MM - WinGD RT flex50DF PDF

RT-flex50DF
Maintenance Manual
“Marine”
Vessel:
Type:
Engine No.:
Document ID: DBAD114048
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
technicalsupport.chts@wartsila.com
E 2016 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
(electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval
systems) without the prior written permission of the copyright holder.
Wärtsilä Services Switzerland Ltd. makes no representation, warranty (express or implied) in
this publication and assumes no responsibility for the correctness, errors or omissions for
information contained herein. Information in this publication is subject to change without notice.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED
HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION
PURPOSES ONLY.
RT-flex50DF
Maintenance Manual
“Marine”
Vessel:
Type:
Engine No.:
Document ID: DBAD114048
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
technicalsupport.chts@wartsila.com
E 2016 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
(electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval
systems) without the prior written permission of the copyright holder.
Wärtsilä Services Switzerland Ltd. makes no representation, warranty (express or implied) in
this publication and assumes no responsibility for the correctness, errors or omissions for
information contained herein. Information in this publication is subject to change without notice.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED
HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION
PURPOSES ONLY.
Modification Service
Engine Documentation
RT-flex50DF Summary for Maintenance Manual

Page No. Modification Title Subject
(MM) Page or
Date No. Manual
new exch.
2015 Maintenance Manual, Issue 2015 x
Date of publication 2015-03-31
0002-1/A1 2015-09 Table of Contents New documents added: 0008-1/A2, 0803-1/A2, 2124- x
1/A2,5555-1/A1, 6420-2/A1, 6545-2/A1, 6606-2/A1, 6708-2/A1,
9258-1/A1
0,2,5,6,9 Index (groups) x
0008-1/A2 2015 EAAD086011 Engine Numbering and New dokument added x
Designation
0352-1/A1 2015-09 EAAD085996 Tightening Instruction The text 'Never Seez NSBT8' changed to 'Never Seez x
(1,3,7) REGULAR GRADE'; Torque value for injection valve group
2722 and pilot injection valve group 2790 added
0360-1/A1 EAAD085476 Masses Groups: 3310, 6506, 6606, 7206: the weight of the bearing x
shell crank pin, SAC A44-SD, ABB-A175, cylinder lubrication
pump added; group 2124: weigh of the cylinder liner GAV50
Mk2 added; group 2708: weight of the cylinder cover with
exhaust valve changed; group 3122: weight of the flywheel
changed and values added; group 3310: weight of the bearing
shell crank pin changed; group 3403: weight of the piston two-
part complete, piston head and piston rod changed;
0803-1/A2 2015 EAAD086011 Engine Cross Section New dokument added x

and Longitudinal
Section
2140-1/A1 2015-09 EAAD085685 Gas Admission Valve New dismantling and assembling tool replaced the old design; x
EAAD085873 paragraph 4 and 5 added
2140-1/A2 2015 EAAD085774 Gas Admission Valve New gas admission valve GAV50-Mk2 added x
2722-1/A1 2015-09 Injection Valve Information about terminal box addded. x
3403-1/A1 EAAD085973 Piston Fig. 'M' to 'S' and 'U' changed, description with the new lifting x
(4,7,8,9) tool updated
5555-1/A1 2015 Pilot Fuel Supply Unit Document moved from group 8 to group 5 and changed the x
name
6420-2/A1 EAAD085839 Scavenge Air Receiver New document added (turbocharger at exhaust side); x
6545-2/A1 EAAD085896 Auxiliary Blower New document added (turbocharger at exhaust side); x
6606-2/A1 EAAD085896 Scavenge Air Cooler Instruction for removal and installation of SAC A44-SD (7Cyl.), x
turbocharger at exhaust side) added
6708-2/A1 Water Separator New document added (turbocharger at exhaust side); x
8733-1/A1 (2,3) 2015-09 EAAD085458 HP Injection Pipe Information about corerct installation of the claw added; x
EAAD085477 grinding tool with the new template added and replaced the old
one
8790-1/A1 HP Fuel Pipe Pilot The title and content changed to HP pipe pilot fuel x
Valve
9258-1/A1 2015 EAAD085973 Sensor Cylinder New document added x
Pressure
9403-5/A1 2015-09 EAAD085973 Tool List Tools: 94017-002, 94018-003, 94022H, 94023A, 94048-M30, x
(3,4,5,11,16, EAAD085996 94653A-A175, 94656A, 94656B, 94661-IL, 94663-IL, 94663A-
22,31,33,35,37) EAAD085896 IL, 94663B-IL, 94663C-IL, 94663D-IL, 94663E-IL, 94663F-IL,
94664-IL, 94667E,94667F,94667G,94667H, 94667I, 94890
added; New design of 94214 replaced the old one; tool 94272
newly defined; new lifting tool 94341 replaced the existing tool;
illustration and dimention changed; pages added and
renumbered
0380-1/A1 2016 maintenance intervals major rework of the whole maintenance list x
whole book 2016 Maintenance Manual New Layout x

1/3 19/03/2018

(MM) Page or
Date No. Manual
new exch.
Group 5 ToC 2018-01 WinGD input ToC 5555-2/A1 added x
2140-2/A1 2017-12 Update Exhaust Valve: Pge 7: Para 5, Steps 10 to 12 changed. x

WinGD Disassemble and
Assemble
2751-2/A1 2017-12 WinGD input Exhaust Valve: Page 6: Procedure changed, x
Disassemble and
Assemble
0330-1/A1 2018-02 WinGD Input Group 5 ToC Page 21: Note added x
Group 2 ToC 2018-02 EAAD087460 Group 5 ToC New documents added to ToC (2708-4/A1, 2708-5/A1 and x
2708-6/A1)
2138-1/A1 2018-02 WinGD Input Lubricating Quill Pge 1: Dismantling tool 94213 added to tool list. Pge2: x
Replace procedure added.
2140-1/A1 2018-02 WinGD Input Gas Admission Valve Pge 7. Steps 10 to 14 changed. x
2708-4/A1 2018-02 EAAD087460 Sealing Face for the New procedure x

Pilot Injection Valve
Position - Grind
Fuel Injection Valve
Position - Grind
Prechanmber - Grind
2751-1/A1 2018-02 Customer Exhaust Valve: Pge 6: Fig. 10 - Flow direction changed. x
input Replacement of
Elastic Studs
2751-2/A1 2018-02 WinGD Input Exhaust Valve: Pge 7: Steps 6 to 10 changed. x
Disassemble and
Assemble
2790-1/A1 2018-02 WinGD Input Pilot Injection Valve: Pge 1: ToC changed. Pge 2: Procedure changed. Pge 5: data x
Removal, added. Pge 7: Data added,
Disassemble, Check,
Assemble, Installation
2722-1/A1 2018-02 WinGD Input Injection Valve: Pge 3: Warning about copper paste added x
Removal and
Installation
2722-2/A1 2018-02 WinGD Input Injection Valve: Pge 7: Warning about copper paste added x
Disassemble, Checks,
Assemble
Group 5 ToC 2018-02 WinGD Input Group 5 ToC Pilot Fuel Supply Pump: Removal and Installation 5555-2/A1 x
inserted. Fuel Pressure Control Valve: Manual Release Valve -
Clean 5562-1/A2 inserted.
5552-5/A1 2018-02 Wartsila Input Lubrication of Supply Procedure changed. New illustration added. x
Unit during
Maintenance
5555-2/A1 2018-02 WinGD Input Group 5 ToC New documemnt: Pilot Fuel Supply Pump: Removal and x
Installation 5555-1/A1
5562-1/A2 2018-02 WinGD Input Fuel Pressure Control New procedure. x
Valve: Manual
Release Valve - Clean
9403-3/A1 2018-02 Wartsila Input Hydraulic Pre- Pges 3 to 11: Sealing kits added. x
tensioning Jacks
2/3 19/03/2018

(MM) Page or
Date No. Manual
new exch.
9403-5/A1 2018-02 WinGD Input Tools List Page 38: 94844 Lubrication device added, Pge 37: Tool 94929 x
and move to Special Recommended Tools on Pge 42. Pge 17:
EAAD087159 Assembly tool 94289E added. Pge 18: New tools 94270-02,
94270-1 and 94270-3 added. Pge 37: Tool 94930 added.
Date of publication 2018-02
3/3 19/03/2018
0 General Information
1 Bedplate and Tie Rod
2 Cylinder Liner and Cylinder Cover
3 Crankshaft, Connecting Rod and Piston
4 Driving Wheels and Shut-off Valve for Starting Air
5 Supply Unit, Injection and Exhaust Valve Control
6 Scavenge Air Receiver and Auxiliary Blower
7 Cylinder Lubrication
8 Piping
MM / RT−flex / Register
9 Crank Angle Sensor Unit, Tools

Intentionally blank
RT-flex50DF Maintenance Group0
General Information Group 0
For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001−1/A1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002−1/A1
Engine Numbering and Designations (Turbocharger at Aft End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008−1/A1
Engine Numbering and Designations (Turbocharger at Exhaust Side) . . . . . . . . . . . . . . . . . . . . . . . 0008−1/A2
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 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1

Torque Values − Standard Screws and Elastic Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 (TC at Driving End) . . . . . . . . . . . . . . . . . . . . . . . . 0803−1/A1
Engine Cross Section and Longitudinal Section (TC at Exhaust Side) . . . . . . . . . . . . . . . . . . . . . . . 0803−1/A2
Winterthur Gas & Diesel Ltd. 1/ 1 RT−flex50DF / MM / 2016

Intentionally blank
RT-flex50DF Maintenance 0000−1/A1
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.
Winterthur Gas & Diesel Ltd. 1/ 1 2016

Intentionally blank
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 Wärtsilä Switzerland Ltd).
The Maintenance Manual has the primary data that follow:

D General Guidelines for Maintenance. These give recommendations about
precautions and applicable procedures.
D Clearance tables, tightening values of screwed connections, masses (weights).
These give data about usual and maximum permitted clearances, engine
components, type and use of different sealing rings etc.
D Maintenance Schedule. This schedule shows the nominal intervals when the
different maintenance operations must be done during standard operation
conditions.
D Design Groups give the instructions and procedures for maintenance work on
specified engine parts.
D Tool 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.

Intentionally blank
Table of Contents
Table of Contents
General Information Group 0
For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001−1/A1
Engine Numbering and Designations (Turbocharger at Aft End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008−1/A1
Engine Numbering and Designations (Turbocharger at Exhaust Side) . . . . . . . . . . . . . . . . . . . . . . . 0008−1/A2
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 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1

Torque Values − Standard Screws and Elastic Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 (TC at Driving End) . . . . . . . . . . . . . . . . . . . . . . . . 0803−1/A1
Engine Cross Section and Longitudinal Section (TC at Exhaust Side) . . . . . . . . . . . . . . . . . . . . . . . 0803−1/A2
Bedplate and Tie Rod Group 1
Bedplate and Thrust Bearing: Foundation Bolts − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112−1/A1
Main Bearing
Waisted Studs − Loosen and Apply Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−1/A1
Main Bearing − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−2/A1
Thrust Bearing
Axial Clearance − Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203−1/A1
Thrust Bearing Pads − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224−1/A1
Engine Stays with Friction Shims: Tension − Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A1

Hydraulic Engine Stays: Oil Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A2
Tie Rod: Tension Checks and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1903−1/A1
Winterthur Gas & Diesel Ltd. 1/ 4 2018−02

0002−1/A1 Maintenance RT-flex50DF
Table of Contents
Cylinder Liner and Cylinder Cover Group 2
Cylinder Liner
Measure the Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−1/A1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−2/A1
Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports . . . . . . . . . . . . 2124−3/A1
Lubricating Quill: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A1

Gas Admission Valve GAV50: Removal, Disassemble, Checks, Assemble, Installation . . . . . . . 2140−1/A1
Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation . . . . . . 2303−1/A1
Cylinder Cover
Cylinder Cover and Water Guide Jacket − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 2708−1/A1
Machining of Sealing Face for Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−3/A1
Cylinder Cover Elastic Studs − Loosen and Apply Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−2/A1
Sealing Face for the Pilot Injection Valve Position − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−4/A1
Sealing Face for the Fuel Injection Valve Position − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−5/A1
Sealing Face for the Prechamber − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−6/A1
Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722−1/A1

Injection Valve: Checks, Disassemble, Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722−2/A1
Starting Air Valve: Removal, Disassemble, Grind, Assemble, Installation . . . . . . . . . . . . . . . . . . . . 2728−1/A1
Exhaust Valve
Removal and Installation of Exhaust Valve, Replacement of Elastic Studs . . . . . . . . . . . . . . . . . . . 2751−1/A1
Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−2/A1
Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−3/A1
Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−4/A1
Pilot Injection Valve: Removal, Disassemble, Check, Assemble, Installation . . . . . . . . . . . . . . . . . 2790−1/A1
Crankshaft, Connecting Rod and Piston Group 3
Crankshaft: Crank Deflection − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103−1/A1
Vibration Damper
Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−1/A1
Axial Damper: Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3140−1/A1

Turning Gear: Teeth and Screwed Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3206−1/A1
Crankcase: Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−1/A1
Top Platform: Configuration of Lifting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−2/A2
Connecting Rod
Bottom End Bearing − Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−2/A2
Top End Bearing − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−3/A2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−4/A2
Top End Bearing − Bearing Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−5/A2
2018−02 2/ 4 Winterthur Gas & Diesel Ltd.

Table of Contents
Crosshead
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−1/A1
Crosshead Pin − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−2/A2
Piston
Top Surface Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403−4/A1
Piston Rings and Ring Grooves: Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425−1/A1

Piston Cooling and Crosshead Lubrication: Inner Pipe − Removal and Installation . . . . . . . . . . . 3603−1/A1
Driving Wheels and Shut-off Valve for Starting Air Group 4
Driving Wheels
Running and Backlash Clearances and Tooth Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−1/A1
Starting Air Shut-off Valve: Clean and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325−1/A1
Supply Unit, Injection and Exhaust Valve Control Group 5
Supply Unit
Servo Oil Pump and Servo Oil Pump Drive − Removal and Installation . . . . . . . . . . . . . . . . . . . . . 5552−1/A1
Camshaft and Bearing Shells − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−2/A1
Gear Wheel on Camshaft − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−3/A1
Supply Unit Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−4/A1
Lubrication of Supply Unit During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−5/A1
Pilot Fuel Supply Unit: Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−1/A1

Pilot Fuel Pump: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−2/A1
Fuel Pump: Removal, Disassemble, Assemble, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−1/A1
Fuel Pressure Control Valve: Removal, Check, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A1
Fuel Pressure Control Valve: Manual Release Valve − Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A2
Fuel Overpressure Safety Valve: Checks and Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−2/A1
Flow Limiting Valve: Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−3/A1
Exhaust Valve Control Unit: Removal, Disassemble, Assemble and Installation, . . . . . . . . . . . . . 5612−1/A1
Regulating Linkage
Adjustment: Heinzmann StG 10-01 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5801−1/A1
Scavenge Air Receiver and Auxiliary Blower Group 6
Scavenge Air Receiver: Clean and do Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6420−1/A1

Scavenge Air Receiver (TC at Exhaust Side): Clean and do Checks . . . . . . . . . . . . . . . . . . . . . . . . . 6420−2/A1
Auxiliary Blower: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545−1/A1
Auxiliary Blower (TC at Exhaust Side): Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545−2/A1
Scavenge Air Cooler: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606−1/A1
Scavenge Air Cooler (TC at Exhaust Side): Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 6606−2/A1

Table of Contents
Water Separator: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708−1/A1

Water Separator Removal and Installation (TC at Exhaust Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708−2/A1
Cylinder Lubrication Group 7

Cylinder Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7218−1/A1
Piping Group 8
Exhaust Waste Gate (Low-load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8135−1/A1

HP Servo Oil Pipe: Removal, Grind, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8447−1/A1
Hydraulic Pipe for Exhaust Valve Drive: Removal, Grind, Installation . . . . . . . . . . . . . . . . . . . . . . . . 8460−1/A1
HP Injection Pipe: Removal, Grind, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8733−1/A1
HP Fuel Pipe: Removal, Grind, Installation (TC at Aft End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8752−1/A1
HP Pipe Pilot Fuel: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8790−1/A1
Crank Angle Sensor Unit, Tools Group 9
Crank Angle Sensor Unit: Proximity Sensor − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9223−1/A1

Cylinder Pressure Sensor: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9258−1/A1
Tools: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−1/A1
Hydraulic Jacks and Pumps: Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−2/A1
Hydraulic Pre-tensioning Jacks

Storage, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−3/A1
General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−4/A1
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−5/A1

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1 to 39
Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 40 to 41

General
General Configuration − Turbocharger at Aft End
Turbocharger
Auxiliary
Blower 1
Auxiliary
Blower 2
1 2 3 4 5
Cylinder
Number
DRIVING END FREE END

1 2 3 4 5 6 7
Main Bearing
Number
WCH002808
Thrust Bearing Pads
DATA FOR
5 CYLINDERS
Rail Unit
FUEL SIDE EXHAUST SIDE
Supply Unit
Counterclockwise Clockwise Rotation

Rotation
WCH002808

Flex Parts:
Fuel Pump 1
Fuel Pump 2
Fuel Pump Actuator 1

FUEL SIDE
Servo Oil Pump 2
Supply Unit
Servo Oil Pump 1
DRAWN FOR DRIVING

5 CYLINDERS END
Crank Angle Sensors
Sensor 2 Sensor 1
FUEL SIDE
013.150/05
FREE END
2016 2/ 2 Winterthur Gas & Diesel Ltd.

General
General Configuration − Turbocharger on Exhaust Side
DRAWN FOR
7 CYLINDERS
Turbocharger
Auxiliary Auxiliary
Blower 1 Blower 2
1 2 3 4 5 6 7
Cylinder
Number
1 2 3 4 5 6 7 8 9
Main Bearing
Number
DRIVING END WCH03435
FREE END
Thrust Bearing Pads
Rail Unit
FUEL SIDE EXHAUST SIDE
Supply Unit
Counterclockwise Clockwise Rotation

Rotation
WCH03435
DATA FOR ONE A175 TURBOCHARGER

Flex Parts:
Fuel Pump 1
Fuel Pump 2

FUEL SIDE
Servo Oil Pump 2
Supply Unit
Servo Oil Pump 1

DATA FOR
5 CYLINDERS
DRIVING
END
Crank Angle Sensor Unit

I-I
DRIVING
END
I Supply Unit
drive
II
Proximity sensor II
WCH02993

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, which must be done on the engine at regular intervals, is described
in the Maintenance Schedule 0380−1. 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 be extended or decreased.
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:
D All personnel must know the fire fighting procedures.
D All personnel must know the health and safety data and environment protection
data related to the operation and maintenance of diesel engines.
D All personnel must know the dangers, functions and operation of cranes and
lifting devices.
D The safety officer must make sure that all precautions are done to prevent
dangerous conditions.
D The operator must select a supervisor to give work tasks to each person who
does maintenance work.
D Make 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.
D Before 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.
D Some media, e.g. fuel, oil are very flammable, thus you must keep such media
away from fire, hot parts etc.
D Make sure that personnel do not smoke in the engine room.
D To 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.

Safety Measures and Warnings
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 or cleaning fluid goes into
these electronic components or control boxes.
CAUTION
Damage Hazard: When electrical 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 electrical welding, you must do the procedure that follows:
1) Stop the engine.
2) Set to off the electronic system. After one minute, you can 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. 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 CO2 gas before

4. Special Safety Procedures

WARNING
Injury Hazard: After engine operation in gas mode, gas fuel can
stay in the gas inlet pipes. There is a risk of explosion. You must
replace the gas fuel with inert gas (e.g. nitrogen). For the
procedure, refer to the documentation of the gas valve unit
manufacturer.
WARNING
Danger: Gas Hazard. Poisonous gas can stay in the cylinder liner.
There is a risk of suffocation. You must put on protective
equipment, a respirator and a harness before you do work in
cylinders where gas can stay.
WARNING
Injury Hazard: Make sure that no personnel and components are
in the danger areas (crankcase, piston underside, propeller shaft,
propeller coupling).
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:
D The engine room crane.
D Lifting tools, ropes, slings and chains.
You must make sure that the lifting equipment is correctly attached to the the item (i.e.
balanced to make sure that the equipment does not tilt or fall).
For more data, refer to 0012−1 and 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 Data).

