Winterthur Gas X35-B User manual

Maintenance Manual
X35-B
Issue 005 2022-01
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

E2020 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.

Modification Service
Engine Documentation
X35-B
Summary for Maintenance Manual
Page No.
Modification
Title
Subject
Page or
Date
No.
Manual
new
exch.
2017
Maintenance Manual, Issue 2017
x
Date of publication 2017-08-18
0330-1/A1
2018-02
WinGD Input
Clearance Table
Pge 21: Note added
x
2751-2/A1
2018-02
WinGD Input
Exhaust Valve:
Disassemble and
Assemble
Pge 6. Paragraph 3.4 - Procedure changed.
x
Group 5 ToC
2018-02
Wartsila Input
Lubrication of Supply
Unit during
Maintenance
New Title Added: 5562-1/A2
x
5562-1/A2
2018-02
Wartsila Input
Fuel Pressure Control
Valve: Manual relase
Valve - Clean
New document added
x
9403-5/A1
2018-02
WinGD Input
Tools List
Pge 25: Tool 94929 moved to Special Recommended Tools on
Pge 28
x
Date of publication 2018-02
3303-4/A2
2018-07
WinGD Input
Connecting Rod
Removal and
Installation
Pge: 2, Step 18: Torque changed to 120 Nm.
x
3403-1/A1
2018-07
WinGD Input
Piston: Removal and
Installation
Pge: 4, Step 34: Torque changed to 120 Nm.
x
3403-2/A1
2018-07
WinGD Input
Piston: Compression
Shims - Change
Pge 3, Step 13 Torque changed to 120 Nm.
x
Date of publication 2018-07
0380-1/A1
2020-04
WinGD Input
Maintenance
schedule
Inspection and
Overhaul
Intervals
Pge: 67 to 75 updated.
x
ToC
2020-04
WinGD Input
Table of content
ToC upated
x
Group 2 ToC
2020-04
WinGD Input
Installation of
Injection Valve with
FAST
New Title Added: 2722-1/A2
x
2722-1/A2
2020-04
WinGD Input
Installation of
Injection Valve with
FAST
New document added
x
Cover Page
2020-04
WinGD Input
Cover page updated
x
Date of publication 2020-04
Appendix
2020-11
WinGD Input
Appendix
New chapter added - Appendix
x
Date of publication 2020-11
3303-4/A2,
3403-1/A1 and
3403-2/A1
2021-09
WinGD Input
Piston installation
Correction of tightening information for piston installation;
torque value changed from 320 Nm to 120 Nm.
x
Date of publication 2021-09
2708-1/A1
2022-01
WinGD Input
Cylinder Liner
Safety Warning Updated.
x
2708-3/A1
2022-01
WinGD Input
Cylinder Liner –
Machining of Sealing
Face for Injection
Valve
Safety Warning Updated.
x
0011-1/A1
2022-01
WinGD Input
General Guidelines for
Maintenance
Procedure Updated
x
1/1 11/01/2022

Maintenance Manual
“Marine”
Vessel:
Type:
Engine No.:
Document ID: DBAD803076
Winterthur Gas & Diesel Ltd. 24hrs Support:
Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd.
CH-8400 Winterthur Zürcherstrasse 12
Switzerland CH 8400 Winterthur
Switzerland
[phone]
[email protected]

E2020 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.

0
1
2
3
4
5
6
7
8
9
MM / X35−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

Table of Contents
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 etc. 0012−1/A1...............................
Clearance Table 0330−1/A1.........................................................................
General Page 1...............................................................................
Crankshaft and Thrust Bearing 2, 3...............................................................
Crankshaft and Main Bearing 4, 5................................................................
Crosshead Guide 6, 7..........................................................................
Cylinder Liner 8, 9.............................................................................
Piston Rod Gland 10, 11........................................................................
Exhaust Valve 12, 13...........................................................................
Top and Bottom End Bearings to Connecting Rod 14, 15.............................................
Piston Cooling and Crosshead Lubricating Link 16, 17...............................................
Piston and Piston Rings 18, 19...................................................................
Driving Wheels for Supply Unit 20, 21.............................................................
Supply Unit 22, 23.............................................................................
Tightening Values
of Important Screwed Connections 0352−1/A1.....................................................
of Standard Screwed Connections 0352−2/A1......................................................
Masses (Weights): Individual Components per Piece in kg 0360−1/A1..................................
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) 0380−1/A1.....................
Engine Cross Section and Longitudinal Section 0803−1/A1...........................................
Bedplate and Tie Rod Group 1
Bedplate and Thrust Bearing: Checking the Foundation Bolts 1112−1/A1..............................
Main Bearing
Loosening and Tensioning of Waisted Studs 1132−1/A1.............................................
Removal and Fitting of a Main Bearing 1132−2/A1..................................................
X35−B / MM / 2020
Winterthur Gas & Diesel Ltd.

