Gear Wheel

1) Remove the 20 screws (2, Fig. 2).
2) Remove the cover (1) from the supply unit casing (3).
1
2
3
WCH02395
Fig. 2
3) Do a check of the pinions (1, and 2 Fig. 3) and the camshaft gear wheel (3) for
wear and damage (refer to 0330−1, Clearance Table, Fuel and Servo Pump
Units).
4) If there is too much wear and / or damage, you must replace the pinions (1, 2)
and the camshaft gear wheel (3).
5) Attach the cover (1, Fig. 2) to the supply unit casing (3)with the 20 screws (2).
Fig. 3 WCH02634

3. Servo Oil Pump − Removal
3.1 Preparation
1) Stop the engine, refer to the Operation Manual 0310−1.
2) Set to off the main bearing oil pump.
3) Remove the HP servo oil pipes (12, Fig. 4) (refer to 8447-1).
4) Remove the two HP fuel pipes from the fuel pumps, refer to 8752−1 paragraph 1
and paragraph 2.
5) Disconnect the electrical connections (7).
4
12
11
3
5
7
WCH02395 10
1 8
Fig. 4
9
6) Remove the drain pipes (8, 10).

7) Remove the inlet pipes (5, 11).
Note: Step 8) is applicable only for the servo oil pump (6). The pipe (9) connects
the servo oil service pump (1) to the servo oil pump (6).
8) Remove the oil pipe (9) from the servo oil pump (6).

3.2 Removal
CAUTION
Injury Hazard: The weight of the servo oil pump is 116 kg. Make sure
that you use the correct equipment to lift and move the servo oil
pump. This will prevent injury to personnel.
1) Put the sling (94650, Fig. 5) around the servo oil pump (1) two times.
94650
2, 3
WCH02397 4
Fig. 5
2) Attach the sling (94650) to the engine room crane.

3) Operate the engine room crane and put sufficient tension on the sling (94650) to
hold the weight of the servo oil pump (1).
4) Remove the four nuts (2) and washers (3).
5) Remove the servo oil pump (1) and the O-ring (not shown).
6) Move the servo oil pump (1) to an applicable area.
7) Lower the servo oil pump (1) to the floor.
8) Remove the sling (94650) from the servo oil pump.
9) Do step 1) to step 8) above to remove the servo oil pump (4).
10) If it is necessary to remove the bearing bushes, refer to paragraph 3.3.

3.3 Bearing Bushes

CAUTION
of the pinion and shaft is
and move the pinion and
shaft. This will prevent
injury to personnel.
3 Note: You do this procedure only if it is
1 necessary to do a check of the
bearing bushes.
2 1) Remove the 20 screws (1, Fig. 6) from
the cover (3).
2) Remove the cover (3) from the
WCH02636
casing (2).
11 4) Move the pump support (10) a small
distance away from the casing (5).
10 4 5) Put the sling (94650) around the
9 shaft (11) two times.
6) Attach the sling (94650) to the engine
8 room crane.
7) Put sufficient tension on the sling
7 (94650) to hold the the shaft (11) and
pinion (4) in position.
5 8) Remove the pump support (10) and the
O−ring.
6
9) Carefully move the pinion (4) and
shaft (11), in the direction of the driving
end, approximately 30 mm out of the
casing (5).
10) Put one more sling (94650) around the
pinion (4) and shaft (11).
11) Attach the sling (94650) to the engine
WCH02393 room crane.
12) Make sure that the two slings (94650)
have equal tension.
13) Carefully tilt the pinion (4) and
shaft (11).
14 12 14) Carefully lift the pinion (4) and
shaft (11) fully out of the casing (5).
15) Lower the pinion (4) and shaft (11) to
an applicable area.
16) Examine the two bearing
13 WCH02637
bushes (12, 14) for wear and damage.
Fig. 6 17) If necessary, replace the bearing
bushes (12, 14).

18) Put oil on the two bearing bushes (12

1 and 14, Fig. 6) and the shaft (13) of the
3 pinion.
19) Use the engine room crane and the two
slings (94650) to lift the pinion (1,
Fig. 7) and shaft (5) into position above
the casing (2).
20) Carefully tilt the pinion (1) and shaft (5),
then lower the pinion and shaft into the
casing (2).
21) Put a small quantity of oil on the
O-ring (4).
22) Remove one of the two slings (94650)
from the pinion (1) and shaft (5).
WCH02639 23) Put the pump support (5) in position.
2
Make sure that the dowel pin (6) in the
pump support engages with the related
hole in the casing (2).
24) Torque the four M16 screws (7) to the
25) Remove the other sling (94650) from
4 5 the pinion (1) and shaft (5).
26) Do the procedures given in step 3) to
step 25) for the bearing bushes of the
other servo oil pump.
27) Attach the cover (3, Fig. 6) to the
WCH02638
casing (2) with the 20 screws (1).
WCH02393
Fig. 7

4. Servo Oil Pump − Installation

CAUTION
Injury Hazard: The weight of the servo oil pump is 116 kg. Make sure
that you use the correct equipment to lift and move the servo oil
pump. This will prevent injury to personnel.
1) Put a new O-ring (1, Fig. 8) in the pump support.

2) Apply a small quantity of oil to the the O-ring (1).
Fig. 8
WCH02393
3) Put the sling (94650, Fig 9) around the servo oil pump (1) two times.
4) Attach the sling (94650) to the engine room crane.
5) Use the engine room crane to put the servo oil pump (4) in position.
6) Attach the servo oil pump (4) to the casing with the four washers (3) and nuts(2).
94049A 94049A
2, 3
WCH02397 4
Fig. 9
7) Remove the sling (94650) from the servo oil pump (4).
8) Do step 1) to step 7) to install the servo oil pump (1).

5. Completion
1) Attach the oil inlet pipes (11, Fig. 10) to the servo oil pumps (4, 6).
4
12
11
6
2
7
10
8
WCH02395 9
1
Fig. 10
2) Attach the drain pipes (8, 10) to the servo oil pumps (4, 6).
3) Attach the oil pipe (9) to the servo oil pump (6).
4) Install the HP servo oil pipes (12) to the servo oil pumps (4, 6) (refer to 8447−1,
paragraph 5).
5) Attach the two rear HP fuel pipes (3) to the fuel pumps (2) (refer to 8752−1,
paragraph 4)
6) Connect the electrical connections (7).
7) Set to on the main bearing oil pump.
8) Set to on the servo oil service pump (1).
10) Set to off the servo oil service pump (1).

Work Card
Exhaust Valve Control Unit (VCU): Oil Filter Check
− Engine stopped Oil filter EX 56145 Qty 1
None Not applicable

Preparation
Do a check of the oil filter on the exhaust valve Ship Engineer 1.0 hours Qty 1
control unit
Related Data

Related Procedures
None

Intentionally blank
Work Card
Fuel Pump Actuator: Regulating Linkage Check
None Lubricating oil

Preparation
Make sure that the regulating linkage moves freely. Ship Engineer 0.5 hours Qty 1
Lubricate movable parts
Related Data

Related Procedures
Connection to fuel pump, 5583−1/A1

Intentionally blank
Maintenance Group6
Scavenge Air Receiver and Auxiliary Blower Group 6
Scavenge Air Receiver − Clean and do Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6420-1/A1
Work Cards
Scavenge Air Receiver: Clean the Flaps and Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC6420−1/A1
Auxiliary Blower − Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545-1/A1
Scavenge Air Cooler − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606-1/A1
Water Separator − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708-1/A1

Intentionally blank
Scavenge Air Receiver

Clean and do Checks
1. Scavenge Air Receiver − Clean and do Checks . . . . . . . . . . . . . . . . . . . . . . . 2
2. Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Relief Valve − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
III
II
I
V
II
II - II
IV
4
IV - IV
3
2
WCH03674
1
III IV
For View III − III, see Fig. 3

I
V
VI
WCH03674
For View VI, see Fig. 2 WCH03674
Fig. 1: Scavenge Air Receiver

Scavenge Air Receiver − Clean and do Checks
1. Scavenge Air Receiver − Clean and do Checks

Read the data in 0380−1, Scavenge Air Receiver for the applicable Inspection and
Overhaul Intervals to clean the scavenge air receiver. You must also clean and do a
check of the scavenge air receiver after each piston overhaul.
1) Open the covers (2 and 4, Fig. 1).
2) Lock the covers (2, 4) in the open position with the pins (1, 3) to prevent
unwanted movement.
3) Clean the scavenge air receiver.
4) Do the checks that follow:
Note: The level switches LS4071A and LS4075A (2, Fig. 2) monitor the water
level in the condensate collectors (3). For engines with two
turbochargers, there are two more level switches (LS4072A and LS4076A)
installed. For more data, refer to the Operation Manual 4003-4 Pipe
Diagram − Water Systems.
a) At regular intervals, look at the sight glasses (1) of the condensate collector (3)
to make sure that water flows.
b) If necessary clean the filters (6) and the drain pipes (4, 5). For more data, refer
to the Operation Manual 8345-1.
c) Do a check of the flaps (7) for damage, free movement and dirt. If necessary,
clean or replace the flaps (see paragraph 2).
VI
III - III
I 1
5 4 WCH02405
WCH03674
For View I, (flaps) see Fig. 3.
Fig. 2: Condensate Collectors

2. Flaps
2.1 Removal
1) Remove the three screws (7, Fig. 3) and the tab washers (4).
2) Remove the two flat bars (9, 10) and the stop plate (6).
3) Remove the screw (3) and the tab washer (4).
4) Remove the guide (2), spacer (8), flap (5) and axle (1).
2.2 Installation
1) Put the axle (1), spacer (8), guide (2) and flap (5) in position.
2) Put the the flat bar (9), stop plate (6), flat bar (10) new locking plates (4), and
screws (7) in position. Do not tighten the screws at this step.
3) Put the screw (3) and new locking plates (4) in position. Do not tighten the
screws at this step.
4) Make sure that the axle (1) and the flap (5) can move freely.
5) Tighten the screws (3, 7).
6) Bend the tab washers (4) to lock the screws (3, 7).
8
7, 4
I
7, 4 1
6
3
5
4
1
2
3, 4
WCH02406
6
10
Fig. 3: Flaps
7) Remove the pins (2, Fig. 1).
8) Close the covers (1).
9) Install the pin (2) in the stowage position.

3. Relief Valve − Check

WARNING
Injury Hazard! Do not disassemble the relief valve. Parts can eject at
high speed and cause injury. If there is damage or a malfunction,
speak to the manufacturer of the relief valve or to WinGD.
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) Do a check of the wire seal (3) and the lead seal (2). If the wire seal and lead
seal are broken, you must replace the relief valve.
I
1
WCH03674
WCH03674
II - II
1 1 2
II
WCH03674
II
Fig. 4: Relief Valve

Work Card
Scavenge Air Receiver: Clean Flaps and Check
Open the covers to get access to the flaps, refer to Applicable tools and equipment
6420-1/A1

Preparation
Do a check of the flaps. Clean the flaps. Ship Engineer 1.0 hours Qty 1
Related Data

Related Procedures
Clean and do Checks, 6420-1/A1

Intentionally blank
Auxiliary Blower
Maintenance
Tools:
2 Manual ratchets 1500 kg (H1, H2) 94016-017 1 Chain (asymmetric) 94019A
2 Spur gear chain block 2000 kg (H3, H4) 94017-021 1 Trolley 94021
4 Shackle 94018C 2 Sling 94650
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Procedure One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Procedure Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. General
Two auxiliary blowers (2, Fig. 1) are attached to the scavenge air receiver (1). For
more data about the auxiliary blower, see the Operation Manual 6545-1 Auxiliary
Blower and Switch Box.
There are two procedures to remove and install an electric motor:
D Procedure One: For engines with one turbocharger, refer to the procedure given
in paragraph 2.
D Procedure Two: One of the electric motors (4) is installed between the two
scavenge air receivers (3, 6). The procedure to remove and install this electric
motor is given in paragraph 3).
Note: Also use Procedure One to remove and install the outer electric motor (5)
on an engine with two turbochargers.
For data about the procedure to clean the impeller and to replace the ball bearing,
refer to the documentation of the auxiliary blower manufacturer.
6 4
2 1 5
WCH02413 WCH02413
Engine with One Turbocharger Engine with Two Turbochargers
Fig. 1

Auxiliary Blower: Maintenance
2. Procedure One
2.1 Preparation
Note: Read and obey the data given in
0012-1 General Guidelines for
Lifting Tools.
1) Stop the engine.
H2 2) Set to off the power supply.
6
94018C from the electric motor (5, Fig. 2).
4) Attach the shackles (94018C) and the
H1 manual ratchets (H1, H2) to the lifting
lugs (6).
I
5) Attach the trolley (94021) to the
beam (7).
5
WCH02412 shackle (94018C).
94650 4 3 2 1 7) Attach the chain block (H4) to the
trolley (94021).
2.2 Removal
I
1) Attach the slings (94650) to the electric
motor (5).
the slings (94650) as shown.
7 3) Put sufficient tension on the slings
94018C (94650) to hold the electric motor (5) in
H3 position.
94021
4) Remove the screws (4) from the
H4 support (3).
94018C casing (1).
H1, H2
94650
Fig. 2 WCH02412

CAUTION
Damage Hazard: Do not put
the electric motor on the
floor without an applicable
support or damage to the
impeller can occur.
6) Operate carefully the manual

4 ratchets (H1, H2, Fig. 3) to move the
electric motor (3) and impeller (2) out of
94018C the casing (1).
7) Lower the electric motor (3) and
H3 impeller (2) to almost the same height
as the platform.
H2
H1 8) Attach the chain block (H3) to the
lug (4).
9) Attach the chain block (H3) to the two
3 slings (94650).
10) Carefully release the tension on the
manual ratchets (H1, H2) until the
94650 2 1 electric motor (3) and impeller (2) are
WCH02412
below the chain block (H3).
12) Attach the chain block (H4) to the two
slings (94650).
chain block (H3) until the electric motor
(3) and impeller (2) are below the chain
block (H4).
14) Remove carefully the chain block (H3).
5 15) Move the electric motor (3) and
94021
impeller (2) out of the area.
H4
16) Put the electric motor (3) and
impeller (2) on an applicable surface.
17) Remove the two slings (94650) and
chain block (H4).
H3
94650 2 WCH02412
Fig. 3

2.3 Installation
1) Attach the two slings (94650, Fig. 4) to
the electric motor (3) and impeller (2).
trolley (94021).
5
94021 3) Attach the chain block (H4) to the
H4 slings (94650).
4) Lift the electric motor (3) and
impeller(2).
5) Move the electric motor (3) and
impeller (2) into position.
H3
1
3
94650 2 WCH02412
Fig. 4

the slings (94650).
7) Put sufficient tension on the chain
block (H3) to hold the electric motor (3)
and impeller (2).
4 slings (94560).
94018C 9) Attach the the manual ratchets (H1,

H2) to the slings (94560).
H3 Note: When you do step 10), make sure
that the electric motor (3) and
impeller (2) stay horizontal.
H1
H2 and the chain block (H3) to move the
electric motor (3) and impeller (2) into
3 the casing (1).
94650 2 1
WCH02412
Fig. 5

11) Install the screws (4, Fig. 6) to the

support (3).
12) Install the screws (2) to the casing (1).
13) Connect the electrical connections to
the electric motor (5).
the area.
94018C 15) Set the auxiliary blower to on.
16) Make sure that the impeller turns in the
H1 correct direction.
H2
5
WCH02412
94650 4 3 2 1
Fig. 6
3. Procedure Two
3.1 Preparation
1) Stop the engine.
2) Set to off the power supply.
from the electric motor (5, Fig. 8).
94018C
manual ratchets (H1, H2) to the
H1 lugs (6).
H2
3.2 Removal
manual ratchets (H1, H2) to the
lugs (6).
2) Attach the two slings (94650) to the
94650 5 4 3 2 1 electric motor (5).
WCH02412
3) Connect the manual ratchets (H1, H2)
Fig. 7 to the slings (94650) as shown.
4) Put sufficient tension on the slings
(94650) to hold the electric motor (5) in
position.
support (3).
casing (1).

CAUTION
Damage Hazard: Do not put
4 the electric motor on the
94018C floor without an applicable
support or damage to the
94019A impeller can occur.
H3 7) Put protection on the pipe (4,Fig. 8)

where the chain block (H3) and the
manual ratchets (H1, H2) can touch.
H1
8) Operate the manual ratchets (H1, H2),
H2 ) to carefully remove the electric motor
(3) and impeller (2) from the casing (1).
I
4 impeller (2) almost to the platform level.
chain (94019A) to the lugs (7).
WCH02412
11) Attach the chain block (H3) to the chain
94650 3 2 1 (94019A) and the slings (94650).
manual ratchets (H1, H2). At the same
I time increase the tension on the chain
block (H3). Continue until the the
electric motor (3) and impeller (2) are
below the chain block (H3).
13) Carefully move the electric motor (3)
94018C and impeller (2) under the pipe (4).
94019A 14) Remove the chain block (H3) from the

slings (94065).
H3
94018C 15) Move the electric motor (3) and the
impeller (2) away from the area.
H1, H2
4
impeller (2) on to an applicable surface.
3 and the slings (94560) from the electric
motor (3) and impeller (2).
3.3 Installation
1) Attach the manual ratchets (H1, H2)
and the slings (94560) to the electric
WCH02412 motor (3) and impeller (2).
Fig. 8
slings (94065).

