WinGD X82-B User manual

Maintenance Manual
X82-B
Issue 001 2020-10
Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. [phone]
Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax [phone]
Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com

© 2020 Winterthur Gas & Diesel Ltd. – All rights reserved
No part of this publication may be reproduced or copied in any form or by any means (electronic,
mechanical, graphic, photocopying, recording, taping or other information retrieval systems)
without the prior written permission of the copyright holder. Winterthur Gas & Diesel Ltd. makes
no representation, warranty (express or implied) in this publication and assumes no responsibility
for the correctness, errors or omissions of information contained herein. Information in this
publication is subject to change without notice.
NO LIABILITY, WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS
ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS
INTENDED FOR INFORMATION PURPOSES ONLY.
www.wingd.com

Table of contents
1 Introduction
1.1 Maintenance Manual - change record........................................22
1.2 Preface..................................................................24
1.3 Technical documentation set................................................26
1.4 Data module codes (procedural data)........................................28
1.5 Data module codes (descriptive data)........................................30
1.6 Data module codes (illustrated parts data)....................................32
1.7 About this book...........................................................34
1.8 About the engine..........................................................36
1.9 List of abbreviations.......................................................42
2 Safety
2.1 Safety precautions and safety rules..........................................48
3 General data for maintenance
3.1 Lifting tools...............................................................52
3.2 Jointing compounds.......................................................56
3.3 Clearances - general......................................................58
3.4 Clearances...............................................................60
3.5 Torque values - standard screws............................................76
4 General maintenance procedures
4.1 Do maintenance work - general procedure................................... 80
4.2 Tighten a round nut with a pre-tensioner..................................... 82
4.3 Loosen a round nut with a pre-tensioner..................................... 86
4.4 Do a check of the pre-tension...............................................90
5 Maintenance schedule
5.1 Maintenance schedule.....................................................94
6 Group 1 - Engine frame and bearings
6.1 Foundation bolts
6.1.1 Bedplate - do a check of the foundation bolts.............................96
6.2 Main bearing - bearing shell number 1
6.2.1 Main bearing - bearing shell - No. 1 - prepare before removal...............98
6.2.2 Main bearing - bearing shell - No. 1 - remove............................100
6.2.3 Main bearing shell - No.1 - do a check..................................108
6.2.4 Main bearing - bearing shell - No. 1 - install............................. 110
6.3 Main bearing - bearing shell number 2 to #
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6.3.1 Main bearing - bearing shell - No. 2 to # - prepare before removal..........118
6.3.2 Main bearing - bearing shell - No. 2 to # - remove........................120
6.3.3 Main bearing shell - No.2 to # - examine................................130
6.3.4 Main bearing - bearing shell - No. 2 to # - install......................... 132
6.4 Main bearing cover - No. 1
6.4.1 Main bearing cover - No.1 - remove....................................140
6.4.2 Main bearing cover - No.1 - install..................................... 146
6.5 Main bearing cover - No. 2 to #
6.5.1 Main bearing cover - No. 2 to # - remove............................... 152
6.5.2 Main bearing cover - No. 2 to #- install................................. 160
6.6 Thrust bearing
6.6.1 Thrust bearing - examine the housing..................................166
6.6.2 Thrust bearing - do a check of the axial clearance with a dial gauge........168
6.6.3 Thrust bearing - do a check of the axial clearance with a inside micrometer. 170
6.6.4 Thrust bearing - remove the pads......................................174
6.6.5 Thrust bearing - install the pads....................................... 180
6.7 Engine stays
6.7.1 Engine stays (friction shims) - do a check of the pre-tension...............186
6.7.2 Engine stays (hydraulic) - do a check of the oil pressure..................188
6.8 Tie rod
6.8.1 Tie rod - do a check of the pre-tension..................................190
6.8.2 Tie rod - remove.....................................................192
6.8.3 Tie rod - install...................................................... 194
7 Group 2 - Cylinder
7.1 Cylinder liner
7.1.1 Cylinder liner - do a check of the bore..................................200
7.1.2 Cylinder liner - remove...............................................206
7.1.3 Cylinder liner - preserve..............................................212
7.1.4 Cylinder liner - grind................................................. 216
7.1.5 Cylinder liner - grind the lubricating groove..............................218
7.1.6 Cylinder liner - grind the scavenge ports................................220
7.1.7 Cylinder liner - install.................................................222
7.2 Lubricating quill
7.2.1 Lubricating quill - remove.............................................228
7.2.2 Lubricating quill - do a functional test...................................230
7.2.3 Lubricating quill - install.............................................. 232
7.3 Piston rod gland
7.3.1 Piston rod gland - remove............................................ 236
7.3.2 Piston rod gland - do a check of the wear...............................240