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................................
Hydraulic Engine Stays: Oil Pressure Checks 1715−1/A2.............................................
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 of Cylinder Liner or Water Guide Jacket 2124−2/A1...............................
Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports 2124−3/A1.............
Lubricating Quill −Removal and Installation 2138−1/A1...............................................
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.............................
Machining of Sealing Surface for Injection Valve 2708−3/A1..........................................
Injection Valve
Removal and Installation 2722−1/A1..............................................................
Disassemble, Checks, Assemble 2722−2/A1.......................................................
Installation of Injection Valve with FAST 2722−1/A2.................................................
Starting Air Valve: Removal, Fitting and Dismantling, Grinding-in & Assembling 2728−1/A1.............
Relief Valve for Cylinder Cover 2745−1/A1...........................................................
Exhaust Valve
Removal and Fitting of Exhaust Valve, Replacing of Elastic Bolts 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..........................................
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 3206−1/A1.....................................................
Crankcase: Utilization of Working Platform 3301−1/A1...............................................
Connecting Rod
Inspection, Removal and Fitting of Bottom End Bearing 3303−2/A1....................................
X35−B / MM / 2020 Winterthur Gas & Diesel Ltd.

Inspection, Removal and Fitting of Top End Bearing 3303−3/A1.......................................
Removal and Fitting (with Piston in Situ) 3303−4/A1.................................................
Removal and Fitting (with Piston Removed) 3303−4/A2..............................................
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..................................................................
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 4104−1/A1.....................
Removal and Fitting of Intermediate Wheel 4104−2/A1..............................................
Replacing the Gear Wheel on the Crankshaft 4104−3/A1.............................................
Shut-off Valve for Starting Air: Cleaning and Function Check 4325−1/A1................................
Supply Unit, Injection and Exhaust Valve Control Group 5
Supply Unit
Servo Oil Pump: Removal and Fitting 5551−1/A1...................................................
Gear Wheel / Safety Device to Servo Oil Pump: Removal and Fitting 5551−2/A1.........................
Fuel Pump: Removal and Fitting 5556−1/A1........................................................
Gear Wheel / Safety Device to Fuel Pump: Removal and Fitting 5556−2/A1.............................
Fuel Rail
Flow Limiting Valve and Normally Open Valve 5562−1/A1............................................
Pressure Control Valve 5562−2/A1...............................................................
Servo Oil Rail
Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling,
Relief Valve 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................................................
Water Separator: Removal and Fitting 6708−1/A1....................................................
X35−B / MM / 2020
Winterthur Gas & Diesel Ltd.

Cylinder Lubrication Group 7
Pulse Lubrication System CLU5 7218−1/A1..........................................................
Piping Group 8
Exhaust Waste Gate (Low-Load Tuning) 8135−1/A1.............................................
Servo Oil Piping: Removing and Fitting of Rising Pipe Package 8447−1/A1.........................
Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding 8460−1/A1................
Fuel Pressure Piping
Removing and Fitting 8733−1/A1.................................................................
Removing and Fitting of Rising Pipe Package 8752−1/A1............................................
Crank Angle Sensor Unit, Tools Group 9
Crank Angle Sensor Unit: Replacement of Proximity Sensor 9223−1/A1...............................
Tools: Explanation 9403−1/A1......................................................................
Hydraulic Jacks, Tools and Pumps: Arrangement and Application 9403−2/A1..........................
Hydraulic Pre-tensioning Jacks
Storing, Servicing and Maintenance 9403−3/A1....................................................
General Application Instructions 9403−4/A1........................................................
Tool List 9403−5/A1................................................................................
Standard ToolsPages pages Pages 1 to 27........................................................
Recommended Special Tools Pages 27 to 32......................................................
Appendix Pages 1 to 54............................................................................
Winterthur Gas & Diesel Ltd.X35−B / MM / 2020