Safety Measures and Warnings
5. Recommendations
1) Read the data in 3301−1 Work Platform.
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 9403−5 Tool 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 removed item.
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 0330−1 Clearance 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 0352−1 and 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 Services 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.

General Guidelines for Lifting Tools
Wire Rope Slings, Span-sets, Eye Bolts, etc.

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Wire Rope Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Span-sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.3 Eye Bolts and Eye Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.4 RUD Eye bolts and RUD Swivel Lugs . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.5 Shackles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Data to Attach Ropes and Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
WARNING
Injury Hazard: Do not stand below a load that hangs. If the load
falls, injury to personnel can occur.
The permitted capacities of the engine crane, lifting tools, ropes, chains, eye bolts,
etc. must always be related to the weights of the parts to be lifted (see also Masses
(Weights) 0360−1).
Note: The permitted load capacity (maximum load) in kg is related to the Work
Load Limit (WLL).
For the removal and installation of engine components or their movement, use only
the applicable tools that are in a satisfactory condition. Ropes that have become worn
and tools that have damage are defective and must be replaced.
For safety and correct handling of the engine room crane, lifting tools or movement of
loads, the sequence that follows is recommend:
1) Find the weight of load.
2) Find the centers of gravity.
3) Use the applicable attachments.
4) Attach and remove the applicable lifting equipment.
2. Lifting Equipment
2.1 Wire Rope Slings

The WLL of the wire rope slings is given below their names in Tools List 9403−5.
2.2 Span-sets
Span-sets have the advantage of easy and simple handling. The code and the color
usually show the maximum permitted load. Loops and knots in the span-sets
decrease their lifting capacity by one third.
2.3 Eye Bolts and Eye Nuts

Only those eye bolts and eye nuts that are in accordance with DIN 580 and
582:2003−08, or that have the same or are more than these values must be used.
This includes the safety factor.
All calculations for components and tools where eye bolts and eye nuts are used are
related to the given standards.

General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc.
Lifting values (for data only):

Table 1: Values
Eye bolts and Lifting capacity [kg]

eye nuts, single-strand double-strand (45°)1)
thread size
45 _
M8 140 100
M10 230 170
M12 340 240
M16 700 500
M20 1200 860
M24 1800 1290
M30 3200 2300
M36 4600 3300
M42 6300 4500
M48 8600 6100
M56 11 500 8300
Note: The data given in Table 1 above are related to DIN 580 and 582:2003−08.
The eye bolt or the eye nut:
D Is fully turned in or screwed down
D Is fully on the seating surface
D Had a check for damage (e.g. corrosion, deformation) before use
D Note 1) Full load is only permitted in the direction of the ring, therefore the eye
bolts or eye nuts must be moved to the correct position. If necessary, use the
distance rings.
If there are through-holes, you must put a washer on the opposite side under the nut
or screw head.
When possible, do not apply an angle of inclination of more than 45° (in all directions
in relation to the ring).
Do not apply lateral loads.
For different use on different objects to be lifted, eye nuts or eye bolts with thread
diameters one size higher should be used.
2.4 RUD Eye bolts and RUD Swivel Lugs

Only those RUD eye bolts and RUD swivel lugs that have a safety factor of 4 can be
used.
Manufacturer:
RUD Ketten
Rieger & Dietz GmbH u. Co
Friedensinsel
D−73432 Aalen
Germany
http://www.rud.com

2.4.1 RUD Eye Bolts

RUD eye bolts must be fully attached to the seating surfaces.
Use the applicable star-profile wrenches to tighten RUD eye bolts with your hand (do
not use an extension).
After the RUD eye bolt is tightened, remove the star-profile wrench (Fig. 1). This will
make sure that the RUD eye bolt can turn freely.
Align the RUD eye bolt with the direction of force before a load is applied.
Note: Do not apply loads in the directions shown in Fig. 2.
DIRECTION DO NOT
OF FORCE APPLY FORCE
IN THESE
DIRECTIONS
Ring
DIRECTION
OF FORCE Star-profile
wrench
Screw
013.444/05
Fig. 1 Fig. 2

2.4.2 RUD Swivel Lugs

RUD swivel lugs must be fully attached to the seating surfaces.
Use an open-ended wrench to tighten the RUD swivel lugs with your hand.
Align the RUD swivel lug with the direction of force before a load is applied (Fig. 3
and Fig. 4)..
Note: If possible, do not apply force in the direction shown in Fig. 5.
DIRECTION NOTE: IF
OF FORCE POSSIBLE,
DO NOT
APPLY FORCE
IN THIS
DIRECTION DIRECTION
OF FORCE
013.445/05
Fig. 3 Fig. 4 Fig. 5
2.5 Shackles
Only those shackles that are in accordance with American Standard RR−C−271A, or
that have the same or are more than these values must be used. This includes the
safety factor.
All calculations for components and tools where shackles are used are related to the
given standards.
Usually, the permitted load on the shackles is specified for one strand.
Note: When tools are combined (e.g. beams with shackles, RUD eye bolts or
RUD swivel lugs and ropes, etc.), the WLL is given for the weakest part
(refer to the data in 9403−5 Tools List).

3. Data to Attach Ropes and Slings

You must know the data that follow:
D A sling with one strand has the total of load weight
D For a sling with two strands, each strand has one half of the load weight
D For a sling with four strands of equal load, each strand has one quarter of the
load weight.
D More stress is applied to strands that have a large angle between the attachment
points.
D Less stress is applied to strands that have a narrow angle between the
attachment points.
Ropes can move on smooth surfaces (pipes and shafts etc). A soft, wooden board
between the rope and the component prevents movement.
Use a cloth or a wooden pallet to prevent damage to ropes. Sharp edges can cut
steel strands.
Always make sure that the load is correctly attached to prevent a fall.
When a rope is wound around an item two times, the friction increases. You can use
this procedure to help prevent movement of a shaft that has surface oil.
You can wind hemp ropes around the hook to prevent movement.
Do not wind steel ropes around loads. As an alternative, put steel ropes across the
load.
Hold ropes in your open hands and keep your fingers clear. Do not hold the load at
the bottom. Always lower the load on to an applicable base on a flat surface.

Intentionally blank
Clearance Table
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Crankshaft and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . 14
Piston Cooling and Crosshead Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 16
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1. General
The clearances in the columns Nominal Dimension in the tables that follow are related
to design and manufacturing values, or to the settings on a new engine.
The values given in the columns Maximum Clearance, Dimension are the possible
results after a long period of operation. The differences in the clearances must not be
less than or more than those given.
On components where the clearance is adjustable (changed thickness of shims,
discs, spacers etc) the values must be those given in Usual Clearance. Where this is
not possible, you must replace worn parts with standard new parts, or repaired parts
with applicable material build-up.
If, during an overhaul, clearances are measured that are almost at the permitted limit,
personnel must make a decision to:
D Replace a component, or
D Let the component stay installed until the next overhaul.
This is related, for example, to the length of the next operation period until the next
overhaul and how much components are worn.

Clearance Table
Crankshaft and Thrust Bearing
013.025/05
Fig. 2
Fig. 1 1

Clearance Table
Crankshaft and Thrust Bearing
Description Measured Nominal Maximum Clearance,

Direction Dimension Dimension
(mm) (mm)
Key No.
Group
(usual, new) (because of worn

components)
1203 Thrust Bearing

1224
−0.5
Thrust bearing pad thickness 67 − 0.6
1 Thrust bearing clearance axial (total) 0.8 to 1.3 2.5

2 Thrust bearing pad, lateral clearance total 6

Clearance Table
Crankshaft and Main Bearing
018.600/09
MAIN BEARING MAIN BEARING No. 2

No. 1 AND FOLLOWING
Fig. 3
1 2 3
Fig. 4 018.663/09

Clearance Table
Crankshaft and Main Bearing

(mm) (mm)
Key No.
Group

components)
1132 Main bearing No. 1

0
Crankshaft outer ∅ 600 − 0.07
Main bearing inner ∅ 600

1 Bearing clearance vertical 0.3−0.6 0.9
1132 Main bearing No. 2 and following
0
Crankshaft outer ∅ 600 − 0.07
Main bearing inner ∅ 600

All main bearing clearances are only correct with tie rods and main bearing
studs tightened.

Clearance Table
Crosshead Guide
Note: Some parts can look different.
HOLDING PLATE 4 4 HOLDING PLATE
x x
5
5
6
1 2
013.027/05
FUEL SIDE
Fig. 5

Clearance Table
Crosshead Guide

(mm) (mm)
Key No.
Group

components)
3326 Crosshead guide

1 Guide way (column) transverse 812
− 0.20
2 Guide shoe transverse 812 − 0.30
3 Guide shoe clearance 0.20−0.90 1.0

4 Guide rail, lateral clearance total 0.80−1.60 2.0
*5 Guide shoe, lateral clearance total 0.10−0.60
− 0
6 Guide shoe, bearing pin outer ∅ 528 − 0.044
+ 0.101
Guide shoe, bearing bore inner ∅ 528 0.044
7 Bearing clearance radial 0.064−0.145 0.25
To measure the clearances, refer to 3326−1.

* The clearance (3) is only correct with tie rods tightened.
* The clearance (5) refers to the space between the white metal of the guide
shoe and the connecting rod. The clearance 5 must be measured near the
holding plates which must rest on the crosshead pin at X.

Clearance Table
Cylinder Liner
3 Approximately 100 mm
to 180 mm
4
WCH03120
Fig. 6

Clearance Table
Cylinder Liner

(mm) (mm)
Key No.
Group

components)
2124 Water guide jacket on cylinder

cover
Water guide jacket Ø + 0.3

760 + 0.1
1 Clearance total 0.40−0.80

750 + 0.9

2124 Water guide jacket on cylinder
liner
Water guide jacket Ø − 0.20

750 − 0.40

695 + 0.1

2124 Cylinder liner
*5 Cylinder liner bore radial 500 503.50
* Make sure that you measure at the correct point.

Clearance Table
Piston Rod Gland
1 5
2 6
013.225/05
Fig. 7

Clearance Table
Piston Rod Gland

(mm) (mm)
Key No.
Group

components)
2303 Piston rod gland

*1 Ring width radial 31 min. 25
*2 Ring width radial 22 min. 20.20
*3 Ring width radial 5 min. 3.20
4 Ring clearance axial 0.05−0.19 0.40
* Ring wear
The difference in value between the nominal dimension and maximum worn area is
equal for all rings, i.e. also for smaller rings.

Clearance Table
Exhaust Valve
VALVE SPINDLE
GUIDE BUSH
~ 2/3 L
L = LENGTH
3
~ 1/3 L
012.999/05
Fig. 9
Fig. 8

Clearance Table
Exhaust Valve

(mm) (mm)
Key No.
Group

components)
2751 Valve spindle
1 Spindle outer ∅ − 0.14 54.40

55 − 0.17
2751 Guide bush
*2 Bore inner ∅ + 0.03 55.35

55 0
*3 Bore inner ∅ + 0.03 56.20

55 0
* Make sure that you measure at the correct points.

Clearance Table
Top and Bottom End Bearings to Connecting Rod
10 mm
2
2
3 3
10 mm
60 mm
5
5
6 6
60 mm
Fig. 10 4 013.028/05

Clearance Table
Top and Bottom End Bearings to Connecting Rod

(mm) (mm)
Key No.
Group

components)
3303 Top end bearing

3326
528 0
Crosshead pin outer ∅ − 0.04
4
Bearing inner ∅ 528

*2 Lateral clearance total 0.40−0.60
3303 Bottom end bearing
Crankshaft outer ∅ 0
600 − 0.07
Bearing inner ∅ 600

* Make sure that you measure at the correct points.

For measuring clearances (1) the crank must be at BDC.

Clearance Table
Piston Cooling and Crosshead Lubrication
Fig. 11 013.029/05

Clearance Table

(mm) (mm)
Key No.
Group

components)
3603 Piston cooling and crosshead

lubrication
Sleeve inner ∅ + 0.15

56 + 0.12
Sleeve length − 0.08

115 − 0.10
1 Radial clearance total 0.30−0.39 0.42

2 Clearance vertical 0.08−0.20 0.25
Inside (telescopic) pipe outer ∅ − 0.18

56 − 0.24

Clearance Table
Piston and Piston Rings
DESIGN WITH THREE

PISTON RINGS
5
1
6
2
3 A B
7
9
4 A B
10
8a
Fig. 12

Clearance Table
Piston and Piston Rings

(mm) (mm)
Key No.
Group

components)
3406 Piston Head
0
1 Head (tapered part) outer ∅ 495 − 0.2
2 Head outer ∅ 0
497.7 − 0.2
3403 Piston ring grooves

3425
3 Height of the top groove vertical + 0.38

17 + 0.33
4 Height of the two lower grooves vertical + 0.33

15 + 0.28
5 Groove depth radial 17.50

3425 Piston rings
3 Top ring height vertical 0

17 − 0.03
4 Lower ring height vertical 0

15 − 0.03
Point A Point B
6 Top ring clearance vertical 0.33−0.41 0.60 0.75
7 Ring clearance vertical 0.28−0.36 0.58 0.75
8 Ring width radial 18.0 ± 0.25
8a Ring width radial 16.5 ± 0.25
3403 Piston skirt
9 Skirt outer ∅ − 0 min. 497.7

499.4 − 0.2
3403 Piston rod
10 Rod outer ∅ − 0.050 min. 199.30

200 − 0.096
Removed piston rings can be installed again if they are in their minimum ring width
until the next overhaul (for more data about the piston rings refer to 3425−1).

Clearance Table
Driving Wheels for Supply Unit
2
4
1
3
Fig. 14 WCH00139
Fig. 13
013.030/05

Clearance Table
Driving Wheels for Supply Unit

(mm) (mm)
Key No.
Group

components)
4103 Intermediate wheel

1 Shaft outer ∅ 160
2 Bearing clearance vertical *0.082−0.147 0.25
3 Axial clearance total 0.6−1.1 1.5
4 Tooth backlash 0.20−0.33 0.55
5 Tooth backlash 0.28−0.42 0.65
*This clearance can only be measured when the intermediate wheel is disassembled.
When you measure the tooth backlash, look at the tooth crown of the tooth flanks in
the longitudinal direction.

Clearance Table
Supply Unit
5
4
013.031/05
1 3 2 7
Fig. 15

Clearance Table
Supply Unit

(mm) (mm)
Key No.
Group

components)
5552 Supply unit
1 Pinion outer ∅ 0
80 − 0.019
Bearing (installed) inner ∅ + 0.10

80 + 0.085
2 Bearing clearance radial 0.085−0.119

5552 Camshaft unit
4 Camshaft outer ∅ 0
120 − 0.022
5 Bearing clearance radial 0.10−0.19

7 Tooth backlash 0.12−0.22
*8 Minimum clearance 2
* Minimum clearance between cam and roller with fuel pump cut out.

Clearance Table
Fuel Pump
30 mm (Ø30−35 mm)
38 mm (Ø36 mm)
PLUNGER and CYLINDER
1
B
171 mm
012.098/04
2 Fig. 17
8
7 4
6
5
013.032/05
Fig. 16

Clearance Table
Fuel Pump

(mm) (mm)
Key No.
Group

components)
5556 Fuel pump

1 Clearance (plunger / cylinder) A−B radial 0.028−0.030 0.037
Clearance (plunger / cylinder) B−C radial 0.018−0.020 0.027
Guide piston outer ∅ 130
Bottom housing inner ∅ 130
2 Clearance radial 0.070−0.125 0.149
3 Piston / lower spring carrier axial 0.02−0.06 0.08
5556 Roller guide
Bush outer ∅ 60
Roller inner ∅ 60
Pin outer ∅ 50
Bush inner ∅ 50
Pin outer ∅ 50
Guide piston (bore) inner ∅ 50
7 Axial clearance of bush total 0.2−0.4 0.5
8 Total clearance between guide piston axial 0.24−0.54
0.7
and roller with pressure discs

Intentionally blank
Tightening Values of Important Screwed Connections
WCH03038
Fig. 1

WCH03038
Fig. 2

WCH030038
WCH03038
Fig. 3

WCH03038
Fig. 4

WCH03038
Fig. 5

WCH03038
Fig. 6


Intentionally blank
Torque Values − Standard Screws and Elastic Stud
Torque Values − Standard Screws and Elastic Studs
1. Torque Values − Standard Screws

It is recommended that the torque values given in the table below are for aII standard
metric screws of grade 8.8. This applies to all threaded connections not shown in
0352−1. The threads and bottom of the head must be lubricated with oil SAE 30.
For the screws in high temperature areas (exhaust pipes, expansion pieces etc), a
lubricant resistant to heat (e.g. NEVER SEEZ NSBT8) is recommended.
If NEVER SEEZ NSBT8 is used, the torque value must be decreased by 20% of the
values given in the table.
These torque values do not apply to turbocharger installations. Refer to the
documents of the turbocharger manufacturer for the correct torque values.
Standard thread Fine thread Torque Value

Grade 8.8 Grade 8.8 [Nm]
M3 M3 x 0.35 0.9
M4 M4 x 0.5 2.1
M5 M5 x 0.5 4.2
M6 M6 x 0.75 7.2
M8 M8 x 1 18
M10 M10 x 1.25 35
M12 M12 x 1.25 60
M14 M14 x 1.5 94
M16 M16 x 1.5 145
M18 M18 x 1.5 200
M20 M20 x 1.5 280
M22 M22 x 1.5 380
M24 M24 x 2 490
M27 M27 x 2 720
M30 M30 x 2 980
M33 M33 x 2 1300
M36 M36 x 3 1700
M39 M39 x 3 2200
M42 M42 x 3 2700
M45 M45 x 3 3400
M48 M48 x 3 4100
M52 M52 x 3 5300
M56 M56 x 4 6600
M60 M60 x 4 8100

2. Elastic Studs − Replacement
2.1 Procedure
1) Read the data in the manual of the jointing compound manufacturer.
2) Remove the unserviceable elastic stud.
3) Remove the grease.
4) Clean the sealing surfaces of the new elastic stud.
5) Remove the grease and other unwanted material from the tap hole and the area
where the elastic stud will be installed.
6) Clean the tap hole and the area where the elastic stud will be installed.
7) If necessary, apply an adhesive primer to the shank of the elastic stud. Make
sure that no adhesive primer goes on to the threads.
8) Use only a stud driver (or two nuts locked together) to fully install the stud into the
tap hole.
9) Torque the elastic stud to the applicable value given in the table below:
3500
3000 400
2500
300
TORQUE [Nm]
2000
TORQUE [Nm]
1500 200
1000
100
500
0 0
10 20 30 40 50 60 70 80 90 100 110 120 10 20 30 40 50 60
Fig. 1 THREAD DIAMETER [mm] Fig. 2 THREAD DIAMETER [mm]
001.769/97

10) For the elastic studs installed in the valve cage, cylinder liner and cylinder jacket
fill the area around the elastic stud with jointing compound (see Fig.3
JOINTING
COMPOUND
SEALING
SURFACES
ELASTIC STUD
Fig. 3 WCH02357
2.2 Jointing Compound

Refer to the table below for the recommended manufacturers of jointing compounds
and adhesive primers.
Jointing Hardener Adhesive Manufacturer

Compound Primer
Elastosil RT 622 B G 790 Wacker-Chemie Gmbh
RT 622 A Geschäftsbereich Silicone
Hanns-Seidel-Platz 4
D-81737 München
Silcoset Silcoset Silcoset Primer AMBERSIL LTD
105 RTV Curing Agent A Wylds Rd
Bridgwater
Somerset
TA6 4DD
Uk-Great Britain
Use only the data in the related manufacturer’s instructions to mix and apply the
jointing compounds, hardeners and adhesive primers.
Materials from other manufacturers are permitted, but must have the qualities given
below:
D The materials must not contain acid.
D The materials must be resistant to oil, marine diesel oil, heavy fuel oil and water
at a temperature of 100_C.
D A short age hardening time is necessary i.e. not more than 24 hours (refer to the
data in the ISO standard reference conditions).
D Materials must flow easily to fill the area around the sealing surface (i.e. no air
pockets).
D The materials must have good adhesion qualities on primed metal surfaces.
D The materials must be easy to prepare and combine.
D The surface shrinkage must be very small, or none.
D The jointing compound must stay in an elastic condition. This will help you if it
becomes necessary to remove the elastic studs.

