WinGD X82-B User manual
Maintenance Manual
“Marine”
Vessel:
Type:
Engine No.:
Document ID:
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
E2017 Winterthur Gas & Diesel Ltd. – 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.
Winterthur Gas & Diesel Ltd. makes no representation, warranty (express or implied) in this
publication and assumes no responsibility for the correctness, errors or omissions for informa-
tion contained herein. Information in this publication is subject to change without notice.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUEN-
TIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS
PUBLICATION IS INTENDED FOR INFORMATION PURPOSES ONLY.
Maintenance Manual
“Marine”
Vessel:
Type:
Engine No.:
Document ID:
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
E2017 Winterthur Gas & Diesel Ltd. – 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.
Winterthur Gas & Diesel Ltd. makes no representation, warranty (express or implied) in this
publication and assumes no responsibility for the correctness, errors or omissions for informa-
tion contained herein. Information in this publication is subject to change without notice.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUEN-
TIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS
PUBLICATION IS INTENDED FOR INFORMATION PURPOSES ONLY.
Summary for Maintenance Manual
(MM)
Page No. Title Subject
Date No.
new exch.
2017 Maintenance Manual, Issue 2017 x
Date of publication 2017-12-06
0330-1/A1 2018 WinGD Input Clearance Table Pge 21: Note added. x
2751-2/A1 2018 WinGD Input
Exhaust Valve:
Disassemble and
Assemble
Pge 7: Procedure changed. x
3326-1/A1 2018 WinGD Input
Guide Shoes -
Clearance Checks and
Installation
Pges 1 to 4: Fig. C added. Data added to para 2.4. Tool
94324C added to procedure.
x
3326-2/A1 2018 WinGD Input
Crosshead Pin -
Removal and
Installation
94325 Double leg chain removed. Pges 4 to 8 - Procedure
cghanged.
x
9403-5/A1 2018 WinGD Input Tools Pge 20: Tool 94325 Double leg chain removed. x
Date of publication 2018-02
Group 8 ToC 2018 WinGD Input Piping New document titles added: 8135-2/A1, 8155-1/A1 x
8135-1/A1 2018 WinGD Input SCR System New document x
8155-1/A1 2018 WinGD Input
SCR Valve Removal
and Installation
New document x
9403-5/A1 2018 WinGD Input Tools Pge 41: New lifting tool 94815 added. x
Date of publication 2018-04
0330-1/A1 Dec-18 WinGD Input Clearance Table Pge 3: Gp1132 bearing shell clearance changed x
Date of publication 2018-12
Modification Service
Engine Documentation
W-X82-B
Manual
Modification
Page or
1/1 05/12/2018
0
1
2
3
4
5
6
7
8
9
MM / X82−B / Register
Driving Wheels and Shut-off Valve for Starting Air
Crankshaft, Connecting Rod and Piston
Cylinder Liner and Cylinder Cover
Bedplate and Tie Rod
General Information
Supply Unit, Injection and Exhaust Valve Control
Scavenge Air Receiver and Auxiliary Blower
Cylinder Lubrication
Piping
Crank Angle Sensor Unit, Tools
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Maintenance Group0
Winterthur Gas & Diesel Ltd. 1/ 1
For Particular Attention 0000−1/A1..................................................
Preface 0001−1/A1...............................................................
Table of Contents 0002−1/A1.......................................................
Engine Numbering and Designations 0008−1/A1......................................
General Guidelines
−for Maintenance: Safety Measures and Warnings 0011−1/A1........................
−for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts 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..............................................................
Tightening Values
−of Important Screwed Connections 0352−1/A1.....................................
−of Standard Screwed Connections 0352−2/A1.....................................
Masses (Weights): Components each in kg 0360−1/A1................................
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) 0380−1/A1........
Engine Cross Section and Longitudinal Section 0803−1/A1.............................
General Information Grou
p
0
Winterthur Gas & Diesel Ltd. X82−B / MM / 2017
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Maintenance 0000−1/A1
Winterthur Gas & Diesel Ltd. 1/ 1
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.
The extent of all supplies and services is set exclusively to the related supply
contract.
3. Data
The specifications and recommendations of the classification societies, which are
essential for the design, are included in this manual.
The data, instructions, graphics and illustrations etc. in this manual are related to
drawings from Wärtsilä Switzerland Ltd. 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 must 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.
2017
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Maintenance 0001−1/A1
Winterthur Gas & Diesel Ltd. 1/ 1
Preface
The instructions contained in this Maintenance Manual are intended to help to ensure
that the maintenance which must be carried out at specific intervals is correctly
carried out.
It is a condition that the personnel who do such important work have the necessary
training and experience.
Information about the operation of the engine as well as descriptions of the function of
the various systems are part of a separate book, the ”Operating Manual” containing
also under 0010−1 explanations of the layout and structure of the Operating and
Maintenance Manuals as well as of the used symbols, signs and special characters.
More detailed instructions on the operation and maintenance of components from
sub-suppliers can be gathered from the instruction leaflets of the respective
manufacturers. Outside makes are, for example, such engine components, tools or
devices which are not manufactured in accordance with production drawings from
Wärtsilä Switzerland Ltd.
