Winterthur Gas X40-B User manual

Maintenance Manual
X40-B
Issue 002 2020-05
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

E2016 Winterthur Gas & Diesel Ltd., Printed in Switzerland – All rights reserved
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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 CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

Modification Service
Engine Documentation
X40-B
Summary for Maintenance Manual
Page No.
Modification
Title
Subject
Page or
Date
No.
Manual
new
exch.
2016
Maintenance Manual, Issue 2016
x
Date of publication 2016-12-27
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 2: Tool nos. for AF36 and AF46 changed. Pge 26: Tube
94581D removed.Tredo joint (94934J) added. Pge 26: Tool
94929 move to Special Recommended Tools on Pge 29.
x
Date of publication 2018-02
ToC
2020
WinGD Input
ToC
New Title Added: 2722-1/A2
x
0380-1/A1
2020
WinGD Input
Maintenance
Schedule
Inspection and
Overhaul Intervals
(Guidelines)
Pages 65 to 73 updated
x
Group 2 ToC
2020
WinGD Input
Installation of
Injection Valve with
FAST
New Title Added: 2722-1/A2 Installation of Injection Valve with
FAST
x
2722-1/A2
2020
WinGD Input
Installation of
Injection Valve with
FAST
New procedure added
x
Date of publication 2020-05
1/1 13/05/2020

0
1
2
3
4
5
6
7
8
9
MM / X40−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, ye 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xhaust Valve 12, 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top and Bottom nd 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......................................................
asses (Weights): Individual Components per Piece in kg 0360--1/A1..................................
aintenance 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..............................
ain Bearing
Loosening and Tensioning of Waisted Studs 1132--1/A1.............................................
Removal and Fitting of a Main Bearing 1132--2/A1..................................................
X40--B / MM / 2020Winterthur 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, easuring 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: Checking, Dismantling, Assembling and Adjusting 2722--1/A1..........................
Injection Valve: 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 xhaust Valve, Replacing of lastic 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: easuring Crank Deflection 3103--1/A1.................................................
Vibration Damper
Taking a Silicone Fluid Sample 3130--1/A1.........................................................
Inspection (G ISLING R 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 nd Bearing 3303--2/A1....................................
Inspection, Removal and Fitting of Top nd Bearing 3303--3/A1.......................................
Removal and Fitting (with Piston in Situ) 3303--4/A1.................................................
Removal and Fitting (with Piston Removed) 3303--4/A2..............................................
X40--B / MM / 2020 Winterthur Gas & Diesel Ltd.

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...............................................................
Fuel Pressure Control Valve: Manual Release Valve −Clean 5562−1/A2...............................
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....................................................
Winterthur Gas & Diesel Ltd. X40--B / MM / 2020

Cylinder Lubrication Group 7
Cylinder Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Special Tools Pages 27 to. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Obtainable on Loan Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Winterthur Gas & Diesel Ltd.X40--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. X40−B / MM / 2016

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