7.3.3 Piston rod gland - install..............................................242
7.4 Cylinder cover
7.4.1 Cylinder cover - remove..............................................246
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7.4.2 Cylinder cover - grind the sealing face for injection valve..................252
7.4.3 Cylinder cover - install................................................256
7.5 Conventional injection valve
7.5.1 Conventional injection valve - remove..................................262
7.5.2 Conventional injection valve - prepare before the test.................... 264
7.5.3 Conventional injection valve - do a functional test........................266
7.5.4 Conventional injection valve - adjust................................... 270
7.5.5 Conventional injection valve - disassemble..............................272
7.5.6 Conventional injection valve - assemble................................278
7.5.7 Conventional injection valve - install....................................284
7.6 Starting air valve
7.6.1 Starting air valve - remove............................................288
7.6.2 Starting air valve - disassemble....................................... 292
7.6.3 Starting air valve - grind..............................................294
7.6.4 Starting air valve - assemble..........................................296
7.6.5 Starting air valve - install............................................. 298
7.7 Exhaust valve
7.7.1 Exhaust valve - remove.............................................. 300
7.7.2 Exhaust valve - disassemble..........................................304
7.7.3 Exhaust valve - remove the seat (recommended procedure).............. 308
7.7.4 Exhaust valve - remove the seat (alternative procedure)..................310
7.7.5 Exhaust valve - do a check of the seat................................. 312
7.7.6 Exhaust valve - grind the seat.........................................316
7.7.7 Exhaust valve - install the seat........................................ 318
7.7.8 Exhaust valve - assemble............................................ 320
7.7.9 Exhaust valve - install................................................328
8 Group 3 - Crankshaft, connecting rod and piston
8.1 Crankshaft
8.1.1 Crankshaft - do a check of the crank deflection..........................336
8.1.2 Crankshaft - install the work platform...................................342
8.1.3 Crankshaft - remove the work platform................................. 344
8.2 Torsional vibration damper
8.2.1 Torsional vibration damper - examine.................................. 346
8.3 Axial vibration damper
8.3.1 Axial vibration damper - disassemble...................................348
8.3.2 Axial vibration damper - assemble.....................................352
8.4 Turning gear
8.4.1 Turning gear - do a check of the screwed connections....................358
8.4.2 Turning gear - lubricate the teeth...................................... 360
8.5 Connecting rod
8.5.1 Connecting rod - prepare before removal...............................364
8.5.2 Connecting rod - remove............................................. 368
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8.5.3 Connecting rod - install...............................................378
8.5.4 Connecting rod - remove the top end bearing........................... 390
8.5.5 Connecting rod - remove the bottom end bearing........................392
8.5.6 Connecting rod - examine the bearing shells............................400
8.5.7 Connecting rod - install the bottom end bearing..........................402
8.5.8 Connecting rod - install the top end bearing.............................412
8.5.9 Connecting rod - remove the top end bearing cover......................418
8.5.10 Connecting rod - install the top end bearing cover........................424
8.6 Crosshead
8.6.1 Crosshead - remove.................................................430
8.6.2 Crosshead - do a check of the clearances.............................. 444
8.6.3 Crosshead - install...................................................448
8.7 Piston
8.7.1 Piston (installed) - do checks of the surface and clearances...............458
8.7.2 Piston - prepare before removal.......................................462
8.7.3 Piston - remove..................................................... 468
8.7.4 Piston - disassemble.................................................472
8.7.5 Piston (removed) - do checks of the surface and clearances.............. 476
8.7.6 Piston - assemble................................................... 480
8.7.7 Piston - install.......................................................484
8.8 Piston ring
8.8.1 Piston ring - remove................................................. 490
8.8.2 Piston ring - examine................................................ 492
8.8.3 Piston ring groove (piston installed) - do a check with a ring piece..........496
8.8.4 Piston ring groove (piston removed) - do a check with a calliper gauge..... 498
8.8.5 Piston ring groove (piston removed) - do a check........................500
8.8.6 Piston ring - install...................................................502
8.8.7 Piston ring - do the preservation.......................................504
9 Group 4 - Supply unit drive and control components
9.1 Driving wheels
9.1.1 Gear wheel crankshaft - examine the teeth..............................508
9.1.2 Gear wheel crankshaft - do a check of the teeth backlash.................510
9.1.3 Driving wheel gear train - monitor the condition..........................514
9.2 Shut-off valve for starting air
9.2.1 Shut-off valve for starting air - disassemble............................. 516
9.2.2 Shut-off valve for starting air - assemble................................522
9.2.3 Shut-off valve for starting air - do a test of the operation.................. 526
10 Group 5 - Supply unit, pumps and control valves
10.1 Servo oil pump
10.1.1 Servo oil pump - do a check for wear and damage.......................530
10.1.2 Servo oil pump - remove............................................. 532