Maintenance Group0
Winterthur Gas & Diesel Ltd. 1/ 1
General Information Group 0
For Particular Attention 0000−1/A1..................................................................
Preface 0001−1/A1.................................................................................
Basic Engine Data 0008−1/A1.......................................................................
General Guidelines
for Maintenance: Safety Precautions and Warnings 0011−1/A1.......................................
for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts etc. 0012−1/A1...............................
Clearance Table 0330−1/A1.........................................................................
General Page 1...............................................................................
Crankshaft and Thrust Bearing 2, 3...............................................................
Crankshaft and Main Bearing 4, 5................................................................
Crosshead Guide 6, 7..........................................................................
Cylinder Liner 8, 9.............................................................................
Piston Rod Gland 10, 11........................................................................
Exhaust Valve 12, 13...........................................................................
Top and Bottom End Bearings to Connecting Rod 14, 15.............................................
Piston Cooling and Crosshead Lubricating Link 16, 17...............................................
Piston and Piston Rings 18, 19...................................................................
Driving Wheels for Supply Unit 20, 21.............................................................
Supply Unit 22, 23.............................................................................
Tightening Values
of Important Screwed Connections 0352−1/A1.....................................................
of Standard Screwed Connections 0352−2/A1......................................................
Masses (Weights): Components Each Item in kg 0360−1/A1...........................................
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) 0380−1/A1.....................
Engine Cross Section and Longitudinal Section 0803−1/A1...........................................
Winterthur Gas & Diesel Ltd. X35−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 Winterthur Gas & Diesel 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 in this Maintenance Manual are to help make sure that maintenance is
done correctly at the specified intervals.
It is a condition that the personnel who do important work have the applicable training
and experience.
Data about the operation of the engine and descriptions of the function of the different
systems are part of the Operation Manual. Chapter 0010−1 in the Operation Manual,
gives descriptions about the Operation and Maintenance Manuals and data about
symbols, signs and special characters.
More instructions about the operation and maintenance of components from
sub-suppliers are found in the instruction leaflets of the related manufacturers (for
example, engine components, tools or devices that are not manufactured in accordance
with production drawings from Winterthur Gas & Diesel Ltd).
The Maintenance Manual has the primary data that follow:
DGeneral Guidelines for Maintenance. These give recommendations about precau-
tions and applicable procedures.
DClearance tables, tightening values of screwed connections, masses (weights).
These give data about usual and maximum permitted clearances, engine compo-
nents, type and use of different sealing rings etc.
DMaintenance Schedule. This schedule shows the nominal intervals when the differ-
ent maintenance operations must be done during standard operation conditions.
DDesign Groups give the instructions and procedures for maintenance work on
specified engine parts.
DTool Lists give data about the applicable tools and devices necessary to do the
maintenance work. The tools and devices are usually supplied wit the engine.
All data in this manual (text and illustrations) are correct at the date of issue. Modification
of data is done regularly.
2017

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Maintenance 0008−1/A1
Winterthur Gas & Diesel Ltd. 1/ 2
Basic Engine Data
2
FREE END
DRIVING END
Thrust Bearing Pads
FUEL
SIDE
EXHAUST
SIDE
Rail Unit
Clockwise
Rotation
Counterclockwise
Rotation
Supply Unit
Turbocharger
Cylinder
Numbers
Auxiliary
Blower 2
WCH00958
Main Bearing
Numbers
Auxiliary
Blower 1
1
1 2 3 4 5
6543 7
Fig. 1: Outline View
2017
General

Maintenance0008−1/A1
Winterthur Gas & Diesel Ltd.
2/ 2
Servo Oil Pump 1
Fuel Pump 1 Fuel Pump 2
Servo Oil Pump 2
DRIVING
END
WCH00552
FUEL
SIDE
WCH00887
Crank Angle
Sensor Unit
IProximity
Sensors
ZS5124C
WCH00636
ZS5123C
II
II
I
Fig. 2: Engine Control System Parts
2017
Engine Control System Parts