Use the
3) Operate carefully the chain block (H3)

and the manual ratchets (H1, H2) to
move the electric motor (3, Fig. 10) and
impeller (2) under the pipe (4).
4) Continue to operate the chain block
94018C (H3) and the manual ratchets (H1, H2).
Make sure that the electric motor (3)
and impeller (2) are below the chain
94019A
block (H3).
H3
H1
H2
4
WCH02412
94650 3 2 1
Fig. 9
5) Carefully lift the electric motor (5,

Fig. 10) and impeller until they are in
position in the casing (1).
6) Install the screws (4) to the support (3).
7) Install the screws (2) to the casing (1).
8) Connect the electrical connections to
the electric motor (5).
94018C 9) Remove all tools and equipment from
H1 the area.
H2
10) Set the auxiliary blower to on.
11) Make sure that the impeller turns in the
correct direction.
94650 5 4 3 2 1
WCH02412
Fig. 10

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Scavenge Air Cooler

Tools:
1 Manual ratchet H3 (1600 kg) 94016-017 2 Safety lugs 94663C
2 Spur-gear chain block H1, H2 ( 2000kg) 94017-021 2 Safety chains 94663D
2 Trolleys (WLL 5000 kg) 94021 2 Double-chain sling 94666
6 Swivel lugs 94048−M30 1 Support 94663I
1 Support − left 94663A 2 Bracket 94664
1 Support − right 94663B 1 Dismantling pipe 94664A
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Removal Procedure − Front SAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Removal Procedure − Rear SAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Installation Procedure − Rear SAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Installation Procedure − Front SAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
I II
1. Preparation
1) Read the data in 0012−1 General
2) Stop the engine.
3) Stop the cooling water pump.
1 4) Close the butterfly valves (1 and 12,
12 Fig. 1) of each scavenge air cooler
(SAC) (5, 8).
11 2
5) Drain the water from each SAC (5, 8).
10 3 6) Remove the drain pipes (6 and 7).
9 4 7) Remove the vent pipes (2 and 11).
8) Remove the outlet pipes (4 and 9).
5
8 9) Remove the inlet pipes (3 and 10).
WCH02408
7 6 Note: For Views I−I and II−II, see Fig. 2.
I II
Fig. 1

Scavenge Air Cooler: Removal and Installation
I-I II - II
11
4
3 9
10
8
7
6
Fig. 2 WCH02408
WCH02408
2. Removal
2.1 Removal Procedure − Front SAC

Note: If the front SAC (3, Fig. 3) only is to be removed, do only paragraph 2.1.
If the rear SAC (2) only, or the two SAC are to be removed, you must first
remove the front SAC (3).
1) Attach the two trolleys (94021) to the rail (1).
2) Attach the two spur-geared chain blocks (H1, H2) to the trolleys (94021).
3) Install the dismantling pipe (94664A) to the attachment points on the rail (1) and
the platform.
Note: For View A and View I, see Fig. 4.
94021 1 94048−M30 94021 H2 94048−M30
A
H2
FRONT REAR
94016−009
I
94664A
WCH02409
3 2
Fig. 3 94663A/B

4) Remove the four holders (18, Fig. 4) from each end of the SAC (5).
5) Remove the flanges (16), O-rings (19) and the inserts (15). Discard the O−rings.
6) Attach the two safety lugs (94663C) to the SAC (5).
7) Attach the supports (94663A, 94663B) to the positions shown with the
screws (20).
8) Torque the screws (20) to 136 Nm.
9) Attach the two safety chains (94663D) to the supports (94663A, 94663B) and the
safety lugs (94663C). Make sure that the length of the safety chains is sufficient
for the full range of travel.
10) Attach three swivel lugs (94048−M30) to the front and rear of the SAC (5).
11) Torque the swivel lugs to the value given in 0352−1.
12) Attach the double-chain slings (94666) to the swivel lugs (94048−M30) on the
front and rear of the SAC (5).
15 16
A
17
94663A 94048−M30 18
19
94663C
20
23
II
94663B 18
WCH02409
94666
II
5
94663C
94663D
5
Fig. 4

13) Attach the manual ratchet (H3, Fig. 5) to the dismantling pipe (94664A) and to
the center swivel lug on the front of the SAC (5).
14) Attach the chain block (H1) to the double-chain sling (94666).
15) Apply a light tension to the chain block (H1).
WARNING
Injury Hazard: The SAC weighs 3400 kg. When you do the step
below, make sure that you do not move the SAC too far. This will
prevent injury to personnel.
16) Operate the manual ratchet (H3) until the rear of the SAC (5) is on the two
supports (94663A and 94663B).
94666 H2
H1
94664A
FRONT REAR
H3
WCH02409
Fig. 5
5 94663D
17) Attach the chain block (H2) to the double-chain sling (94666) on the rear of the
SAC (5).
19) Remove the two safety chains 94663D (see Fig. 6).
H1 13 H2
21
WCH02409
5
Fig. 6
21) Remove the dismantling pipe (94664A).
22) Carefully move the chain blocks (H1, H2) together with the SAC (5) along the rail
(13) until H1 touches the end stop (21).

23) Carefully operate the chain block (H1, Fig. 7) to lower the front of the SAC (5). At
the same time, carefully move the chain block (H2).
24) Continue with step 23) above until the SAC (5) is in a vertical position.
H1
H2
WCH02409
H1
H2
5
WCH02409
Fig. 7
25) Carefully operate the chain blocks (H1, H2) to lower the SAC (5) on to an
applicable surface.
26) Remove the spur-geared chain blocks (H1, H2) from the SAC (5).
27) Remove the swivel lugs (94048−M30) from the SAC (5).

2.2 Removal Procedure − Rear SAC

1) Remove the front SAC, refer to paragraph 2.1.
2) Remove the screws (17, Fig. 8), then remove the four holders(18) from the rear
SAC (12).
3) Remove the flanges (16), O-rings (19) and the inserts (15). Discard the O-rings.
4) Put the bracket (94664) in position between the two scavenge air receivers.
5) Torque the screws (22) to 136 Nm.
13 94048−M30 94048−M30
94664A
H3
I
WCH02409
12
I
22 94664
22
94664
18
16
16 15
12
17
22 18
19
WCH02409
94664
Fig. 8 18
6) Attach three swivel lugs (94048−M30) on both side of to the SAC (12).
7) Torque the swivel lugs to the value given in 0352−1.
8) Attach the dismantling pipe (94664A) to the attachment points on the rail (13) and
the platform.

9) Attach the manual ratchet (H3, Fig. 9) to the dismantling pipe (94664A).
10) Attach the manual ratchet (H3) to the dismantling pipe (94664A) and the center
swivel lug on the SAC (12).
94048−M30
H3
94666C
94664A
WCH02409
12
Fig. 9
11) Operate the manual ratchet (H3, Fig. 10). Move the SAC (12) until it is in the front
position.
12) Attach the two safety lugs (94663C) to the SAC (12).
H3
94663A WCH02409
94663D 12
94666
12
94663C
94663D
12
Fig. 10

13) Attach the two safety chains (94663D, Fig. 10) to the supports (94663A, 94663B)
and the safety lugs (94663C). Make sure that the length of the safety chains is
sufficient for the full range of travel.
14) Attach the double-chain slings (94666) to the swivel lugs (94666) on the front and
rear of the SAC (12).
15) Attach the front chain block (H1, Fig. 11) to the double-chain sling (94666).
H1 H2
94664A
H3
94666
WCH02409
12
Fig. 11
WARNING
Injury Hazard: The SAC weighs 3400 kg. When you do the step
below, make sure that you do not move the SAC too far. This will
17) Operate carefully the manual ratchet (H3) to move the SAC (12) until the rear of
the SAC is on the two supports (94663A, 94663B).
18) Attach the chain block (H2) to the double-chain sling (94666) on the rear of the
SAC (12).
19) Apply a light tension to the spur-geared chain block (H2).
20) Remove the two safety chains (94663D).
22) Remove the dismantling pipe 94664A.

23) Carefully move the chain blocks (H1 and H2, Fig. 12) together with the SAC (12)
along the rail (13) until the chain block (H1) touches the end stop (21).
H1 13 H2
21
WCH02409
12
Fig. 12
24) Carefully operate the chain block (H1, Fig. 13) to lower the front of the SAC (12).
At the same time, carefully move the chain block (H2).
25) Continue with step 24) above until the SAC (12) is in a vertical position.
H1 H2 13
WCH02409
WCH02409
12
Fig. 13
26) Carefully lower the SAC (12) on to an applicable surface.

27) Remove the chain blocks (H1, H2) from the SAC (12).
28) Remove the swivel lugs (94048−M30) from the SAC (12).

3. Installation
3.1 Installation Procedure − Rear SAC

1) Make sure that all surfaces of the SAC (12) and the related surfaces in the
scavenge air receiver are clean and have no damage.
2) Attach the support (94663I, Fig. 14) to the rear of the SAC housing.
H2 13
H1
94663I
REAR
12
WCH02409
Fig. 14
3) Attach the chain blocks (H1, H2 ) to the trolleys on the rail (13).
4) Attach the six swivel lugs (94048−M30) to the front and rear of the SAC (12).
5) Torque the six swivel lugs (94048−M30) to the value given in 0352−1.
6) Attach the chain blocks (H1, H2) to the SAC (12).
7) Put the SAC (12) in position.
8) Operate the chain block (H1) to lift the front of the SAC (12). At the same time,
move the chain block (H2) rearward (see Fig. 15).
13
H1
H2
12 WCH02409
Fig. 15

9) Continue with step 10) above until the SAC (12, Fig. 16) is in a horizontal
position. Make sure that the rear of the SAC is on the supports (94663A/B).
10) Attach the manual ratchet (H3) to the support (94663I) and the center rear swivel
lug on the SAC (12).
13 H2
94663I
H1
12
H3
WCH02409
94663A/B
Fig. 16
11) Operate the manual ratchet (H3) to apply a light tension to the wire rope.
12) Remove the chain block (H2) from the double-chain sling (94666).
13) Operate the manual ratchet (H3) to move the SAC (12) rearward. At the same
time, move the chain block (H1) rearward until the SAC is in the position shown
in Fig. 17.
H1
H3
WCH02409
94663B 12
Fig. 17
14) Remove the chain block (H1) from the double-chain sling on the SAC (12).

15) Continue to operate the manual ratchet (H3) until the wheel of the SAC (12, Fig.
18) is on the lip of the opening.
16) Open the inspection cover (20) to get access into the under−slung part.
17) Apply a layer of high−temperature silicon sealing compound (ABT.250) to each
side of the SAC (12) and the related surfaces in the housing in the scavenge air
receiver.
18) Apply a layer of high−temperature silicon sealing compound (ABT.250) to the
sealing surfaces of the SAC (12).
19) Close the inspection cover (19).
20) Operate the manual ratchet (H3) until the SAC is fully in.
21) Remove the wire rope from the manual ratchet (H3) and the rear double-chain
sling (94666).
94663I
H3
WCH02409
94664 12 18
18
15 16
17
19
18
20
Fig. 18

22) Remove the two double-chain slings from the SAC (12).
23) Remove the six swivel lugs from the SAC (12).
25) Remove the support (94663I).
26) Remove the bracket (94664).
27) Put the insert (15) in position on the SAC(12).
28) Put a new O−ring (19) in position on the flange (16).
29) Attach the holders (18) to the SAC 12 with the screws (17).
30) Torque the screws (17) to the value given in 0352−1.
3.2 Installation Procedure − Front SAC

1) Make sure that all the surfaces of the SAC (5, Fig. 19) and the related surfaces in
the scavenge air receiver are clean and have no damage.
2) Apply a layer of silicon compound to each side of the SAC (5) and the related
surfaces in the housing in the scavenge air receiver.
3) Apply a layer of silicon compound to the sealing surfaces of the SAC (5).
4) Attach the support (94663I) to the rear of the SAC housing.
94663I
WCH02409
13
H1
H2
WCH02409
Fig. 19

5) Attach the chain blocks (H1, H2) to the trolleys on the rail (13).
6) Attach the six swivel lugs to the front and rear of the SAC (5).
7) Attach the chain blocks (H1, H2) to the SAC (5).
8) Put the SAC (5) in position as shown.
9) Operate the chain block (H1, Fig. 20) to lift the front of the SAC (5). At the same
time, move the chain block (H2) rearward.
10) Continue with step 9) above until the SAC (5) is in a horizontal position. Make
sure that the rear of the SAC is on the supports (94663B).
13 H2 94663I
H1
FRONT REAR
WCH02409
94663B H3
Fig. 20
11) Attach the manual ratchet (H3) to the support (94663I) and the center rear swivel
lug on the SAC (5).
12) Apply a light tension to the manual ratchet (H3).
13) Remove the chain block (H2) from the double-chain sling (94666).
14) Operate the manual ratchet (H3, Fig. 21) to move the SAC (5) into the scavenge
air receiver. At the same time, move the chain block (H1) until the SAC is in the
position shown.
15) Remove the chain block (H1) from the double-chain sling on the SAC (5).
H1
WCH02409
94663B 5 H3
Fig. 21

16) Open the inspection cover (20, Fig. 22) to get access into the under−slung part.
17) Apply a layer of high−temperature silicon sealing compound (ABT.250) to each
side of the SAC (12) and the related surfaces in the housing in the scavenge air
receiver.
18) Apply a layer of high−temperature silicon sealing compound (ABT.250) to the
sealing surfaces of the SAC (12).
19) Close the inspection cover (19).
20) Continue to operate the manual ratchet (H3) until the the SAC (5) is fully in.
H3
WCH02409
94663A 5 94663I
94663B
18
18
15 16
17
19
18
20
Fig. 22

21) Remove the two double-chain slings (94666) from the SAC (5).
22) Remove the six swivel lugs (94048−M30) from the SAC (5).
24) Remove the tool (94663I).
25) Remove the supports (94663A and 94663B).
26) Remove the chain blocks (H1, H2) and the trolleys (94021).
27) Put the insert (15) in position on the SAC (5).
28) Put a new O-ring (19) in position on the flange (16).
29) Attach the holders (18) to the SAC (5) with the screws (17).
30) Torque the screws (17) to the value given in 0352−1.
4. Completion
1) Install the drain pipes (4 and 10, Fig. 23).
2) Install the vent pipes (7, 8).
3) Install the outlet pipes (6 and 9, Fig. 23).
4) Install the inlet pipes (3 and 11).
5) Open the butterfly valves (1 and 12, Fig. 1) of each SAC (5, 12).
6) Release the air in each SAC (5, 12).
7) Start the cooling water pump.
8) Make sure that there are no water leaks.
9) Make sure that no scavenge air flows between the SAC (5, 12) and the SAC
housings.
10) Stop the cooling water pump.

I II
1
I-I
2
5
12
FRONT REAR 3
6
12
WCH02408
I II
WCH02408
II - II
11
9
10
Fig. 23 WCH02408

Intentionally blank
Water Separator

Tools:
2 Manual ratchet, WLL 1600 kg H1/H2 94016−017 2 Shackle, WLL 3250 kg 94018A
2 Manual ratchet, WLL 3000 kg H3/H4 94016−031 3 Lifting tool 94667
1 Holder 94667H 1 Holder 94667G
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Front Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Rear Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rear Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Front Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Preparation
1) Read the data in 0012−1. General

Guidelines for Lifting Tools
2) Remove the front and rear cover from
the housing of the water separator (1,
see Fig. 1 and Fig. 2).
3) Install the tools (94667) to the front and
H1 rear of the water separator (1).
4) Install the holder (94667H) to the front
1 frame (5) as shown.
94667 5) Install the holder (94667G) to the rear
5 frame (6) as shown.
4 6) Remove the bottom plate (3) and the
H3 94667H beam (2).
holder (94667H) and the tool (94667).
holder (94667G) and the tool (94667).
shackle (94018A) on the gallery above
water separator.
2
WCH02415
3
94667
Fig. 1 94667G
H4
6
WCH02416
Fig. 2

Water Separators: Removal and Installation
1
2. Removal Procedure
2 2.1 Front Water Separator

H1
94667 to pull the water separator (4)
sufficiently so you can attach the
4 tool (94667) to the water separator.
2) Attach the tool (94667) to the top of the
water separator (4).
94667
H3 tool (94667).
3 4) Apply a light tension to the manual
94667H ratchet (H1).
the water separator (4) from the
receiver until you can get access to the
WCH02415 four screws (2, 3). At the same time,
operate the manual ratchet (H1) to hold
the mass of the water separator.
Fig. 3
6) Remove the the two top screws (2) and
the two bottom screws (3) between the
front and rear water separators.
the water separator (4) a small distance
to disconnect the water separator.
P3 P2 P1 8) Remove the manual ratchet (H3) and
the holder (94667H).
9) Remove the tool (94667) from the front
94018A
of the water separator (4).
H2
10) Attach the shackle (94018A, Fig. 4) to
H1 the gallery.
shackle (94018A).
2 lifting tool (94667) on the water
separator (1).
increase the tension. At the same time,
operate the manual ratchet (H2) to
WCH02415
decrease tension and keep the water
separator level.
the shackle (94018A) from the
Fig. 4
point (P1).