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10.1.3 Servo oil pump - install...............................................536
10.2 Fuel pump
10.2.1 Fuel pump - remove................................................. 540
10.2.2 Fuel pump - disassemble.............................................544
10.2.3 Fuel pump - assemble............................................... 550
10.2.4 Fuel pump - install...................................................558
10.2.5 Fuel pump - do a test of the operation..................................562
10.3 Fuel pump actuator
10.3.1 Fuel pump actuator - calibrate.........................................566
10.3.2 Fuel pump actuator - adjust...........................................570
10.4 Fuel pressure control valve
10.4.1 Fuel rail - remove the pressure control valve............................ 574
10.4.2 Fuel rail - do a check of the pressure control valve.......................576
10.4.3 Fuel rail - install the pressure control valve..............................580
10.5 Fuel overpressure safety valve
10.5.1 Fuel rail - remove the overpressure safety valve.........................582
10.5.2 Fuel rail - do a check of the overpressure safety valve....................584
10.5.3 Fuel rail - install the overpressure safety valve...........................588
10.6 Injection control unit
10.6.1 Injection control unit - remove.........................................590
10.6.2 Injection control unit - install...........................................594
10.6.3 Injection control unit - do the preservation...............................598
10.7 Supply unit
10.7.1 Supply unit camshaft and bearing shell - prepare before removal.......... 600
10.7.2 Supply unit camshaft and bearing shell - remove........................ 604
10.7.3 Supply unit camshaft and bearing shell - install..........................608
10.7.4 Supply unit bearing bush - remove.....................................612
10.7.5 Supply unit bearing bush - install...................................... 614
10.7.6 Supply unit camshaft and bearing shell - do the follow-on work............ 616
10.8 Exhaust valve control unit
10.8.1 Exhaust valve control unit (VCU) - remove..............................620
10.8.2 Exhaust valve control unit (VCU) - disassemble......................... 622
10.8.3 Exhaust valve control unit (VCU) - assemble............................624
10.8.4 Exhaust valve control unit (VCU) - install............................... 626
11 Group 6 - Scavenge air components
11.1 Scavenge air receiver
11.1.1 Scavenge air receiver - examine.......................................632
11.1.2 Scavenge air receiver - do a check of the relief valve.....................636
11.1.3 Scavenge air receiver - remove the flaps............................... 638
11.1.4 Scavenge air receiver - install the flaps.................................640
11.2 Auxiliary blower
11.2.1 Auxiliary blower - remove.............................................642
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11.2.2 Auxiliary blower - install.............................................. 648
11.3 Scavenge air cooler
11.3.1 Scavenge air cooler - remove.........................................654
11.3.2 Scavenge air cooler - install...........................................662
11.4 Water separator
11.4.1 Water separator - remove.............................................666
11.4.2 Water separator - install..............................................672
12 Group 7 - Cylinder lubrication
12.1 Cylinder lubrication system
12.1.1 Cylinder lubrication system - do a functional test.........................678
12.1.2 Cylinder lubrication system - bleed.....................................680
12.1.3 Cylinder lubricating pump - remove.................................... 684
12.1.4 Cylinder lubricating pump (pulse) - examine.............................688
12.1.5 Cylinder lubricating pump - install......................................692
13 Group 8 - Pipes
13.1 HP servo oil pipe
13.1.1 HP servo oil pipe - remove............................................696
13.1.2 HP servo oil pipe - grind the sealing face............................... 700
13.1.3 HP servo oil pipe - install............................................. 704
13.2 Hydraulic pipe exhaust valve
13.2.1 Hydraulic pipe exhaust valve - remove................................. 708
13.2.2 Hydraulic pipe exhaust valve - grind the sealing face.....................712
13.2.3 Hydraulic pipe exhaust valve - install...................................716
13.3 HP fuel pipe
13.3.1 HP fuel pipe (fuel rail to injection valve) - remove........................ 720
13.3.2 HP fuel pipe (fuel rail to injection valve) - grind the sealing face............724
13.3.3 HP fuel pipe (fuel rail to injection valve) - install..........................728
13.3.4 HP fuel pipe (fuel pump to fuel rail) - remove............................732
13.3.5 HP fuel pipe (fuel pump to fuel rail) - grind the sealing face................740
13.3.6 HP fuel pipe (fuel pump to fuel rail) - install..............................744
14 Group 9 - Monitoring instruments
14.1 Crank angle sensor unit
14.1.1 Crank angle sensor unit (flywheel) - proximity sensor - remove............ 752
14.1.2 Crank angle sensor unit (flywheel) - proximity sensor - install..............756
14.1.3 Crank angle sensor unit (supply unit) - proximity sensor - remove..........760
14.1.4 Crank angle sensor unit (supply unit) - proximity sensor - install........... 764
15 Tools
15.1 General for tools.........................................................770
15.2 Standard tools...........................................................772
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15.3 Recommended tools..................................................... 814
16 Tightening instructions
16.1 Tightening instructions....................................................824
17 Maintenance overview
17.1 Maintenance overview....................................................826
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