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.
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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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List of tables
1 Introduction
1-1 Change record ............................................................................................. 22
1-2 Data module codes (procedural data) ......................................................... 28
1-3 Data module codes (descriptive data) ......................................................... 30
1-4 Data module codes (illustrated parts data) .................................................. 32
1-5 List of abbreviations and acronyms ............................................................. 42
3 General data for maintenance
3-1 Lifting capacities (for information only) ........................................................ 53
3-2 Jointing compound ...................................................................................... 56
3-3 Crankshaft and thrust bearing - clearances ................................................ 60
3-4 Crankshaft and main bearings .................................................................... 62
3-5 Crosshead guide ......................................................................................... 63
3-6 Cylinder liner ............................................................................................... 64
3-7 Piston rod gland .......................................................................................... 65
3-8 Exhaust valve - spindle and guide bush ...................................................... 66
3-9 Connecting rod - top and bottom end bearings ........................................... 67
3-10 Piston and piston rings ................................................................................ 68
3-11 Supply unit - drive wheels ........................................................................... 71
3-12 Fuel and servo pump units .......................................................................... 73
3-13 Fuel pump ................................................................................................... 75
3-14 Torque value - applicable decrease ............................................................. 76
3-15 Torque values - standard screws ................................................................. 77
7 Group 2 - Cylinder
7-1 Exhaust valve, clearance X ......................................................................... 313
7-2 Damper settings .......................................................................................... 324
8 Group 3 - Crankshaft, connecting rod and piston
8-1 Maximum permitted difference in mm ......................................................... 339
8-2 Crank-web deflection limits in mm ............................................................... 340
8-3 Recommended suppliers ............................................................................. 362
8-4 ISO VG 1000/1500 suppliers ....................................................................... 410
8-5 ISO VG 1000/1500 suppliers ....................................................................... 413
8-6 Torque values .............................................................................................. 481
8-7 Examples of wear rate ................................................................................. 494
8-8 Examples of remaining service life .............................................................. 494
10 Group 5 - Supply unit, pumps and control valves
10-1 Distance X for VCU ..................................................................................... 628
13 Group 8 - Pipes
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13-1 Distance X for HP servo oil pipe .................................................................. 701
13-2 Distance X for hydraulic pipe exhaust valve ................................................ 717
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List of illustrations
1 Introduction
1-1 Side view (generic) ...................................................................................... 37
1-2 End view (generic, seen from the driving end) ............................................ 38
1-3 Standard and LEFT engine (generic, seen from the driving end) ............... 39
1-4 Engine numbering (generic) ........................................................................ 40
3 General data for maintenance
3-1 RUD-eye bolts ............................................................................................. 54
3-2 RUD-swivel lugs .......................................................................................... 55
3-3 Crankshaft and Thrust Bearing ................................................................... 60
3-4 Crankshaft and Main Bearing ...................................................................... 61
3-5 Crosshead Guide ........................................................................................ 63
3-6 Cylinder Liner .............................................................................................. 64
3-7 Piston rod gland .......................................................................................... 65
3-8 Exhaust valve .............................................................................................. 66
3-9 Connecting rod - top and bottom end bearings ........................................... 67
3-10 Piston and piston rings ................................................................................ 68
3-11 Supply unit - drive wheels ........................................................................... 70
3-12 Fuel and servo pump units .......................................................................... 72
3-13 Fuel pump ................................................................................................... 74
4 General maintenance procedures
4-1 Tighten a round nut (examples) ................................................................... 83
4-2 Loosen a round nut (examples) ................................................................... 87
4-3 Do a check of the pre-tension (examples) ................................................... 91
6 Group 1 - Engine frame and bearings
6-1 Foundation bolts .......................................................................................... 97
6-2 Crankshaft and flywheel - lift ....................................................................... 102
6-3 Bearing shell - remove ................................................................................ 104
6-4 Bearing shell - lift ......................................................................................... 105
6-5 Bearing shell - lift ......................................................................................... 113
6-6 Bearing shell - move .................................................................................... 115
6-7 Crankshaft and flywheel - lift ....................................................................... 116
6-8 Crankshaft and flywheel - lift ....................................................................... 123
6-9 Bearing shell No_2_to_n ............................................................................. 125
6-10 Bearing shell_move ..................................................................................... 127
6-11 Bearing shell - move .................................................................................... 135
6-12 Bearing shell No_2_to_n ............................................................................. 137
6-13 Crankshaft and flywheel .............................................................................. 138
6-14 Cover and oil pipe ....................................................................................... 142