The Maintenance Manual has the parts that follow:
1) General guidelines for maintenance
2) Clearance tables, tightening values of screwed connections, masses (weights)
3) Maintenance schedule
4) Design groups
5) Tool lists
Also:
1) The General Guidelines for Maintenance contain, in addition to recommendations
on precautionary measures to be taken, also suggestions for carrying out the
work.
2) The above mentioned tables inform about normal and maximum acceptable
clearances, the tightening of important screwed connections, weights of
individual engine components as well as the type and use of various sealing
rings.
3) The Maintenance Schedule indicates nominal intervals in which various
maintenance operations are to be carried out. Please note that the maintenance
intervals are based on experience and are subject to operation of the engine
under standard conditions.
4) Detailed instructions are given in the Design Groups on the procedure of
maintenance work on certain engine parts.
5) Tools and devices necessary to carry out maintenance are described in the Tool
Lists, and are generally supplied with the engine.
All information contained in the text and illustrations of this manual are correct at the
time of printing.
Modifications will be incorporated in the next edition.
2017
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Maintenance 0002−1/A1
Table of Contents
1/ 5 2018−04
Winterthur Gas & Diesel Ltd.
General Information Group 0
For Particular Attention 0000−1/A1..................................................
Preface 0001−1/A1...............................................................
Engine Numbering and Designations 0008−1/A1......................................
General Guidelines
−for Maintenance: Safety Measures and Warnings 0011−1/A1........................
−for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts 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..............................................................
Tightening Values
−of Important Screwed Connections 0352−1/A1.....................................
−of Standard Screwed Connections 0352−2/A1.....................................
Masses (Weights): Individual Components per Piece in kg 0360−1/A1...................
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) 0380−1/A1........
Engine Cross Section and Longitudinal Section 0803−1/A1.............................
Table of Contents
Maintenance0002−1/A1
Table of Contents
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2017 Winterthur Gas & Diesel Ltd.
Bedplate and Tie Rod Group 1
Bedplate and Thrust Bearing: Checking the Foundation Bolts 1112−1/A1.................
Main Bearing
−Loosening and Tensioning of Elastic Studs 1132−1/A1..............................
−Removal and Fitting of a Main Bearing 1132−2/A1.................................
Thrust Bearing
−Checking the Axial Clearance 1203−1/A1.........................................
−Removal and Fitting the Thrust Bearing Pads 1224−1/A1............................
Engine Stays with Friction Shims: Checking the Pre-tension 1715−1/A1..................
Tie Rod: Checking the Pre-tension and Tensioning the Tie Rods 1903−1/A1..............
Cylinder Liner and Cylinder Cover Group 2
Cylinder Liner
−Measuring Bore Wear 2124−1/A1................................................
−Removal and Fitting 2124−2/A1..................................................
−Removal and Fitting with reduced room height 2124−2/A2...........................
−Removing the Wear Ridge, Re-dressing Lubricating Grooves
and Scavenge Ports 2124−3/A1..................................................
Lubricating Quill: Removal and Fitting (with Pulse Jet Lubrication) 2138−1/A2.............
Piston Rod Gland: Dismantling and Assembling, Measuring the Wear 2303−1/A1.........
Cylinder Cover
−Removal and Fitting of Cylinder Cover and Water Guide Jacket 2708−1/A1............
−Loosening and Tensioning of Cylinder Cover Elastic Studs 2708−2/A1................
−Machining of Sealing Face for Injection Valve 2708−3/A1............................
Injection Valve: Checking, Dismantling, Assembling and Adjusting
(Injection Valve with FAST) 2722−1/A2...............................................
Starting Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling 2728−1/A1..
Relief Valve for Cylinder Cover: Checking Blow-off Pressure 2745−1/A1.................
Exhaust Valve
−Removal and Fitting of Exhaust Valve, Replacing of Elastic Studs 2751−1/A1..........
−Dismantling and Assembling 2751−2/A1..........................................
−Replacing and Grinding the Valve Seat 2751−3/A1.................................
−Grinding the Seating Surface on the Valve Head 2751−4/A1.........................
Maintenance 0002−1/A1
Table of Contents
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Winterthur Gas & Diesel Ltd.
Crankshaft, Connecting Rod and Piston Group 3
Crankshaft: Measuring Crank Deflection 3103−1/A1..................................
Vibration Damper
−Taking a Silicone Fluid Sample 3130−1/A1........................................
−Inspection (GEISLINGER Vibration Damper) 3130−2/A1............................
Axial Damper: Dismantling and Assembling 3140−1/A1................................
Turning Gear: Checking the Toothing (6 to 8 Cylinder Engines) 3206−1/A1...............
Turning Gear: Checking the Toothing (9 to 12 Cylinder Engines) 3206−1/A2..............
Crankcase: Utilization of Working Platform 3301−1/A1................................
Connecting Rod
−Loosening and Tensioning the Connecting Rod Studs 3303−1/A1....................
−Inspection, Removal and Fitting of Bottom End Bearing 3303−2/A1...................
−Inspection, Removal and Fitting of Top End Bearing 3303−3/A1......................