P3 P2 P1 15) Attach the manual ratchet (H1, Fig. 5)

and the shackle (94018A) to the
point (P3).
94018A 16) Attach the manual ratchet (H1) to the
H1 lifting tool (94667) of water separator.
operate the manual ratchet (H2) to
94667 decrease tension and keep the water
separator level.
2 lifting tool (94667).
19) Lower the water separator on to an
applicable surface.
WCH02415
the water separator.
21) Remove the tool (94667) from the
Fig. 5 water separator.
2.2 Rear Water Separator

front of the water separator (2).
2) Attach the holder (94667H) to the
housing on the receiver.
P2 P1 3) Attach the manual ratchet (H3) to the
holder (94667H) and the tool (94667).
4) Attach the shackle (94018A) to the
94018A point (P2).
H1 2
H2 5) Attach the manual ratchet (H2) to the
shackle (94018A) and the tool (94667).
6) Apply a light tension to the manual
ratchet (H2).
94667 the water separator (2) sufficiently so
H3 2 that you can attach the tool (94667). At
94667 H4
the same time, operate the manual
ratchet (H2) to hold the mass of the
94667H water separator.
94667
8) Attach the tool (94667) to the top of the
WCH02415
water separator.
94667G 9) Apply a light tension to the manual
ratchet (H1).
Fig. 6 10) Operate the manual ratchet (H3) to pull
the water separator fully from the
receiver. Keep the tension on the
manual ratchets (H1, H2) to hold the
mass of the water separator (2).
11) Remove the holder (94667H) and the
12) Remove the tool (94667) from the front
of the water separator (2)

P2 P1 13) Attach the manual ratchet (H2, Fig. 7)

to the tool (94667) on the water
separator (2).
H2 1 14) Remove the manual ratchet (H4) from
H1 the rear of the water separator (2).
94667
2
WCH02415
Fig. 7
P3 P2 P1 15) Attach the shackle (94018A, Fig. 8) to

the gallery.
94018A 16) Attach the manual ratchet (H2) to the
H2 shackle (94018A).
H1 lifting tool (94667) on the water
separator (2).
2 operate the manual ratchet (H2) to
decrease tension and keep the water
separator level (2).
the shackle (94018A) from the
WCH02415 point (P1).
Fig. 8 20) Attach the manual ratchet (H1) and the

shackle (94018A) to the point (P3).
P3 P2 P1 21) Attach the manual ratchet (H1) to the

lifting tool 94667 of water separator (2).
94018A to increase the tension. At the same
H1 time, operate the manual ratchet (H2)
to decrease tension and keep the water
separator level (2).
94667 lifting tool (94667).
24) Lower the water separator (2) on to an
applicable surface.
2
the water separator (2).
26) Remove the tool (94667) from the
Fig. 9
WCH02415

P2 P1
3. Installation
94018A
H2 1 3.1 Rear Water Separator
H1
1) Attach the tools (94667, Fig. 10) to the
applicable positions on the water
separator (2).
3 94667 Note: When you do step 2), make sure
94667G
94667 that the lugs (3) are at the front.
2
2) Use the manual ratchets and shackles
94667 used before to get the water separator
H4 (2) to the position shown.
WCH02415
3) Connect the manual ratchet (H4) to the
tool (94667) on the rear of the water
separator (2).
P2 P1 4) Operate the manual ratchet (H4) to
move the water separator (2) into the
94018A receiver (1) a small distance.
H2 1 Note: When you do step 5) keep the
H1 tension on the manual ratchet (H2)
to hold the mass of the water
separator (2).
the tool (94667) from the top of the
94667 94667G
94667 move the water separator (2) almost
H4 fully into the receiver (1). At the same
WCH02415 time, operate the manual ratchet (H2)
2 to hold the mass of the water separator.
Fig. 10
the tool (94667) from the front of the
P2 P1
3.2 Front Water Separator
1) In paragraph 3.1, do step 1) to step 7),
1 then continue with step 2) below.
H1
2) Align the the front and rear water
separators (2 and 4, Fig. 11).
3) Attach the water separators (2, 4)
together with the two top screws (5)
5 and the two bottom screws (3).
94667G 4) Remove the manual ratchet (H1) and
94667 the tool (94667) from the top of the
H4 the water separators (2, 3) fully into the
WCH02415
3 2 receiver (1).
Fig. 11

6) Remove the manual ratchets (H1, H2,

H3 and H4, Fig. 12).
P2 P1
7) Remove the holder (94667G).
8) Remove the tool (94667) from the rear
94018A water separator.
1
H2 9) Remove the shackles from the points
(P1, P2).
94667G
H4
WCH02415
94667
Fig. 12
10) Install the cover (1, Fig. 13) to the

receiver.
11) Install the bottom plate (2).
12) Install the beam (2).
13) Install the cover (4) to the receiver.
the work area.
1
2
3
Fig. 13

Maintenance Group7
Cylinder Lubrication and Balancer Group 7
Cylinder Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7218−1/A1
Work Cards
Cylinder Lubrication Pump: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC7218−1/A1
Integrated Electric Balancer (iELBA)

Bearing Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7758−1/A1
Replacement of Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7762−1/A1

Intentionally blank
Cylinder Lubrication System

1. Cylinder Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Cylinder Lubricating System − Operate . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Cylinder Lubrication Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Cylinder Lubricating System − Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Cylinder Lubrication Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Oil Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Duplex Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Clogged Filter Element − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Filter Element − Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Cylinder Lubricating 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, refer to the Operation Manual, 4002−2, paragraph 3.2 and paragraph
3.21.
1) In the LDU-20, get the MAIN page.
2) In the navigation menu, select Cylinder Lubrication.
3) In the CYL. LUBRICATION page, field Manual lub. to Cyl. #, select the applicable
cylinder number.
4) If necessary, change the number of lube pulses (in the range 0 to 200) in the field
# of Manual Lub. Pulses.
Note: You can operate the 4/2-way solenoid valve (4, Fig. 1) to release manually
one lube pulse.

Cylinder Lubricating System
Note: Some parts

DRIVING END can look different.
I 1
I
2 3 4
019.002/09
5 6
10 9 8 7
WCH02282
Fig. 1: Cylinder Lubrication Pump − Location

1.2 Function Check

WARNING
1) If necessary, bleed the cylinder lubricating system (refer to paragraph 3).

2) Make sure that the applicable piston is in the TDC position. If the piston is not in
the TDC position, do step a) to step c):
a) Engage the turning gear.
b) Operate the turning gear to move the applicable piston to the TDC position.
c) Disengage the turning gear.
3) Set to on the cylinder lubricating system for the related cylinder (refer to
paragraph 1.1).
Note: During usual operation, the ECS controls the cylinder lubrication.
4) Operate manually one lube pulse from the cylinder lubrication system:
a) Use a pin or a screwdriver (6, Fig. 1) to push in the plunger (5) of the 4/2-way
valve (4).
5) Look through the scavenge air ports in the cylinder liner while the lubricating
system operates.
6) Make sure that the lubricating oil flows on to the cylinder liner wall (refer to the
Operation Manual 7218-1, paragraph 8.2 and paragraph 8.3).
7) Make sure that the oil that flows has no air. If necessary, bleed the cylinder
lubricating pump (2) and the oil pipes (10) (refer to paragraph 3).
8) Set to off the cylinder lubricating system for the related cylinder.
2. Cylinder Lubrication Pump

For data about the cylinder lubricating pump (2), refer to the Operation Manual
7218-1, paragraph 5.
2.1 Checks
1) Examine the cylinder lubricating pump (2) for damage and leaks.
2) Do a function check of the cylinder lubricating system (refer to paragraph 1.2).

3. Cylinder Lubricating System − Bleed

Bleed the cylinder lubrication pump and oil pipes each time you do maintenance on
the cylinder lubricating system.
3.1 Cylinder Lubrication Pump

To bleed the cylinder lubrication pump (2, 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 (2).
1) Make sure that the cylinder lubrication pump (2) is set to off.
2) Loosen the vent screw (3).
3) Keep the vent screw (3) open until oil that flows has no air.
4) Tighten the vent screw (3).
5) Clean the external surface of the cylinder lubrication pump (2).
6) If necessary, bleed the oil pipes (10), (refer to paragraph 3.2).
7) Do a function check of the cylinder lubricating system, (refer to paragraph 1.2).
3.2 Oil Pipes

To bleed the oil pipes (10), do the steps that follow:
1) Set to on the cylinder lubricating system, (refer to paragraph 1.1).
2) Use an open-ended spanner to hold the screw-in union (9) in position.
3) Loosen the nut (8) of the screw-in union (9) a maximum of two turns.
4) Keep the nut (8) of the screw-in union (9) open until oil that flows has no air.
5) Tighten the nut (8) of the screw-in union (9).
6) Clean the external surface (7) of the lubricating quill.
7) If necessary, bleed the cylinder lubrication pump (2) (refer to paragraph 3.1).
8) Do a function check of the cylinder lubricating system (refer to paragraph 1.2).

4. Duplex Filter
For data about the duplex filter (1, Fig. 2), see the Operation Manual 7218-1.
4.1 Clogged Filter Element − Replace

1) Close the ball valve (2).
2) Remove the cover from the rail unit.
3) Move the lever (3) to select the clean filter element.
4) Remove the three nuts (6) on the applicable filter chamber (5), then remove the
cover (4).
5) Replace the clogged filter element.
Note: As an alternative, you can clean the clogged filter element (refer to
paragraph 4.2).
6) Attach the cover (4) to the filter chamber (5) with the three nuts (6).
7) Clean the external surface of the duplex filter (1).
8) Install the cover you removed before to the rail unit.
9) Open the ball valve (2).
4.2 Filter Element − Clean

For data about the procedure to clean the filter element, refer to the documentation of
the filter element manufacturer.

Note: Some parts

can look different.
FREE END
WCH02359
FUEL SIDE
2 3
WCH03679
6 4
Fig. 2: Duplex Filter

Work Card
Cylinder Lubrication Pump: Replace
− Engine stopped Cylinder lubricating pump EX 72060 Qty 1

− No pressure in the cylinder lubrication system
Remove the pipes from the applicable pump. Applicable tools

Preparation
Replace the lubricating pump with new item, or a Ship Engineer 2.0 hours Qty 1
pump that had a overhaul in a WinGD workshop.
Refer to the supplier documentation.
Related Data

Related Procedures
Bleed the cylinder lubrication system, 7218−1/A1

Operate the cylinder lubricating system, refer to the
Operation Manual 4002−2, paragraph 3.2 and
paragraph 3.21.

Intentionally blank
Integrated Electric Balancer, Bearing Replacement and

Adjustment
Tools:
1 Adjusting tool 94701 1 Lifting tool 94704
1 Transportation tool 94702 2 Alignment tools 94705
1 Turning device 94703 Magnetic drill
Reamer for taper pin
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Counterweights − Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Top Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Bottom Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Bearings − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Bearing − Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Bearing − Outer Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Backlash − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Bearings − Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. General
The Integrated Electric Balancer (iELBA) can be installed as follows:
D One ELBA installed at the driving end, or
D One ELBA installed at the free end, or
D Two ELBA installed (one at the driving end and one at the free end).
It is only necessary to replace the bearings. You must always replace the bearings as
a pair.
For the first bearing replacement, speak to or send a message to WinGD to get data
from approved personnel.
For more data about the Integrated Electric Balancer, refer to the Operation Manual,
chapter 7752−1.
For the maintenance schedule, refer to 0380−1.
For the clearances, refer to the Clearance Table 0330−1, Group 7758.
DRIVING END FREE END 1 I-I

8 3
2
4 I
3 6
7
1
5 1
4
WCH03680
I 1
Fig. 1
Fig. 1: Location of ELBA
1 Bearing cover 5 Bearing
2 Electric motor 6 Bearing pin
3 Bottom gear wheel 7 Bottom counterweight
4 Top counterweight 8 Top gear wheel

DRIVING END
2. Preparation
1) Stop the engine, refer to Operation
Manual, 0310−1.
2) Make sure that the electric motor (2,
Fig. 1) has stopped.
1
3) Stop the lubricating oil supply and close
the oil inlet.
4) At driving end, put an oil tray under
applicable oil pipe (1, Fig.2).
5) Remove the applicable oil pipes (1) to
WCH03680 get access to the balancer shafts.
Fig. 2
3. Counterweights − Lock
3.1 Top Counterweight

1) Apply lubricating oil to the thread and
bottom of the head of the clamping
screw (4, Fig. 3) and the nut (6).
2) Remove the two screws (2) from the
main cover (1).
1
3) Put the two clamping screws (4) and
the nuts (6) in position on the upper
counterweight (10).
I
4) Torque the clamping screws (4) to
60 Nm.
2
5) Torque the nut (6) to 60 Nm.
6) Put the the M12 bolt (5) in position
through the clamping screw (4).
I-I
7) Torque the M12 bolt (5) to 60 Nm.
3
3.2 Bottom Counterweight
I
WCH03465 4 bottom of the clamping screw (7) and
5
the nut (9).
6 2) Remove the two screws (3) from the
Fig. 3 cover (1).
10 3) Put the two clamping screws (7) and

the nuts (9) in position on the lower
counterweight (11).
4) Torque the clamping screws (7) to
11 60 Nm.
5) Torque the nut (9) to 60 Nm.
7 6) Put the M12 bolt (8) in position through
8
the clamping screw (7).
9 7) Torque the M12 bolt (8) to 60 Nm.

I I-I
4. Bearings − Replace
ENGINE OUTER
SIDE SIDE CAUTION
of the bearing is 70 kg. Use
II and move the bearing. This
personnel and damage to
equipment.
CAUTION
Damage Hazard: To prevent
damage to equipment, do
I WCH03465
not remove two bearings at
the same time.
WCH03085 Note: On the outer side, use the crane

and an applicable manual ratchet
II to lift and move the bearing.
5
Note: On the engine side, use an
2 applicable manual ratchet and an
eye bolt to lift and move the
4 1 bearing.
III
4.1 Bearing − Engine Side
3
2 4.1.1 Removal
1) Attach an eye bolt to the applicable
position in the gallery above the the
bearing (5, Fig. 4). Attach an applicable
manual ratchet to the eye bolt.
bottom of the head of the special screw
(8, part of tool 94702).
3) Put the special screw (8) through the
OUTER SIDE
bearing cover (9) on the outer side.

EB
4) Torque the special screw (8) to
III 150 Nm.
2 6
5 5) Remove the four screws (3) and the
3 7 locking plates (7) on the bearing cover
ENGINE SIDE
at the engine side.

8
6) Remove the bearing cover (4).
7) Remove the eight screws (2) and the
9 locking plates (6) from the bearing (5).
Fig. 4


94704
manual ratchet. Move the lifting tool in
front of the bearing (6, Fig. 5).
2
5 II 9) Tighten the screw (4) with your hand.
I 6 7
4 10) Turn the nut (5) against the bearing (6)
to push the lifting tool (94704) against
II the pin (3).
11) Put two M20 x 140 mm bolts into the
8 two threads (7) in the bearing (6).
8 12) Tighten equally the two M20 x 140 mm
7 bolts to push out the bearing (6).
III Note: The bearing (6) will move on to the

lifting tool (94704), see Step A.
8
13) Tighten the screw (2) to hold the
bearing (6).
I 14) Loosen the nut (5). Operate the manual
ratchet to hold the weight of the
bearing (6), see Step B.
1
ENGINE SIDE
III 15) Carefully remove the screw (4).
2 16) Operate the manual ratchet to move

the bearing (6) to an applicable area.
OUTER SIDE
4 17) Remove the two taper pins (8).

18) Lower the bearing (6).
5 19) Remove the lifting tool (94704).
94704 3 20) Remove the two bolts (7).
6
Step A Step B
M20 5
Fig. 5

94704
4.1.2 Installation
2 1) Make sure that the new bearing is
5 clean, dry and in good condition. Apply
4 Molykote D to the bearing surface.
Note: Do not install the two taper pins (8,
Fig. 5).
6
bearing (6, Fig. 6).
3) Attach the manual ratchet to the lifting
tool (94704).
5) Operate the manual ratchet to move
the bearing (6) in front of the pin (3).
94704
LOCTITE 6) Apply Loctite No. 640 to the surface of
2 the bearing (6).
MOLYKOTE D
ENGINE SIDE
7) Apply Molykote D to the surface of the

pin(3).
OUTER SIDE
8) Install the screw (4) together with the

nut (5) through the bearing (6) into the
4 pin (3).
5 9) Remove the screw (2).
10) Align the taper pin bores with the
3 1
column (1).
Fig. 6
11) Turn the bearing (6) until the pin bores
in the bearing are at 90° to the bores in
the column (1).
12) Tighten the nut (5) and move the
bearing (6) into the correct position on
the column (1).
Note: Operate the manual ratchet if the
pin (3) is too low.
5
2
ENGINE SIDE
OUTER SIDE
14) Put four (of the eight) bolts M20x70 (2,

Fig. 7) in position. Do not tighten the
four bolts at this step.
15) Adjust the backlash and the parallelism
of the gear wheels, refer to
paragraph 5.2.
2
WCH03465
Fig. 7

I I-I
4.2 Bearing − Outer Side
ENGINE OUTER
SIDE SIDE 4.2.1 Removal
1) Remove the four screws (3, Fig. 8)
from the bearing cover (4) at the outer
side.
II
3) Remove the eight screws (2) from the
bearing (5).
4) Attach the lifting tool 94704 to the
crane and move it in front of the
bearing (6) (STEP A).
I WCH03465
5) Turn the screw (4) into the pin (3) and
tighten slightly.
6) Tighten the nut (5) to push the lifting
WCH03085
II tool 94704 against the pin (3).
5 7) Put two M20 x 140 mm screws into the

2 two threads (7, view III) in bearing (6).
4 6 III 8) Tighten equally the two M20 screws to

III 7 push out the bearing (6).
D The bearing (6) will move on to the lifting
3 tool 94704 (STEP 2).
8 9) Tighten screw (2) to hold the bearing
8 (6).
7 10) Operate the crane to hold the weight of
the bearing (6).
11) Carefully remove screw (4) and put the
bearing in an applicable area.
STEP A STEP B 12) Remove the two taper pins (8).
13) Remove the lifting tool 94704.
OUTER SIDE
14) Remove the two bolts (7).