6-15 Thrust device ............................................................................................... 143
6-16 Bearing cover .............................................................................................. 144
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6-17 Bearing cover - move .................................................................................. 145
6-18 Thrust device ............................................................................................... 147
6-19 Bearing cover - install .................................................................................. 148
6-20 Bearing cover - move .................................................................................. 149
6-21 Bearing cover - oil pipe ................................................................................ 150
6-22 Oil pipe and round nuts ............................................................................... 154
6-23 Thrust device ............................................................................................... 155
6-24 Roller support .............................................................................................. 156
6-25 Bearing cover No.2 to # - lift and lower ....................................................... 157
6-26 Bearing cover No. 2 to # - remove .............................................................. 158
6-27 Thrust device ............................................................................................... 162
6-28 Bearing cover No. 2 to #_move ................................................................... 163
6-29 Bearing cover No.2 to # - install .................................................................. 164
6-30 Bearing cover - oil pipe ................................................................................ 165
6-31 Visual examination ...................................................................................... 167
6-32 Axial clearance ............................................................................................ 169
6-33 Axial clearance - micrometer ....................................................................... 171
6-34 Cover - remove ............................................................................................ 175
6-35 Thrust pad - removal ................................................................................... 177
6-36 Thrust pad - install ....................................................................................... 182
6-37 Thrust pads - configuration .......................................................................... 183
6-38 Cover - install .............................................................................................. 184
6-39 Engine stays - pressure check .................................................................... 189
6-40 Pre-tension checks ...................................................................................... 191
6-41 Tie rod - removal ......................................................................................... 193
6-42 Tie rod - install ............................................................................................. 195
6-43 Tie rod - apply tension ................................................................................. 196
7 Group 2 - Cylinder
7-1 Cylinder liner - dimension check ................................................................. 203
7-2 Water guide jacket ....................................................................................... 208
7-3 Lifting tool (example) ................................................................................... 209
7-4 Cylinder liner (example) - move .................................................................. 210
7-5 Cylinder liner - storage ................................................................................ 213
7-6 Cylinder liner - storage 2 ............................................................................. 214
7-7 Cylinder liner - grind .................................................................................... 217
7-8 Lubricating grooves - grind .......................................................................... 219
7-9 Scavenge ports - grind ................................................................................ 221
7-10 Insulation bandage ...................................................................................... 223
7-11 Cylinder liner (example) .............................................................................. 224
7-12 Water guide jacket (example) ...................................................................... 225
7-13 Lubricating quill (example) .......................................................................... 229
7-14 Lubricating quill ........................................................................................... 231
7-15 Sealing surface ............................................................................................ 233
7-16 Lubricating quill (example) .......................................................................... 234
7-17 Piston rod gland - remove and install .......................................................... 237
7-18 Piston rod gland - disassemble ................................................................... 238
7-19 Piston rod gland (example) ......................................................................... 241
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7-20 Piston rod gland - assemble ........................................................................ 244
7-21 Piston rod gland - remove and install .......................................................... 245
7-22 Cylinder cover - pipes and expansion piece (example) ............................... 248
7-23 Lifting tool - pre-tensioner (example) ........................................................... 249
7-24 Cylinder cover, exhaust valve cage and water guide jacket (example) ....... 250
7-25 Cylinder cover and exhaust valve cage (example) ...................................... 251
7-26 Fuel injection valve position - grind ............................................................. 254
7-27 Assemble before installation (example) ...................................................... 258
7-28 Lifting tool - pre-tensioner (example) ........................................................... 259
7-29 Injection valve - removal .............................................................................. 263
7-30 Preparation of injection valve for test .......................................................... 265
7-31 Adjust the opening pressure of the injection valve (X82 or X82-B) ............. 271
7-32 Injection valve (example) - disassemble ..................................................... 274
7-33 Nozzle tip (example) - replace ..................................................................... 276
7-34 Nozzle body - installation ............................................................................ 279
7-35 Nozzle body - installation ............................................................................ 280
7-36 Injection valve (example) - assemble .......................................................... 281
7-37 Injection valve (example) - install ................................................................ 285
7-38 Starting air valve - preparation .................................................................... 289
7-39 Starting air valve - removal .......................................................................... 290
7-40 Starting air valve - disassemble .................................................................. 293
7-41 Starting air valve - grind .............................................................................. 295