Maintenance 0011- 1/A1
Winterthur Gas & Diesel Ltd. 1/ 10
General Guidelines for Maintenance
Safety Precautions and Warnings
1. General 1..........................................................
2. General Safety Precautions 1........................................
3. Safety Notes 4......................................................
4. General Safety Warning and Caution 5................................
5. Personal safety and protection equipment 7...........................
6. General safety guidelines for Hot work 8..............................
7. General safety lifting instructions 10...................................
1. General
The maintenance tasks necessary for the engine at regular intervals are given in the
Maintenance Schedule 0380- 1 of this manual and is a general guide. The
maintenance intervals are related to the mode of operation, the power and the quality
of the fuel used. For more data, refer to the Maintenance Schedule.
The maintenance intervals can change in relation to data collected during operation.
Note: The recommendations related to safety procedures and maintenance
given below are mandatory. All other safety recommendations not given
here must also be obeyed.
2. General Safety Precautions
The aim of this book is to give correct information about operation and maintenance
of the engine. It is important to take the maximum safety in the engine room. All the
engine room staff must follow these general safety precautions and safety guidelines
given below as usual procedure :
Use the data given below as a guide to the personnel.
DLighting
Make sure that there is good permanent lighting available at applicable places in the
engine room.
Make sure that the sufficient number of portable lamps available at different locations
intheengineroom.
Make sure that special lamp is available to insert through the scavenge ports.
DCleanliness
Keep the engine and engine room as clean as possible. Also keep the area above
and below floor plates clean. Keep the electronic control boxes on the rail unit clean
and dry.
Make sure that no dust, grit, sand or chemical vapor can go into the engine room.
This will help to prevent a fire in the engine room.
If there is a risk of grit and sand blow into the engine room when the ship is at port,
ventilation must be stop, skylights and engine room door must be close.
Do not do weld or other work near the engine except if done in closed and protected
environment, this will prevent spread of grit or swarf particles. Make sure that the
turbocharger intake filters are covered.
Keep the external part of the engine clean and maintain the paintwork to find the
leakages easily.
2021

Maintenance0011- 1/A1
Winterthur Gas & Diesel Ltd.
2/ 10
DFire
Make sure that fire- fighting equipment is available in the engine room. Keep covers
and casings of the engine closed until the engine is sufficiently cool.
Clean the area around the relief valves free of oil, grease etc. This will prevent risk of
fire cause by hot air or gas when the relief valves are open.
Do not weld or use naked lights in the engine room. Make sure that no explosive
gases, vapour or liquids are available which can cause fire or explosion.
Be careful when using paint and solvents which has a low flash point. There is a risk
of fire and explosion.
Be careful when the crankcase doors are open before the engine is at suitable
temperature, weld or use of naked flames can cause risk of explosion and fire. Same
is applicable to oil tanks and spaces below the floor at the time of inspection.
Make sure that the emergency exits are clearly marked and easy to access.
Do not use the porous insulating materials soaked in oil due to leakages. These
materials are highly inflammable and must be replace with new materials.
DTools
Make sure that hand tools are available on tool panels and easy to access when
required. Keep the special tools near the work area in the engine room.
Make sure that all tools have protection from corrosion.
Keep all the tools and devices ready to use and make sure that no large objects are
available on the floors and passages near engine area. Always keep the engine area
clean.
DSpare Parts
Keep the large spare parts near the work area and must be easy to access for the
engine room crane.
Make sure that the spare parts have protection from corrosion and mechanical
damage.
Replace used spare parts as soon as possible.
Check and maintain the stock of spare parts at regular intervals and refill the stock if
required.
DLow temperature - Freezing
To avoid freezing, drain all the cooling water from the engine, pumps, coolers and
pipe systems.
Note: Make sure that engine is cool down before repair and maintenance work.
DCheck and Maintain
Do a check of measuring equipment, filter element and lubricating oil condition.
DFrost hazard
If the ambient air temperature decreases below 0°C and the engine is not in
operation, the water in the pipe systems can freeze. To prevent this, drain the pipe
systems or increase the temperature in the engine room.
DAlarms
If the ambient air temperature decreases below 0°C and the engine is not in
operation, the water in the pipe systems can freeze. To prevent this, drain the pipe
systems or increase the temperature in the engine room.
All the alarms are important and most serious alarm are with slow- down and
2021