ENGINE SIDE
5 2
7
4
3
4
6
6
Fig. 8

94704
4.2.2 Installation
2 1) Make sure that the bearing (6, Fig. 9) is
8 5 clean, dry and in good condition. Apply
Molykote D to the surface of the
8 bearing.
4
Note: Do not install the two taper
6 pins (8).
STEP A STEP B
bearing (6).
1 3) Attach the crane to the tool (94704).
OUTER SIDE
ENGINE SIDE

MOLYKOTE D 5) Operate the crane to move the bearing
94704 (6) in front of the pin (3).
2 6) Apply Loctite No. 640 to the surface of

the bearing (6).
5
4 7) Apply Molykote D to the surface of the
pin(3).
3 4 8) Install the screw (4) together with the
3
5 nut (5) through the bearing (6) into the
6 pin (3).
9) Remove screw (2).
LOCTITE 10) Align the taper pin bores with the
cover (1).
Fig. 9
11) Turn the bearing (6) until the pin bores
in the bearing are at 90° to the bores in
the column (1).
12) Tighten the nut (5) and move the
bearing (6) in the correct position on
the column (1) (STEP B).
Note: Operate the crane if the pin (3) is
too low.
13) Remove lifting tool (94704).
14) Install four (of the eight) bolts M20x70

OUTER SIDE
ENGINE SIDE
(2, Fig. 10) in position. Do not tighten

the four bolts at this step.
15) Adjust the backlash and the parallelism
of the gear wheels, refer to
paragraph 5.2.
2
Fig. 10 WCH03465

3 2 5. Check
1 7
ENGINE SIDE
OUTER SIDE
4 6 5.1 Bearing Clearance
I Note: For the first bearing replacement,
speak to or send a message to
WinGD to get data from approved
5 personnel.
1) On the engine side, remove the four
screws (5, Fig. 11) and the locking
9 I plates from the bearing cover (4).
3) On the outer side, remove the four
screws (7) from the bearing cover (6).
1 4) Remove the bearing cover (6).
2 5) Use a feeler gauge to measure the
clearance between the pin (1), the
bearings (2, 3) at the top position (9).
6) Compare clearance with the data given
in 0330−1, Group 7758.
Fig. 11
7) If the clearance is more than the
permitted maximum, replace the
bearing.
5.2 Backlash − Measure

1) Remove the eight screws (4, Fig. 12)
5 and the cover (5).
8 2) Make sure the screws (4, Fig. 3) are
4 removed.
Note: You can get access to the service
7 hole (8, Fig. 12) in the engine.
Fig. 12 6 WCH03465
3) Measure the backlash between the
motor pinion and the bottom gear
wheel.
4) Remove the four screws (7) on the
bottom bearing cover (6) at the outer
side.
5) Attach the device (94703) as follows:
a) Install the socket insert (5, Fig 13)
with the screw (6) on the pin (4) of
94703 the bottom bearing.
6
b) Torque the screw (6) to 100 Nm.
Fig. 13 5

LEAD WIRE CAUTION

1 Injury Hazard: Do not put
your hands between the
gears that move. This can
2 Note: You can get access to the pinion

and bottom gear wheel (1, Fig. 14)
through a hole at the inner area
behind the column.
94703 Note: When you do step 6), use pliers to
attach the lead wire.
6) Attach lead wire of Pb99.9 fine and a
diameter of 1.00 mm between the
electric motor pinion (2) and the bottom
gear wheel (1).
7) Refer to 0330−1 Group 7758 to get
Fig. 14 backlash data.
8) Operate the device (94703) to turn the
gears. The lead wire moves between
the electric motor pinion (2) and the
bottom gear wheel (1).
9) Measure the backlash.
10) If the backlash of the bottom gear
wheel (1) and the electric motor pinion
(2) is in the permitted tolerance, do as
follows:
a) Loosen the bearings of the top
gear wheel.

4 5.3 Bearings − Adjust

1 Note: Before you do this task for the first
time, speak to, or send a message
to an applicable Service Partner
(e.g. WinGD) to get data.
3 1) Loosen all bearings.
2) Remove the taper pins from all
2 bearings.
3) Lift the top bearing.
5 4) Lift the bottom bearings until the

backlash between the pinion and the
bottom gear wheel is in the permitted
tolerance.
Fig. 15
5) Lower the bottom bearing until the
backlash in the permitted tolerance.
6) Turn the bearings 90° .
7) Use a drill to make new holes for the
taper pins.
8) Measure the backlash.
9) If the backlash of the bottom gear
wheel (2, Fig. 15) and the electric
motor pinion (3) is in the permitted
tolerance, do as follows:
a) Loosen the bearings of the top
gear wheel.
11 4
10 6
10) Make sure all the screws (6, 10, 7, and

8, Fig. 16) are loose or removed. One
screw for each bearing must stay in
position to hold the bearing.
9 5 11) If you have installed new bearings (4,
8 7 11, 5, 9) turn the bearings 90° .
12) Use a drill to make new holes for the
taper pins after the adjustment
procedure.
Fig. 16 WCH03469

1 13) Apply oil to the eight screws (5,

16 2 Fig. 17).
15 17 3
14) Attach the four alignment tools (94705)
I I 4 with the eight screws (5) (two tools for
94705 the front and rear each bearing).
15) Torque the eight screws (5) to 490 Nm.
5
4 16) Turn the two screws (14) to lift the front
and rear top bearings (15, 16), which
removes the load from the bottom gear
14 wheel (9).
13 6 17) Adjust the backlash between the
12 electric motor pinion (6) and the bottom
gear wheel (9).
11
10 18) Measure the backlash, refer to
7 paragraph 5.2.
7 Note: During step 19) and step 20), make
9
sure that the top and bottom
5 bearings are parallel.
8 19) Adjust the bottom bearings (10, 11) as

follows:
WCH03468 a) Turn the two screws (8) to adjust
the height of the bottom bearings.
94705
b) Turn the four screws (7) to adjust
the horizontal position of the
bottom bearings.
I-I
20) Adjust the top bearings (15, 16) as
18 follows:
a) Turn the two screws (14) to adjust
the height of the top bearings.
17 b) Turn the four screws (4) to adjust

the horizontal position of the top
bearings.
21) Make sure that the adjusted bearings
are turned 90° .
22) Measure the backlash again, refer to
paragraph 5.2.
23) Use a magnetic drill and a reamer to
make holes of depth 21 mm in the
WCH03469
covers (18) for the 25x70 mm taper
Fig. 17 pins (two holes for each of the four
covers).
24) Put two taper pins (17) for each bearing
in the new holes.

6
6. Completion
1
1) Attach the eight M20x70 bolts (1,
Fig. 18) to the outer side of each
bearing.
ENGINE SIDE
OUTER SIDE
I 2) Torque the eight M20x70 bolts (1) to
the value given in 0352−2,
paragraph 1.
2
5 3) Apply Loctite No. 640 to the surfaces
2 3 that touch on the bearing cover (3).
4) Attach the bearing cover (3) to the
4
WCH03465 bearing with the four M16x35
screws (3).
LOCTITE No. 640
5) Torque the four M16x35 (3) to the value
I given in 0352−2, paragraph 1.
6 7
6) Attach the locking plates (7) to the
engine side of each bearing with the
2 8 eight M20x70 bolts (6).
5 7) Torque the eight M20x70 bolts (6) to
paragraph 1.
8) Remove the four alignment tools
94705.
Fig. 18
9) Apply Loctite No. 640 to the surfaces
that touch on the bearing cover (2).
10) Attach the bearing cover (5) to the
bearing on the engine side with the four
M16x35 screws (2).
11) Torque the four M16x35 screws (2) to
paragraph 1.
12) Install the oil pipes (1, Fig.2) that you
removed before.
13) Open the oil inlet.
14) Set to on the lubricating oil supply.

Intentionally blank
Electric Balancer Sensor Unit
Proximity Sensor − Replacement
1. General
I 1
One proximity sensor is installed on each
end of the engine. The proximity sensors
give the position and speed of the balance
weights (3, Fig. 1).
The proximity sensors are installed in the
I
positions that follow:
D ZS5401C on the Driving End
D ZS5405C on the Free End
The proximity sensors are connected to the
3 terminal box (1).
Two more proximity sensors (ZS5141C and
ZS5142C) for engine speed and crank
position are installed above the flywheel (2)
near the crank angle sensors (view II).
II
WCH03567
I-I
1 II
ZS5401C
DRIVING END
ZS5405C
FREE END
2 ZS5142C
Fig. 1 ZS5141C
WCH03463

Electric Balancer Sensor Unit: Replacement of Proximity Sensor
I-I 2. Procedures
2.1 Balance Weights Proximity

Sensors − Replace
3
from the applicable proximity sensor
(ZS5401C or ZS5405C, Fig. 2).
1 2) Loosen the nut (2).
ZS5401C
DRIVING END 3) Remove the applicable proximity
sensor (ZS5401C or ZS5405C).
2 4) Attach the new sensor fully into the

sensor adapter (1).
ZS5405C 5) Tighten the lock nut (2).
FREE END 6) Connect the electrical connection the
1 proximity sensor.
7) Do a check of the Alarm System in the
Fig. 2 WCH03462 LDU for Signal Failure (refer also to the
Operation Manual, Chapter 4002−2).
Note: Some designs do not have a
connection to the Alarm System.
These designs have a control box
(Lenze Drive), which shows a
signal failure. This control box is
installed in the control cabinet.
2.2 Flywheel Proximity Sensors

− Replace
Note: Refer to Fig. 1, view II for the
ZS5141C
location of the proximity sensors.
from the applicable proximity sensor
ZS5142C (ZS5141C or ZS5142C, Fig. 3).
2) Measure the distance (Y). Use this
distance when you install the new
4 proximity sensor.
1
3) On the applicable proximity sensor,
2 loosen the nut and lock nut (1).
4) Remove the applicable proximity
sensor.
Y
4 mm
5) Put the new proximity sensor in the

3 holder (2) to the measured
distance (Y).
WCH03462 Note: If the proximity sensor (ZS5141C)
Fig. 3 is directly above the crank angle
mark, do step 6) and step 7, then
continue from step 8).

Electric Balancer Sensor Unit: Replacement of Proximity Sensor
6) Put the new proximity sensor (ZS5141C) in the holder (2, Fig. 3) until the sensor
touches the crank angle mark (3).
7) Turn the proximity sensor (ZS5141C) back four turns (4mm).
8) Tighten the nut and lock nut (1).
9) Connect the electrical connection to the applicable proximity sensor.
10) Do a check of the Alarm System in the LDU for Signal Failure (refer also to the
Operation Manual, Chapter 4002−2).

Intentionally blank
Maintenance Group8
Piping Group 8
Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8135−1/A1

HP Servo Oil Pipe: Removal, Grind the Sealing Faces and Installation . . . . . . . . . . . . . . . . . . . . . . 8447−1/A1
Hydraulic Pipe − Exhaust Valve Drive: Removal, Grind the Sealing Faces and Installation . . . . 8460−1/A1
HP Fuel Pipe (Injection Valve): Removal, Grind the Sealing Faces and Installation . . . . . . . . . . . 8733−1/A1
HP Fuel Pipe: Removal, Grind the Sealing Faces and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8752−1/A1
HP Fuel Pipe − Pilot Fuel Pipe: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8790−1/A1
Work Cards
Gas Supply Pipe: Shut-off and Vent Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC8903−1/A1

Intentionally blank
Exhaust Waste Gate (Low-load Tuning)
1. General
The Low-load Tuning (LLT) uses a specially designed turbocharger system and
specified engine parameters. These parameters are related to fuel injection and
exhaust valve control and get the 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 (3, Fig. 1) is not necessary. For a general
inspection, refer to the instructions in the documentation of the manufacturer.
To do a function check, refer to 8135−1 in the Operation Manual and the Maintenance
Schedule 0380−1, Exhaust Waste Gate (LLT).
3
4
WCH02239
Note: Some parts

can look different.
Fig. 1: Exhaust Waste Gate
1 Exhaust manifold 5 Cardan rod
2 Exhaust by-pass line 6 Control actuator
3 Butterfly valve 7 Solenoid valve
4 Orifice 8 Air spring air pipe

Intentionally blank
HP Servo Oil Pipe

Removal, Grind Sealing Faces and Installation
Tools:
1 Grinding tool 94841 Emery cloth (as necessary)
1 Stencil 94841A 1 Hand drill
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Sealing Faces − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Preparation
2) Make sure that the servo oil service pump is set to off.
3) Put an oil tray under the applicable servo oil pump (1, Fig. 1).
EXHAUST SIDE For Views I−I to IV−IV: DRIVING END

see Fig. 2 for Removal
and Fig. 5 for Installation
I
II
II
III III
IV
IV
WCH03682 WCH03682
Fig. 1: Servo Oil Pipes

HP Servo Oil Pipe: Removal, Grind Sealing Faces and Installation (with Dynex SOP)
I-I 4) Loosen the screw plug (22, Fig. 2) to

5 drain the HP servo oil pipes (3, 12 and
13).
4
5) On the flange (1), loosen the four
screws (2).
SF 6) Push down the flange (1) to get air into
the HP servo oil pipe (3).
II- II After approximately one minute, the oil will

drain from the servo oil pipes.
1
6
3
2. Removal
3 2
7 CAUTION
Damage Hazard: Make sure
WCH03682
8 that you do not cause
SF 9 damage the sealing faces
or the HP servo oil pipes.
1) Remove the four screws (20) from the

10
SF flange (21).
11
2) Move the flange (21) up.
flange (15).
WCH03682
12
4) Move the flange (15) away from the the
intermediate piece (16).
5) Remove the two screws and
III-III
19 washers (17) from the intermediate
SF
piece (16).
13 6) Carefully remove the HP servo oil
pipe (13).
WCH03682 7) Apply protection to the sealing

12 faces (SF) to prevent damage.
14 8) Remove the four screws (18) from the
18 SF 17 16 15
flange (19).
IV-IV 9) Move the flange (19) away from the

intermediate piece (16).
13
20 10) Remove the intermediate piece (16).
21
flange (10).
23
12) Move the flange (10) down.
SF 13) Carefully remove the HP servo oil

pipe (12).
14) Apply protection to the sealing
faces (SF) to prevent damage.
WCH03682
Fig. 2 22

15) Loosen the two screws (9, Fig. 2) on the intermediate piece (8).
16) Remove the four screws (6) from the flange (7).
17) Move the flange (7) up.
18) Remove the four screws (2) from the flange (1).
19) Carefully remove the HP servo oil pipe (3) from the valve housing (5).
20) Apply protection to the sealing faces (SF) to prevent damage.
3. Sealing Faces − Grind

To get a clean and smooth finish on the
94841A hydraulic pipe, do step 1) to step 20):
1) Put the stencil (94841A, Fig. 3) on the
back of the emery cloth.
2) Use the applicable grade of the emery
cloth related to the quantity of metal
you want to remove.
Emery Cloth 3) Use a pencil or a ball pen to make the
inner shape.
1 94841 5) Remove the four screws (T2) and the
grinding tool (94841).
Hand Drill 6) Apply Molyslip Copaslip paste to the
threads and faces of the four
screws (T2).
7) Remove the cover (T1).
8) Put the emery cloth you cut out into the
9) Put the grinding tool (94841), emery
cloth and the cover (T1) in position on
T1
T2 the hydraulic pipe (1).
1 SF 10) Torque symmetrically the the four
screws (T2) to 2.0 Nm.
11) Put the hydraulic pipe (1) in a vice, as
Emery vertically as possible.
Cloth
12) Adjust the speed of the hand drill to
94841 between 200 rpm and 500 rpm.
13) Align the hand drill and the grinding
Fig. 3 WCH03101
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 the circular marks around the sealing face of the pipe are concentric.
17) Change the emery cloth for a smoother grade, then do step 1) to step 16) again until
you get a smooth finish.
18) Replace the emery cloth with a polishing cloth as a last step to polish the HP servo oil
pipe.
19) Clean the HP servo oil pipe (1).
20) If necessary, do step 1) to step 19) for the other servo oil pipes.
1
4. Adjustment
1) Make sure that the claw (4, Fig. 4) is
correctly attached to the HP servo oil
pipe (1).
2) Do a check of the O-ring (3). If the
O-ring is unserviceable, remove and
2 discard it.
3) Make sure that there is a distance of
5.5 mm between the end of the HP
servo oil pipe (1) and the claw (4).
Note: You can adjust the claw (4) with an
4
open-ended wrench.
3
5.5 mm
WCH03682
Fig. 4

I-I
5
5. Installation
4
1) Remove all of the protection from the
sealing faces (SF) in the valve housing
(5, Fig. 5), the intermediate pieces (8,
SF 16) and the servo oil pump (23).
2) Apply oil to the the threads of all the
II- II screws (2, 6, 11, 14, 18, and 20)
1 3) Carefully put the HP servo oil pipe (3)
6 in position in the valve housing (5) and
3 the intermediate piece (8).
3 2
7 4) Torque symmetrically the four
screws (2) to 20 Nm.
WCH03682
8 5) Torque symmetrically the four
SF 9 screws (6) to 20 Nm.
6) Attach the intermediate piece (16) to
the plate (20). Do not torque the
10 screws (17) at this step.
SF
11 7) Carefully put the HP servo oil pipe (12)
in position in the intermediate piece (8)
and the intermediate piece (16).
12
WCH03682 8) Torque symmetrically the four
9) Torque symmetrically the four
III-III screws (18) to 20 Nm.
19 SF 10) Carefully put the HP servo oil pipe (13)
in position in the intermediate piece (16
13 and the servo oil pump (23).
WCH03682 screws (14) to 20 Nm.
12
14
18 SF 17 16 15
13) Torque the screws (9) on the
IV-IV intermediate piece (8) to 20 Nm.
13 14) Torque the two screws (17) on the
20 intermediate piece (16) to 20 Nm.
21
23
SF
WCH03682
22
Fig. 5

Intentionally blank
Hydraulic Pipe − Exhaust Valve Drive

Removal, Grind Sealing Faces and Installation
Tools:
1 Grinding tool 94841
1 Stencil 94841A
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
For view II − II see

1 2
Fig. 4 and Fig. 7
II II
I
For view I − I see
Fig 3 and Fig. 7 4
I 3 WCH036684
Fig. 1 Exhaust Valve Control Unit
1 Flange 4 Flange
2 Top housing 5 Hydraulic pipe
3 Exhaust valve control unit (VCU)

Hydraulic Pipe − Exhaust Valve Drive: Removal, Grind Sealing Faces and Installation
1. Preparation
WARNING
Injury Hazard: The servo oil system has high pressure. Replace a
defective hydraulic pipe only when the engine has stopped.
WARNING
Injury Hazard: You must 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.

2) Set to off the servo oil service pump.
3) Make sure that there is no pressure in the servo oil system refer to the Operation
Manual 0520-1, paragraph 2.3.
4) Set to off the main bearing oil supply.
5) Put an oil tray under the applicable
5 hydraulic pipe (1, Fig. 2).
1
6) Loosen the screws (5) on the flange (2)
to drain the applicable hydraulic
2 pipe (1) through the check bore (3) in
4 the housing of the VCU (4).
3
WCH036684
Fig. 2

2. Removal
I-I
CAUTION
that you do not cause
damage the sealing faces
or the hydraulic pipes.

from the flange (3).
2) Carefully move the flange (3) away
from the VCU (2).
3 SF faces (SF) to prevent damage and
contamination.
1
Fig. 3 WCH03684
II - II 4) Remove the four screws (2, Fig. 4)

1 2 SF 5) Carefully move the flange (4) away
from the top housing (3).
CAUTION
of the hydraulic pipe is
approved equipment or
sufficient personnel to lift
WCH03684 and move the hydraulic
pipe.
6) Carefully remove the hydraulic pipe (1).