7-42 Starting air valve - assemble ....................................................................... 297
7-43 Starting air valve - installation ..................................................................... 299
7-44 Exhaust valve - preparation ......................................................................... 301
7-45 Exhaust valve - removal .............................................................................. 302
7-46 Exhaust valve - disassemble ....................................................................... 306
7-47 Guide bush - removal .................................................................................. 307
7-48 Valve seat - remove ..................................................................................... 309
7-49 Valve seat - alternative procedure ............................................................... 311
7-50 Valve seat clearance ................................................................................... 314
7-51 Valve seat - grinding tool ............................................................................. 317
7-52 Valve seat - install ........................................................................................ 319
7-53 Guide bush - installation .............................................................................. 321
7-54 Valve spindle - installation ........................................................................... 323
7-55 Damper setting (example) ........................................................................... 324
7-56 Valve stroke sensor, throttle and non-return valve ...................................... 325
7-57 Exhaust valve - installation .......................................................................... 329
7-58 Expansion piece - installation ...................................................................... 330
7-59 Exhaust valve - complete the installation .................................................... 331
8 Group 3 - Crankshaft, connecting rod and piston
8-1 Dial gauge position ...................................................................................... 337
8-2 Crank positions for clockwise direction ....................................................... 338
8-3 Definitions of positions ................................................................................ 339
8-4 Definition of deflection ................................................................................. 341
8-5 Platforms ..................................................................................................... 343
8-6 Platforms ..................................................................................................... 345
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8-7 Axial vibration damper - housing and pipes ................................................ 349
8-8 Axial vibration damper ................................................................................. 350
8-9 Axial vibration damper - move ..................................................................... 351
8-10 Axial vibration damper - install .................................................................... 354
8-11 Axial vibration damper - bolts ...................................................................... 355
8-12 Axial vibration damper - housing and pipes ................................................ 356
8-13 Turning gear - do a check ............................................................................ 359
8-14 Turning gear and gear wheels ..................................................................... 361
8-15 Pyroshield .................................................................................................... 362
8-16 Klüberfluid ................................................................................................... 362
8-17 Connecting rod ............................................................................................ 365
8-18 Stop plate .................................................................................................... 366
8-19 Connecting rod - move ................................................................................ 371
8-20 Connecting rod - remove ............................................................................. 373
8-21 Connecting rod - move 2 ............................................................................. 375
8-22 Connecting rod - move 2 ............................................................................. 380
8-23 Connecting rod - install 1 ............................................................................. 382
8-24 Connecting rod - install 2 ............................................................................. 384
8-25 Crosshead - install ....................................................................................... 386
8-26 Toggle lever - attach .................................................................................... 387
8-27 Piston - attach ............................................................................................. 388
8-28 Top end bearing - remove ........................................................................... 391
8-29 Bottom end bearing cover - move ............................................................... 394
8-30 Bottom end bearing shell - remove ............................................................. 395
8-31 Supports ...................................................................................................... 396
8-32 Bottom end bearing ..................................................................................... 397
8-33 Top bearing shell - remove .......................................................................... 398
8-34 Visual examination ...................................................................................... 401
8-35 Top bearing shell - move ............................................................................. 405
8-36 Bottom end bearing ..................................................................................... 406
8-37 Supports ...................................................................................................... 407
8-38 Bottom end bearing - install ......................................................................... 409
8-39 Top end bearing - move ............................................................................... 414
8-40 Crosshead - lower ....................................................................................... 415
8-41 Bearing lubrication ....................................................................................... 416
8-42 Preparation .................................................................................................. 420
8-43 Equipment - install ....................................................................................... 421
8-44 Top bearing cover - removal ........................................................................ 422
8-45 Top bearing cover - move ............................................................................ 425
8-46 Top bearing cover - install ........................................................................... 427
8-47 Toggle lever - remove .................................................................................. 432
8-48 Crosshead bearing - temperature sensor .................................................... 433
8-49 Tools - prepare ............................................................................................ 434
8-50 Bracket - attach ........................................................................................... 435
8-51 Tools - attach ............................................................................................... 436