Intentionally blank
Masses (Weights)
Components of each Group in kg

Group Component Design kg
1
1115 Main bearing cover 177
1134 Main bearing shells (upper and lower) 46.8
1203 Holder for thrust bearing 44.6
1224 Thrust bearing pad 40.6
1717 Casing, upper part free end 390

Casing, lower part free end 575
1720 Oil baffle, upper part driving end 195

Oil baffle, lower part driving end 90
1730 Bearing housing to supply unit drive 545
1903 Tie rod M80x6 thread ∅ 254

Tie rod nut 4
Intermediate ring 9.7
2
2106 Elastic stud in cylinder block M56 28.4
2124 Cylinder liner (complete) 2345

Cylinder liner to GAV50-Mk2 2344
(complete)
2130 Water guide jacket (upper) 80.5

Water guide jacket (lower) 98
2140 Gas admission valve 30.4
2303 Piston rod gland 86.9
2708 Elastic stud for valve cage 15.7

Cylinder cover without accessories 1072
Cylinder cover with exhaust valve 1598
2722 Injection valve 12.9
2728 Starting valve 18.7
2751 Exhaust valve 450
2754 Exhaust valve spindle 41.7
2790 Pilot injection valve 32.7

Individual Components per Piece in kg

3
3103 Balance weight on crankshaft 307
3122 Flywheel light 1530−2030

heavy 8000
3140 Axial detuner Two parts 408
3303 Connecting rod 1399
3306 Connecting rod shaft 1426
Bottom bearing half for bottom end 137

bearing with elastic bolts
3310 Bottom bearing shell half for bottom 13.5

end bearing
Top bearing shell half for bottom end 20
bearing
Bearing shell crank pin 38
3312 Bearing cover crosshead for top end 148

bearing
3315 Bearing shell crosshead for top end 43

bearing
3326 Crosshead with guide shoes 1440

Crosshead pin 1040
Guide shoe (Free End side) 188
Guide shoe (Driving End side) 184
3403 Piston two-part, with piston rod and 881

piston rod gland
Piston head 204
Piston skirt 39
Piston rod 571
Spray plate with oil pipe 41.5
3603 Inside (telescopic) pipe to piston 18.9

cooling and crosshead lubrication
4
4106 Crankshaft gear wheel 1-part 375
2-part 579
4120 Intermediate wheel with bearing pins 315
and bearings for supply unit
Bearing pair for intermediate wheel 50.4
4325 Starting air shut-off valve 207

Individual Components per Piece in kg

5
5552 Supply unit with pumps, driving
wheels 5−6 Cyl. engines 1750
7−8 Cyl. engines 2000
150
Servo oil pump (Dynex) 5−6 Cyl. engines 168
Camshaft with gear wheel 7−8 Cyl. engines 189
5556 Fuel pump 162

5612 Exhaust valve control unit 43.4
6
6506 Turbocharger ABB−A165 2300
ABB− A175 2600
ABB−A265 2700
6545 Auxiliary blower with electric motor 1434

Electric motor 184 to 283
6606 Scavenge air cooler SACA46−SF 1142

TROPICAL
SACA44−SD 2760
6708 Water separator 220

7
7206 Cylinder lubricating pump 5−8 Cyl. engines 13.2
8
8139 Expansion piece exhaust valve 35
8790 Supply unit for pilot fuel system 367

Intentionally blank
Maintenance Schedule
Inspection and Overhaul Intervals (Guidelines)

Group Component Procedure Intervals and Service
Life (operation hours)
0
Lubricating oil − Laboratory analysis 3000
Main fuel and − Do a check of the filter elements for white 3000
lubricating oil metal particles (clean or replace the filter as
filters necessary). Obey the manufacturer’s
instructions
Cooling water − Calculate the quality, concentration of inhibitor Weekly

and pH value (obey the instructions of inhibitor
manufacturer)
1
1112−1 Bedplate − Do a pre-tension check of the foundation bolts. 12000
First check after 1500 Operation hours (Op. H)
− Do a check of the the condition of rubber 30000 (replacement

gasket in the vertical oil drain to the sump tank recommended)
(see SPC 9722). First time as soon as possible
after the ship is supplied.
− Estimated service life: Bedplate foundation Service life of the

bolts engine
Crankcase − Do a visual examination, 100 Op. h after 1500 to 3000

overhaul works: Look for white metal particles
from bearings and for other problems.
− Estimated service life: crankcase Service life of the

engine
1132−2 Main bearing − An inspection of the bearing shell is only At indications of

necessary if the bearing clearance, crankshaft excessive wear or
deflection, wire check oil analysis or crankcase damage
inspectionindicates excessive wear or damage
− Do a check of the bearing clearance, refer to 6000

0330−1
− Estimated service life: Main bearing shell 90000 (replace if

necessary)
1203−1 Thrust bearing − Do a check of the axial and vertical clearances 6000 to 8000
− Make sure that the bottom drain is not blocked 6000 to 8000
1224−1 − An inspection of the thrust bearing pads is only At indications of

necessary if the bearing clearance, oil analysis excessive wear or
or crankcase inspectionindicates excessive damage
wear or damage
− Estimated service life: Thrust bearing 90000 (replace if

necessary)


1715−1 Engine Stays − Friction type: Do a check of the pre-tension of 6000 to 8000
screws. Remove corrosion marks from friction
elements. First time after the sea trial
− Hydraulic type: Do a check of the oil pressure Monthly

on the gauge
1903−1 Tie Rod − Do a check of the pre-tension. If necessary, 24000 to 30000

apply tension again. First time one year after
the ship is supplied
− Estimated service life: Tie rod Service life of the

engine
2
2124−1 Cylinder Liner − Measure the cylinder liner (in installed position) At each piston removal
2124−2 − Remove the cylinder liner As necessary
− Replace the O−rings At each liner removal
− Replace the soft iron joint ring between the At each piston removal
cylinder liner and cylinder cover
− Replace the O−rings of the water guide jacket At each liner removal
and transition tubes
− Do a condition check of the antipolishing ring At each piston removal
2124−3 − Remove unwanted material in the bore At each piston removal
− Dress the lubricating grooves As necessary
− Clean the scavenge ports. Dress their edges As necessary
− Estimated service life: Cylinder liner Up to 90000
2138−1 Lubricating Quill − Do a function and tightness check At each piston removal
(Pulse
Lubrication)
− Do a function check of the non-return valves At each piston removal
2140−1 Gas admission − Do a function and tightness check of the GAV 6000
valve (GAV)
− Do an overhaul of the valve seat of the GAV 18000 to 21000
− Do a visual check of the compensator at the At each GAV removal

gas inlet pipe
− Estimated service life: Valve spindle, includes 36000

the guide, stroke sensor and rail valve
− Estimated service life: Housing and servo drive Service life of engine
2303−1 Piston rod gland − Clean the piston rings, find the worn areas At each piston removal
− Estimated service life: Piston rod gland 36000 (refers to rings)


2708−1 Cylinder cover − Do a check of the combustion space for At each piston removal
damage and worn areas
− Estimated service life: Cylinder cover Service life of engine

(re-manufacture as
necessary)
2722−1 Injection valve − Do an external tightness check Before engine start

(main fuel after a longer engine
injector) stop
− Do a function check (nozzle tip inspection, 6000

opening pressure).
− Replace the O−rings 6000
− Replace the injection valve 24000
− Estimated service life: Injection valve 24000
− Estimated service life: Nozzle spare parts set 6000

(e.g. coupling nut and nozzle body with
needle)
2728−1 Starting air − Do a check of the pipes upstream of the Weekly

valve starting air valve during operation. If the pipes
are too hot, disassemble the starting air valve
− Remove and disassemble one starting air 6000 to 8000

valve. From the condition, calculate the time of
overhaul for remaining valves
− Make sure that the nut on the solenoid is tight. Monthly

If necessary tighten the nut.
− Solenoid valve − do a random function check 6000
− Solenoid valve − do an overhaul 18000
− Estimated service life− Starting valve Service life of engine
2745−1 Relief valve to − Do a check of the blow-off pressure As necessary

cylinder cover


2751−1 Exhaust valve − General inspection of valve housing, valve At each piston removal
to spindle and valve seat (when the exhaust
valve is not disassembled)
2751−4 − Do a check of the condition and worn areas of Initial inspection at

the valve spindle (if necessary, grind the valve 18000, then each
seat) 36000
− Valve drive: Do a check of the piston seal ring / Initial inspection at

air spring and rod seal ring / guide bush 18000, then each
36000
− Do a check of the condition and worn areas of Initial inspection at

the valve seat 18000, then each
36000
− Do a random check of the valve drive, outer 18000

and inner pistons, damper, thrust piece
− Estimated service life: Exhaust valve spindle 108000

(Nimonic) (re-manufacture as
necessary)
− Exhaust valve seat 72000 (re-manufacture

as necessary)
2790−1 Pilot injection − Do an external check for tightness Before engine start
valve after a long engine
stop
− Do a check of the opening pressure 8000
− Replace the nozzle spare parts set 8000
− Replace the O−rings 8000
− Replace the pilot injection valve 24000
− Replace the pre-chamber 18000
− Estimated service life: Nozzle spare parts set 8000

3
3103−1 Crankshaft − Measure the crank deflection. Always if the 6000
ship grounded and after each docking
3130−1 Torsional − Get a silicon oil sample from the viscous First time after 15000
vibration vibration damper (use the results of the 1st to 18000
damper sample. The manufacturer will make a decision
about the intervals to get more samples)
3130−2 − Do an inspection and disassemble the In accordance with

vibration damper instructions of damper
manufacturer
3140−1 Axial damper − Disassemble and do an inspection 36000 to 48000


3206−1 Turning gear − Inspection interval of turning gear In accordance with the
instructions of the
turning gear
manufacturer
− Lubricate the tooth flanks of the pinion and 2000

flywheel. Related to visual inspections, but at
the latest, each 2000 Op. h of the engine
− Do a check of the screwed connections, first 12000

time after one year
Connecting rod − Do a check of the bearing clearances (refer to 6000 to 8000

bearings 0330−1)
− Do a check of the bearing edge with wire 6000 to 8000
3303−2 − Bottom end bearing inspection is only At indications of

necessary if the bearing clearance, wire check, excessive wear or
oil analysis or crankcase inspectionindicates damage
excessive wear or damage.
3303−3 − Top end bearing inspection is only necessary if At indications of

bearing clearance, wire check, oil analysis or excessive wear or
crankcase inspectionindicates excessive wear damage
or damage.
− Estimated service life: Connecting rod bottom 90000. Replace if

end bearings necessary
− Estimated service life: Connecting rod top end 90000. replace if

bearings necessary
3326−1 Guide shoe, − Do a check of the clearances 6000 to 8000

crosshead pin
3403−1 Piston − Remove and clean 18000 to 36000 (on

condition)
− Do a check of the tightness on the piston After installation

through the scavenge ports in the installed
position (oil pump in operation)
3403−3 − Disassemble and assemble (open the cooling As necessary

space and clean, minimum one piston each
three years)
3403−4 − Do a check of the of the piston top surface At each piston removal
− Do a visual check through scavenge ports of 500 to 1000

the piston, piston rings and cylinder liner
− Measure the piston ring grooves. Do an 18000 to 36000 (on

inspection of the chromium plating. Add new condition)
chrome as necessary
− Estimated service life: Piston ring grooves 18000 − 36000
− Piston head surface, full re-manufacture 72000


Piston − Do a check of the condition of the piston 1500 to 3000

underside underside and clean as necessary
− Make sure that the drains and holes are not 1500 to 3000
blocked
3425−1 Piston rings − Measure the thickness of chrome-ceramic 1500 to 2000

layer
− Replace the piston rings. Use the remaining 18000 to 36000 (on
thickness of chrome-ceramic layer to make a condition)
decision.
− Estimated service life: Piston rings 18000 to 30000

4
Start interlock − Do a check of the electrical and pneumatic Quarterly
interlocks (refer to the Operation Manual
4003−1)
4103−1 Driving wheels − Do a check of the tooth condition 6000 to 8000
− Do a check of the running clearance and tooth 6000 to 8000

backlash
− Estimated service life: driving wheels Service life of engine
Starting air − Release the pressure in the starting air inlet After each
shut-off valve (manifold) pipe maneuvering period
4325−1 − Disassemble, clean and do a check (important 30000 to 36000

parts are: seat, springs and sealing rings)
− Do an overhaul of the common start valve 18000

(SPC: Control Valve, Group 4325−2)
− Estimated service life: Starting air shut-off Service life of engine

valve
Control air filter − Drain the filter Weekly
− Clean the filter 6000

5
5551−1 Servo oil pump − Replace the servo oil pump with new item or a 42000
pump that had an overhaul in a Wärtsilä
workshop
5552−1 Servo oil pump − Do a check of the pinion and driving wheels to 3000
drive the servo oil pump drive
− Do a check of the bearing bushes to the pinion 24000
− Do a check of the filter below the plug in the 2000

compensator for particles
− Estimated service life: supply unit pinion 90000

bearing bushes


5552−2 Fuel oil pump − Camshaft: Do a check of the running surface 3000
drive of cams, rollers and roller guides (first time
after 500 Op. h)
− Camshaft: Do a check of the bearing 12000

clearances at random positions
− Camshaft: Do a check of the thrust bearing 36000

clearances
− Estimated service life: supply unit camshaft 90000

bearings
5555−1 Pilot fuel supply − Lubricate the flexible coupling of the pilot fuel 1500 to 3000
unit pump
− Replace the pilot fuel pump 24000
− Replace the oil filter cartridges. (the filter 1 000

cartridges must be replaced earlier if the
pressure difference indicator shows high
pressure increase
− Clean the wire gauze and filter housing. 1000
− Estimated service life: Pilot fuel pump 24000
5556−1 Fuel pump − Do a random flow check of lubricating oil 6000
− Do an overhaul of the fuel pump 18000
− Estimated service life: Fuel Pump 18000
5562−1 Fuel pressure − Do a check of the shutdown function (refer to 3000

control valve the Operation Manual 4003−1)
(PCV)
− Do a function check (refer to the Operation 6000

Manual 5562−1)
− Do an overhaul Only necessary if the

PCV fails
− Estimated service life: PCV Service life of the

engine
5562−2 Fuel − Do a function check on a test bench 24000 to 36000

overpressure
safety valve /
Relief Valve
5564−1 Flow limiting − Do an inspection. Clean the piston rod and 12000
Valve (FLV) piston running surface
− Do an overhaul, or replace with a new FLV or a 24000

Wärtsilä serviced item
− Estimated service life: FLV 24000


Servo oil rail − Replace the hoses (each five years at a 30000
minimum)
5612−1 Exhaust valve − Do a random check of the piston and slide rod 36000
control unit
− Do a check of the servo oil filter 18000
− Estimated service life: Exhaust valve control Service life of engine

unit
5583−1 Fuel pump − Make sure that the regulating linkage moves 3000
or Actuator freely. Lubricate parts that can move.
5556−1
6
6420−1 Scavenge air − Do a check of the scavenge air receiver and 4000 to 6000
receiver clean the air flaps
− Clean the receiver 4000 to 6000
− Make sure water drain pipes and orifices are 1500 to 3000
not blocked
Turbocharger − Wash-clean the compressor during operation Refer to the Operation

Manual
− Wash-cleaning or dry clean the turbine during Refer to the Operation

operation Manual
Air filter − Do a check of the filter Each six months
− Clean the filter at a np increase of 50% As necessary

compared to the shop test value at the same
engine load (refer to the Operation Manual
6510−1)
6545−1 Auxiliary blower − Clean the impeller and casing 24000 to 36000
− Replace the ball bearing 24000 to 36000


6606−1 Scavenge air − Clean the scavenge air cooler (air side) during As necessary
cooler operation each week. Later if np (pressure
decrease through the SAC) increases
compared to the shop test value at the same
engine load (refer to the Operation Manual
6606−1)
− Do a check of the condensate collector Daily

through the sight glass (refer to the Operation
Manual 8345−1)
− Make sure that the condensate collector is not 1500 to 3000

blocked (refer to the Operation Manual
8345−1)
− Check scavenge air cooler sealing Quarterly
− Bleed Daily
− Remove the scavenge air cooler for overhaul As necessary
6708−1 Water separator − Do a check of the condensate collector Daily

scavenge air through the sight glass (refer to the Operating
Manual 8345−1)
− Make sure that the condensate collector is not 1500 to 3000

blocked (refer to the Operating Manual
8345−1)
− Do a check of the the water separator 1500 to 3000

elements (if necessary clean them)
− Remove the water separator for overhaul As necessary

7
7218−1 Lubricating − Replace the lubricating pump with new item, or 30000
pump a pump that had an overhaul from a Wärtsilä
workshop.
Filter − Replace the filter element upstream of the the As necessary

replacement cylinder lubricating system
− Estimated service life: Cylinder lubricating 30000

pump
Servo oil service − Do a check of the flow rate and maximum 30000
pump pressure
Starting air − Drain (remove water) Before and after each

pipes on and maneuvering period
upstream of the
engine
Pressure − Compare and calibrate according to the 6000 to 8000

gauges and master instruments
pyrometers


7218 Pipe holders − Make sure that the fasteners are tight. Tighten As necessary
cont’d the screws if necessary (first time after 100
Op. h.)
8
8135−1 Exhaust Waste − During a longer operation period at low engine
Gate (LLT) load, manually open the butterfly valve a
minimum of one time each week (refer to the
Operation Manual 8135−1) In accordance with the
− General inspection instructions of the valve
manufacturer
8447−1 Servo oil pipes − Grind sealing faces As necessary
Non-return valve − Random check 18000
8460−1 Hydraulic pipe − − Grind the sealing faces As necessary

exhaust valve
drive
8733−1 HP pipe to − Grind the sealing faces As necessary

injection valve
(on cylinder
cover)
8744−1 Supply unit, fuel − Make sure that the pipes are not blocked 6000
drain pipes
8752−1 HP fuel pipe − Grind the sealing faces As necessary
8903 Gas supply pipe − Shut off and vent valves: Do a tightness check 6000
of the ball valves and the shaft sealing
− Do a visual check of the compensators 6000
− Estimated service life Service life of the

engine
9
9223−1 Crank angle − Replace the proximity sensor As necessary
sensor
(proximity
sensors on gear
wheel at driving
end)
Oil mist detector − Refer to the manufacturer’s instructions Six monthly
ECS − Replace the modules: CCM−20, MCM−11 and 48000 to 50000

LDU−20, refer to the Operation Manual
4002−1.
− Do a visual check of the cables Quarterly

The maintenance intervals shown are for guidance and can be different in relation to
the installation. The correct intervals apply to the points given below. These intervals,
which are related to the duration of operation, can be longer or shorter:
D Environmental and operation conditions
D Diesel engine fuels and quality of lubricating oil (refer to the Operation Manual
0710−1 and 0750−1)
D Gas fuel specifications (see 0770−1)
D Engine load
D Fuel, lubricating oil and cooling water treatment (refer to the Operation Manual
0720−1 and 0760−1)
D Do an overhaul in accordance with the Maintenance Manual
D The correct spare parts are used
D Monitor the engine
D The engines are in accordance with the specifications of Winterthur Gas & Diesel
Ltd.
Refer to 0803−1/A1 / 0803−1/A2 for the cross section and longitudinal illustrations.
These illustrations show the important parts and their Group numbers.
3. Engine Control System

Refer to the Operation Manual, Group 4 for data about the Engine Control System
and Control Elements.