4 3
faces (SF) to prevent damage and
contamination.
Fig. 4


hydraulic pipe (1, Fig. 5) , do step 1) to
94841A step 20):
1) Put the template (94841A) on the back
of the emery cloth.
you want to remove.
Emery Cloth
3) Use a pencil or a ball pen to make the
inner shape.
94841 5) Remove the four screws (T2) and the
4
6) Apply Molyslip Copaslip paste to the
Hand Drill threads and faces of the four
screws (T2).
the hydraulic pipe (1).
T1 T2
4 10) Torque symmetrically the the four
SF screws (T2) to 2.0 Nm.
11) Put the hydraulic pipe (1) in a vice, as
Emery horizontally as possible.
Cloth 12) Adjust the speed of the hand drill to
between 200 rpm and 500 rpm.
94841
13) Align the hand drill and the grinding
WCH03207 tool (94841) accurately with the
hydraulic pipe (1) as shown.
Fig. 5
15) Regularly remove the unwanted
material from the grinding tool (94841).
16) Make sure that the circular marks around the sealing face of the hydraulic pipe (1)
are concentric.
17) Change the emery cloth for a smoother grade, then do step 1) to step 16) again until
you get a smooth finish.
18) Replace the emery cloth with a polishing cloth as a last step to polish the hydraulic
pipe (1).
19) Clean the hydraulic pipe (1).
20) If necessary, do step 1) to step 19) for the other hydraulic pipes.

4 4. Adjustment
1) Remove the protection from the
1 hydraulic pipe (4)
2) Make sure that the claw (3, Fig. 6) is
correctly attached to the hydraulic
pipe (4).
3) Do a check of the O-rings (1, 2). If the
3 O-rings are unserviceable, replace
them.
2 5.5 mm between the end of the
hydraulic pipe (4) and the claw (3).
WCH03684 5.5 mm
Fig. 6 Note: You can adjust the claw (3) with an
open-ended wrench.
5. Installation
II - II
1 2 SF CAUTION
that you do not damage
the sealing faces (SF) or
the hydraulic pipes. Do not
apply lateral force to the
hydraulic pipe and the
flanges.
WCH03684 1) Remove all 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
4 9.5 mm 3
screws (2, 5).
3) Carefully put the hydraulic pipe (1) in
I-I position in the top housing (3) and the
VCU (7).
1
8.0 mm between the flange (4) and the
top housing (3).
SF 7) Make sure that there is a distance of
8.0 mm between the flange (6) and the
5 VCU (7).
9.5 mm
6 Note: After 1000 operation hours, do
step 4) to step 7) again.
7
8) Set to on the main bearing oil supply.
WCH03684
Fig. 7

Intentionally blank
HP Fuel Pipe (Injection Valve)

Removal, Grinding and Installation
Tools:
1 Grinding tool 94871
1 Stencil 94871A
2 1
1. Preparation
1) Stop the engine, refer to the Operation
2
Manual 0310−1.
6 I
2) Make sure that there is no pressure in
the fuel rail as follows:
3 a) Set to off the fuel booster pump
4 5 I (plant).
b) Close the shut-off valves to the
fuel inlet and return pipes.
c) Operate the button on the
Note: Some parts pressure control valve (4, Fig. 1)
can look different. to release the pressure in the fuel
rail.
d) On the Local Display Unit (LDU),
make sure that the pressure
shows zero.
WCH02603 3) Set to off the electrical trace heating
I-I system.
2
7
8 2. Removal
CAUTION
3 SF or the HP injection pipes.
1) On the applicable HP injection pipe (2),

disconnect the electrical connection (6).
WCH03686
2) Remove the applicable pipe
II III - III
2 bracket (1).
III
3) Remove the pipe bracket (5).
11 9 4) On the injection valve (3) remove the
four screws (7) from the flange (8).
10
5) On the flange (11), remove the four
III screws (9).
6) Carefully remove the applicable HP
injection pipe (2) from the injection
WCH03686 valve (3) and the flow limiter valve (10).
WCH03686
SF 7) Apply protection to the sealing faces
Fig. 1 (SF) and the open ends of the HP
injection pipe (2).

HP Fuel Pipe (Injection Valve): Removal, Grinding and Installation

To get a clean and smooth finish on the HP
94871A injection pipe, do the procedure that follows:
1) Put the template (94871A, Fig. 2) on
the back of emery cloth.
you want to remove.
Emery Cloth
the inner shape.
5) Remove the four screws (T2) and the
1 94871 grinding tool (94871).
6) Apply Molyslip Copaslip paste to the
Hand Drill threads and faces of the four
screws (T2).
the HP injection pipe (1).
T1
T2 10) Torque symmetrically the four
Emery Cloth screws (T2) to 2.0 Nm.
SF
11) Put the HP injection pipe (1) in a vice,
as vertically as possible.
12) Adjust the speed of the hand drill
between 200 rpm and 500 rpm.
94871 13) Align the hand drill and the grinding
1 WCH02726
tool (94841) accurately with the HP
Fig. 2
injection pipe (1) as shown.
15) Regularly remove unwanted material
from the grinding tool (94871).
16) Make sure that the circular marks around the sealing face of the pipe are
concentric.
18) Replace the emery cloth with a polishing cloth as a last step to polish the HP
injection pipe.
19) Clean the HP injection pipe (1).
20) If necessary, do step 1) to 19) for the other HP injection pipes.

HP Fuel Pipe (Injection Valve): Removal, Grinding and Installation
4. Installation
CAUTION
2 1
2 that you do not damage
I the sealing faces or the HP
6
injection pipes.
1) If necessary, replace the O-rings (7and

3
4 5 I 11, Fig. 3).
2) Make sure that the claws (9, 12) are
correctly attached to the HP injection
pipe (2).
Note: You can adjust the claws (9, 12)
with an open-ended wrench.
sealing faces in the injection valve (3)
and the flow limiter valve (15).
4) Make sure that there is distance of
5.8 mm between the ends of the HP
WCH02603 injection pipe (2) and the claws (9, 12).
5) Apply Never-Seez NSBT to threads of
I-I the screws (8, 14).
2 7
6) Carefully put the HP injection pipe (2)
8 in position in the injection valve (3) and
the flow limiter valve (15).
10
9 screws (8) to 60 Nm.
7
12.0 mm between the flange (10) and
12.0 mm
5.8 mm the injection valve (3).
SF screws (14) to 60 Nm.
3
WCH03686
12 mm between the flange (13) and the
flow limiter valve (15).
III - III 11) If necessary, install the insulation to the

2 II HP injection pipe (2).
2 11
III
12) Install the pipe clamps (1, 5).
14 13
15 12
11 12.0 mm
III
5.8 mm
WCH03686
WCH03686
Fig. 3 SF

Intentionally blank
HP Fuel Pipe
Removal, Grinding and Installation
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Grinding tool 94870 Grinding tool 94870F
1 Screw-on sleeve 94870E Locknut 94870G
Template 94870H
FUEL SIDE DRIVING END

I I For View I − I see
Fig. 3, Fig. 6 and
Fig. 15
1
1
2
II
3
For View II − II see
Fig. 5, Fig. 7, Fig. 14 II
and Fig. 15
3
For View IV, see
Fig. 8, Fig. 10,
Fig. 13 and Fig. 14 IV III 4
For View III − III

see Fig. 2, Fig. 4,
Fig. 9, Fig. 12
III and Fig. 13
Fig. 1 WCH03687 WCH03687

HP Fuel Pipe: Removal and Installation
1. Preparation
WARNING
Injury Hazard: The fuel system has high pressure. Replace a
defective HP fuel pipe only when the engine has stopped. You must
obey the data given in the Operation Manual 0520-1.
WARNING
Injury Hazard: Always put on gloves and safety goggles when you
do work on hot components. When screws and plugs are opened,
steam or fuel can come out and cause injury.
CAUTION
Damage Hazard: Make sure that you do not cause damage the
sealing faces or the HP fuel pipes. Do not apply lateral force to the
HP fuel pipes and the flanges.

2) Set to off the fuel supply pump.
3) Set to off the trace heating.
4) If the HP fuel pipes must be replaced, remove the insulation (2, Fig. 1) from the
HP fuel pipes (3).
5) If necessary, disconnect the trace heating pipes.
6) Remove the clamps (1).
7) Put an oil tray under the applicable fuel pump.
8) Loosen the four screws (2, Fig. 2) on
III - III the flange (5) a maximum of three
turns.
1
Note: The fuel will drain through the
drain bore (4) into the fuel leakage
2 pipe.
5 9) Move the HP fuel pipe (1) up. Make
sure that there is a distance of
approximately 3.0 mm between the fuel
pump cover (3) and the HP fuel
4 pipe (1).
WCH03687
SF
3.0 mm
Fig. 2

I-I
10) Loosen the four screws (2, Fig. 3) on
the flange (3) a maximum of three
turns.
11) Move the flange (3) away from the
valve housing (4) and make sure that
air goes into the HP fuel pipe (1).
4
WCH03687 3 2 1
Fig. 3
12) Open the screw plug (2, Fig. 4). If there

III - III is no fuel, the HP fuel pipe (1) is fully
drained.
1
13) Tighten the screw plug (2).
WCH03687
Fig. 4

II - II 2. Removal
CAUTION
1
or the HP fuel pipes.
from the intermediate piece (3).
SF
WCH03687
Fig. 5

I-I
from the valve housing (4).
4
CAUTION
of the HP fuel pipe is
and move the HP fuel pipe.
5) Carefully remove the HP fuel pipe (1).

WCH03687 3 2 1
SF faces (SF) to prevent damage and
contamination.
Fig. 6

II - II
7) Remove the four screws (3, Fig 7) from
the flange (2).
SF
WCH03687
Fig. 7
9) Remove the four screws (2, Fig 8) from

IV the flange (3).
CAUTION
WCH03687 and move the HP fuel pipe.
SF 4 3 2 1
11) Carefully remove the HP fuel pipe (1).
Fig. 8
III - III
1
2 contamination.
SF 14) Carefully move the flange (4) away

from the fuel pump cover (3).
Fig. 9 WCH03687


IV 16) Carefully move the flange (2) away
CAUTION
WCH03687 17) Carefully remove the HP fuel pipe (4).

4 3 2 1 SF 18) Do a check of the sealing faces (SF). If
you find damage, do the procedure
Fig. 10 given in paragraph 3.
contamination.


To remove deep notches of more than
94870H 0.1 mm, use emery cloth of medium to
coarse grain (30 to 80 CAMI). For finish
grinding, use emery cloth with fine or
ultra-fine grains (100 to 600 CAMI).
pipe, do the procedure that follows:
Emery Cloth 1) Put the template 94870H on the back
of the emery cloth, see Fig. 11.
016.738/08
you want to remove.
the inner shape.
5) Put the cut shape into the cone of the
1 grinding tool 94870F as shown.
94870F
6) Tighten the countersunk screw (1).
Grained Face 7) Remove the pipe claw.
8) Put the HP fuel pipe in position in a
TIGHTENED vice.
CONDITION 9) Attach the nut (94870G) on to the
thread of the HP fuel pipe (2).
1. 2.
10) Attach the sleeve (94870E) to the
nut (94870G).
11) Attach the grinding tool (94870F) to the
016.739/08
hand drill.
12) Move the grinding tool (94870F) into
2 94870G 94870E the sleeve (94870E) until the grinding
tool lightly touches the HP fuel pipe (2).
13) Adjust the hand drill speed to a
maximum of 1500 rpm.
2 14) Operate the hand drill for between
3 seconds and 5 seconds.
15) Remove the grinding tool (94870F)
016.739/08
from the sleeve (94870E).
16) Use a low-pressure air supply to clean
94870F Hand Drill the HP fuel pipe.
17) Do a check of the sealing face. If
necessary, use a new piece of emery
cloth and do step 3) to step 16) again.
SF Note: If the notches are large, you must
decrease the length of the HP fuel
pipe. Make sure that there is a
distance of 0.5 mm between the
016.739/08
countersunk screw (1) and the end
min.0.5 mm face of the HP fuel pipe.
18) Remove the nut (94870G) and sleeve
(94870E).
Fig. 11

III - III 4. Installation
5 CAUTION
1 Injury Hazard: The weight
2 approved equipment or
1) Do a check for damage of the

4 O-rings (1 and 3, Fig. 12). If necessary,
WCH03687
replace the O-rings.
3
sealing faces (SF).
SF 14.0 mm
3) Make sure that the claw (4) is correctly
Fig. 12 attached to the HP fuel pipe (5).
Note: You can adjust the claw (4) with an
open-ended wrench.
14.0 mm between the end of the HP
fuel pipe (5) and the claw (4).
5) Make sure that the O-rings (1, 3) are in
position.
6) Apply Never-Seez NSBT to the threads
of all the screws (2).

IV CAUTION
Damage Hazard: Do not
1 2 apply lateral force to the
HP fuel pipe and the
flanges. Damage the
sealing faces (SF) and the
3 4 HP fuel pipe can occur.
7) Loosen the screws (2, Fig. 16) on the

support (1) of the intermediate
piece (6).
8) Carefully put the HP fuel pipe (5) in
WCH03687 position in the fuel pump cover (8) and
6 5 the intermediate piece (6).
SF
39.5 mm 9) Make sure that the HP fuel pipe (5) is in
the correct position. Align the
marks (MA) on the HP fuel pipe (5) and
the flange (9).
III - III 10) Torque the screws (4, 7) as follows:

a) Torque symmetrically the four
5
screws (4, 7) to 30 Nm.
A
b) Make sure that the flanges (3, 9)
7
are in the correct position and not
9 tilted.
c) Torque symmetrically the four
SF
36.5 mm
d) Torque symmetrically the four
8
WCH03687 the fuel pump cover (8).
the intermediate piece (6).
A
5
MA
MA
WCH03687
Fig. 13

II - II 13) Loosen the screws (6, Fig. 14) on the

support (5) of the intermediate
piece (1).
CAUTION
6 and move the HP fuel pipe.
SF
1 14) Carefully put the HP fuel pipe (3) in
5 position in the intermediate piece (1)
and the intermediate piece (7).
39.5 mm
15) Make sure that the HP fuel pipe (3) is in
the correct position.
4
2 16) Torque the screws (2, 8) as follows:
3 WCH03687
are in the correct position and not
tilted.
IV
8 9 17) Make sure that there is a distance of
WCH03687
7 SF
3 39.5 mm
Fig. 14

54.0 mm II - II CAUTION
8 of the HP fuel pipe is
7
6
39.5 mm 19) Carefully put the HP fuel pipe (1,
Fig. 15) in position in the intermediate
5 4 piece (5) and the valve housing (4).
SF 20) Make sure that the HP fuel pipe (1) is in

3 the correct position.
1 21) Torque the screws (7, 9) as follows:
2
are not tilted and in the correct
position.
WCH03687
I-I the intermediate piece (1).
SF 41.5 mm between the flange (10) and
the valve housing (11).
24) Tighten the screws (2) on the
support (3).
54.0 mm between the steel ring (4) and
the slide ring (5).
11
WCH03687 10 9 8
41.5 mm
Fig. 15

5. Completion
1) If applicable, install the insulation (2, Fig. 1) to the HP fuel pipes (3).
2) Install the clamps (1).
3) If necessary, connect the trace heating pipes.
4) Set to on the trace heating.
5) Set to on the fuel supply pump.

HP Pipe − Pilot Fuel

1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Pilot Fuel Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Pilot Fuel Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Pilot Fuel Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Pilot Fuel Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
II For View I − I, see

Fig. 2, Fig. 3, Fig. 4
and Fig. 5
For View III, see

Fig. 3 and Fig. 4
III For View IV, see

I I Fig. 2 and Fig. 5
2
WCH03688
II
3
Pilot Fuel
Pipe
Pilot Fuel
Pilot Fuel Pipe
Pipe IV
Fig. 1
1 Clamp 3 Pilot fuel supply unit

2 Rail unit

1. Preparation
WARNING
Injury Hazard: The pilot fuel system has high pressure. Replace a
defective HP pilot fuel pipe only when the engine has stopped. You
must obey the data given in the Operation Manual 0520-1.
WARNING
Injury Hazard: Always put on gloves and safety goggles when you
do work on hot components. When screws and plugs are opened,
steam or fuel can come out and cause injury.
CAUTION
Damage Hazard: Make sure that you do not cause damage the
sealing faces or the HP pilot fuel pipes. Do not apply lateral force to
the HP pilot fuel pipes and the flanges.

2) Set to off the fuel supply pump.
3) Make sure that the pilot fuel supply unit (3, Fig. 1) is set to off.
2. Removal
2.1 Pilot Fuel Pipe
1) Remove the pipe clip (1).
2) Put an oil tray under the applicable pilot fuel pipe (2, Fig. 2).
3) Loosen the coupling nut (1) a maximum of two turns.
4) Loosen the coupling nut (5) a maximum of three turns.
Note: Make sure that the fuel drains into the oil tray.
5) Fully loosen the coupling nuts (1, 5).
6) Carefully remove the HP pilot fuel pipe (3) from the distributor blocks (4, 6).
7) Remove and discard the O-rings (3, 7).
8) Attach protection to all openings and sealing faces to prevent contamination.
9) To remove the remaining pilot fuel pipes, refer to paragraph 2.2.
I-I IV
2
5
7
4 WCH03688
3
SF
6
1
WCH03688
2
SF
Fig. 2

2.2 Pilot Fuel Pipes

1) Put an oil tray under the applicable pilot fuel pipe (2, 5).
2) Loosen the coupling nut (1) a maximum of two turns.
3) Loosen the coupling nut (6) a maximum of three turns.
Note: Make sure that the fuel drains into the oil tray.
4) Fully loosen the coupling nuts (1, 6).
5) Carefully remove the HP pilot fuel pipe (2, 5) from the distributor block (3) and the
pilot injection valve.
6) Remove and discard the O-rings (4, 7)
7) Attach protection to all openings and sealing faces to prevent contamination.
III
6
2, 5
7
5 I-I
1 2
Injection
Valve
SF
4 WCH03688 7
WCH03688 SF
3
Fig. 3

3. Installation
3.1 Pilot Fuel Pipes

1) Remove all protection from the openings and sealing faces.
2) Do a check for damage of the sealing faces.
3) Put new O-rings (4, 7, Fig. 4) in position on the applicable pilot fuel pipe (2, 5).
4) Put the applicable pilot fuel pipe (2, 5) in position in the injection valve and the
distributor block (3).
5) Make sure that the claws (8, 10) are correctly attached to the applicable pilot fuel
pipe (2, 5).
Note: You can adjust the claws (8, 10) with an open-ended wrench.
6) Apply Never-Seez NSBT8 to the threads of the coupling nuts (1).
7) Make sure that there is a distance of 6.5 mm between the end of the pilot fuel
pipe (2, 5) and the claws (8, 10).
8) Torque the coupling nuts (1, 9) to 30 Nm.
III
6
2, 5
7
5 I-I
1 2
Injection
Valve
SF
4 7
3 WCH03688 SF
WCH03688
2, 5 1 6.5 mm
10 6.5 mm
Fig. 4

3.2 Pilot Fuel Pipe

1) Remove all protection from the openings and sealing faces.
2) Do a check for damage of the sealing faces.
3) Put new O-rings (3 and 8, Fig. 5) in position on the pilot fuel pipe (2).
4) Put the pilot fuel pipe (2) in position in the injection valve and the distributor
blocks (4, 7).
5) Make sure that the claws (5, 9) are correctly attached to the pilot fuel pipe (2).
Note: You can adjust the claws (5, 9) with an open-ended wrench.
6) Apply Never-Seez NSBT8 to the threads of the coupling nuts (1, 6).
7) Make sure that there is a distance of 6.5 mm between the end of the pilot fuel
pipe (2) and the claws (5, 9).
8) Torque the coupling nuts (1, 6) to 30 Nm.
9) Attach the pipe clip (1, Fig. 1).
I-I
6.5 mm
5
4 WCH03688
3 1
SF
1
2 2
IV
2
6
2
8
6
7
WCH03688 9
SF
6.5 mm
Fig. 5
4. Completion
1) Set to on the pilot fuel supply unit (3, Fig. 1).
2) Set to on the fuel supply pump.