−Removal and Fitting 3303−4/A1..................................................
−Removal of Bearing Cover to Top End Bearing 3303−5/A1..........................
Crosshead
−Checking the Clearances and Fitting the Guide Shoes 3326−1/A1....................
−Removal and Fitting of a Crosshead Pin 3326−2/A1................................
Piston
−Removal and Fitting 3403−1/A1..................................................
−Tilted Removal and Fitting 3403−1/A2............................................
−Changing the Compression Shims 3403−2/A1.....................................
−Dismantling and Assembling 3403−3/A1..........................................
−Checking Piston Top Surface 3403−4/A1..........................................
Piston Rings: Checking Wear of Piston Rings and Ring Grooves 3425−1/A1..............
Driving Wheels and Shut-off Valve for Starting Air Group 4
Driving Wheels
−Checking the Running and Backlash Clearances and Condition of Teeth 4103−1/A1....
−Replacing the Gear Wheel on the Crankshaft 4103−2/A1............................
Shut-off Valve for Starting Air: Cleaning and Function Check 4325−1/A1.................
Maintenance0002−1/A1
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2017 Winterthur Gas & Diesel Ltd.
Supply Unit, Injection and Exhaust Valve Control Group 5
Fuel Pump
−Dismantling and Assembling 5556−1/A1..........................................
−Removal of a Jammed Pump Plunger 5556−2/A1..................................
Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling 5562−1/A1....
Fuel Overpressure Safety Valve: Checking and Setting 5562−2/A1......................
Injection Control Unit: Removal and Fitting 5564−1/A1.................................
Fuel Pump Unit
−Removal and Fitting of Camshaft and Bearing Shells 5581−1/A1.....................
−Lubrication of Fuel Pump Unit During Maintenance Works 5581−2/A1.................
Fuel Pump Actuator
−Connection with Fuel Pump (6 to 8 Cylinder Engines) 5583−1/A1....................
−Connection with Fuel Pump (9 to 12 Cylinder Engines) 5583−1/A2...................
Servo Pump Unit
−Removal and Fitting of Servo Oil Pump and Drive (with Dynex SOP) 5591−1/A1.......
−Removal and Fitting of Servo Oil Pump and Drive (with Bosch SOP) 5591−1/A2.......
Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling 5612−1/A1.....
Scavenge Air Receiver and Auxiliary Blower Group 6
Checking the Air Flaps and Cleaning the Scavenge Air Receiver 6420−1/A1..............
Auxiliary Blower: Maintenance 6545−1/A1............................................
Scavenge Air Cooler: Removal and Fitting 6606−1/A1.................................
Scavenge Air Cooler: Removal and Fitting for 3 Turbochargers 6606−1/A2...............
Water Separator: Removal and Fitting 6708−1/A1.....................................
Scavenge Air Waste Gate: Dismantling and Assembling 6735−1/A1.....................
Cylinder Lubrication Group 7
Lubrication Pump CLU4−C: Checking the Gas Pre-charge Pressure 7218−1/A2...........
Maintenance 0002−1/A1
Table of Contents
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Winterthur Gas & Diesel Ltd.
Piping Group 8
Exhaust Waste Gate (Low-Load Tuning) 8135−1/A1...................................
Selective Catalytic Reduction System 8135−2/A1.....................................
SCR Valve −Removal and Installation 8155−1/A1.....................................
HP Servo Oil Pipe
−Removing, Fitting and Regrinding (with Dynex SOP) 8447−1/A1.....................
Hydraulic Pipe for Exhaust Valve Drive: Removing, Fitting and Regrinding 8460−1/A1.....
HP Fuel Pipe
−Removing, Fitting and Regrinding of Sealing Faces 8733−1/A1......................
−Removing, Fitting and Regrinding (6 to 8 Cylinder Engines) 8752−1/A1...............
−Removing, Fitting and Regrinding (9 to 12 Cylinder Engines) 8752−1/A2..............
Crank Angle Sensor Unit, Tools Group 9
Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 9223−1/A1.............
Tools: Explanation 9403−1/A1......................................................
Hydraulic Jacks and Pumps: Arrangement and Application 9403−2/A1...................
Hydraulic Pre-tensioning Jacks
−Overview, Storing, Servicing and Maintenance 9403−3/A1...........................
−General Application Instructions 9403−4/A1.......................................
Tool List 9403−5/A1...........................................................................
−Standard Tools Pages 1 to 41...................................................
−Recommended Special Tools Pages 42 to 46......................................
−Special Tools Obtainable on Loan Pages 47 to 49..................................
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Maintenance 0008−1/A1
Winterthur Gas & Diesel Ltd. 1/ 2
Engine Numbering and Designations
EXHAUST
SIDE
FUEL
SIDE
WCH01188
Rail Unit
Fuel Pump Unit
FS
Clockwise Rotation
Servo Pump Unit
Fuel Pump Unit
ES
Fig. 1
1 2 3 4 5 6 7 8 9
6543
289
110
711 12
Turbocharger 1 Turbocharger 2
FREE
END
DRIVING
END
Cylinder
Numbering
Main Bearing Numbering
Thrust Bearing Pads
General
2017
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