Winterthur Gas X40-B User manual
Maintenance Manual
X40-B
Issue 002 2020-05
Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. +41 (0)52 264 8844
Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax +41 (0)52 264 8866
Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com
E2016 Winterthur Gas & Diesel Ltd., Printed in Switzerland – 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 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
Intentionally blank
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.
2016
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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.
2016
Intentionally blank
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
2016
General
Maintenance 0011−1/A1
Winterthur Gas & Diesel Ltd. 1/ 4
General Guidelines for Maintenance
Safety Precautions and Warnings
1. General 1..........................................................
2. General Safety Precautions 1........................................
3. Precautions before the Start of Maintenance 2.........................
4. Special Safety Procedures 3.........................................
5. Recommendations 4................................................
1. General
The maintenance tasks necessary for the engine at regular intervals are given in the
Maintenance Schedule 0380−1of 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 general safety conditions are as follows:
DAll personnel must know the fire fighting procedures.
DAll personnel must know the health and safety data and environment protection
data related to the operation and maintenance of diesel engines.
DAll personnel must know the dangers, functions and operation of cranes and
lifting devices.
DThe safety officer must make sure that all precautions are done to prevent
dangerous conditions.
DThe operator must select a supervisor to give work tasks to each person who
does maintenance work.
DMake sure that fluids that drain or are released cannot cause explosions, fires or
accidents during maintenance. Keep the engine and the areas around the engine
clean to help prevent accidents and increase the quality of the work.
DBefore you start maintenance on the engine, make sure that if necessary, the
pressure in the related systems is released and fluids are drained. Make sure
that you record the pressures and quantities.
DSome media, e.g. fuel, oil are very flammable, thus you must keep such media
away from fire, hot parts etc.
DMake sure that personnel do not smoke in the engine room.
DTo prevent injury, make sure that all surfaces where personnel can walk or stay
do not have oil, fuel etc and are kept clean and dry.
2016
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2/ 4
3. Precautions before the Start of Maintenance
CAUTION
Damage Hazard: Do not use water or cleaning fluid to clean the
electronic components and control boxes on the engine and the rail
unit. Damage can occur if water goes into these electronic
components or control boxes.
CAUTION
Damage Hazard: When electric welding is done near or on the
engine, electromagnetic fields or peak voltage can occur. this can
cause damage to the electronic components of the Engine Control
System.
Before you do electric welding, you must do the procedure that follows:
1) Stop the engine.
2) Set to off the electronic system. There must be an elapsed time of one minute
before you continue.
3) If the welding area is in a radius of two meters from an electronic module and/or
a sensor, disconnect the modules and/or sensors.
4) Close the covers of all electronic boxes and apply protection to the cables,
sensors, etc. to prevent damage from sparks and heat.
5) Use a conductive material connected to earth to give protection to the check and
control units.
6) Make sure that the welding cable goes directly to the welding point without
unnecessary loops. Also, make sure that the welding cables are not parallel to
cables of the electronic units.
Before you start the maintenance on the engine, specially the running gear, do the
procedure that follows:
1) Close the shut-off valves on the starting air bottles.
2) Close all the shut-off valves in the control air supply unit.
3) Open the drains on each starting air bottle to release all the pressure.
4) On the starting air shut-off valve, operate the handwheel to move the shut-off
valve to the position CLOSED.
5) On the main starting air pipe, open the vent and drain valve. Keep the vent and
drain valve in the open position until maintenance is completed.
6) On the starting air shut-off valve, open the vent valves. Keep the vent valves in
the open position until maintenance is completed.
7) Open all indicator valves on the cylinder covers. Keep the indicator valves in the
open position until maintenance work is completed.
8) Engage the turning gear and lock the lever (refer to the Operation Manual,
3206−1 and 0750−1). The gear pinion must be in the engaged position.
Note: If the engine was stopped because the running gear or bearings have
become too hot, do not open the crankcase doors before an elapsed time
of 20 minutes.