8-52 Connecting rod - move ................................................................................ 437
8-53 Crosshead - move ....................................................................................... 438
8-54 Crosshead - remove .................................................................................... 439
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8-55 Crosshead - remove .................................................................................... 441
8-56 Guide shoes - remove ................................................................................. 442
8-57 Clearance checks ........................................................................................ 445
8-58 Dimensions check ....................................................................................... 446
8-59 Guide shoe - move ...................................................................................... 450
8-60 Crosshead - move ....................................................................................... 451
8-61 Guide shoes - install .................................................................................... 452
8-62 Connecting rod - move ................................................................................ 454
8-63 Tools - remove ............................................................................................. 455
8-64 Toggle lever - attach .................................................................................... 456
8-65 Crosshead bearing - temperature sensor .................................................... 457
8-66 Top surface - dimensions check .................................................................. 459
8-67 Piston ring - clearance ................................................................................. 460
8-68 Piston - Preparation ..................................................................................... 463
8-69 Piston - Preparation before removal (example) ........................................... 465
8-70 Piston - remove (example) .......................................................................... 469
8-71 Piston - Preparation before disassembly ..................................................... 473
8-72 Piston - disassemble (example) .................................................................. 474
8-73 Top surface - dimensions check .................................................................. 477
8-74 Piston groove clearance - calliper gauge .................................................... 477
8-75 Piston - assemble (example) ....................................................................... 482
8-76 Piston - move (example) ............................................................................. 485
8-77 Piston - install (example) ............................................................................. 486
8-78 Piston rod gland - attach (example) ............................................................ 487
8-79 Piston - attach (example) ............................................................................ 488
8-80 Piston ring - remove (example) ................................................................... 491
8-81 Piston rings - measure ................................................................................ 493
8-82 Equation wear rate ...................................................................................... 494
8-83 Equation service time .................................................................................. 494
8-84 Chrome ceramic layer ................................................................................. 495
8-85 Piston ring clearance ................................................................................... 497
8-86 Piston groove clearance - calliper gauge .................................................... 499
8-87 Piston groove clearance - ring piece ........................................................... 501
8-88 Piston rings - install (example) .................................................................... 503
9 Group 4 - Supply unit drive and control
components
9-1 Driving wheel - gear tooth backlash ............................................................ 512
9-2 Shut-off valve for starting air - prepare for disassembly .............................. 517
9-3 Shut-off valve for starting air - disassemble ................................................ 519
9-4 Shut-off valve for starting air - assemble ..................................................... 524
9-5 Shut-off valve for starting air - operation test .............................................. 528
10 Group 5 - Supply unit, pumps and control valves
10-1 Fuel pump ................................................................................................... 541
10-2 Guide pin removal ....................................................................................... 545
10-3 Guide piston and roller removal .................................................................. 546
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10-4 Toothed rack removal .................................................................................. 547
10-5 Pump cylinder removal ................................................................................ 548
10-6 Non-return valve removal ............................................................................ 549
10-7 Pump cylinder installation ............................................................................ 551
10-8 Pump cover installation ............................................................................... 552
10-9 Toothed rack assembly ................................................................................ 553
10-10 Pump plunger and bottom housing assembly ............................................. 554
10-11 Plunger position check ................................................................................ 555
10-12 Fuel pump installation ................................................................................. 559
10-13 Fuel pump - oil flow ..................................................................................... 563
10-14 Calibration illustration .................................................................................. 567
10-15 Actuator - adjust .......................................................................................... 571
10-16 Actuator - adjust -2 ...................................................................................... 572
10-17 Pressure control valve - remove .................................................................. 575
10-18 PCV - do a check ........................................................................................ 577
10-19 Pressure control valve - install .................................................................... 581
10-20 Fuel overpressure safety valve ................................................................... 583
10-21 Fuel overpressure safety valve - pressure check ........................................ 586
10-22 Fuel overpressure safety valve - installation ............................................... 589
10-23 Injection control unit - remove ..................................................................... 592
10-24 ICU - move .................................................................................................. 593
10-25 Injection control unit - install ........................................................................ 595
10-26 ICU - connect pipes ..................................................................................... 596
10-27 Covers ......................................................................................................... 601
10-28 Rollers - lift .................................................................................................. 602