Engine Cross Section and Longitudinal Section (TC at Driving End)
Cross Section
8460−1
2728−1
8733−1
2124−1 to
2124−3
5612−1
4325−1
6420−1
6606−1
3603−1 8447−1
3326−1
6545−1
3326−2
8752−1
5556−1
5801−1
3301−1
5552−1 to
5552−5
4103−1
1112−1
WCH00676
Fig. 1: Cross Section

Engine Cross Section and Longitudinal Section (TC at Driving End)
Longitudinal Section
2751−1 to
2751−4
2722−1
2708−1 to
2708−3
3425−1
3403−1 to
3403−4
2138−1
1903−1
6420−1
2303−1
6606−1
6708−1
3303−1 to
3303−5
3140−1
1132−1
1132−2 9223−1
1203−1
1224−1
3130−1
WCH00677
Fig. 2: Longitudinal Section

Engine Cross Section and Longitudinal Section (TC at Exhaust Side)
Cross Section
8460−1
8733−1
2728−1
5562−1
3603−1
8447−1
6606−1
3326−1
6708−1
3326−2
6420−1
8752−1
5556−1
5801−1
3301−1
3206−1
5552−1 to
5552−5
4103−1
1112−1
WCH00123
Fig. 1: Cross Section

Engine Cross Section and Longitudinal Section (TC at Exhaust Side)
Longitudinal Section
2751−1 to
2751−4
2722−1
2708−1 to
2708−3
3425−1
2124−1 to
2124−3 3403−1 to
3403−4
1903−1
2138−1
4325−1
2303−1
3303−1 to
3303−5
3140−1
1132−1
1132−2
1203−1
1224−1
3130−1
4103−3
WCH03431
Fig. 2: Longitudinal Section

Bedplate and Tie Rod Group 1
Bedplate and Thrust Bearing: Foundation Bolts − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112−1/A1
Main Bearing
Waisted Studs − Loosen and Apply Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−1/A1
Main Bearing − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−2/A1
Thrust Bearing
Axial Clearance − Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203−1/A1
Thrust Bearing Pads − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224−1/A1
Engine Stays with Friction Shims: Tension − Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A1

Hydraulic Engine Stays: Oil Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A2
Tie Rod: Tension Checks and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1903−1/A1

Intentionally blank
Bedplate and Thrust Bearing
Foundation Bolts − Check

Tools:
1 Feeler gauge 94122 2 Pressure gauges 94934A
1 Pre-tensioner 94145 1 HP hose 94935
1 HP oil pump 94931
1. General
You must do a check of the tension of the foundation bolts and studs at longer
intervals e.g. during overhauls, refer to 0380−1.
In the area of the thrust bearing, attach the foundation bolt as follows:
D With the foundation bolts (1, Fig. 1) and sleeves (2), or
D With the installed foundation studs (4, Fig. 2).
The remaining area is attached with the foundation bolts (1, Fig. 3) without the
sleeves.
Note: Do the procedure given in 9403−4 General Application Instructions for the
hydraulic pre-tensioning jacks.
1
4 1
2
3 3
012.948/05
Fig. 1 Fig. 2 Fig. 3

2. Tension Check
1) Clean the threads of the foundation bolts (5, Fig. 4) and the seating surfaces.
2) Apply Molykote G paste to the threads of the foundation bolts, or installed
studs (5).
3) Put the pre-tensioner (94145) in position on the foundation bolt (5)
4) Open the vent screw (8).
5) Turn the pre-tensioner (94145) fully down. Make sure that there is little, or no
clearance at (X).
6) Connect the pre-tensioner (94145) to HP oil pump (94931). Refer to 9403−2.
7) Close the relief valve (9) and operate the HP oil pump until oil that has no air
flows from the vent screw (8).
8) Close the vent screw (8).
9) Apply a pressure of 1500 bar to the foundation bolt (5). Keep the pressure
constant.
Note: Do not move the piston (1) of the pre-tensioner (94145) above the red
groove (2).
10) Use a feeler gauge to do a check for clearance through the slot (4) between the
nut (7) and the bedplate (6).
11) If there is a clearance, do step a) to step c). If there is no clearance, continue
from step 12)
a) Make sure that the pressure on the foundation is 1500 bar.
b) Use the round bar (3) to tighten the round nut (7).
c) Do step 10) again.
12) Open the relief valve (9) to release the pressure to zero.
13) Remove the pre-tensioner (94145).
Note: If all foundation bolts are loose and must be tightened again, do the
procedure given in paragraph 4.
94934A
94935
8
1
2
94145
X
3
7
5
012.949/05
6
94934A 9 94931
Fig. 4

3. Foundation Bolts − Loosen

If all foundation bolts must have tension applied again, start with the studs at the
driving end and continue from one side to the other side to the free end of the engine.
1) Attach the pre-tensioning jack (94145) on the foundation bolt (5, Fig. 5).
2) Turn the pre-tensioning jack (94145) fully down.
3) Turn back half a turn the pre-tensioning jack (94145) to get the clearance (4).
4) Connect the pre-tensioning jack (94145) to the HP oil pump (94931).
5) Open the vent screw (9).
6) Close the relief valve (10).
7) Operate the HP oil pump (94931) until oil that has no air flows from the vent
screw (9).
8) Close vent screw (9).
9) Operate the HP oil pump (94931) to get a pressure of 1530 bar.
Note: Do not move the piston (1) of the pre-tensioning jack (94145) above the
red groove (2).
10) Turn the nut (8) back one turn.
11) Open the relief valve (10) to release the pressure to zero.
12) Remove the pre-tensioning jack (94145).
94934A
94935
9
1
2
3
4
7
5
012.950/05
6
94934A 10 94931
Fig. 5

4. Foundation Bolts − Apply Tension

You must apply tension to the foundation bolts (metal and synthetic) in two steps as
follows:
1) Attach the pre-tensioning jack (94145) as given in paragraph 2, step 1) to step 8).
2) Apply a pressure of 900 bar to the foundation bolt.
3) Apply a pressure of 1500 bar to the foundation bolt. Keep the pressure constant.
4) Do step 10) to step 13).

Main Bearing
Waisted Studs − Loosen and Apply Tension

Tools:
2 Double pre-tensioner 94114B 4 Coupling elements 94934G
1 Feeler gauge 94122 3 HP hose 94935
1 Pressure gauge 94934A 1 Hydraulic unit 94942
1 Distributing piece 94934C
1. General
The 1st main bearing cover (2, Fig. 2) has only two waisted studs. You use the same
double pre-tensioning jacks (94114B). Connect only the applicable jack to the
hydraulic unit.
1) If installed, remove the temperature monitor for piston cooling from the main
bearing cover before you install the double pre-tensioning jacks (94114B).
2) Clean the threads of the waisted studs (9, Fig. 1) and the faces of the round
nuts (7).
3) Apply oil to the threads of the waisted studs (9).
Note: Do the procedure given in 9403−4 General Application Instructions for
pre-tensioning jacks.
2. Pre-tension Jacks − Install

1) Put the double pre-tensioning jacks
(94114B) in position on the studs (9).
1 2 3 2) Open all vent screws (1).
3) Push the pistons (10) against the
x double cylinders (8) with round nuts (7)
until there is little or no clearance
4 at (X).
4) Use the round bar (3) to turn back the
10 round nuts (7) approximately ¾ of a
9 turn to get the clearance (4).
8
Note: To apply tension to the waisted
7 studs, the round nuts (2) must be
6 5 on the piston.
018.685/09
Fig. 1

Main Bearing: Waisted Studs − Loosen and Apply Tension
5) Connect the two double pre-tensioning jacks (94114B, Fig. 2) to the hydraulic
unit (94942).
94934G
94114B
94942
1
94934 94935
94934A
018.675/09
Fig. 2
3. Waisted Studs − Loosen

7
1) Install the double pre-tensioning jacks
1 (94114B), refer to paragraph 2.
6 2) Start the hydraulic unit (94942).
2
3) When oil that has no air flows out,
94114B close the vent screws (7, Fig. 3) on the
pre-tensioning jacks (94114B).
3 4) Operate the hydraulic unit until a
pressure of approximately 1530 bar
4
shows.
Note: Do not move the piston (5) of the
pre-tensioning jack (94144B)
5 above the red groove (2).
018.676/09 5) Use the round bar (4) to turn the round

nuts (3) back approximately ¾ of a turn
to get the clearance (5, Fig. 1).
Fig. 3
6) Stop the hydraulic unit (94942) and
release the pressure to zero.
7) Remove the double pre-tensioning
jacks (94144B).

Main Bearing: Main Bearing: Waisted Studs − Loosen and Apply Tension
4. Waisted Studs − Apply Tension

After you install the main bearing cover (see 1132−2), apply tension to the waisted
studs (3) as follows:
1) Install the double pre-tensioning jacks (94114B) as given in paragraph 2.
2) Start the hydraulic unit (94942).
3) When oil that has no air flows out, close the vent screw (7, Fig. 3) on the
pre-tensioning jacks (94114B).
4) Operate the hydraulic unit (94942), to get a pressure of 1000 bar. Keep the
pressure constant.
5) Use the round bar (4) to tighten all the nuts (3).
Note: Make sure that there is no clearance between the main bearing girder (1,
Fig. 2) and the main bearing cover (2).
6) Mark the position of the nuts (1, Fig. 4) on the bearing cover (1st Step).
1ST STEP 2ND STEP
009.758/02 y 013.432/05
y x
x
TIGHTENING
ANGLE
Fig. 4
7) On the hydraulic unit (94942), increase the pressure to 1500 bar. Keep the
pressure constant.
8) Use the round bar (4, Fig. 3) to tighten fully all the nuts (3). Use the feeler gauge
(94122) to do a clearance check through the slot (5).
9) On the hydraulic unit (94942), decrease the pressure to zero.
10) Remove the double pre-tensioning jacks (94114B).
Note: Make sure that all the nuts are turned approximately i.e. the tightening
angle must be 20° between the 1st Step and 2nd Step, see Fig. 4. If larger
differences occur, do step 1) to step 10) above again.
11) Use the special feeler gauge (94123) to do a check of the vertical clearance
(refer to 0330−1 Clearance Table, Crankshaft and Main Bearing’).
Note: All main bearing clearance values are applicable only with tightened tie
rods and waisted studs.

Intentionally blank
Main Bearing
Main Bearing − Removal and Installation

Tools:
2 Manual ratchet (800 kg) 94016 (H1, H2) 1 Wire rope 94120A
1 Spur-geared chain block (2000 kg) 94017−001 (H3) 1 Support 94141
1 Shackle (4750 kg) 94018B 1 Work platform 94142
1 RUD eye bolt 94040−M20 2 Nuts 94142A
1 Thrust device 94110 1 Ring 94332
1 Transportation tool 94116A 1 Tool 94335
1 Lug 94116B 1 HP oil pump 94931
1 Trolley (500 kg) 94116 1 Connection block 94934
1 Assembly / disassembly tool 94117 1 Hydr. distributors 94934A
1 Deviation pipe 94117A 3 HP hoses 94935
1 Device 94119B 2 Hydraulic jacks 94936
1 Turning-out device 94118A
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Main Bearing Covers No. 2 to No. 8 − Removal . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Tools − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Main Bearing Cover − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Main Bearing Cover No.1 − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Main Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Hydraulic Jacks − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Crankshaft − Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Bearing Shell No. 1 − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Bearing Shell No. 2 to No. 8 − Removal . . . . . . . . . . . . . . . . . . . . . . . 11
5. Main Bearing Shells − Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. Bearing Shell and Bearing Cover − Installation . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Bearing Shell − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Main Bearing Cover − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1. Preparation
WARNING
Injury and Damage Hazard: Do not turn the crankshaft when the
work platforms, tools and/or supports, are installed. This will
cause injury to personnel and damage to equipment.
WARNING
1) Read the data in:

D 0012−1 General Guidelines for Lifting Tools
D 1132−1 Waisted Studs − Loosen and Apply Tension
D 3301−1 Work Platform.
To identify parts, the main bearing covers and main bearing shells must have marks
applied after removal.
2) Operate the turning gear to turn the crank to the exhaust side approximately
90_after TDC.
3) Set to off the main oil supply pumps.
4) Stop the oil lubrication to the main bearing.

Note: Some parts can look different

1 2. Main Bearing Covers
No. 2 to No. 8 −
2
Removal
2.1 Tools − Installation

1) Remove the oil pipe(1, Fig. 1) from the
main bearing cover (2).
WCH02325
2) Apply protection to all openings.
Fig. 1
3) Attach the work platform (94142,

Fig. 2).
4) Use the feeler gauge (94123) to do a
check of the bearing clearance, refer to
0330−1.
94142
Fig. 2

7 1 2 WARNING
6 3 Injury Hazard: Do not use
5
the thrust device 94110 as
a lifting device. Injury to
4
personnel can occur.
94116B
94110 CAUTION
Damage Hazard: Use the
thrust device (94110) only
for the removal of the main
bearing covers. Damage to
equipment can occur if you
018.595/09 use incorrect equipment
Fig. 3
5) Apply tension to the four elastic studs
(6, Fig. 3). and remove their nuts, refer
to 1132−1.
6) Attach the lug (94116B) to the main
bearing cover (4).
7) Make sure that the thrust device
(94110) is clean.
8) Apply Molykote G-Rapid Plus to the
spindle of the special screw (1) and the
thrust piece (5).
9) Attach the thrust device (94110) as
given in the instructions on the name
plate (2).
10) Turn back fully the spindle.
11) Attach the slugging wrench AF60.
12) Attach the thrust device (94110) to the
1 main bearing cover (4).
94332
13) Put the four screws (3) in the positions
2 shown.
94018B 14) Torque the four screws (3) to 24 Nm.
15) Use the slugging wrench to turn the
94040−M20 special screw (1) and expand the main
bearing cover (4).
2.2 Main Bearing Cover −

Removal
1) Attach the eye bolt (94040−M20, Fig. 4)
to the guide shoe.
2) Torque the eye bolt (94040−M20) to
115 Nm.
018.597/09
3) Attach the rings (94332) and shackle
(94018B) to the cylinder block (1).
Fig. 4
4) Torque the screws (2) to 200 Nm.

94335 5) Attach the deviation pipe (94117A,

II Fig. 5) to the column.
6) Attach the tool (94335) between the
reinforced double-I girders.
H3
7) Attach the manual ratchet (H1) to the
shackle (94018B) and the
H1 lug (94116B).
8) Lift the main bearing cover (3) until it is
fully removed from the elastic studs.
9) Operate the manual ratchets (H1, H2)
I
to move the main bearing cover (3) in
engine longitudinal direction below the
3 crosshead.
H2
10) Attach the chain block (H3).
2
1 11) Operate the manual ratchets (H1, H2)
and the chain block (H3) to move the
I
main bearing cover (3) to the column
door.
12) Remove the manual ratchets (H1, H2).
13) Operate the chain block (H3) to remove
the main bearing cover (3) from the
94117A II crankcase.
Note: When you do step 15), make sure
that you do not cause damage to
II - II the bearing shell (2) and the
surfaces of the main bearing cover
(3).
14) Lower the main bearing cover (3) on to
the wooden underlay (1).
94018B
H1
94116B
H2
Fig. 5

VIEW ON FLYWHEEL 1
FROM AFT END 3. Main Bearing Cover
No.1 − Removal
1) Remove the pipe (6, Fig. 6)
2) Remove the casing (1).
3) Remove the oil pipe (2) from the main
bearing cover.
6
4) Remove the top half of the oil baffle.
5) Apply protection to the slinger rings on
the crankshaft.
6) Apply tension to the four elastic studs
2 (3) and remove the round nuts (4), refer
to 1132−1.
5 7) Use the feeler gauge (94123) to do a

check of the bearing clearance, refer to
3 0330−1.
4 8) In paragraph 2.1, do step 5) to

step 15).
Fig. 6 9) Put the trolley (94117) in position as

shown in Fig. 7).
attachment ring (1) and the lug
(94116B) on the main bearing cover.
11) Operate the manual ratchet (H1) to lift
the main bearing cover from the elastic
studs.
trolley (94117) and the lug (94116B) on
94116 H1 the main bearing cover.
H2
94116B
I
13) Apply tension to the chain of the
manual ratchet (H2) to hold the weight
of the main bearing cover.
14) Carefully operate the manual ratchet
(H2) to increase the tension. At the
same time, carefully operate the
manual ratchet (H1) to release the
tension until the main bearing cover is
WCH00682 directly below the manual ratchet (H2).
15) Remove the manual ratchet (H1) from
the attachment point (1) and the main
I bearing cover.
16) Carefully move the trolley (94116) and
1
the bearing cover to the driving end.
H1
Fig. 7

17) Attach the manual ratchet (H1, Fig. 8)

3
to the main bearing cover and the
attachment point (3) as shown.
H3
between the attachment rings in the
gallery to move the main bearing
cover (2) to the fuel side.
H1 19) Attach the chain block (H3) to the main
bearing cover (2) (when the main
bearing cover is directly below the
attachment point (3) in the gallery).
H2 20) Remove the manual ratchets (H1, H2).
2 Note: When you do step 21), make sure
1 that you do not cause damage to
the bearing shell (2) and the
surfaces of the main bearing cover
(3).
21) Operate the chain block (H3) to lower
the main bearing (1) on the wooden
underlay.
Fig. 8
4. Main Bearing Shell − Removal
4.1 Hydraulic Jacks − Installation

WARNING
that no personnel are near the flywheel or in the engine.
CAUTION
Damage Hazard: Do not remove two adjacent main bearing shells
at the same time. Damage to the engine can occur.
1) Remove the work platform (94143).

2) Operate the turning gear to turn the applicable crank to the exhaust side
approximately 90_ after TDC.
3) Lock the turning gear to prevent movement.
4) Install the work platform (94143).

Note: When you remove the bottom bearing shell No. 1, you must use the jack
(1, Fig. 9) to hold the weight of the flywheel. To give protection to the
flywheel teeth, put a copper or aluminum plate between the jack and the
flywheel.
5) Put the support (94141) in position on the two main bearing girders (2) parallel to
the engine axis.
6) Put the hydraulic jacks (94936) on to the support (94141).
7) Connect the HP oil pump (94931) to the hydraulic jacks (94936).
94931
94934A
94934
94935
I
013.213/05
94936
94141
2
013.214/05
Fig. 9

4.2 Crankshaft − Lift

1 1) Measure and record the lateral bearing
clearances (y1 and y2, Fig. 10)
between the crankshaft (2) and the
bottom bearing shell (3, 4)
approximately 50 mm below the
bearing.
50 mm 2) Put the dial gauge (1) above the
crankshaft (2) as shown.
0.2 mm 3) Set the dial gauge to zero.
4) Look at the dial gauge and operate the
HP oil pump (94931) to lift the
crankshaft (2) to 0.2 mm.
009.810/02
3, 4 2 5) Make sure that the value on the dial
gauge is 0.2 mm.
6) Make sure that there is no clearance
Fig. 10
between the adjacent bearing cover
and the crankshaft (2).
7) Keep the pressure constant.
8) Measure the lateral bearing clearances (y1 and y2). Compare these values with
the values recorded in step 1).
9) If the value of the lateral bearing clearance is more than 0.1 mm, lower the
crankshaft and do step a) to step c).
a) Install the hydraulic jacks in a position where the lateral bearing clearance is
smaller.
b) Operate the HP oil pump to lift the crankshaft.
c) Lift the crankshaft to 0.2 mm.