Note: During all engine operations (short or usual), the crankcase doors must
be locked with the clamps.
Note: Where carbon dioxide (CO2) is used to extinguish a fire in the engine,
there is a risk of suffocation. Make sure that all related spaces have good
airflow to remove all CO2gas before
2016
Safety Measures and Warnings
Maintenance 0011−1/A1
Winterthur Gas & Diesel Ltd. 3/ 4
4. Special Safety Procedures
WARNING
Injury Hazard: Make sure that no personnel and components are in
the danger areas (crankcase, piston underside, propeller shaft,
etc). The propeller coupling also turns.
WARNING
Injury Hazard: Before you operate the turning gear, make sure that
no personnel are near the flywheel, or in the engine.
A safety person must be in position outside the engine when personnel do work inside
the engine. If necessary, the safety person can give the applicable aid.
Personnel who do work in the engine must put on the correct safety equipment.
Safety equipment to prevent suffocation must also be included.
The permitted load capacity of the equipment that follows must be sufficient for the
parts to be lifted:
DThe engine room crane.
DLifting tools, ropes, slings and chains.
You must make sure that the lifting equipment is correctly attached the the item (i.e.
balanced to make sure that the equipment does not tilt or fall).
For more data, refer to 0012−1and 0360−1.
Use wood, leather or guards between the item and the rope or chain to give
protection to sharp edges, mating faces etc.
Always put on gloves, a face shield and safety goggles when you operate hydraulic
tools.
Keep your hands away from ropes, slings and chains that have tension. Do not go
under loads that hang.
Parts removed from the engine must be safely attached in the engine room to prevent
movement.
Make sure that when engine components are removed, covers are put in position
over the openings.
Note: For more data, refer to the Operation Manual, 0210−1 Safety Precautions
and Warnings (General Information).
2016
Safety Measures and Warnings
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4/ 4
5. Recommendations
1) Read the data in 3301−1Grid and Platform Elements.
2) Do the work carefully. Make sure that all parts and equipment are clean. Use only
the applicable tools and equipment for the maintenance tasks. For data about the
tools and equipment, refer to 9403−5Tool List.
3) Make sure that the tools and equipment are serviceable before you use them.
4) Calibrate gauges before you use them. Also, calibrate gauges at regular
intervals.
5) Do regular checks of hydraulic tools to make sure they are serviceable.
6) Apply protection to the running surfaces and sealing faces of parts that were
removed to prevent damage.
7) When pipes are removed, dirt can go into the openings. Apply protection to the
openings in the pipe and the part.
8) Before you start the engine, make sure that repaired parts, replaced parts, or
parts that had an overhaul are serviceable.
9) Make sure that all pipes that were removed and installed are tightened correctly.
10) Do regular checks of parts that move. If the maximum permitted value is the
same or more than that given in 0330−1Clearance Tables, the parts must be
replaced.
11) Use spare parts from the spares stock on board. When you order new parts, get
the code numbers and description from the Spare Parts Catalog.
12) When you tighten nuts, bolts or screws, make sure that you do not cause
damage to the thread. Turn the nut, bolt or screw with your hand until the metal
parts touch. Use only the specified lubricants on the threads.
13) Where torque values are shown, refer to the data given in 0352−1and 0352−2.
14) Devices that lock nuts, bolts etc must be correctly installed. Use lockwire, tab
washers and lock plates once only.
15) For threads of screws and studs in very hot areas, (e.g. exhaust pipe or
turbocharger) apply a lubricant that is resistant to high temperatures before
assembly. This will help when it becomes necessary to remove these items.
16) Always replace O-rings during an overhaul of components, or during removal and
installation procedures. The O-rings must be of the correct dimensions in
accordance with Wärtsilä specifications.
17) The installation of piston sealing rings and rod seal rings must be done carefully
to prevent deformation and distortion. Before installation, put the rings into very
hot water.
2016
Safety Measures and Warnings
Table of contents
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