Intentionally blank
Work Card
Gas Supply Pipe: Shut-off and Vent Valves
Applicable tools

Preparation
Do a check of the tightness of ball valves. Do a Crew 2.0 hours Qty 1

check of the shaft sealing
Related Data

Related Procedures

Intentionally blank
Maintenance Group9
Crank Angle Sensor Unit, Tools Group 9
Crank Angle Sensor Unit: Replacement of Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9223−1/A1

Cylinder Pressure Sensor: Replacement of Cylinder Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . 9258−1/A1
Tools: Description of Tool Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−1/A1
Work Cards
UNIC Control System: Replace the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WC9362−1/A1
Hydraulic Pre-tensioning Jacks and Pumps

Configuration and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−2/A1
Overview, Storage, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−3/A1
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−4/A1
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−5/A1

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1 to 35
Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 36 to 38

Intentionally blank
Crank Angle Sensor Unit
Proximity Sensor − Replace
1. General
The crank angle sensor (CAS) unit (Fig. 1) is installed on the supply unit drive at the
driving end. The CAS has four proximity sensors (ST5131−34C). There are two crank
angle systems (for redundancy) that monitor the teeth on the intermediate wheel (1).
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 (4) for TDC and BDC.
II - II
II
I
III
II 1
WCH03215
III
ST5131C
I
ST5132C
ST5133C
ST5134C
3 2
ZS5123−24C
ZS
Crank Angle Mark 5123−24C
ST
5131−34C
WCH02267
Fig. 1: Crank Angle Sensor Unit

Crank Angle Sensor Unit: Proximity Sensor − Replace
2. Procedures
2.1 Proximity Sensors (ST5131−34C) − Replace

WARNING
1) Stop the engine.

2) Operate the turning gear to get a tooth (1, Fig. 2) of the intermediate wheel
opposite the applicable proximity sensor (2).
3) Put a mark on the applicable cable to identify its position.
4) Disconnect the applicable electrical connection from the proximity sensor (2).
5) Loosen the locknut (4).
6) Remove the proximity sensor (2) from the holder (3).
7) Attach the new proximity sensor to the holder (3).
8) Turn the proximity sensor (2) fully down until the tip of the proximity sensor (2)
touches the holder (3).
Note: During installation/commissioning the clearance between the flywheel
tooth (1) and the holder (3) is set to 2.0 mm.
Note: The wall thickness of the holder (3) is 1.5 mm.
9) Loosen the proximity sensor (2) a half turn to get a clearance of 4.0 mm between
the flywheel tooth (1) and the bottom face of the proximity sensor (2).
10) Carefully tighten the locknut (4) with your fingers.
11) Connect the electrical connection to the proximity sensor (2). Refer to the mark
made before to identify the correct cable.
I 2 mm
2 3 4
1
I
3
WCH03215
Fig. 2

Crank Angle Sensor Unit: Proximity Sensor − Replace
2.2 Proximity Sensors (ZS5123C−24C) − Replace

WARNING
1) Stop the engine.

2) Operate the turning gear to get the applicable crank angle mark (2, Fig. 3) on the
flywheel wheel opposite the unserviceable proximity sensor.
3) Put a mark on the applicable cable to identify its position.
4) Loosen the locknut (1).
5) Remove the proximity sensor (4) from the holder (3).
6) Attach the new proximity sensor to the holder (3).
7) Make sure that the proximity sensor (4) touches the applicable crank angle
mark (2).
8) Loosen the proximity sensor (4) until you get a clearance of 4.0 mm between the
crank angle mark and the bottom face of the proximity sensor.
9) Carefully tighten the locknut (1) with your fingers.
10) Connect the electrical connection to the proximity sensor (4). Refer to the mark
made before to identify the correct connection.
ZS5124C ZS5123C
I 4
WCH03215
3
1
4.0 mm
2
Fig. 3
For the function of the Crank Angle Sensor Unit, read the data in the Operation
Manual, 4002−1 paragraph 4.6.
For the Inspection and Overhaul Intervals refer to Maintenance Schedule 0380−1,
Crank Angle Sensor Unit.

Intentionally blank
Cylinder Pressure Sensor

Replacement of Cylinder Pressure Sensor
Tools:
1 Disassembly and assembly tool 94022H
1. General
For data about cylinder pressure balancing control, refer to the Operation Manual
4002-1, paragraph 3.10.
For the signal failure list, refer to the Operation Manual, 4002-2, chapter 3.25.
2. Replace
1) Make sure that there is no pressure in
cylinder cover (2).
2) Disconnect the electrical cable from the
pressure sensor (1) PT3601.
3) Attach the tool (94022H) to the casing
I of the pressure sensor (1).
4) Carefully remove the pressure
sensor (1).
5) Put the pressure sensor in a clean dry
area.
6) Apply a thin layer of oil to the thread of
the pressure sensor (1).
I 7) Attach the tool (94022H) to the

pressure sensor (1).
WCH03692
8) Install fully the new pressure
sensor (1).
9) Torque the pressure sensor (1) to
25± 5Nm.
I-I 10) Lock the sensor with the locknut.
11) Connect the electrical connector to the
pressure sensor (1).
94022H
12) Do a check of the pressure sensor as
1
follows:
2 a) On the Local Control Panel, get
the signal failure list.
b) Make sure that the pressure
sensor PT3601−0n appears.
Note: n = cylinder number (e.g.
PT3601−08 is cylinder number
eight).
Fig. 1
WCH03408

Intentionally blank
Work Card
Engine Control System: Replace the Modules
Set to off the control system Applicable tools

Disconnect the applicable power supplies to
defective items

Preparation
Replace the modules: CCM−20, MCM−11 and Ship Engineer 2.0 hours Qty 1
LDU−20, refer to the Operation Manual 4002−4. Service Engineer 2.0 hours Qty 1
Related Data

Related Procedures

Intentionally blank
Tools
Description of Tool Categories
1. General
The tools necessary for the maintenance of the engine are divided into three groups:
D Standard Tools
D Recommended Special Tools
D Special tools available on loan.
When it becomes necessary to order more tools or replacements, the tool number
and the tool description, which must include the engine type, must be shown (refer to
9403−5).
The instructions on the configuration and application, overview, storage, servicing and
maintenance of the hydraulic pre-tensioning jacks are given in 9403−2, 9403−3 and
9403−4.
A set of tools is supplied for important components from sub-suppliers, which must be
isolated from the engine tools.
Note: Some 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 for
some engine designs. Thus, are not part of the engine tools supply.
3. Recommended Special Tools

These tools and devices let you do specified maintenance more easily, and in a
shorter time, than with the standard tools.
You can make an order for these tools with the engine, or after the engine is supplied.
4. Special Tools Available On Loan

These are tools and devices that are loaned for the movement and for assembly of
the engine. The tools are to be given back to the engine manufacturer after the
engine assembly is completed.

Intentionally blank
Hydraulic Jacks and Pumps
Configuration and Application

Tools:
1 HP oil Pump, 2800 bar 94931 6 Adapter piece 94934F
1a Adapter piece 94934F 7 Distributing piece 94934C
2 Hydraulic unit, 2000 bar 94942 8 Coupling element 94934G
3 HP hose 94935 9 Flexible hose 94935A
4 Pressure gauge 94934A 10 Oil pipe drain 94935C
5 Connection block 94934
1 4
2
1a
3
3
4 5
6 3 9
E
7
A/G C
3 B
10
F D
8
H
I
A For tie rods (jack: 94180), elastic studs to F For elastic studs to main bearing (94114)
exhaust valve cages and bottom connection rod
bolts (94252), top connection rod bolts (94315)
and elastic studs on supply unit (94557)
B For elastic studs to cylinder cover (94215A) G For elastic studs to piston, piston rod and
crosshead (94340)
C To lift the crankshaft for removal and installation H Thrust device for main bearing cover (94110)
of main bearing shells (94936)
D Oil drain after use of pre-tensioning jacks I For checks and setting of fuel overpressure
safety valve
E For foundation bolts (94145), turning gear
(94320) and for supply unit lifting tool (94430A)

Intentionally blank
Hydraulic Pre-tensioning Jacks
Storage, Servicing and Maintenance
1. General
The hydraulic pre-tensioning jacks must be kept in their tool boxes when not in use.
After you use the pre-tensioning jacks, close the connections with plugs and apply
grease. We recommend that, for each jack, you keep a sealing kit (KJ−) in stock.
Always make sure that new back-up rings and O-rings are installed in their correct
positions, as shown in the data that follows.
Note: Carefully install new back-up rings and O-rings to prevent damage. Do
not use tools that have sharp edges.
Back-up rings that are not cut, must be put into hot water before you install them.
1.1 Dimensions of Back-up Rings and O-rings

Tool Position of application of Part Back-up Ring O-ring
No. pre-tensioning jack (uncut)
Dimension (mm)
oj x ij x t ij x s
94110 Thrust device for main bearing cover piston 94 x 84.6 x 1.7 81.92 x 5.33
cylinder 60.2 x 54 x 1.4 53.57 x 3.53
94114 Elastic bolts to main bearing piston 136 x 123.8 x 2.5 123.19 x 6.99
cylinder 99.4 x 90 x 1.7 91.44 x 5.33
94145 Foundation bolts and engine stays piston 123 x 113.6 x 1.7 113.67 x 5.33
cylinder 102 x 93 x 1.7 91.44 x 5.33
94180 Tie rods piston 230 x 217.8 x 2.5 215.27 x 6.99
cylinder 158.2 x 146 x 2.5 145.42 x 6.99
94215A Elastic bolts to cylinder cover piston 196 x 183.8 x 2.5 183.52 x 6.99
cylinder 126.4 x 117 x 1.7 116.84 x 5.33
94252 Elastic bolts to exhaust valve cage piston 175 x 162.8 x 2.5 158.12 x 6.99
and bottom connecting rod studs cylinder 121.4 x 112 x 1.7 110.49 x 5.33
94315 Elastic bolts to top connecting rod piston 113 x 103.6 x 1.7 100.97 x 5.33
bearing cylinder 81.2 x 75 x 1.4 75.79 x 3.53
94320 Turning gear piston 104.5 x 95.1 x 1.7 97.79 x 5.33
cylinder 74.2 x 68 x 1.4 72.62 x 3.53
94340 Piston, piston rod and crosshead piston 62 x 55.8 x 1.4 53.57 x 3.53
cylinder 50.2 x 44 x 1.4 44.04 x 3.53
94430A Roller lifting tool − supply unit piston 87 x 77.6 x 1.7 75.57 x 5.33
cylinder 60.2 x 54 x 1.4 53.57 x 3.53
94557 Elastic studs on supply unit piston 86 x 76.6 x 1.7 75.57 x 5.33
cylinder 66.2 x 60 x 1.4 59.92 x 3.53
s Back-up ring
oj ij O-ring
Fig. 1 oj ij
002.696/98 011.032/03

Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance
2. Pre-tensioning Jacks
Tool 94110 Thrust Device for Main Bearing Cover
1 O-ring 5 Adapter piece
2 Back-up ring 6 Closing valve
3 Cylinder 7 Back-up ring
4 Piston 8 O-ring
9 Vent screw
8 2
6
5
3
MAXIMUM STROKE
32 MM
9
Fig. 2 WCH02305

Tool 94114 Double pre-tensioning jack for elastic bolts to main

bearing
1 Double cylinder 7 O-ring
2 Adapter piece 8 Back-up ring
3 Closing valve 9 Backing bush
4 Vent screw 10 Tension sleeve
5 O-ring 11 Piston
6 Back-up ring 12 Round nut
94114−KJ Kit with back-up rings and O-rings

for double pre-tensioning jack
I-I
I
3 2
94114−KJ
I
8
7 5
6
12
11
MAXIMUM STROKE
1 10 MM
10
WCH02304
Fig. 3

Tool 94145 Pre-tensioning jack for foundation bolts and engine stays
1 Vent screw 6 O-ring
2 Cylinder 7 Back-up ring
3 Piston 8 O-ring
4 Adapter piece 9 Back-up ring
5 Closing valve
94145−KJ Kit with back-up rings and

O-rings for pre-tensioning jack
5
94145−KJ
4 1
9 2
6
MAXIMUM STROKE
12 MM
7
WCH02306
Fig. 4

Tool 94180 Pre-tensioning jack for tie rods

1 Back-up ring 6 Piston
2 O-ring 7 Vent screw
4 Back-up ring 9 Closing valve
5 Cylinder
94180−KJ Kit with back-up rings and O-rings

for double pre-tensioning jack
7 8 94180−KJ
5
1
2
3
4
MAXIMUM STROKE
35 MM
Fig. 5 WCH02308

Tool 94215A Pre-tensioning jack for elastic bolts to cylinder cover

1 Vent screw 6 Cylinder
4 O-ring 9 Closing valve
5 Back-up ring
94215A−KJ Kit with back-up rings and

1
9
8
94215A−KJ
7
6 3
4
5
WCH02917
MAXIMUM STROKE
22 MM
Fig. 6

Tool 94252 Pre-tensioning jack for elastic bolts to exhaust valve cage
and bottom connecting rod studs
1 Closing valve 6 Back-up ring
2 Adapter piece 7 Cylinder
5 O-ring

94252−KJ
1
9
2 3
8
4
5
6
MAXIMUM STROKE
9 MM
WCH02310
Fig. 7

Tool 94315 Pre-tensioning jacks for elastic bolts to top connecting

rod bearing
5 Back-up ring

94315−KJ
9
8 1
2
7 3
4
5
MAXIMUM STROKE
5 MM
WCH02311
Fig. 8

Tool 94320 Pre-tensioning jacks for elastic bolts to turning gear

2 Gasket 7 Cylinder
5 O-ring

94320−KJ
1
9
3
8 2
4
7
5
6
MAXIMUM STROKE
8 MM
Fig. 9 WCH02312

Tool 94340 Pre-tensioning jack for piston and piston rod foot to
crosshead
2 Adapter Piece 7 Cylinder
5 O-ring

9 2
94340−KJ
MAXIMUM
3 STROKE 4 MM
4
5
6
WCH03694
Fig. 10

Tool 94430A Pre-tensioning jack for roller lifting tool (supply unit)
5 Back-up ring
94430A−KJ Kit with back-up rings and

1
8
94430A−KJ
7 MAXIMUM
STROKE 8 MM
5 6
4
3
2
016.712/08
Fig. 11

Tool 94557 Pre-tensioning jacks for elastic bolts to top end bearing
(supply unit)
5 Back-up ring

1
94557−KJ
8 MAXIMUM STROKE
7 8.5 MM
5 6
4
3
2
016.713/08
Fig. 12

Hydraulic Pre-tensioning Jacks
General Instructions
Hydraulic pre-tensioning jacks for:
Version 1: Version 2:
Foundation bolt and engine stay 94145 Main bearing 94114
Tie rod 94180
Cylinder cover 94215A
Exhaust valve cage and 94252
bottom connecting rod studs
Top end bearing 94315
Turning gear 94320
Piston, piston rod foot 94340
Roller lifting tool (fuel pump) 94430A
Supply unit (fuel pump unit) 94557
1. General
WARNING
Injury Hazard: Hydraulic tools can cause injury to personnel.
Always put on gloves, a face shield and safety goggles when you
do work with hydraulic tools.
There are two versions of hydraulic jack preparation:

D Version 1 − the piston (2) is attached directly on to the elastic bolt / elastic
stud (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 sure that the built-in
non-return valves can operate.
5) Do a check of the oil in the HP oil pump or hydraulic unit.
6) When you must add oil, read the specification of the pump manufacturer.
7) Use an engine lubricating oil that has a viscosity of SAE 30 to SAE 40.
Note: In unusual conditions, you can also use cylinder lubricating oil.
8) For data about the sealing rings on the hydraulic jacks, see 9403−3.
9) To install elastic studs, see 0352−2.

Hydraulic Pre-tensioning Jacks: General Instructions
Version 1
2. Loosen
LOOSEN APPLY TENSION
2.1 Version 1 − Preparation
7 6 1) Make sure that the vent screw (6,
2 Fig. 1) is open.
9 2) Put the hydraulic jack on to the elastic

stud (5).
x
1 3) Turn the hydraulic jack until it is tight.