4.3 Bearing Shell No. 1 −

Removal
CAUTION
Damage Hazard: Do not
remove two adjacent main
bearing shells at the same
time. Damage to the engine
can occur.
Note: The applicable main bearing cover

H1 is removed.
1) Make sure that the crankshaft is lifted
to 0.2 mm. Refer to paragraph 4.1 and
paragraph 4.2.
94118A
to the platform.
3) Remove the Allen screws (1) from the
bearing girder.
3
4) Attach the device (94119B) to the
2 manual ratchet (H1).
5) Attach the turning-out device (94118A)
to the main bearing shell (3).
6) Put the wire ropes (3) along the outer
edges of the bearing shell to the other
side and attach them to the device
I (94119B) as shown.
94118A
94119B
1
018.604/09
Fig. 11

7) Operate the manual ratchet (H1,

Fig. 12) to turn the bearing shell (1) to
the position as shown.
Note: If the bearing shell (1) does not
H1 move, the device (94119B) must be
attached to the other side of the
turning-out device (94118A). The
bearing shell must be moved back
I
to its initial condition and the
removal procedure done again.
94116A 8) Remove the turning-out
1 device (94118A).
9) Attach the tool (94116A) to the bearing
shell (1).
94116A
018.601/09
Fig. 12

trolley (94116 Fig. 13) and the tool
(94116A) as shown.
Note: During step 11), make sure that
94116 each end of the bearing shell (1)
H2 does not touch the bearing girder.
94116A the bearing shell (1). At the same time,
operate the manual ratchet (H2) to
keep tension on the chain.
12) Carefully remove the manual
ratchet (H1).
13) Move the trolley (94116A), manual
ratchet (H2) and the bearing shell until
there is sufficient clearance to lower the
bearing shell.
Fig. 13 14) Carefully lower the bearing shell on to a

wooden underlay.

4.4 Bearing Shell No. 2 to No. 8

− Removal
WARNING
94117 Injury Hazard: Before you
H1 94120A operate the turning gear,
94119B make sure that no
II personnel are near the
I flywheel or in the engine.
CAUTION
remove two adjacent main
bearing shells at the same
time. Damage to the engine
can occur.
Note: The bearing cover and the top

main bearing shell are removed.
I
2) Unlock the turning gear.
3) Operate the turning gear to turn the
applicable crank to the exhaust side
approximately 90_ after TDC.
1 4) Lock the turning gear to prevent
movement.
5) Attach the work platform (94143).
6) Lift the crankshaft, refer to paragraph
4.1 and 4.2.
018.601/09 2
7) Remove the two Allen screws (2) from
the bearing shell.
8) Attach the device (94117, Fig. 14) to
the column with its dowel pin and
II spring clip.
9) Attach the turning-out device (94118A)
94120A to the bearing shell.
94120A 10) Put the ropes of the turning-out device

94118A (94118A) along the outer edges of the
of the bearing shell to the other side
94119B and attach them to the
device (94119B).
column and the wire rope (94120A).
Fig. 14


Fig. 15) to turn the bearing shell until
you can attach the tool (94116A).Attach
H1 the tool (94116A) to the bearing shell
I (1).
13) Attach the tool (94116A) to the bearing
shell (1).
14) Remove the device (94117), wire rope
(94120A), device (94119B) and
turning-out device 94118A.
15) Remove the manual ratchet (H1) and
attach it to the transportation
tool (94116A).
16) Operate the manual ratchet (H1) to turn
fully the bearing shell.
I
Note: As an alternative, you can attach
the manual ratchet (H1) to the
turning-out device to turn fully the
bearing shell.
17) Make sure that there is clearance
between each end of the bearing shell
94116A and the bearing girder.
18) Attach the deviation pipe (94117A,
Fig. 16) to the column.
Fig. 15 19) Attach the lifting ring (94332) and the

shackle (94018B) to the cylinder block
with the two screws (3).
94335 3 20) Torque the screws (3) to 200 Nm.

94018B 21) Attach the lifting tool (94335) between
reinforced double-I girders.
H3 22) Attach the manual ratchet (H2) to the
94332 shackle (94018B) and the
transportation tool (94116A).
94017
H2 Note: During step 22), make sure that
94018B
each end of the bearing shell (1)
H1 does not touch the bearing girder.
94116A I 23) Operate the manual ratchet (1) to lift
the bearing shell (2). At the same time,
2 operate the manual ratchet (H2) to
94116A keep tension on its chain.
1
24) Remove the manual ratchet (H1).
I 25) Attach the chain block (H3) to the
device (94116A).
26) Operate the manual ratchet (H2) and
the chain block (H3) to remove the
WCH00683
bearing shell (2) from the crankcase.
94117A
27) Lower the bearing shell (2) on to the
Fig. 16 wooden underlay (1).

5. Main Bearing Shells − Inspection

CAUTION
Damage Hazard: Do not use a scraper in the running area of the
bearing shell. Damage to the bearing shell can occur.
1) Use a soft cloth to clean the bearing shell.

2) Do a check the bearing shell for damage such as breakouts or cracks.
3) Use Scotchbritet to remove light scratches and running marks.
4) If the running marks are not symmetrical (axial or radial) speak to, or send a
message to Wärtsilä Services Ltd.
5) If necessary, replace the bearing shells.
6) Do an inspection of the surface of the bearing pin. if necessary, repair the
surfaces that have scratches.
6. Bearing Shell and Bearing Cover − Installation
CAUTION
Damage Hazard: Use only the applicable tools for installation. The
sizes of the bearing shells are different (narrow and wide).
The bearing cover and bearing shell have the marks DRIVING END and must be
installed correctly in the bearing girder in their initial positions.
Before installation, make sure that the items that follow are clean and in good
condition:
D All tools
D The crankshaft pin
D The girder bore for the bearing shell
D Bearing shells.
6.1 Bearing Shell − Installation

1) Apply a very thin layer of Molykote paste G to the rear face of the bottom bearing
shell before each installation.
2) Make sure that the crankshaft pin and the running surface of the bearing shell are
clean and fully lubricated with clean engine oil.
Note: The bearing shells have different dimensions. For bearing shell No. 1, use
the equipment shown in Fig. 11, Fig. 12 and Fig. 13. For bearing shells
No. 2 to No. 8, use the equipment shown in Fig. 14, Fig. 15 and Fig. 16.
3) Attach the transportation tool (94116A) to the bearing shell and the applicable
manual ratchet.
4) Lower the bearing shell into position on the crankshaft. Make sure that each end
of the bearing shell does not touch the bearing girder.
5) Put the ropes of the turning-out device (94118A) below the crankshaft and
connect it to the device (94119B).
6) Remove the transportation tool 94116A.
7) Carefully move the bearing shell into the bearing girder on the fuel side.
8) Carefully put the Allen screws into the bearing shell.
9) Release the pressure from the HP oil pump (94931) to fully lower the crankshaft.
10) Remove the hydraulic jacks (94936) and the HP oil pump (94931).

6.2 Main Bearing Cover −

Installation
1) Make sure that the work area and all
I II tools and equipment are clean and in
good condition.
2) Use the applicable equipment to get
the bearing cover in the correct position
I II
above the crankshaft as follows:
D For bearing covers No. 2 to No. 8
refer to paragraph 2.
D For bearing cover No. 1, refer to
018.677/09
paragraph 3).
3) Attach the Allen screws (1, Fig. 17) to
bearing girder (2) on the fuel side.
I-I II - II
4) Clean all surfaces of the bearing cover
and the bearing girder.
4
5) Lower the bearing cover on to the
3 1 bearing girder. Make sure that the two
spring dowels (3) engage correctly.
1
2 6) Apply tension to the elastic studs (3,
Fig. 18), refer to 1132−1.
7) Tighten the round nuts (4).
Fig. 17 8) Remove the protection from the oil
bores.
VIEW ON FLYWHEEL 1 9) Clean the pipe (2).
FROM AFT END
10) Install the pipe (2) to the bearing
cover (5).
11) Do step a) and step b) if the cover (1)
was removed.
a) Install the cover (1).
6 b) Install the pipe (6).

12) Remove all tools and equipment from
the work area.
13) Measure the bearing clearance and
compare the value measured in
paragraph 2, step 4) with the value
given in the clearance table 0330−1.
2
Note: If the clearance is in the limits
given, the bearing can be removed
5 and installed again.
3 14) After each installation of a new bearing

shell, measure the crank deflection,
4 refer to 3103−1.
15) Set to on the main oil supply pump.
WCH02325
16) Do a check of the oil supply to the main
Fig. 18 Note: Some parts can look different bearing.

Thrust Bearing
Axial Clearance − Checks

Tools:
1 Inside micrometer 94101
1 Feeler gauge 94238
1. Procedure One
1) Start the engine in the direction AHEAD
to move the crankshaft fully forward.
2) Stop the engine.
3) Put the dial gauge (8, Fig. 1) in position
on the oil baffle (top part) (9) and
9 1 record the value.
8
4) Remove the dial gauge (8).
2 5) Start the engine in the direction

REVERSE to move the crankshaft fully
rearward.
6) Stop the engine.
THRUST 7) Put the dial gauge (8) in position on the
oil baffle (top part) (9) and record the
7 3 value.
11 8) Remove the dial gauge (8).
6 9) Compare the values with those given in

the engine documents on the Check
Dimensions page (see also 0330−1
Clearance Table, Crankshaft and
Thrust Bearing).
If the measured values are more than the
012.968/05
nominal values given, the thrust pads are
worn.
10) After maintenance on the area of the
thrust bearing, do step a) to step d):
4
a) Remove the cover (4).
b) Do a check of the thrust bearing
housing.
5
c) If necessary, remove particles
Fig. 1 from the area (11).
d) Install the cover (4).
11) Each 6000 to 8000 operation hours,
make sure that the opening (5) is clear.

Axial Clearance − Checks
2. Procedure Two
II-II
1) Start the engine in the direction AHEAD
to move the crankshaft fully forward.
I The crankshaft must touch the thrust
pads (3, Fig.1).
2) Stop the engine.
3) Make sure that the crankshaft does not
move.
4) Use the micrometer (94101, Fig. 2) to
measure the distance between the
coupling flange (1) and the oil baffle
(top part) (2).
5) Record the value.
6) Remove the micrometer (94101).
7) Compare the value with those given in
Dimensions page, see also 0330−1
Thrust Bearing.
The difference between the distance X and
the value given in the engine documents is
related to the wear of the thrust pads (7,
Fig. 1).
I 8) Start the engine in the direction
ASTERN to move the crankshaft fully
forward. The crankshaft must touch the
thrust pads (3, Fig.1).
9) Stop the engine.
10) Make sure that the crankshaft does not
move.
11) Use the micrometer (94101, Fig. 2) to
measure the distance between the
II II coupling flange (1) and the oil baffle
(top part) (2).
X
2 1 012.969/05
12) Record the value.
94101
13) Remove the micrometer (94101).
14) Compare the value with those given in
Dimensions page, see also the 0330−1
Thrust Bearing.
Fig. 2
The difference between the distance X and
the value given in the engine documents is
related to the wear of the thrust pads (7,
Fig.1).

Thrust Bearing
Thrust Bearing Pads − Removal and Installation

Tools:
1 Turning-out device 94155 1 Turning-out device 94155A
(for 1-part gear wheel) (for 2-part gear wheel)
2 Spur-geared chain block (H1, H2) 94018−006 1 Eye bolt 94040−M12
1. Removal
1) Read the data in 0012−1 General Guidelines for Lifting Tools.
2) Remove the casing (8, Fig. 1) together with the oil baffle (top part) (9).
3) Attach the chain blocks (H1, H2, Fig. 2) to the attachment points in the gallery.
4) If necessary, remove the cover (7, Fig. 1) to get access to the arbor support (2).
5) Record the positions of the thrust bearing pads.
6) Remove the four bolts (1) from the applicable the arbor supports (2 or 5).
7) Attach the eye bolt (94040−M12) to the applicable arbor support (2 or 5).
8) Attach the chain block (H1 or H2) to the applicable arbor support (2 or 5).
9) Remove the applicable arbor support (2 or 5).
10) Do step 6) to step 9) for the other arbor supports.
I-I
II 7
6
8
9
1
5 2
3, 4
WCH00403
II
2 5 2
Note: For View II − II, see Fig. 2
I I
Fig. 1

11) Attach the eye bolt (94040−M12) to the thrust bearing pad (2 or 3, Fig. 2).
12) Attach the chain blocks to the eye bolt (94040−M12).
13) Attach the turning-out device (94155 or 94155A).
WARNING
14) Operate the turning gear to turn the crankshaft in the applicable direction. At the
same time, operate the chain blocks (H1,H2) to keep tension on their chains.
Note: While the gear wheel (4) turns, the turning-out device 94155 moves the
thrust bearing pads. The first thrust bearing pad will come out.
15) Operate the chain blocks (H1, H2) to move the thrust bearing pad to the exhaust
side.
16) Lower the thrust bearing pad on to a stable area.
17) Do the procedure above for the remaining thrust bearing pads that you must
remove.
Note: If some of the thrust bearing pads ae removed, the remaining thrust
bearing pads will keep the crankshaft in position. If all thrust bearing
pads from the same side are removed, e.g. all the astern pads, the
crankshaft can move.
18) To prevent crankshaft movement, do as follows:
a) Get a piece of hardwood that has the same dimensions as a thrust bearing pad.
b) Put the hardwood in the position of the removed thrust bearing pads.
2. Installation
1) Make sure that the thrust bearing pads are clean.
2) Apply clean engine oil to the thrust bearing pads.
Note: You must install thrust bearing pads that you removed before in the same
positions. Use your notes and see the configuration for the correct
position of thrust bearing pads on engines with fixed pitch propellers
(FPP) and controllable pitch propellers (CPP) respectively.
3) If necessary, remove the piece of hardwood.
4) Attach the eye bolt (94040−M12) to the thrust bearing pad (2 or 3).
5) Attach the chain blocks (H1, H2) to the thrust bearing pad (2 or 3).
6) Put the first thrust bearing pad in position. Make sure that the thrust pad touches
the turning-out device (94155 or 94155A).
7) Operate the turning gear to turn the crankshaft in the applicable direction.
8) Put the subsequent thrust bearing pad in position.
9) Do step 1) to step 7) above fro each thrust bearing pad.
Note: When all thrust bearing pads are in position the top, outer thrust bearing
pads must be at the equal height.
10) Remove the turning-out device (94155 or 94155A).

I-I
II - II
H1 H2
94155
94155A
6 4
94040−M12
94155
94155A
012.959/05
5, 5a 6
I 2, 3 1
Fig. 2 012.960/05
11) Install the arbor supports (2, or 5, Fig. 1) as follows:

a) Attach the eye bolt (94040−M12) to the applicable arbor support.
b) Lift then lower the applicable arbor support into position.
c) Remove the eye bolt (94040−M12).
d) Apply Loctite No. 222 to the four bolts (1).
e) Do step a) to step d) for the other arbor supports.
f) Do a check of the clearances between the arbor supports and the thrust bearing
pads, see 0330−1 Clearance Table, Crankshaft and thrust bearing.
Note: When you replace new thrust bearing pads (or thrust bearing pads that
have new metal), you must make sure that the thickness (final dimension)
corresponds exactly with the neighbouring pads.
Note: When you replace a full set of thrust bearing pads (or full set of thrust
bearing pads that have new metal), you must adjust the clearances to the
original values, refer to 0330−1 Clearance Table, Crankshaft and Thrust
Bearing and 1203−1.

CONFIGURATION OF THRUST BEARING PADS WITH FIXED PITCH PROPELLER

5−Cyl and 6−Cyl ENGINES
ASTERN CLOCKWISE AHEAD

ROTATING ENGINE
VIEW FROM DRIVING END VIEW FROM DRIVING END

PADS AT DRIVING END PADS ON ENGINE SIDE
ASTERN COUNTERCLOCKWISE AHEAD

ROTATING ENGINE
DRIVING END ENGINE SIDE SUPPORT SURFACE
PROPELLER THRUST PROPELLER THRUST

ASTERN AHEAD
012.833/05
Astern Pads Ahead Pads

Fig. 3

CONFIGURATION OF THRUST BEARING PADS FOR CONTROLLABLE PITCH PROPELLER

5−Cyl and 6−Cyl ENGINE

ROTATING ENGINE


ROTATING ENGINE
SUPPORT SURFACE
DRIVING END ENGINE SIDE

ASTERN AHEAD
012.835/05
Fig. 4 Astern Pads Ahead Pads

CONFIGURATION OF THRUST BEARING PADS FOR FIXED PITCH PROPELLER

7−Cyl and 8−Cyl ENGINE

ROTATING ENGINE


ROTATING ENGINE
SUPPORT SURFACE
DRIVING END ENGINE SIDE

ASTERN AHEAD
012.834/05
Fig. 5
Astern Pads Ahead Pads

Engine Stays with Friction Shims
Engine Stays with Friction Shims

Tension Checks
Tools:
1 Feeler gauge 94122 2 Pressure gauge 94934A
1 Pre-tensioner jack 94145 1 HP hose 94935
1 HP oil pump 94931
1. General
The engine stays (1, Fig. 1) are related to the design of the ship. The engine stays
are installed as follows:
D Two engine stays are installed on the exhaust side, or the fuel side.
D Two engine stays are installed at the free end.
D Two engine stays are installed at the driving end.
The engine stays have friction shims (3).
You must do a tension check of the bolts (2) at the specified intervals (refer to 0380−1
Engine stays with friction shims.
Note: To do the tension checks on the engine stays, you use the same jack
(94145) as that used for the the foundation bolts. The nameplate has the
stamp 1500 bar. The tension value for the engine stays is 310 bar only.
I I
1 FREE END
EXHAUST SIDE
II
1 012.996/05
II
2
ENGINE SIDE
Fig. 1

Engine Stays with Friction Shims: Tension Checks
2. Tension Checks
1) Clean the threads of the bolts (2, Fig. 1) and the seating surfaces.
2) Apply Molykote G paste to the threads of the bolts (2).
3) Refer to 9403−2 and 9403−4 . Attach the pre-tensioner and the applicable
equipment as shown in Fig. 2.
4) Operate the HP oil pump (94931) to get a pressure of 310 bar.
5) Put the feeler gauge (94122) through the slot (6) to do a check for clearance
between the nut (3) and its seating. If there is no clearance, the bolt tension has
not changed and you can do step a) and step b). If there is a clearance, do
step 6).
a) Operate the vent screw (1) to release the pressure to zero.
b) Remove the tools and equipment.
6) If there is clearance, the tension of the bolt has changed since the last check and you
must do step a) to step d) below:
a) Use a round bar (7) to tighten the nut (3).
b) Use the feeler gauge (94122) to make sure there is no clearance.
c) Operate the vent screw (1) to release the pressure to zero.
d) Remove the tools and equipment.
Note: The data to loosen the bolts is given in 9403−4.
94934A
1
x
2
94935
7
3 Note: Disc springs
6 must be compressed
94931 94934A
4
2 5
017.672/08
Fig. 2 012.902/05
1 Vent screw 5 Ring

2 Bolt 6 Slot
3 Nut 7 Round bar
4 Disc spring

Hydraulic Engine Stays
Oil Pressure Checks
1. General
Usually two hydraulic engine stays (1, Fig.1) are installed on the exhaust side and two
on the fuel side of the engine. This can be different because of special installations.
You must compare the oil pressures on the pressure gauges (8) of the hydraulic
cylinders (3) at regular intervals.
If one of the pressure gauges (8) shows a pressure of less than 10 bar, (defective
O-rings, valves that have leaks, defective screwed connections, or accumulator) you
must do the procedure that follows:
1) Decrease to 10 bar the pressure in the other hydraulic cylinder.
2) Repair the defective engine stay as soon as possible.
3) Adjust the oil pressure of the engine stays to the correct setting. Refer to the
instructions in the manufacturer’s manual.
1 1
WCH03472
8
ENGINE SIDE
6
WCH03472 5 4
Fig. 1
1 Hydraulic engine stays 5 Ball valve

2 Accumulator 6 Rod
3 Hydraulic cylinder 7 Damping control valve
4 Plug ⅜ inch NPT 8 Pressure gauge

Intentionally blank
Tie Rod
Tension Checks and Replacement Procedure

Tools:
1 Rod 94005 2 Coupling elements 94934G
2 Pre-tensioner 94180 3 HP hoses 94935
1 Connection block 94934 1 Hydraulic unit 94942
1 Hydraulic distributor 94934A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Tie Rods − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.4 Apply Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. General
We recommend that you do a check of the tension of all tie rods one year after
commissioning, refer to 0380−1 Maintenance Schedule, Tie rod. If necessary, apply
tension to the specified value. Random checks can be done during overhauls.
1
2. Tension Check
2 1) Remove the protection cover (1, Fig. 1)
from all tie rods (2).
3 2) Clean the surfaces of the intermediate
ring (4).
Note: Start with the tie rods (a−a) in the
4 middle of the engine, then b−b,
etc).
3) Attach the two pre-tensioners (94180)
to two tie rods (2, a−a Fig. 1).
4) Apply a tension of 1500 bar to the tie
rods (2), refer to 9403−4.
WCH00667
L
5) If possible, tighten the round nuts (3).
6) If the round nut (3) cannot move, do
step a) to step b):
L L1 a) Put a round bar (94005) through
the opening of the jack and into a
94180
hole in the round nut .
2 b) Use a hammer to loosen, then
tighten the nut. Make sure that the
3
edge of the hole has no
94005 deformation.
7) Remove the pre-tensioners (94180),
refer to 9304−1.
8) Apply a layer of Molykote paste G to
g f e a b c d
the threads of the tie rod (2) to prevent
corrosion.
9) Install the protection cover (1).
g f e a b c d 10) Do step 3) to step 9) for the remaining
Fig. 1 tie rods.