10-29 Oil baffle ...................................................................................................... 603
10-30 Bearing shells - remove ............................................................................... 605
10-31 Camshaft - remove ...................................................................................... 606
10-32 Camshaft ..................................................................................................... 609
10-33 Camshaft - install ......................................................................................... 610
10-34 Oil baffle - install .......................................................................................... 611
10-35 Bearing bushes ........................................................................................... 613
10-36 Bearing bushes ........................................................................................... 615
10-37 Filling piece ................................................................................................. 617
10-38 Covers ......................................................................................................... 618
10-39 Exhaust valve control unit - remove ............................................................ 621
10-40 Exhaust valve control unit - disassemble/assemble .................................... 623
10-41 Exhaust valve control unit - disassemble/assemble .................................... 625
10-42 Exhaust valve control unit - install ............................................................... 627
10-43 Connection piece of VCU ............................................................................ 628
11 Group 6 - Scavenge air components
11-1 Scavenge air receiver - visual examination ................................................. 634
11-2 Level switches and filters ............................................................................ 635
11-3 Relief valve .................................................................................................. 637
11-4 Flaps - remove ............................................................................................ 639
11-5 Flaps - install ............................................................................................... 641
11-6 Electric motor (driving end) - move ............................................................. 643
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11-7 Electric motor (driving end) - remove .......................................................... 644
11-8 Electric motor (free end) - move .................................................................. 645
11-9 Auxiliary blower - remove ............................................................................ 646
11-10 Auxiliary blower - move ............................................................................... 650
11-11 Electric motor (free end) - install ................................................................. 651
11-12 Auxiliary blower (driving end) move ............................................................ 652
11-13 Electric motor (driving end) - install ............................................................. 653
11-14 Scavenge air cooler (example) - prepare .................................................... 656
11-15 Scavenge air cooler (example) - prepare front side .................................... 657
11-16 Scavenge air cooler (example) - prepare rear side ..................................... 658
11-17 Scavenge air cooler (example) - pull out ..................................................... 659
11-18 Scavenge air cooler (example) - put down .................................................. 660
11-19 Scavenge air cooler (example) - prepare for installation ............................. 664
11-20 Scavenge air cooler (example) - follow up front and rear side .................... 665
11-21 Water separator - view 1 ............................................................................. 667
11-22 Water separator - view 2 ............................................................................. 668
11-23 Water separator - view 3 ............................................................................. 669
11-24 Water separator - view 4 ............................................................................. 670
11-25 Water separator - view 5 ............................................................................. 671
11-26 Water separator - view 6 ............................................................................. 673
11-27 Water separator - view 7 ............................................................................. 674
11-28 Water separator - view 8 ............................................................................. 675
11-29 Water separator - view 9 ............................................................................. 676
12 Group 7 - Cylinder lubrication
12-1 Cylinder lubrication system (example) - do a functional test ....................... 679
12-2 Cylinder lubrication system - bleed ............................................................. 682
12-3 Cylinder lubricating pump (MK-E, example) - remove ................................. 686
12-4 Cylinder lubricating pump - examine ........................................................... 690
12-5 Cylinder lubricating pump (MK-E, example) - install ................................... 693
13 Group 8 - Pipes
13-1 Servo oil pipes - remove .............................................................................. 698
13-2 HP servo oil pipe - grind and adjust ............................................................ 702
13-3 Servo oil pipes - install ................................................................................ 706
13-4 Hydraulic pipe (exhaust valve) - remove ..................................................... 710
13-5 Hydraulic pipe (exhaust valve) - grind sealing face ..................................... 714
13-6 Hydraulic pipe (exhaust valve) - install ........................................................ 718
13-7 HP fuel pipe (fuel rail to injection valve) - remove ....................................... 722
13-8 HP fuel pipe (fuel rail to injection valve) - grind ........................................... 726
13-9 HP fuel pipe (fuel rail to injection valve) - install .......................................... 730
13-10 HP fuel pipe fuel pump to fuel rail - prepare ................................................ 734
13-11 HP fuel pipe (fuel pump to fuel rail) - prepare ............................................. 735
13-12 HP fuel pipe (fuel pump to fuel rail) - remove .............................................. 737
13-13 HP fuel pipe (fuel pump to fuel rail) - sealing face - Grind ........................... 742
13-14 HP fuel pipe (fuel pump to fuel rail) - views ................................................. 746
13-15 HP fuel pipe (fuel pump to fuel rail) - install ................................................. 748
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14 Group 9 - Monitoring instruments
14-1 Proximity sensor (flywheel) - remove .......................................................... 754
14-2 Proximity sensor (flywheel) - install ............................................................. 758
14-3 Proximity sensor - remove ........................................................................... 762
14-4 Proximity sensor - install ............................................................................. 766
15 Tools
15-1 Standard Tools ............................................................................................ 772
15-2 Recommended Tools ................................................................................... 814
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