Make sure that there is no clearance
at X.
4
8 10 2.2 Version 2 − Preparation
5 1) Make sure that the vent screw (6,
Fig. 2) is open.
016.696/08
2) Put the hydraulic jack over the elastic
Fig. 1 stud (5).
3) Use the round bar to lightly tighten the
round nut (4).
Version 2
2.3 Procedure
1) Turn back the round nut (4), or the
hydraulic jack (refer to Table 1 below).
LOOSEN APPLY TENSION
2) On the HP oil pump, close the relief
valve.
3 3) Connect the hydraulic jack to the HP oil
7 6 pump or the hydraulic unit.
2 4) Put a hose on the vent screw (6) and a
9 container below the hose to drain the
oil.
x
1 5) Operate the HP oil pump.

6) Close the vent screw (6) when oil that
has no air flows out.
8
Note: Do not move the piston (2) above
4
10 the limit of the red groove (9).
5 7) Operate the HP oil pump to slowly

increase the pressure to approximately
Fig. 2 016.697/08
20 bar to 30 bar more than the value
give in Table 1.
8) Keep the pressure constant and use
the round bar to loosen the round nut
(refer to Table 1 below).
9) On the HP oil pump,or hydraulic unit,
decrease the pressure to zero.
10) Remove the hydraulic jack.

3. Apply Tension
1) Turn the round nut (4) fully down (Fig. 1 and Fig. 2). Make sure that there is no
clearance at the slot (10).
2) Put one reference mark (Y) on the nut and one on the part below (X) (see Fig. 3
and Fig. 4).
009.752/02 010.031/02
MARKS FOR Y TIGHTENING

X X
COMPARISON ANGLE
Fig. 3 Fig. 4

1) Make sure that the vent screw (6, Fig 1) is open.
2) Put the hydraulic jack on the elastic stud (5).
3) Turn the hydraulic jack until it is tight. Make sure that there is no clearance at X.

1) Put the hydraulic jack over the elastic stud (5, Fig. 2).
2) Use the round bar to lightly tighten the round nut (4).
Note: If necessary, turn back the hydraulic jack a small distance to get access
to the hole in the round nut (4).
3.3 Procedure
1) On the HP oil pump, close the relief valve.
2) Connect the hydraulic jack to the HP oil pump or the hydraulic unit.
3) Operate the HP oil pump.
4) Close the vent screw (6) when oil that has no air flows out.
5) Slowly increase the pressure to the nominal value, then keep the pressure
constant (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 bar more than the value give in Table 1.
Note: Do not move the piston (2) above the limit of the red groove (9).
8) Use the round bar (8) to tighten the round nut (4) nut.
9) Put the feeler gauge through the slot (10) to make sure that there is no clearance
between the round nut (4) and the seating.
10) Compare the angle between the reference marks (X and Y) on the round nut (4)
and the Comparison value in the Table. If there is a large difference, you must
investigate the cause and do the procedure again.
11) On the HP oil pump,or hydraulic unit, decrease the pressure to zero.
12) Remove the hydraulic jack.

Table 1 − Hydraulic Jacks − Values and Comparison
Application Group Jack Tightening Comparison Reset Jack / Lubricating

Value [bar] [_( mm] Round Nut Agent 2)
[turns]
Foundation bolts 1112−1 94145 (1st step 1000) 1500 − ¼ MOLYKOTE
paste G
Main bearing 1132−1 94114 1500 − 1¼ Oil
Engine stays 1715−1 94145 170 − ¼ MOLYKOTE
paste G
Tie rods 1903−1 94180 1500 from 100 to 1500 bar 3½ MOLYKOTE
13.5 to 15.5 mm paste G
Cylinder cover 2708−2 94215A 1500 495_ 1¼ Oil

Exhaust valve 2751−1 94252 1500 165_ 1 Oil
cage
Turning gear 3206−1 94320 (1st step 600) 1500 − ½ Oil
Top con rod 3303−1 94315 (1st step 1100) 1500 1st to 2nd step 15_ ½ Oil
Bottom con rod 3303−1 94252 (1st step 700) 1500 1 to 2 step 65_
st nd 1 Oil
Piston rod foot 3403−1 94340 (1st step 1000) 1500 1st to 2nd step 20_ ½ Oil
Piston head 3403−3 94340 1500 75_ ½ Oil
Bearing, supply 5581−1 94557 1500 − ½ Oil
unit
Roller lifting tool, 5556−21) 94430A 1500 84_ ½ No lubricant
supply unit
1) For cutting out and cutting in a fuel pump, refer to the Operation Manual
5556−2.
2) For lubrication on threads and contact surfaces.

Tool List
Standard Tools
94000 Combination wrenches, set complete

Includes:
34 wrenches AF6 to AF60
To send an order for single wrenches
94000−6 state AF
WCH03387
94000−60 Example: . . . . . 94000−6
94000−60
94001 Open end wrenches

94001−85 1 Piece . . . . . AF85
94001−110 1 Piece . . . . . AF110
WCH03387
94002 Ring slugging wrenches, set complete

Includes:
13 wrenches AF27 to AF110
WCH03369
94002−27 state AF
94002−110 Example: . . . . . 94002−27
94002−110
94003 Allen keys, set complete

Includes:
9 Allen keys AF3 to AF17
94003−3 state AF WCH03318
94003−17 Example: . . . . . 94003−3

94003−17
94005 Round bars

for round nuts
94005−4 1 Pieces . . . . Ø 4 mm (M27 − M33)
94005−6 1 Pieces . . . . Ø 6 mm (M36 − M56)
94005−9.5 1 Pieces . . . . Ø 9.5 mm (M60 − M80) WCH03319
94005−14 1 Pieces . . . . Ø 14 mm (M85 − M100)
Ø
94007 Circlip pliers

94007−C8 1 Piece . . . . . Type C 8
94007−C19 1 Piece . . . . . Type C 19
94007−C40 1 Piece . . . . . Type C 40 WCH03320
94007−C85 1 Piece . . . . . Type C 85
94007−A10 1 Piece ..... Type A 10

94007−A19 1 Piece ..... Type A 19
94007−A40 1 Piece ..... Type A 40
94007−A85 1 Piece ..... Type A 85 WCH03320
94007−A41 1 Piece . . . . . Type A 41

WCH03320

Standard Tools
94009 Handle
94009−M5 1 Pieces . . . . M5x150
94009−M8 1 Pieces . . . . M8x100
94009−M10 1 Pieces . . . . M10x100 WCH03370
94011 1 Torque spanner ½ inch

No ratchet mechanism WCH02296
(Range 12 Nm to 68 Nm)
94011A 1 Torque spanner ½ inch
No ratchet mechanism
WCH02296
94012 1 Torque spanner ¾ inch

94012A adapter piece ¾ inch to ½ inch,
94012B shell type ratchet ½ inch to ½ inch WCH03324
94016−009 2 Manual ratchets

WLL 1000 kg, stroke 4 m


WCH03371
94017−006 2 Spur-geared chain block

94017−021 2 Spur-geared chain block

WCH03371
Shackle
94018A 4 WLL 3250 kg
94018B 4 WLL 4750 kg
94018C 4 WLL 8500 kg WCH02297
Chain
94019A 1 1089x1323 mm, WLL 5300 kg
94019B 1 1089x1089 mm, WLL 5300 kg
WCH02297

Standard Tools
94021 2 Trolley
WLL 5000 kg
WCH02297
Socket wrench inserts

94022A−10 AF10
94022A−SC Screwdriver
WCH02295
Socket wrench inserts ¾”

94022B−19 AF19
94022B−36 AF36
94022B−41 AF41
94022B−46 AF46
94022B−50 AF50
94022B−60 AF60
94022F Adapter piece ½ inch to ¾ inch WCH02295
94022G Adapter piece ½ inch to ⅜ inch

Crowfoot Wrench
94022C−22 AF22
94022C−24 AF24
94022C−42 AF42 WCH02295
Socket wrench inserts ⅜ inch

94022D−06 AF06
94022H 1 Disassembly and assembly tool
AF19
X
X = 313
WCH033226
94023A 1 Assembly tool

AF13 X
X = 225
WCH03326
94025 1 Tool box with socket wrench set

½ inch
(AF10−24, 26, 27, 28, 30,32, 33, 34, WCH03326
36)
94026 1 Tool box with hex. head drivers

½ inch
(AF5−10, 12, 14, 17) WCH03326

Standard Tools
94045 Eye bolt

94045−M8 6 Pieces .... M8
94045−M10 4 Pieces .... M10
94045−M12 3 Pieces .... M12
94045−M16 4 Pieces .... M16
94045−M20 2 Pieces .... M20
94045−M24 4 Pieces .... M24
94045−M30 3 Pieces .... M30 WCH03370
94045−M36 4 Pieces .... M36

94045−M48 6 Pieces .... M48
94048 Swivel lug

94048−M30 6 Pieces . . . . M30
WCH00113
94050 Tool for pressure measurement B G

for pneumatic elements
94050B 1 Pressure gauge 0−100 bar
94050C 1 Adapter
94050G 1 Pressure gauge 0−10 bar
94050H 2 Stop valve
WCH02814
H C
94051 Tool for pressure measurement A

for pneumatic elements
94051A 1 Pressure generator 700 bar
94051B 1 HP hose
94051C 1 1/4 inch connector C
94051D 1 1/4 inch NPT connector B
D
WCH00644

Standard Tools
94101 1 Inside micrometer Set

(7 pieces with a measuring range
50 mm to 1010 mm), with case
WCH02258
94110 1 Thrust device

To remove and install the
main bearing cover
X = 880 mm
Mass approx. 84 kg
X
WCH02251
94114 2 Double pre-tensioner

for elastic studs to main bearing, X
including a metal box
X = 311 mm
Mass approx. 68 kg
WCH02251
94116A 1 Lifting tool

X
To remove and install the main bearing
shell
X = 224 mm
(WLL 60 kg) WCH02247
94116B 1 Lifting tool

shell
X = 319 mm
(WLL 90 kg)
X
WCH02247
94116C 1 Lifting lug

cover
X = 120 mm
(WLL 900 kg) X WCH02247

Standard Tools
94117 1 Roller support

cover
X = 232 mm
(WLL 1200 kg)
X WCH02247
94117B 1 Deviation pipe

To remove and install the:
− main bearing, cover, shell
− connecting rod, cover, shell
− etc. X
X =700 mm
WCH02247
94118A 1 Turning-out device

To remove and install the main
bearing shell at the driving end
X = 234mm
(WLL 800 kg) X X
94118B 1 Turning-out device

To remove and install the main
bearing shell
X= 330 mm
(WLL 800 kg)
WCH02247
WCH02247
94119 1 Lifting plate X

shell
X = 347 mm
(WLL 800 kg)
WCH02247
94122 1 Feeler gauge X

X = 100 mm
Blade thickness 0.05 mm to 1.00 mm
(13-part) WCH03327

Standard Tools
94123 1 Bearing feeler gauge

for main bearing
X = 620 mm
Blade thickness 0.1 mm to 1.1 mm WCH03328
(11-part)
X
94126 1 Depth gauge

with case
X = 310 mm
WCH02250
94141A 1 Bracket X
main bearing shells
X = 300 mm
Y = 345 mm
Z = 1130 mm
Mass approx. 245 kg
Y
Z
WCH02253
94141B 1 Bracket X
main bearing shells (FCV3 Crank only)
X = 300 mm
Y = 345 mm
Z = 1130 mm
Mass approx. 245 kg
Y
Z
WCH02253

Standard Tools
94142 1 Work platforms

X =770 mm WCH02246
Z = 240 mm
Z
Mass approx. 10.4 kg
(max. loading 200 kg/m2) X
94143 1 Work supports

Includes: 3 grids each
X =1969 mm
Z = 947 mm
Mass approx. 136 kg
(Mass of 1 grid approx. 45 kg)
(max. loading 200 kg/m2) Z X
WCH02246
94145 1 Pre-tensioner X
for foundation bolts and engine stays
X = ∅ 156 mm
Y = 151 mm
WCH03329
94155 1 Carrier
To remove the thrust pads
X = 397 mm
Y = 169.5mm
Y X
Z = 310 mm
WCH02254
Z
94180 2 Pre−Tensioner X
for tie rods
X = 308 mm
Y = 375 mm
Mass approx 93.9 kg
Y
WCH03365

Standard Tools
94201 1 Lifting device

To remove and install the cylinder
Liner
X = 1195 mm 94201D 94201A
Mass approx. 265 kg
(WLL 6900 kg)
consisting of:
94201A, B, C, D
94201A 1 Lifting tool
X = 1116 mm
Mass approx. 168 kg
94201B 2 Holder X
X = 1182 mm 94201C 94201B
Mass approx.36.4 kg WCH02256
94201C 2 Flange coupling

X = Ø164 mm
94201D 1 Shackle
94202L 1 Chain
X = 1060mm
WLL 8000 kg
WCH02588
X
94208 1 Disassembly tool

To remove and install the antipolishing
ring
X = 638.5 mm
WCH03412
X
94209 1 Hook set

To remove and install the antipolishing
ring
X = 1000 mm
WLL 750 kg
X
WCH03345

Standard Tools
94210−005 1 Ring
For SAC A74−SD
X = 224 mm
WLL 5500 kg
X
WCH03477
X
94213 1 Disassembly tool
X = 104 mm
WCH02256

Standard Tools
94214 1 Disassembly and assembly tool

for gas admission valve
X = 473 mm
Includes:
94214C 1 Disassembly and
assembly tool
94214D 1 Disassembly and
assembly tool 94214H
94214C 94214G
94214E 1 Bush
94214F 1 Angle steel X
94214G 5 Hexagon head screw
M6x16 94214E
94214H 6 Hexagon socket head 94214F
cap screw M10x45
94214I 1 Gasket 94214D WCH033
Sealing between bush

and for gas admission
valve
94214K 3 O−Ring
94214A 1 Handle
X = 37.5 mm
X
WCH03331
94214B 1 Pressure reducing valve

X = 172 mm
WCH03331
94214L 2 Screw M10

X = 140 mm
94214M 2 Hexagon nut M10

SW 15 WCH03700

Standard Tools
94215A 8 Pre-tensioner
X
for cylinder cover studs
X = 224 mm
WCH03226
94224 1 Ladder
For the cylinder liner bore X
X = 350 mm
Y = 3550 mm
WCH03372
94225 1 Gauge
X
To measure the cylinder liner bore
(includes:
inside micrometer tool 94101)
X = 3423 mm WCH03372
94230 2 Distance holders

for removal and fitting of piston rod
gland and piston,
including 2 screws M16x50
X = 1100 mm X
WCH02259

Standard Tools
94231A 2 Clamping rings

Thick 62
X = 326mm B
C
D
94231B 2 Distance pieces
Thick 12
X = 344 mm
A
94231C 2 Distance pieces
Thick 11 WCH03373
X = 344 mm
94231D 2 Distance pieces X

Thick 9
X = 344 mm
94231E 1 Template
for fitting scraper rings
X = 262 mm
WCH03373
94232 1 Covering X
To cover the bore of the piston rod
gland in the cylinder jacket (when
piston and gland are removed)
X = ∅ 516 mm
Mass approx. 40 kg
WCH03373
94233 1 Assembly tool

To apply tension to the springs
In the piston rod gland and insulation X
bandage
X = 150 mm
WCH03373
94252 2 Pre-tensioner
for exhaust valve cage /
Bottom connecting rod
X = ∅ 229.6 mm
WCH02261

Standard Tools
94259 2 Pressure element

For the exhaust valve
X = 243 mm
WCH03377
94261 1 Valve seat disassembly and

assembly device
X = 616 mm
Mass approx. 43 kg
X
WCH03376
94263 2 Jack screws M12x110

To assemble the guide bush to the
exhaust valve,
includes:
2 hexagon nuts M12
WCH03388
94265 1 Suspension
for the cylinder cover
(WLL 2900 kg)
X = 696 mm X Y
Y = 243 mm
Mass approx. 46 kg WCH03388
94269C−41 1 Torque wrench extension

To loosen and tighten the
clamp nut (AF41) on the injection valve
with FAST
X = 106 mm
Y = 55 mm
94269C−55 1 Socket wrench insert X

To loosen and tighten the
clamp nut (AF55) on the injection valve
with FAST
X = 155 mm Y
WCH01208
Y = 55 mm
94269C−65 1 Torque wrench extension

To tighten the coupling nut
(AF65) on injection valve with FAST
X = 144.5 mm
Y = 75 mm

Standard Tools
94270−01 1 Grinding device

To grind the fuel injection valve bore
bore.
X = 523 mm 94270−1D
WCH03882
94270−02 Grinding device

To grind the pilot injection valve bore
bore.
X = 374 mm
94270−2D
X
WCH03882
94270−03 Grinding device

To grind the prechamber bore. Y
X = 172 mm
94270−3D
Y = 130 mm
WCH03882
94270C 2 Hexagon head bolt

For the injection valve
X = 170 mm
X
WCH02263

Standard Tools
94270D 2 Stud bolt

X = 176 mm
X
WCH02263
94270E 2 Stud bolt

X = 176 mm
without nut
X
WCH03340
94270F 1 Support plate

X = 104 mm
94270G 2 Hexagon head screw with dog point

M12x90
X = 176 mm
X
WCH03340

Standard Tools
94272 1 Tool injector test bench

To set and do a test of of the:
− injection valve
− safety valve
X
− relief valve
X = 1458 mm
includes:
94269A−55 1 Slugging wrench

To loosen the
Coupling nut 94269A−55 WCH03335
(AF55 to pilot
injection valve)
X= 219 mm 94269A−65
X
94269A−65 1 Slugging wrench
To loosen the
Coupling nut (AF65) WCH01208
X= 232 mm
X
WCH01208
94269B 1 Hydraulic cylinder
To loosen and
tighten the coupling
nut on the injection valve WCH01208
X = 395 mm 94269B
94272B 1 Connecting piece 94272B

To adjust the X
injection valve
X = 133 mm
X
94272F 1 Adapter
For the pilot injection
valve WCH02260
X = 134.5 mm
94272F
See next page
WCH02804

Standard Tools
94272 Continued
X
9427X 1 Assembly tool
X = 150 mm
Y = 100 mm X
WCH03335
Y
94273
94273 1 Valve holder

For the OBEL test bench
To attach the injection Y
valve
X = 576 mm
Y =468 mm
X
WCH03070
94275
94275 1 HP hose
For the OBEL test bench
WCH01208
To do tests and loosen /
X
tighten the coupling nut
on the injection valve
X = ca. 1000 mm
Max. working pressure
1800 bar