I
1 3. Tie Rods − Replace
2
3.1 Preparation
I 3 1) Remove the protection cover (1, Fig. 2)
4 from the tie rods (2).
2) Clean the surface of the intermediate
ring (5).
5
3) Remove the set screws (7).
4) Refer to 9403−4, then attach the two
pre-tensioners (94180) to two tie rods
II (2), e.g. a−a). See Fig.1.
5) Loosen the round nuts (4), refer to
5 9403−4.
6 3.2 Removal
II 1) Use two round nuts screwed together
I I to loosen fully the tie rod (2).
2) Attach an applicable eye bolt (e.g.
M20) to the tie rod (2).
2
CAUTION
Injury Hazard: The weight
of the tie rod is
approximately 254 kg. Use
the correct equipment for
removal.
I-I 3) Attach the crane to the eye bolt.

6 4) Lift the tie rod (2) from the cylinder
jacket (5).
7
3.3 Installation
1) Apply Molykote paste G to the bottom
thread of the M80x6 tie rod (2).
2) Make sure that the bush (6) is installed.
3) Attach an applicable eye bolt to the tie
rod (2).
4) Attach the crane to the eye bolt.
5) Lower the tie rod (2) into the cylinder
jacket (5).
6) Turn the tie rod (2) until the bottom is
flush with the nut (9).
7) Clean the top surfaces of the cylinder
III _ III jacket (5).
III 8) Make sure that the intermediate ring (4)
8 is installed.
9) Apply Molykote paste G paste to the
top thread of the tie rod (2) and to the
top surface of intermediate ring (4).
WCH00667 10) Attach the round nut (3) to the tie
11 rod (2).
10
III 9
11) Lift the tie rod (2), then fully tighten the
round nut (3).
12) Apply tension to the tie rods (2), refer to
Fig. 2 FLUSH paragraph 3.4.

3.4 Apply Tension

L
Note: Start with the tie rods in the middle
of the engine (a−a, then b−b etc).
1) Make sure that the set screws (7,
L L1 Fig. 2) are removed.
94180 2) Put the two pre-tensioning jacks
(94180, Fig.3) on the to two tie rods (2).
2
3) Apply a tension of 100 bar, refer to
3 9403−4.
94005 4) Record the length of the tie rods (2)
at L.
5) Apply a tension of 1500 bar.
g f e a b c d 6) Record the length of the tie rods (2)

at L1.
Note: The extension DL of the tie rod (2)
must be between 13.0 mm and
g f e a b c d 14.5 mm (DL = L1 − L).
7) Remove the pre-tensioning jacks
Fig. 3 (94180).
8) Install the set screws (7).
9) Apply acid-free grease to the threads of
the tie rods (2) that show.
10) Attach the protection covers (1, Fig. 2).
11) Do step 1) to step 10) for the remaining
tie rods.

Intentionally blank
Cylinder Liner and Cylinder Cover Group 2
Cylinder Liner
Measure the Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−1/A1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−2/A1
Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports . . . . . . . . . . . . 2124−3/A1
Lubricating Quill: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A1

Gas Admission Valve GAV50: Removal, Disassemble, Checks, Assemble, Installation . . . . . . . 2140−1/A1
Piston Rod Gland: Removal, Disassemble, Measure Worn Parts, Assemble, Installation . . . . . . 2303−1/A1
Cylinder Cover
Cylinder Cover and Water Guide Jacket − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 2708−1/A1
Cylinder Cover Elastic Studs − Loosen and Apply Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−2/A1
Machining of Sealing Face for Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−3/A1
Sealing Face for the Pilot Injection Valve Position − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−4/A1
Sealing Face for the Fuel Injection Valve Position − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−5/A1
Sealing Face for the Prechamber − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−6/A1
Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722−1/A1

Injection Valve: Checks, Disassemble, Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722−2/A1
Starting Air Valve: Removal, Disassemble, Grind, Assemble, Installation . . . . . . . . . . . . . . . . . . . . 2728−1/A1
Exhaust Valve
Removal and Installation of Exhaust Valve, Replacement of Elastic Studs . . . . . . . . . . . . . . . . . . . 2751−1/A1
Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−3/A1
Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−4/A1
Pilot Injection Valve: Removal, Disassemble, Check, Assemble, Installation . . . . . . . . . . . . . . . . . 2790−1/A1
Winterthur Gas & Diesel Ltd. 1/ 2 RT−flex50DF / MM / 2018−02

Intentionally blank
Cylinder Liner
Measure the Cylinder Liner

Tools:
1 Gauge 94225 1 Ladder
1 Tool cylinder liner measuring 94226
WARNING
Danger: Gas Hazard.
1 2 Poisonous gas can stay in
Setting Screw the cylinder liner. There is
a risk of suffocation. You
must make sure that
A
poisonous gas is removed
B before you go into the
cylinder liner. You must put
on a harness attached to a
safety person before you
RIDGE OF
do work in cylinders where
MATERIAL
gas can stay.
3
WARNING
Injury Hazard: Before you
operate the turning gear,
make sure that no
94225 personnel are near the
flywheel, or in the engine.
94101
CAUTION
Injury Hazard: Hot parts
can cause injury to
personnel. Be careful when
you do work in areas
where there are hot parts.
Note: Measure the the cylinder liner

before you remove a piston.
F
1) Remove the cylinder cover, refer to
2708−1.
2) Operate the turning gear to move the
piston to BDC.
3) Put on a harness that is attached to a
safety person. If necessary, the safety
person can pull you out of the cylinder
liner if there is an emergency.
4) Lock the lever of the cooling water
valve in the closed position. This
makes sure that no cooling water can
go into the cylinder liner.
5) Clean the area (1, Fig. 1) above the
running surface (2).
Note: Some parts
can look different 6) Remove the bottom part of the
016.682/08 gauge (94225).
Fig. 1

Measure the Cylinder Liner
7) Put the gauge (94225, Fig. 1) in position on the top face of the cylinder liner (3) in
line with the longitudinal axis of the engine.
8) Make sure that the top hole (A) is above the ridge in the non-running surface of
the cylinder liner (3).
9) Read the values from when the bore was measured before. You compare these
values with the new values.
10) Put the micrometer (94101) in the top hole (A) to measure the distance. Record
the value.
11) Put the micrometer (94101) in position in the subsequent hole (B) in the gauge
(94225), then record the value.
12) Do step 11) above for the remaining holes below (A and B).
13) Move the gauge 90_ (in line with the transverse axis of the engine).
14) Do the steps above again to measure the bore in the positions (F up to A).
15) Use the formula below to calculate the rate of wear:
WR = (D1−D2) x 1000
T1
Where:
WR = Rate of Wear (mm/1000 hours)
T1 = Total running hours (h)
D1 = Maximum liner diameter of running surface (point B and below) (mm)
D2 = Liner diameter of non-running surface (point A) (mm)
16) For the maximum permitted inner diameter, refer to 0330−1 Clearance Table,
Cylinder liner.
17) Remove all unwanted particles from the cylinder liner bore.
18) Clean the cylinder liner bore.
Note: To remove the ridge of material at the top of the cylinder bore, refer to
(see 2124−3).

Cylinder Liner
Removal and Installation

Tools:
3 Manual ratchets 94016−004 2 Flange couplings 94201C
3 Shackles 94018D 1 Shackle 94201D
1 Lifting device 94201 1 Chain 94202L
consisting of: 1 Dismantling tool 94208
1 Lifting tool 94201A 1 Assembly tool 94345E
2 Holders 94201B
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Cylinder Liner − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Lifting Tool − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Cylinder Liner − Safe Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Lifting Tool − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Water Guide Jacket − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Water Guide Jacket − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Insulation Bandage − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Insulation Bandage − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. Cylinder Liner − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Preparation
2) Drain the cylinder cooling water from the related cylinder.
3) Remove the cylinder cover (1, Fig. 1) together with the water guide jacket (2),
refer to 2708−1.
4) Remove the piston together with the piston rod gland, refer to 3403−1 and
2303−1.
5) Remove all lubricating quills and their pipes, refer to 2138−1.
6) Remove the gas admission valve, refer to 2140−1.

Cylinder Liner: Removal and Fitting
2. Cylinder Liner −
Removal
1) Remove the screws (4, Fig. 1).
I
2) Remove the pipe connection (3) and
the transition tubes (5) from the water
guide jacket (2).
1
Note: The transition tubes (5) are a
push-fit into the pipe
connections (3).
WCH03059
3
Fig. 1
2
3) Loosen the screws (2 and 5, Fig. 2).

4) Remove the cylinder holders (3, 6).
Note: The cylinder holders (3, 6) keep
the the cylinder liner (1) in
position.
5 6 1
2 3
4 4
WCH030059
WCH03086
Fig. 2

94201 2.1 Lifting Tool − Install

1) Put the two flange couplings (94201C,
1 Fig. 3) in position on the cylinder
liner (1).
94201B 2) Apply Molyslip Copaslip paste to the
threads of the screws (3).
3) In each flange coupling, torque the four
screws (3) to 140 Nm.
2
I 4) Use the engine room crane to put the
lifting tool (94201) in position on the
cylinder liner (1).
5) Apply Molyslip Copaslip paste to the
WCH03060
threads of the special screws (2).
I 6) Attach the two holders (94201B) to the
flange couplings (94201C) with the
special screws (2).
7) Torque the special screws (2) to
140 Nm.
2
94201C
WCH02342
94201C
Fig. 3
8) Connect the crane hook to the shackle

of the lifting device (94201, Fig. 4).
9) Operate the engine room crane to
94201 carefully lift the cylinder liner together
with the water guide jacket.
10) Move the cylinder liner cylinder liner
over the rail unit.
11) Lower the cylinder liner on to an
applicable wooden underlay.
Fig. 4

2.2 Cylinder Liner − Safe

94202L 94202L Storage
1) Attach the shackle (94201D, Fig. 5) of
94201D the lifting tool (94201) as shown.
94201 2) Attach the chain (94202L) to the

shackle (94201D) and the crane hook.
3) Put the wooden underlay (2) in position
as shown.
4) Carefully push the cylinder liner in the
direction shown and at the same time
lower the cylinder liner.
5) Put the wooden chocks (1) in position
to prevent movement of the cylinder
liner.
6) Fully lower the cylinder liner.
1
2 7) Remove the chain (94202L) from the
lifting tool (94201).
8) Carefully turn the cylinder liner 90_ and
put more wooden underlays (2) in
1 position.
2
9) Put the two wooden chocks (1) in
position to prevent movement.
1 10) Remove the lifting tool (94201) from the
cylinder liner.
11) Remove the insulation bandage, refer
to paragraph 4.
12) To remove the cylinder liner from water
guide jacket, refer to paragraph 3.
Fig. 5
1
2
2.3 Lifting Tool − Removal

1) Remove the two special screws (2,
Fig. 6).
94201
2) Remove the screws (1), then remove
the two flanges (94201C).
3) Use the engine room crane to remove
the lifting device (94201) from the
1 cylinder liner.
2
4) Lower the lifting device (94201) to an
94201C applicable surface.
5) Remove the crane hook from the
shackle of the lifting tool (94201).
Fig. 6 WCH03060

6
3. Water Guide Jacket −
7
Removal
1) Remove the cylinder liner, refer to the
procedures in paragraph 1 to
1 paragraph 2.2.
2) Loosen the two screws (3, Fig. 7).
3) Remove the cylinder holders (4, 5).
2 4) Attach the three shackles (94018D) to
the lifting tool (94201).
5) Attach the three eye bolts to the water
guide jacket (1).
3 6) Attach the three manual ratchets
3 4 (94016−004) to the three eye bolts (8)
and the shackles (94018D).
5
7) Apply a light tension to the manual
ratchets (94016−004).
8) Remove the three bolts (9) that hold
the water guide jacket to the cylinder
WCH030059
liner.
WCH03086
Note: During step 9), make sure that you
do not cause damage the top of
94202L
the cylinder liner.
9) Operate the manual ratchets
(94016−004) to lower the water guide
94201
jacket (1).
10) If the water guide jacket (2) does not
come away from the cylinder liner, do
step a) and step b):
a) Put three applicable M12 screws
94018D in the threaded holes of the
holder (7).
b) Turn equally the three M12 screws
to push down the water guide
94016−004 jacket.
(94016−004) to lower the water guide
jacket on to a wooden underlay. Make
sure that you keep the water guide
jacket level.
12) Remove the manual ratchets
8
(94016−004) from the three eye bolts
(8) and the shackles (94018D).
1 13) Attach the lifting tool (94201) to the
9 cylinder liner (see paragraph 2.1).
Note: Some parts 14) Carefully lift then move the cylinder
WCH02913
can look different liner to a different position.
Fig. 7


6 7
Installation
1) Install the insulation bandage, refer to
paragraph 6.
1
2) Attach the lifting tool (94201) to the
cylinder liner, refer to paragraph 2.1.
3) Lift, move and lower the cylinder liner
into the water guide jacket (1, Fig. 7).
2
4) Attach the three shackles (94018D) to
the lifting tool (94201).
5) Attach the eye bolts (8) to the water
guide jacket (1).
3 6) Attach the three manual ratchets
3 4 (94016−004) to the three eye bolts (8)
5 and the shackles (94018A) on the lifting
tool (94201).
Note: Make sure that you do not cause
damage the top of the cylinder
liner.
WCH030059
WCH03086
(94016−004) to lift the water guide
jacket (1) to the applicable position on
94202L the cylinder liner. Make sure that you
keep the water guide jacket level.
8) Attach the water guide jacket (1, Fig. 8)
94201 to the cylinder liner with the three
screws (9).
9) Attach the cylinder holders (4, 5) with
the screws (3).
10) Remove the manual ratchets
(94016−004), the shackles (94018D)
94018D and the lifting tool (94201).
11) Remove the eye bolts (8).
94016−004
1
9
Note: Some parts
WCH02913
can look different
Fig. 8

5. Insulation Bandage −
Removal
1 1) Remove the cylinder liner, refer to the
procedures in paragraph 1 to
paragraph 2.2.
2) Remove the water guide jacket, refer to
paragraph 3.
3) Use the assembly tool (94345E, Fig. 9)
to remove all the tension springs (2).
4) Remove the plate (3).
5) Remove insulation bandage (1).
6. Insulation Bandage −
Installation
6) Put the insulation bandage (1) around
the water channel on the cylinder liner.
Note: Make sure that the insulation
bandage (1) has an overlap of
approximately 30 mm.
7) Put the plate (3) in position over the
WCH03065 insulation bandage (1).
8) Use the assembly tool (94345E) to
attach all the tension springs (2).
I
9) Make sure that there is a clearance of
3 10 mm between the ends of the
1 plates (3).
II
Approx. 30 mm
3
I 10 mm
Fig. 9

7. Cylinder Liner −
Installation
1) Install the lifting tool (94201, Fig .10)
and the chain (94202) to the cylinder
liner, refer to paragraph 2.1.
2) Clean the seating surfaces of the
cylinder liner (1) and the cylinder
jacket.
3) Install the cylinder holders (3, 6) with
the screws (5) to the cylinder liner (1).
1
4) Lift, move and lower the cylinder liner
(1) above the cylinder jacket.
5 6
2 3 5) Carefully lower the cylinder liner (1)
almost on to the cylinder jacket.
6) Align the pins (4) with the holes in the
cylinder jacket.
4 4 7) Fully lower the cylinder liner (1).
WCH030059
Fig. 10 WCH03086
I
8) Replace the O-rings (2 and 6, Fig. 11).
9) Attach the pipe connections (8) and the
2 transition tube (3) to the water guide (7)
with the screws (4).
I 3 10) Remove the lifting tool (94201).
4
1
5
8. Completion
WCH03059
6
1) Install all lubricating quills, refer to
Fig. 11 2138−1.
2) Operate the flex lube pump on the
related cylinder liner until oil flows from
all the lubricating grooves.
3) Install the piston piston rod gland, see
3403−1 and 2303−1.
4) Install the piston rod gland, refer to
2303−1.
5) Install the cylinder cover together with
the upper water guide jacket, see
2708−1.

Cylinder Liner
Remove Unwanted Material, Dress the Lubricating

Grooves and Scavenge Ports
Tools:
1 Grinding device 94299
1. General
During operation, the cylinder liner becomes worn and an edge of unwanted material
collects immediately above the location where the top piston ring travel stops. Also,
the lubricating grooves decrease in depth and the corner radii of the scavenge ports
become smaller.
Before each piston removal, you measure the bore of the cylinder liner (for more data
refer to 2124−1.
2. Preparation
1) Remove the cylinder cover, refer to 2708−1.
2) Remove all lubricating quills, refer to 2138−1.
3) Put applicable protection below the cylinder liner. This keeps unwanted particles
out of the bore.
3. Unwanted Material − Remove

CAUTION
Damage Hazard: Make sure that you do not cause damage to the
running surface of the cylinder liner when you operate the grinding
tool.
1) Read the data in the Instruction Manual for the grinding tool.
2) Attach the grinding tool (94299, Fig. 1) to the cylinder liner, refer to the Instruction
Manual.
3) Connect the grinding tool (94299) to an applicable air supply.
4) Operate the grinding tool (94299) to carefully remove the unwanted material from
the cylinder liner (1).
5) Make sure that you get a radius r = 8 mm.