Standard Tools
94272 Continued
94272A 1 Valve holder

To do checks of the fuel
overpressure safety
valve WCH03335
X =170 mm
94272A
94272B 1 Connecting piece
X
To adjust the injection
94272B
valve
X = 130 mm X
94272C
94272C 1 Valve holder
To do checks and X
Adjust the relief valve
on the cylinder Cover
X = 68 mm

Standard Tools
94278A 1 Nozzle disassembly tool

for injection nozzle disassembly
X = AF 46 mm
X WCH02740
94278B 1 Nozzle assembly tool

for injection nozzle assembly
X = AF 41 mm
X WCH02740
94279 1 Template
To do checks of the wear rate on the
exhaust valve seat X
X = 160 mm
WCH02381
94289 1 Assembly tool (bush with dowel pin)

for dismantling and assembling
injection valve
X = 120 mm X
WCH00896
94289A 1 Bush
injection valve
X = 70 mm
WCH00897 X
94289B 1 Bush
injection valve
X = 42 mm
WCH00897 X

Standard Tools
94292 1 Template
To do checks of the wear rate of the
exhaust valve spindle
X = 300 mm
WCH02386
X
94305 1 Crankshaft equipment

To measure the crank deflection
(in wooden box)
X = 364 mm
WCH03342
X
for the connecting rod studs on the top
end bearing
X = 138 mm
X WCH02265
For the turning gear pre-tensioning,
X = 130 mm
WCH02264
94321 1 Link
For the connecting rod assembly
X = 268 mm
X
WCH02266

Standard Tools
94322 2 Support
For the crosshead
X = 460 mm
X
WCH02266
94322A 1 Support (Engines with ELBA)

For the crosshead
X = 800 mm
X
WCH03102
94324 1 Lifting tool

For the connecting rod assembly
X = 336 mm
(WLL 8200 kg)
X
WCH02266
94325 1 Chain
To remove the crosshead pin
2 slings of 424 mm
Mass approx. 4 kg
(WLL 1500 kg)
WCH02432
94326 1 Console Frame

To remove and install the bottom end
bearing shell
X = 340 mm
Mass approx. 21 kg X
(WLL 60 kg)
WCH03382

Standard Tools
94327 1 Chain
To remove and install the bottom
connecting rod bearing shell
4 slings of 654 mm
(WLL 1120 kg)
WCH02420

For the connecting rod bearing
assembly X
X =710 mm
Includes:
94333A 2 Bolts Y
Y = 299 mm
WCH03344
94334 1 Bracket
To remove and install the connecting
rod (∅ 880 mm), includes:
X = 1448 mm
Mass approx. 134 kg
WCH02270
94334A 1 Connecting element with shackle

X = 116 mm
(WLL 4500 kg)
X
WCH02270
94335 1 Stop plate

with screw M24x45
To do an inspection of the top end
bearing
X = 226 mm
X
WCH02380

Standard Tools
94335A 1 Chain
To lift / lower top bearing cover
2 slings of 314 mm
WCH02380
94336 1 Connecting flange X

for the lubrication of the top and bottom
end bearings
X = ∅ 140 mm
WCH03343
94337 2 Lifting tools

with 4 screws M20x90
for the connecting rod
X = 478 mm
WLL:
X
− vertical 4000 kg
− horizontal 2600 kg
WCH02270
94338 1 Piston ring tensioning device

X = 550 mm
Y = 296.1 mm X
Ring type SCP2CC13 = 13 mm
94338A 1 Piston ring tensioning device

X = 550 mm
Y = 296.1 mm
Ring type GTP1CC22 = 22 mm 94338 or
94338A Y
WCH02274

Standard Tools
For piston rod foot fastening and piston
head.
includes a metal box
X = ∅ 76 mm
WCH02273

For the removal and installation of the
piston
X = 345 mm
X
WCH03345
94342 1 Assembly tool X

To install a piston
X = Æ 818 mm
WCH03345
94344 1 Disassembly and assembly tool

for the removal and installation of
piston and rod gland and piston
includes:
94344A 1 Distance piece
X = 405 mm
94344B 2 Chains
WCH03345

Standard Tools
94350 1 Device
To hold the piston and piston rod gland
X = 1030 mm
Y = 1351 mm
Z = 1342 mm
Mass approx. 420 kg
Z
X
WCH03345
94364A 3 Jacking screws

To remove the piston head
M20x220
94364B 2 Jacking screws

To remove the spray plate
M12x70
94364C 3 Jacking screws WCH03383
To remove the piston skirt

M20x70
94366 1 Template X
To do a check of the piston crown
contour
X = 788.1 mm
WCH03383
94410 1 Adjustment devices

To align the intermediate wheel
X = 248 mm
X
WCH02276
94430 1 Roller lifting tools

for cutting out and cutting in the fuel
pump,
includes: elastic bolts and round nut
X = 197 mm
X
WCH02278

Standard Tools
94430A 1 Pre-tensioner X
for roller lifting tool
X = ∅ 108 mm
WCH02278
94550 1 Clamping ring 2-parts

X = ∅ 210 mm
WCH02281
94551 1 Fitting and dismantling device

To remove and install the guide pin on
the fuel pump
X = 334 mm
WCH02281

with hexagon head screws M14x40
To remove and install the fuel pump
X = ∅ 120 mm
(WLL 600 kg)
WCH02281

Standard Tools
94552A 1 Cover
X = ∅ 290 mm
94552B 1 Blind flange

94552C 94552A
X = ∅ 130 mm X
X
X
94552C 1 Blind flange
X = ∅ 100 mm
94552D 1 Screw plug 94552D 94552B

94552E X X
X = 15 mm WCH03701
94552E 1 Plug
X = 19 mm
94553 2 Rod
Guide rod for the fuel pump WCH02281
X = 470 mm X
94555 2 Distance piece

For teh fuel pump
X = 95 mm
X
WCH02281
94556 1 PCV test block with tube

To do a pressure check of the pressure
control valve
X = 954 mm
X
WCH02283

Standard Tools
94557 2 Pre-tensioning jacks X

For the elastic bolts on the camshaft
bearing
X = ∅ 112 mm
WCH03347
94566 2 Support
For the camshaft assembly, Y1
Includes the clamp nut
X = 925 mm
Y1 = 180 mm
X
WCH02278
94664 2 Bracket
To replace the scavenge air cooler
X = 1796 mm
WCH02285
94664A 1 Dismantling pipe

X = 3599 mm
X WCH02285
94666 1 Chains (double sling)

scavenge air cooler
X = 625 mm X
WCH02285

Standard Tools
94566B 1 Holder
for camshaft assembly,
Includes the hexagon socket screw
X
X = 290 mm
WCH02278
94566C 1 Holder
for the camshaft assembly,
includes hexagon socket screw
X = 290 mm X
WCH02278
94567 1 Assembly template X

To remove and install the bearing shells
of the fuel pump unit
X = 90 mm
WCH02278
94567A 1 Assembly template

To install the bearing shells to the fuel X
pump unit
X = 177 mm
WCH02278
94567B 1 Jacking screw X

To assemble the camshaft
X = ∅ 75 mm
WCH02278

Standard Tools
94569 1 Blank flange

For the fuel pump,
includes screws M14x25
X = ∅ 120 mm
X WCH02278
94569A 1 Blank flange

For the intermediate piece,
includes screws M14x50
X = ∅ 116 mm
X
WCH02278
94592 1 Fuel pump rack

For the fuel pump 94592C
X = 1039 mm
Mass approx. 86.6 kg 94592B
includes:
94592E
94592A 1 Oil trough
94592B 2 Limiter
X
with 4 screws M16x50
and washers
94592D
94592C 2 Screws M20
94592A
94592D 4 Screws (M12x100)
WCH02281
94592E 2 Screws (M12x90)
94592M 1 Mirror
WCH02281
94593 1 Guide bracket

for pre-tensioning device
X = ∅ 370 mm
Mass approx. 23.5 kg 94593C
94593A 1 Ring 94593D
94593B 1 Ring (2-part) 94593A
94593C 2 Guide rods
94593B
94593D 4 Screws M12x130 94593E
With special nuts
94593E 2 Screws M30x110 X WCH02281

Standard Tools
94597 1 Mandrel
To install the seal into the bottom spring
carrier and the bottom housing of the
fuel pump X
X = ∅ 70 mm
94597A 1
Mandrel WCH02281
To install the seal into the bottom spring X
carrier
X = ∅ 40 mm
94598
94598 1 Pneumatic impact wrench

To loosen and tighten the fuel pump on
the fuel pump unit
X = 271 mm
94598A
X
94598A 2 Extensions
X = 400 mm
94598B
94598B 1 Socket wrench insert
X = 100 mm
WCH02281
X
94650 2 Sling
X = 1750 mm
WCH02379

Standard Tools
In case of a turbocharger breakdown

Cover to exhaust manifold outlet:
94653A−M60 for MET 60 MB, X = 680 mm, 12 holes
94653A−A175 for ABB 175, X = 948 mm, 16 holes
Cover to turbocharger inlet:

94653B−M60 for MET 60 MB, X = 680 mm, 16 holes
94653B−A175 for ABB 175, X = 726 mm, 16 holes
94653B−A265 for ABB 265, X = 680 mm, 12 holes
n/a for ABB 270, use 94653A−A270
n/a for ABB 275, use 94653A−A275
Cover to scavenge air receiver:

94653C−M60 for MET 60 MB, X = 640 mm, 16 holes
94653C−A175 for ABB 175, X = 680 mm, 16 holes
X
94653C−A265 for ABB 265, X = 555 mm, 16 holes 000.487/93

Cover to turbocharger outlet:

94653D−M60 for MET 60 MB, X = 600 mm, 16 holes
94653D−A175 for ABB 175, X = 900 mm, 16 holes
n/a for ABB 265, use 94653C−A265
94663A 1 Support left

Includes a safety chain 94663D and
94663C
safety lug
To remove and install the scavenge air 94663D
cooler
X = 681 mm
(WLL 3800 kg)
X
WCH02285
94663B 1 Support − right

94663C
Includes a safety chain 94663D and
safety lug 94663C 94663D
To remove and install the scavenge air
cooler
X = 681 mm
(WLL 3800 kg)
Mass approx. 39.5 kg X
WCH02285

Standard Tools
94663I 1 Support
To install the scavenge air cooler
X = 960 mm
WCH02285

To remove the water separator,
X
includes:
4 Hexagon head screw M12x30
X = 300 mm
(WLL = 240 kg
WCH02287
94667G 1 Holder
To remove the water separator
X = 420 mm
X
WCH02287
94667H 1 Holder
To install the water separator X
X = 540 mm
WCH02287

Standard Tools
94701 1 Adjusting tool

For the ELBA assembly
X = 139 mm X
WCH03385
94702 1 Transportation tool

X = 200 mm WCH03385
94703 1 Turning device

X = 1089 mm
X
WCH03385

X = 368 mm X
WCH03385
94705 2 Alignment tools

X = 326 mm
WCH03385

Standard Tools
94831 1 Blind flange X

To blank off the starting air pipe during
emergency operation
X = ∅ 235 mm
WCH02289
94841 1 Grinding tool 94841

For the hydraulic pipe
X = ∅ 65 mm, R100 94841A
94841A 1 Stencil
Y = 65 mm
X
Y
WCH02756
94870 1 Grinding device

94870F
For the HP fuel pipe
X = 166 mm 94870E
includes:
94870G X
94870E 1 Screw-on sleeve
AF60
WCH02751
94870F 1 Grinding tool
with countersunk screw
M8 94870H
94870G 1 Lock nut
M36x2, AF46
X
94870H 1 Template
X = 70 mm WCH02751
94871 1 Grinding tool 94871

for the injection pipe
X = ∅ 60 mm, R30.5 94871A
94871A 1 Stencil
Y = 50 mm
X
Y
WCH02751

Standard Tools
94573 Assembly Tool

X
for gear coupling on pilot fuel pump
X = 70 mm
Y = 181 mm
x
Y
WCH03847
94930 1 SW-download package

ECS for uni-tool
includes:
WCH03349
94930A 1 UBS to CAN adapter ca. 1000 80
94930B 1 CAN cable (approx. 2.5 m)
94930C 1 Ethernet adapter cable
(software tool)
94844 1 Lubrication device

for supply unit lubrication during
maintenance
X = 600 mm Y
Adaptors: Y1
Y = 40 mm X
Y1 =45 mm Z
Flexible hose:
Z = 3500 mm
WCH03845

Standard Tools
Hydraulic parts and pump

94931 1 HP oil pump
Operation pressure. Maximum 94934F
permitted pressure is 2800 bar
WCH03390
94934F 1 Adapter piece
94934 2 Connection block
WCH03390
94934A 2 Pressure gauges
WCH03390
94934C 1 Distributing piece
WCH03390
94934G 4 Coupling elements
WCH03390
94934H 1 Pressure gauge

0−25 bar
WCH02228
94934I 1 Connection nipple

To do a test of the lubrication quill
94934J 1 Tredo joint 94934J

To connect the nipple 94934I 94934I WCH03390

Standard Tools
94935 5 HP hoses
X
with closing valves and coupling
sockets
X = 2130 mm
WCH03390
Operation pressure max. 2000 bar
94935A 5 Flexible hoses

X
with closing valves and coupling
sockets
X = 1210 mm
WCH03390
94935C 1 Hose
To drain oil from pre-tensioning jacks
WCH03390
94936 2 Hydraulic ram

with closing valves
Operation range 933 kN to 1002 kN
(95 t to 100 t)
WCH03390
94942 1 Hydraulic unit

WCH03390

Recommended Special Tools

for cylinder cover pre-tensioners
X1
Includes: 94209A
94209A 1 Wire rope sling with 94215D
hook 94215C
94215C 8 Shackle 94215G
94215D 8 Hooks
X1 = 1000 mm
WCH03375
94215G 1 Lifting tool
94234 1 Platform X
for piston rod gland removal inside the
engine
X = ∅ 850 mm
WCH02382

For the piston rod gland removal in the
engine X
X = 453 mm
WCH03474
94259 2 Pressure element

For the exhaust valve
X = 243 mm
WCH03377

94291 1 Valve grinding device complete

94291A
For the valve spindle and valve seat
94291A 2 Grinding discs

(C-M No. 11373-01-01)
WCH03339 WCH03339
94299 1 Grinding device X

X = ∅ 834 mm
WCH02384
94300 1 Tool Cupboard

X
X = 725 mm
Y = 1000 mm
Z = 717 mm
Mass approx. 133 kg
WCH02253
Z
94349 1 Plate
For the piston pressure tests
X = 336 mm
X
WCH02275

94356 1 Equipment case

with instruments
To measure the thickness of chrome-
ceramic-layer on the piston rings
WCH01216
94366A 1 Template X
To do a check of the piston crown
contour
(when the piston is installed)
X = 849.7 mm WCH03383
94929 2 Connecting cables with plugs

for emergency cylinder lubrication
Connector (plug C)
Plug B with cable: length = 0.5 m
Plug C with cable: length = 2.5 m
WCH01087
94412E Fork Wrench

X = 110 mm
X
WCH03702
94412F Tightening device

X = 277 mm
WCH03702

94595 1 Hydraulic ram

for assembling fuel pump
X = ∅ 270 mm
consisting of:
WCH02281
94595D 1 Piston reset device with short push

rod
X = 255 mm
X
WCH02281
94595E 2 Screw M30x400

X = 418.7 mm
X
WCH02281
94595C 2 Long push rod

X = 470 mm
X
WCH02281

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Maintenance Manual

Document ID: DBAD226888

Winterthur Gas & Diesel Ltd. 24hrs Support:

Document ID: DBAD226888

Winterthur Gas & Diesel Ltd. 24hrs Support:

X72DF Summary for Maintenance Manual

5555-2/A1 2018-01 Update WinGD Fuel Pressure Control New document x

Date of publication 2018-01

Date of publication 2018-02

1 Bedplate and Tie Rod

2 Cylinder Liner and Cylinder Cover

3 Crankshaft, Connecting Rod and Piston

4 Driving Wheels and Shut-off Valve for Starting Air

5 Supply Unit, Injection and Exhaust Valve Control

6 Scavenge Air Receiver and Auxiliary Blower

9 Crank Angle Sensor Unit, Tools

General Information Group 0

For Your Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1

Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1

Bedplate: Foundation Bolts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112−1/A1

Winterthur Gas & Diesel Ltd. X72DF / MM / 2016

Engine Stays with Friction Shims: Pre-tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A1

Hydraulic Engine Stays: Oil Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A2

Tie Rod: Pre-tension Check and Tie Rods Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1903−1/A1

Cylinder Liner, Cylinder Cover and Fuel Injection Group 2

Lubricating Quill: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A1

2016 / MM / X72DF Winterthur Gas & Diesel Ltd.

Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722−1/A1

Starting Valve: Removal, Disassemble, Grinding, Assemble, Installation . . . . . . . . . . . . . . . . . . . . 2728−1/A1

Winterthur Gas & Diesel Ltd. X72DF / MM / 2018−10

Pilot Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2790−1/A1

Crankshaft, Connecting Rod and Piston Group 3

Crankshaft: Crank Deflection − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103−1/A1

Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−1/A1

Axial Damper: Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3140−1/A1

Turning Gear: Teeth and Screwed Connections − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3206−1/A1

Crankcase: Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−1/A1

2016 / MM / X72DF Winterthur Gas & Diesel Ltd.

Driving Wheels and Shut-off Valve for Starting Air Group 4

Starting Air Shut-off Valve: Cleaning and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325−1/A1

Winterthur Gas & Diesel Ltd. X72DF / MM / 2016

Pilot Fuel Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−1/A1

Fuel Pressure Control Valve: Removal, Check, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A1

Fuel Pressure Control Valve: Manual Release Valve − Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A2

Fuel Overpressure Safety Valve: Removal, Check and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−2/A1

Flow Limiting Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−3/A1

Fuel Pump Actuator

Servo Pump Unit

X72DF / MM / 2018−02 Winterthur Gas & Diesel Ltd.

Scavenge Air Receiver − Clean and do Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6420-1/A1

Cylinder Lubrication and Balancer Group 7

Cylinder Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7218−1/A1

Integrated Electric Balancer (iELBA)

Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8135−1/A1