94299
WCH02352
Unwanted material
r = 8.0 mm
TDC
2.0 mm to 3.0 mm
1.0 mm
3 2
Fig. 1

Cylinder Liner: Re-dressing Lubricating Grooves and Scavenge Ports
4. Lubricating grooves
CAUTION
Damage Hazard: Make sure that you keep the initial shape of the
lubricating grooves when you remove sharp edges.
1) If the depth of the lubricating grooves (1, Fig. 2) has decreased to less than
1.5 mm, do as follows:
a) Use emery cloth or an oil stone to get the the lubricating grooves (1) back to their
original depth.
I-I
1 I 1 R1
I I
R2−3
I
2.0 mm
Fig. 2
5. Scavenge ports
CAUTION
Damage Hazard: When you polish the scavenge ports, make sure
that you do not cause damage to the running surface of the
cylinder liner.
Note: The scavenge ports (1, Fig. 3) are as seen in new cylinder liners.
1) Use emery cloth to polish the surfaces of the scavenge ports (1). Make sure that
you keep the shape of the scavenge ports the same as those shown.

Cylinder Liner: Re-dressing Lubricating Grooves and Scavenge Ports
II
III II-II
Rounded Edges
1
II
III
WCH00106
Fig. 3 015.739/07
WCH03094
2) After the repair is completed, fully clean the lubricating grooves and the bore of
the cylinder liner.
3) Remove unwanted particles, which may have passed into the scavenge space
through the ports.
4) Manually operate the cylinder lubrication until oil flows from all the lubricating
points. This will flush away unwanted metal dust.

Lubricating Quill

Tools:
1 HP oil pump 94931 1 Connection nipple (G¼ in.) 94934I
1 Hydraulic distributor with 94934H 1 HP hose 94935
pressure gauge 0 bar to 25 bar) 1 Dismantling tool 94213
1. General
If it is not necessary to remove the cylinder liner (1, Fig. 1), you must not drain the
cylinder cooling water.
Steps 1) to 3) are only necessary if the cylinder liner (2) must be removed.
1) If necessary, remove the holders (3).
2) Disconnect the six pipes (1).
3) Seal the pipes (1) with applicable plugs to prevent contamination.
1 DRIVING END
2 4
1
3
5
WCH02869
3
Fig. 1
2. Removal Procedure
1) Loosen the nuts (4) of the screw-in union and the angle union and disconnect the
pipe (5) from the lubricating quill (3).
Note: Make sure that you do not damage the oil pipe (5).
2) Seal the oil pipes (3, 5) with an applicable plug to prevent contamination.
3) Remove the two screws (7).
4) Remove the lubricating quills (8).
5) If necessary, do a function check of the lubricating quills, see paragraph 3.

Lubricating Quill
3. Nozzle Tip − Replace

1) Remove the two bolts (2, Fig. 2) and the plate (1) from the distance sleeve (3).
2) Put the distance sleeve (3) on (5) of the lubricating quill.
3) Attach the plate (1) to the nozzle tip (4). Engage the collar on the plate with the
recess on the lubricating quill (5).
4) Turn equally the two bolts (2) to remove the nozzle tip (4) from the holder (5).
5) Remove the distance sleeve (3).
6) Attach a new new nozzle tip (4) to the holder (5).
7) Make sure that the nozzle tip (4) is correctly attached to the holder (5).
8) Do the procedure in paragraph 4.
94213 I-I
3 1
1 2
I 5
I A
3
2
WCH03861
Fig. 2

Lubricating Quill
4. Lubricating Quill − Function Check
4.1 General
You do a function check to make sure that the non-return valve (3, Fig. 3) operates
correctly. The pressure that opens the non‐return valve is 5.0 bar.
During the function check, keep the lubricating quill (2) in a horizontal position.
For the function check, use an oil with a viscosity as given in the specifications that
follow:
D SAE 50 at 40_C (approximately 200 cSt)
D SAE 30 at 25_C (approximately 190 cSt).
4.2 Procedure
1) If necessary, remove the screw-in union (1) of the lubricating quill.
2) Install the nipple (94934I) to the lubricating quill (2).
3) Attach the HP hose to the nipple (94934I) and to the hydraulic distributor and
pressure gauge (94934H).
4) Install the the hydraulic distributor and pressure gauge (94934H) to the HP oil
pump (94931).
5) Hold the lubricating quill (2) up and operate the pump (94931) until oil that flows
has no air.
6) Open the relief valve (4) and decrease the pressure to 2.0 bar.
7) Close the relief valve (4).
8) Hold the lubricating quill (2) in a horizontal position.
9) Operate the HP oil pump (94931) to increase the pressure in steps of 1.0 bar
until the non-return valve (3) opens.
10) Record the opening pressure shown on the pressure gauge.
Note: The minimum permitted opening pressure is 4.25 bar. If necessary,
replace the defective lubricating quill (2).
94934I
WCH03490
1 2 3
94935
Fig. 3 94931 4 94934H

Lubricating Quill
5. Installation
CAUTION
Damage Hazard: The surfaces of the cylinder liner and the nozzle
tip make a metallic seal. The seat angles in the cylinder liner and
on the nozzle tip are different. Do not use a gasket between the
cylinder liner and the nozzle tip, or damage to the equipment can
occur.
Note: When you install the lubricating quill , replace all components, i.e. nozzle
tip, non-return valve and holder (see Fig. 4).
1) Make sure that the sealing surfaces (3) are clean and have no damage.
2) Make sure that the marks (MK) are in line. If the marks are not in line, send the
lubricating quill to Wärtsilä.
3) Apply oil to the threads and surfaces of the screws (4).
4) Put the lubricating quill (1) in position.
5) Torque the two screws (4) to 10 Nm.
WCH03490
Holder Nozzle
I 2
Non-return Tip
Valve
W
MK
4
WCH03489
Fig. 4

Lubricating Quill
6) Remove the plugs from the oil pipe (5, Fig. 5).
7) Connect the pipe (5) to the lubricating quill (7) and the applicable pipe (8).
8) Tighten the nuts (4, 6) of the screw-in union and angle union.
9) Step a) to step c) is only necessary if the cylinder liner was installed.
a) Remove the plugs from the six pipes (1).
b) Connect the six pipes (1).
c) If necessary, attach the holders (3) to the six pipes (1).
10) Bleed the oil pipes 8, refer to 7218−1, paragraph 3.2.
11) If necessary, bleed the cylinder lubricating oil pump, refer to 7218−1, paragraph
3.1.
12) Do a function check of the cylinder lubricating system, see 7218−1,
paragraph 1.2.
1 DRIVING END
2 4
1
3
5
WCH02869
Fig. 5

Intentionally blank
Gas Admission Valve (GAV)
Removal, Disassemble, Assemble, Checks, Installation

Tools:
1 Assembly tool 94023A 1 Pressure reducing valve 94214B
1 Eye bolt 94040-M8 1 Handle 94214A
1 Disassembly / assembly tool 94214 1 Disassembly / assembly tool 94890
2 Screws 94214L 2 Nuts 94214M
1 Disassembly / assembly tool 94214C 1 Pusher 94214D
1 Bush 94214E 1 Steel plate 94214F
2 Screws 94214L 2 Allen screws (M6x12) 94214G
2 Allen screws M6x50) 94214H 1 Gasket 94214I
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Hydraulic Drive − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Valve Bush and Valve Guide − Remove . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Valve Spindle − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Valve Seat − Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7. Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1 Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2 Manual Check − Free Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3 Valve Seat − Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1. General
For general overhaul and spare part kits, speak to, or send a message to Wärtsilä
Services Switzerland Ltd.
1) Read the data in the:
D Operation Manual, 0210−1 Safety Precautions and Warnings
D Operation Manual, 2140 Gas Admission Valve (GAV)
D Operation Manual, 8014−1, Gas Fuel System
D Operation Manual, 4003−12, Diagram Gas Fuel.
2) For the inspection intervals, refer to the Maintenance Schedule 0380−1, Gas
Admission Valve.
2. Preparation
WARNING
Danger: Some gas can leak during the removal of the GAV. Do not
use equipment that can cause a spark. Make sure that all equipment
that can case a spark is not in the work area. This will prevent an
explosion, or a fire.
1) Stop the engine, refer to the Operation Manual, 0310−1 paragraph 3.
2) Set to off the main bearing oil pumps (use the service pump for tests).
3) Make sure that the pressure in servo oil supply pipes is zero.
4) Make sure that the pressure in the gas pipe, high pressure pipe and lubricating
oil pipe is zero.
5) Make sure that the drain from the gas control valve is open.

Gas Admission Valve: Removal, Disassemble, Assemble, Checks, Installation
6) Apply Molykote G-Rapid Plus to the

tool (94890, Fig. 1).
7) Remove the screws (3) on each side of
the compensator (1).
8) Put the tool (94890) in position on the
compensator (1) as shown.
1 Note: The tool (94890) is shorter than the
installed length of the
compensator (1).
2 9) Attach the tool (94890) to the flanges of
the compensator (1) with the four
screws (5).
I 10) Tighten the four screws (5).
11) Tighten the two bolts (6) at the same
time to compress the compensator (1).
WCH03405
4 3 12) Continue to tighten the bolts (6) until
you can remove the compensator (1).
13) Carefully remove the tool (94890)
I together with the compensator (1).
5 II 14) Do a check of the condition of the six
O-rings (7) (on the flange couplings) if
necessary, replace the O-rings.
15) Remove the tool (94890) from the
compensator (1).
16) Put the compensator in a dry, clean
area.
6
II
94890
II -II
1
94890
6
7
WCH03404
Fig. 1

3. Removal
WARNING
Danger: If a gas detector
alarm is activated, keep
away from the engine. The
natural gas is flammable.
I
There is a risk of fire or
explosion.
WARNING
Injury Hazard: When you
open valves and shut-off
devices, hot fluids or
WCH03403 gases can be released. To
prevent injury, always open
I slowly the valves and
shut-off devices. Look
away from the where the
1 gas is released.
2 3 94040−M8
4 Note: For safety it is recommended that
5 you have a portable gas detector.
6 Access to the gas admission valve (GAV)
on the fuel side is from the bottom platform,
through the clearance between the bottom
7
plates on the top platform.
Access to the GAV on the exhaust side is
on the same level as the top platform, below
the cylinder cooling pipes. These pipes
must be moved to get more access to the
10 GAV.
1) Put an oil tray under the GAV (5,
Fig. 2).
2) Make sure that the power supply to the
9 8 rail valve (10) is set to off.
3) Disconnect the electrical connections to
Fig. 2 the rail valve (10) and the valve stroke
sensor (6).
4) Loosen the four screws (2).
Note: During step 5) make sure that you do not damage the sealing face of the
pipe (1)
5) Remove the pipe (1).
6) Remove the lubricating oil pipe (7) and the return pipe (9) from the GAV (4).
7) Seal the openings of the pipes (7, 9) with plugs to prevent contamination.
8) Install the eye bolt (94040-M8) to the GAV in the position shown.
9) Install an applicable lifting tool to the eye bolt.
10) Remove the six Allen screws (5).
11) Move the gas admission valve carefully to a clean working place.
12) Close the opening of the gas distribution pipe 2 with a flange or a plug.

4. Disassemble
4.1 Hydraulic Drive − Removal

1) Loosen the four Allen screws (6, Fig. 3).
2) Carefully remove the cover (5) together with the rail valve (7).
3) Remove the coupling nut (9) on the valve stroke sensor (10)
4) Remove the valve stroke sensor (10) and the sleeve (9).
5) Remove the piston (8) and the O-ring (4).
6) Loosen symmetrically the six screws (1).
7) Carefully remove the cover (3) together with the O-rings (2).
8) Discard the O-rings (2).
II
II - II
1
WCH03493
I
II
10
WCH03493
9 I-I 2 3
4 5 6
7
WCH03493
Fig. 2 8

1 4.2 Valve Bush and Valve Guide

− Remove
2 If it is necessary to remove the valve
bush (2, Fig. 4) and the valve guide (4), do
step 1) to step 5):
1) Remove the six Allen screws (1) from
the valve bush (2).
2) Put the two screws (94214L) and the
screws (94214M) into the valve
bush (2) as shown.
WCH03493
3) Turn equally the nuts (94214M) to
remove the guide bush (2) and the
valve guide (4) from the housing (5).
4) Remove and discard the two
O-rings (3).
94214L
5) Do the checks given in paragraph 7.
94214M
4
5
WCH03493
Fig. 3

4.3 Valve Spindle − Removal

1) Apply Molykote G Rapid Plus to the rod
(2, Fig. 5) of the tool (94214).
2) Attach the plate (94214F) to the bush
(94214E) with the four screws
(94214G).
3) Put the plate (94214F) together with
the bush (94214F) into a vice.
4) Make sure that the sealing faces (6, 7)
are clean.
94214H
5) Install the soft metal gasket (94214I)
94214F between the sealing faces (6, 7).
6) Put the valve bush (10) into the bush
(94214E).
7) Apply Molykote G Rapid Plus to the
rods of the tool (94214C).
8) Attach the tool (94214C) to the valve
94214G
bush (10) and the bush( 94214E) with
WCH03394
the six screws (94214H).
9) Tighten the six screws (94214H) to
10 Nm.
10) Attach the pusher (94214D) on the
other side of the bush (94214E) with
1 the two M6x65 screws (9).
11) Turn the special screw (8) fully in.
12) Turn the rod (1) to compress the
spring (5),and push the valve cotter (2)
out of the spring carrier (11).
94214C 13) Remove the valve cotter (2).

14) Remove the pusher (94214D).
2
11 15) Turn the valve spindle (3) out.
3
4 16) Turn the rod (1) back to release the
tension in the spring (5).
94214K 5 17) Remove the tool (94214C).
18) Remove the spring (5).
10 19) Remove the valve spindle (3).
94214E 20) Clean the valve spindle (3).
94214I 21) Do a check of the valve spindle (3) for

damage, specially the sealing
6 surface (6).
22) Carefully put the valve spindle (3) into
7
94214D the valve guide (4). Move the valve
spindle in and out. Make sure that the
9 valve spindle moves smoothly.
8
Note: When held in the position shown,
the valve spindle (3) must move
smoothly out of the valve guide
Fig. 4
with no aid.

94214B 5. Pressure Test

1) Apply lubricating oil to the valve
spindle (3, Fig. 6).
2) Put the valve spindle (3) in position in
the valve guide (4).
3) Install the pusher (94214D) to the bush
(94214E) with the two M6x65
screws (9).
4) Turn fully in the special screw (8).
5) Turn the rod (1) to compress the
1 spring (5).
6) Attach the valve cotter (2) to the valve
spindle (4).
7) Turn the rod (1) back to release the
tension in the spring (5). Make sure
that the valve cotter (2) is installed
94214C correctly in the spring carrier (11).
8) Attach the pressure reducing valve
2 (94214B) to the bush (94214E).
11 3
9) Connect a pressurized air supply to the
4
pressure reducing valve (94214B).
94214K 5 10) Set the pressure reducing valve
(94214B) to 10 bar.
10 11) Apply WD40 to the area of the sealing
94214E faces (6, 7) (or an approved alternative)
as a spray to the area of the valve seat
and the soft metal seal.
94214I
12) The test is satisfactory if:
6
a) Up to five bubbles each second
7 come from the valve seat.
94214D
b) No bubbles come from the soft
9 metal seal.
8
13) If the test results are different than
Fig. 5
those given, do the procedure given in
paragraph 6.
14) Remove the pressurized air supply and
the pressure reducing valve.

6. Valve Seat − Lap

1) Remove the spring (5, Fig. 5), refer to
94214A paragraph 4.3.
2) Attach the handle (94214A) to the valve
3 spindle (3, Fig. 7) as shown.
3) Apply lubricating oil to the valve
spindle (3).
4
4) Put the valve spindle (3) into the valve
guide (4).
5) Use oil based lapping paste and a corn
94214E size of between 0.5 microns to 4.0
microns.
6) Lap the valve seat.
WCH03394
Fig. 6 7) Do the pressure test again. If the
leakage is unsatisfactory, replace the
valve spindle and valve guide.
7. Checks
After disassembly of the GAV, do the checks that follow:
7.1 Visual Check

Do the checks on the:
D Valve seat for damage, unwanted material or corrosion (use engineers blue)
D Valve stem and valve guide for hard running marks
D Valve cotters for damage or cracks
D Compression spring for fretting or cracks
D O-rings in the housing for damage from disassembly
D Valve spindle for scratches or other damage (use engineers blue)
D Soft metal sealing i.e fluted seal ring in the nozzle for damage or corrosion
D Nozzle for corrosion or particles
D Servo piston for hard running marks
D Servo housing for hard running marks
D Orifice for dirt
D Membrane and plug of the valve stroke sensor
D O-rings on the rail valve and the compensator flange couplings
Note: If you find damage, the related part must be replaced. Speak to, or send a
message to Wärtsilä Services Switzerland Ltd. for more data.

7.2 Manual Check − Free Movement

Note: Do not use oil when you do step 1) and step 2)
1) Make sure that the valve spindle and valve guide move freely as follows:
a) Remove the oil from the running surface of valve spindle and valve guide.
b) Make sure that the spindle is clean and dry.
c) Carefully put the valve spindle into the valve guide.
d) Move the valve spindle in the valve guide. Make sure that the valve spindle
moves freely.
e) Put the valve guide and valve spindle in the vertical position.
f) Make sure that the valve spindle moves down freely.
2) Make sure that the servo piston moves freely in its housing.
7.3 Valve Seat − Leakage Check

1) Connect a pressurized air supply to the pressure reducing valve (94214B).
2) Connect the pressure reducing valve (94214B) to the valve guide.
3) Set a low pressure setting on the pressure reducing valve (94214B).
4) Apply a water and liquid soap mixture to the valve seat.
5) Make sure that there are no bubbles.
6) If necessary, lap the valve seat.

8. Assemble
Note: During this procedure, make sure
1 that you do not cause damage to
the surface of the valve housing
2 and the O-rings (9, Fig. 8).
1) Clean all parts and bores.
2) Make sure that the O-rings (9) are in
B
3 good condition.
3) Apply oil to the O-rings (9).
4) Replace the gasket (13).
5) Put the new O-rings (12) in the valve
housing (16).
A
4 6) Put the items that follow into the valve
17 housing (16):
5
16 6 D Guide bush (7)
7
8 D Spring dowel pin (8)
D Valve spring (10)
9
10 D Spring carrier (5)
D Valve spindle (15).
15
Note: The valve cotter is installed, see
11 paragraph 5.
7) Apply Never-Seez High Temperature
WCH03493 Stainless lubricant to the threads and
12 surfaces of the six Allen screws (6).
8) Torque symmetrically the six Allen
14 13 screws (6) to 10 Nm.
9) Measure the distance A between the
end of the valve spindle (14) and the
cover (17). The distance must be
8.5 mm.
Fig. 7 10) Clean the piston hole in the cover (2).

11) Apply lubricating oil to the piston (3).
12) Put the piston (3) fully into the
cover (2).
13) Measure the piston stroke B.
14) Calculate the valve clearance B − A.
D The valve clearance B − A must be
between 0.20 mm and 1.22 mm. If the
value is too low, the valve will not fully
close.
15) Apply oil to the new O-ring (16).
16) Put the O-ring (15) into the cover (17).
17) Attach the cover (17) to the valve
housing (15).

18) Attach the cover (4, Fig. 9) to the valve

housing (6).
19) Apply Never Seez High Temperature
I Stainless lubricant to the threads and
surfaces of the six Allen screws (1).
10 20) Torque symmetrically the six Allen
1
21) Put the valve stroke sensor (2) into the
cover (4).
WCH03493
22) Tighten fully the valve stroke sensor (2)
until it touches the spring carrier (7).
I 23) Turn back one full turn the valve stroke

sensor (2). This gives a clearance CL
of 1. ± 0.1 mm.
24) Apply Never See NSBT to the threads
II of the sleeve (3).
I-I
25) Hold the valve stroke sensor (2) in
position.
9 26) Put the sleeve (3) in position on the

valve stroke sensor (2).
2
8 27) Torque the sleeve (3) to 20 Nm.
28) Clean the surfaces of the cover (9) and
7
3 the cover (4).
4 29) Put the cover (9) together with the rail
CL valve (11) on the cover (4). Do not
5
cause damage to the O-ring (8).
6 30) Apply Never Seez to the threads of the
M6x50 Allen screws (10).
WCH03493
31) Torque the M6x50 Allen screws (10) to
10 Nm.
II
11
10
Fig. 8

I 1
2 3 94040−M8 9. Installation
4
1) Attach the eye bolt (94040−M8, Fig. 10)
5
to the housing of the GAV (4).
6
2) Lift and move the GAV (4) to the
applicable position at the cylinder liner.
I
7
3) Make sure that all surfaces that will
touch are clean.
4) Apply Never Seez High Temperature
Stainless lubricant to the four Allen
screws (5).
10 5) Torque the four Allen screws to 40 Nm.
6) Attach the drain pipe (9) and the
adjustable angle union (8) to the
GAV (4).
9 8
7) Attach the lubricating oil pipe (7) to the
GAV.
I-I
8) Make sure that the sealing face of the
oil pipe (1) has no damage. If there is
1
damage, grind the sealing faces (refer
to 8460−1).
9) Adjust the claw (11) with an
open-ended wrench until there is a
3
distance of 5.5 mm between the claw
and the end of the pipe (1) .
10) Attach the flange (3) and the
11
high-pressure hydraulic pipe (1) to the
GAV (4).
11) Apply oil to the threads and surfaces
WCH03494 5.5 mm that touch of the four Allen screws (2).
12) Torque the four Allen screws (2) to
Fig. 9 20 Nm.
13) Connect the electrical connections to
the rail valve (10).
94023A 14) Use the tool (94023A, Fig. 11) to attach

the electrical connection (1) to the
Fig. 10 WCH03394

10. Completion
1) Make sure that the compensator (1,
Fig. 12), the O-rings (7), the coupling
flanges and the surface of connecting
block and are clean and in good
condition.
1
2) Put the tool (94890) in position on the
compensator (1) as shown.
2 Note: The tool (94890) is shorter than the

installed length of the
compensator (1).
3) Attach the tool (94890) to the flanges of
I
the compensator (1) with the four
screws (5).
WCH03405 4) Tighten the four screws (5).
4 3
5) Tighten the two bolts (6) at the same
time to compress the compensator (1).
6) Continue to tighten the bolts (6) until
I
the compensator (1) is sufficiently
5 II compressed for installation.
7) Make sure that the O-rings (7) are in
their correct positions.
Note: During step 8) make sure that the
O-rings (7) stay in position.
8) Put the compensator (1) and tool
(94890) in position between the
connecting block (4) and the flange (2).
9) Make sure that the holes in the
compensator (1) align with the holes in
6
II the flanges (2).
94890 10) Loosen the two bolts (6) at the same
time to release the tension of the
compensator (1).
compensator (1).
II -II 12) Put oil on the threads of the screws (3).
1 13) Attach the compensator (1) to the
94890
flanges (2) with the screws (3).
5 14) Tighten the screws (3).
6
7
WCH03404
Fig. 12

15) Do a leakage check of the high-pressure hydraulic pipe.

16) Do a pressure test of the opening pressure, refer to Operation Manual.
Note: For a functional check of the gas admission valve the engine must be
stopped.
17) Set to on the service pump to get the servo oil pressure to approximately 100 bar,
refer to the Operation Manual 4002−2.
18) For a stroke signal test of the GAV, refer to the Operation Manual 4002−2,
paragraph 3.14, GAV Manual Valve Test.
19) To start the engine and to change to gas mode, refer to the Operation Manual
0275−1 and 4002−2/A1 Gas Fuel Pressure.

Piston Rod Gland
Removal, Disassemble, Measure Worn Parts, Assemble,

Installation
Tools:
2 Distance holders 94345 2 Distance pieces 94345F−9
1 Clamp ring (2-part) 94345B 2 Distance pieces 94345F−11
1 Gauge 94345C 2 Distance pieces 94345F−13
2 Spring assembly tools 94345E 2 Work supports 94143
2 Work platforms 94142
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Worn Parts − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. General
WARNING
Injury Hazard: Before you operate the turning gear, make sure that
no personnel are near the flywheel, or in the engine.
CAUTION
Damage Hazard: Each time you operate the turning gear, you must
remove the platform (94142). This will prevent damage to
equipment. After you use the turning gear, you can install the
platform (94142) again.
The removal of the piston rod gland is done at the same time as the piston removal.
Examine the piston rod gland for wear and damage during each overhaul of the
piston (refer to 0380−1, Piston rod gland). If necessary, replace the unserviceable
parts.
When you assemble the piston rod gland, make sure that all parts are in a serviceable
condition.
2. Preparation
1) Remove the piston together with the piston rod gland, refer to 3403−1 Piston −
Removal and Installation.
2) Install the work platforms (94142) and the work supports (94143). Make sure that the
grids and work supports are correctly attached.

Removal, Disassemble, Measure Worn Parts, Assemble, Installation
3. Removal
1
piston to BDC.
2) Lock the turning gear.
3) Make sure that the two distance
94345 holders (94345, Fig. 1) are installed on
to the piston rod foot (2).
4) Remove the four inner bolts (3, Fig. 2)
from the support (4).
5) Make sure that the piston rod gland is
2
in the correct position on the two
hinged covers (3) of the tool (94350).
013.223/05
Fig. 1
2 3
94345B
94350
94345
Fig. 2 016.571/08
Fig. 3

4. Disassemble
CAUTION
Injury Hazard: The eight
outer screws must be
1 removed after the piston
6
rod gland is disassembled.
2 This will prevent injury to
3 personnel.
1) Remove the bolts (3, Fig. 4) and

4 screws (4) from the housing (2).
2) Push the two parts of the housing (2)
away from the piston rod (1).
5
Fig. 4 3) Remove the two parts of the
housing (2).
4) Remove the parts that follow (see
1 Fig. 5):
D Tension springs (8)
8
7 D Scraper rings (2, 7)
6 D Gaskets (5, 6)
5 D Pin (1)
4 D Ring supports (3, 4).
2
5. Worn Parts − Measure
Note: Refer to 0330−1 Clearance Table,
Piston Rod Gland for the maximum
permitted dimensions of worn
3 parts. If necessary, replace the
worn parts.
1) Compare the wear of the parts that
follow:
Fig. 5
D Scraper rings (2, 7)
D Gaskets (5, 6)
2) If necessary, replace the tension
springs (8).
3) If necessary, replace the scraper
rings (2, 7).
4) If necessary, replace the O-ring (5,
Fig. 4)

1
2 II - II
3
4
5
6
FUEL SIDE
II 7
I I
II
WCH03495
I-I
10
8
1, 2
3, 4
Fig. 6: Gland Box − General Views

1 Locking Plate 6 Bolt
2 Screw 7 Spring dowel pin
3 Locking Plate 8 2−part housing
4 Screw 9 Screw
5 Support 10 O-Rings

6. Assemble
1) Attach two parts of the clamp ring
(94345B, Fig. 7) to the piston rod (2).
2) Put the ring support (4) and the 3-part
scraper ring (5) on the clamp ring
(94345B).
attach the tension spring (3) to the ring
support (4).
4) Put the two distance pieces
(94345F−9) on the ring support (4).
1
5) Put the next ring support (4) and the
3-part scraper ring (5) on the distance
94345B piece 94315F−9).
94350
attach the tension spring (6) to the ring
support (4).
7) Put the two distance pieces
2 (944345F−11) in position on the ring
support (4).
94345
8) Put the next ring support (4) and the
3-part scraper ring (5) on the distance
016.571/08 piece 94315F−11). Make sure that
there is an equal distance between the
three parts.
9 3 attach the tension spring (6) to the ring
support (4).
8
10) Move the two distances pieces
7 13 mm
(94345F−11) up.
6 94345F−13 11) Do step 8) and step 10) for the next two
009.654/02 ring supports and 3-part scraper rings.
12) Put the distance piece (94345F−13) in
position.
4, 5 11 mm
13) Put the two 4-part gaskets (7) and the
94345F−11
two 4-part gaskets (8) in position.
009.655/02 14) Put the 4-part scraper ring (9) on the
distance piece 94315F−13).
94345B 9 mm attach the tension spring (3) to the
94345F−9 scraper ring (9).
16) Remove all distance pieces (94345F).
009.656/02
17) Remove the clamp ring (94345B).
94345E
Fig. 7 004.284/98

7. Installation
1) Apply lubricating oil to the piston rod (2,
Fig. 8) and to the all O-rings.
94350
2) Put the template (94345C) in position
over the assembled rings. Make sure
that all parts are in their correct
94345C positions. If necessary, correct their
positions.
3) Push together the two parts of the
1
housing (5, Fig. 9). Make sure that the
spring dowel pin (7) is engages
correctly.
2 4) Torque the screws (6) to the value
given in 0352−2, Torque Values for
Standard Screws, paragraph 1.
94345 5) Apply lubricating oil to the bores in the
94345C
cylinder block, the housing and the
O-ring.
016.571/08
6) Attach the O-ring (8) to the housing (5)
7) Make sure that the distance holders
(94345) are attached to the piston rod
foot.
Fig. 8
8) Install the piston rod gland, refer to
3403−1.
9) Put new locking plates (3) and the inner
bolts (4) in position.
1 10) Tighten the inner bolts (4).
2 11) Lock the inner bolts (3) with the locking
3 plates (4).
4 WARNING
5 operate the turning gear,
make sure that no
I flywheel, or in the engine
II II Note: Make sure that the piston rod

gland moves freely into the
I cylinder jacket and does not tilt.
12) Operate the turning gear to carefully
move the piston to TDC until the piston
rod gland is in the correct position in
WCH03495 the cylinder jacket.
I-I
13) Apply oil to the outer bolts (1).
II - II 14) Put new locking plates (2) and the
8 outer bolts in position.
9 15) Tighten the outer bolts (1).
16) Lock the outer bolts (1) with the locking
plates (2).
7
3, 4 17) Operate the turning gear to move the
piston to BDC.
Fig. 9 18) Remove all tools and equipment.
1, 2

Cylinder Cover
Cylinder Cover and Water Guide Jacket − Removal and

Installation
Tools:
1 Tool 94265
2 Special eye bolts 94265A
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Cylinder Cover − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Water Guide Jacket − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Water Guide Jacket − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Cylinder cover − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Preparation
WARNING
Injury Hazard: You must put on safety goggles and gloves when
you do work on hot components. Oil can come out as a spray and
cause injury.
1) Stop the engine, refer to the procedure in the Operation Manual 0310−1.
2) Let the engine temperature decrease.
3) Make sure that all tools and equipment are clean.
4) Close manually the starting air valves. Refer to the Control Diagram 4003−2 in
the Operation Manual.
5) Close the cylinder inlet butterfly valves to the cooling water system.
6) Open the drain valve to the cylinder cooling water from the applicable cylinder,
refer to the Operation Manual 8017−1, paragraph 3.
7) Close the valves from the gas supply. Make sure that there is no pressure in the
gas pipes.
8) Close the valves from the fuel supply and pilot fuel supply. Make sure that there
is no pressure in HP fuel pipes.
9) Remove the hydraulic pipe to the exhaust valve, refer to 8460−1.
10) Remove the HP fuel pipe, refer to 8733−1.
11) Remove the applicable HP pilot fuel pipes, refer to 8790−1.
12) Make sure that there is no pressure in the cooling water pipe (1).
13) Remove the cooling water pipe.
14) Remove the expansion piece, refer to 2751−1, paragraph 1.
15) Close the starting air valve. Disconnect the air pipe from the cylinder cover.
16) Remove the oil leakage pipe and the pilot fuel pipe.
17) Disconnect the air pipe from the exhaust valve housing.
18) Record the positions of the connections to the injectors.
19) Disconnect all connections from the injectors.
20) Disconnect all other connections from the cylinder cover and the exhaust valve.
21) Remove the round nuts from the elastic studs on the cylinder cover (2) refer to
2708−2.

Cylinder Cover and Water Guide Jacket − Removal and Installation
94265
2. Cylinder Cover −
Removal
CAUTION
of the cylinder cover with
the top water guide jacket
and the exhaust valve is
the correct equipment to lift
94265A and move the cylinder
cover.
5 1) Attach the special eye bolts (94265A,
Fig. 1) to the elastic studs (1) on the
exhaust valve cage (5).
1
2) Attach the tool (94265) to the engine
room crane and the special eye bolts
2 (94265A).
3) Operate the engine room crane and the
3 tool (94265) to lift the cylinder cover (2)
together with the exhaust valve
012.895/05
cage (5) and the top water guide
jacket (3).
4
4 4) Lower the cylinder cover (2) (together
Wooden Supports with the exhaust valve cage (5) and the
top water guide jacket (3)) on to the
wooden supports.

Removal
1) Use the applicable tools to remove the
screws (4).
2) Operate the engine room crane to lift
the cylinder cover (2) approximately
10 mm. Make sure that the top water
guide jacket (3) stays on the wooden
supports.
3) Lift, then lower the the cylinder cover
and exhaust valve on to other wooden
supports.
special eye bolts (94265A).
2 5) Remove and discard the O-rings (3,
Fig. 2).
Fig. 1

94265
Installation
1) Clean all the sealing faces and O-ring
grooves.
2) Apply oil to the sealing faces of the top
water guide jacket (3, Fig. 2).
3) Apply oil to the new O-rings (6, 7).
4) Put the new O-rings (6) into the
94265A grooves of the transition tubes.
5) Put new O-rings into the grooves in the
5 cylinder cover (2)
6) Attach the tool (94265) to the special
eye bolts (94265A) on the cylinder
1 cover (2).
2 move the cylinder cover (2) and
exhaust valve into position above the
I top water guide jacket (3).
3
8) Make sure that the holes in the cylinder
012.895/05
liner (2) align with the holes for the
bolts in the top water guide jacket (3).
4 9) Carefully operate the engine room
I 4
crane to lower the cylinder liner (2) on
to the top water guide jacket (3).
10) Attach the cylinder liner (2) to the top
water guide jacket with the screws (4).
I-I
2
7
6
Fig. 2

5. Cylinder cover −
94265 Installation
1) Make sure that the compression space
is free from particles or dirt.
2) Make sure that the seating surfaces on
the cylinder cover (2, Fig. 3) and
cylinder liner (6) are clean and do not
have damage.
3) Put a new 2.0 mm soft iron joint ring (5)
in the cylinder liner (6). Make sure that
94265A the joint ring is flat.
4) Clean the elastic studs of the cylinder
liner (6).
4
5) Apply Molykote paste G to the threads
of the elastic studs of the cylinder
1 liner (6).
6) Attach the special eye bolts (94265A)
to the elastic studs (1) on the exhaust
2
valve cage (4).
3 7) Attach the tool (94265) to the engine
room crane and the special eye
012.895/05 bolts (64265A).
and move the cylinder cover (2)
(together with the exhaust valve cage
(4) and top water guide jacket (3)) into
position above the cylinder liner.
Note: During step 9), make sure that the
cylinder cover aligns correctly with
the elastic studs of the cylinder
2 liner (6).
9) Operate carefully the engine room
crane to lower the cylinder liner (2) on
to the cylinder liner (6).
10) Remove the tool (94265) and the
3 special eye bolts (94265A).
11) Attach the round nuts to the elastic
studs on the cylinder liner (6). Make
sure that the round nuts move freely.
5
12) Apply tension to the elastic studs, refer
to 2708−2.
13) For the configuration of the pre−tension
6 jacks, refer to 9403−2.
Fig. 3

6. Completion
1) Install the expansion piece, refer to 2751−1, paragraph 4.
2) Install the hydraulic pipe to the exhaust valve, refer to 8460−1.
3) Install the HP fuel pipe, refer to 8733−1.
4) Install the applicable HP pilot fuel pipes, refer to 8790−1.
5) Connect the cooling water pipe.
6) Connect the electrical connections to all injectors.
7) Connect all connections to cylinder cover and exhaust valve.
8) Connect the starting air pipe.
9) Open the valves you closed before (one valve each time) and do a check for
leaks.
10) Connect all other connections to the cylinder cover and exhaust valve.
11) Fill the cylinder cooling water system.
12) Set to on the cooling water pump
13) Make sure that cooling water is at the usual operation pressure and temperature.
14) Do a check for leaks.
15) Remove all tools and equipment from the work area.

Intentionally blank
Cylinder Cover
Cylinder Cover Elastic Studs − Loosen and Apply Tension

Tools:
1 Hydraulic tensioning device 94215 1 Hydraulic distributor 94934A
includes: 3 HP hoses 94935
8 Pre-tensioning jacks 94215A 1 Hose 94935C
2 Connection pieces with HP hoses 94215B 1 Hydraulic unit 94942
1 Connection block 94934
1. Preparation
1) Read the data in 9403−4 for the configuration of hydraulic pre-tensioning jacks.
2) If the cylinder cover must be replaced, refer to 2751−1.
2. Pre-tensioning Jacks − Attach

1) Clean the threads of the eight elastic
studs (5, Fig. 1) and the area around
the round nuts (4).
Note: You can attach the pre-tensioning
1 jacks (94215A) with the vent
8
screws (3) open, or connect the
hose (94935C) to the adaptor (1). If
2 you connect the hose (94935C) to
the adaptor, put an oil tray in an
X 3 applicable position to collect oil.
2) Attach all pre-tensioning jacks on the
elastic studs until there is little or no
clearance at X.
3) Turn back the pre-tensioning jacks to
7 4 get the clearance (6).
5
6
012.963/05
Fig. 1

4) Connect the two connection pieces (94215B, Fig. 2) and their HP hoses to the
hydraulic jacks (94215A).
5) Connect the hydraulic unit (94942) to the connection pieces (94215B).
94215B
94215B
I
94215A
94934
94935
94934A 012.962/05
Fig. 2 94942
3. Loosen
1) Attach the pre-tensioning jacks, refer to paragraph 2.
2) Operate the hydraulic unit (94942).
3) Close the vent screws (1, Fig. 1) when oil that has no air flows out.
4) Operate slowly the hydraulic unit to increase the pressure to between
approximately 1550 bar to 1560 bar.
Note: Do not move the pistons (1, Fig. 3) above the limit of the red groove (2).
5) Use the round bar (6) to turn the round nuts (4) back approximately two full turns.
6) Release pressure to zero bar.
7) Remove the pre-tensioning jacks.

7
4. Apply Tension
1 1) Turn the round nuts (4, Fig. 3) fully
down.
2 2) Use a feeler gauge to make sure that
there is no clearance at the slot (5).
3
3) Put one reference mark (Y) on the
round nuts (4) and one reference
mark (X) on the parts below.
6 4) Attach pre-tensioning jacks (94252) on
4 the elastic studs as given in
5 paragraph 2. Do not turn back the
round nuts.
5) Connect the pre-tensioning jacks
(94252) to hydraulic unit (94942)
6) Operate the hydraulic unit (94942).
012.964/05
7) Close the vent screws (7) when oil that
has no air flows out.
8) Operate slowly the hydraulic unit
(94942) to increase the pressure to
1500 bar. Keep the pressure constant.
9) Make sure that there are no leaks.
Note: Do not move the pistons (1) above
the limit of the red groove (2).
010.031/02
10) Use the round bar (6) to tighten the
Y round nuts (4).
009.752/02
X X Y 11) Use a feeler gauge to make sure that
there is no clearance at the slot (5).
Marks for Tightening Angle 530° 12) On the hydraulic unit, decrease the
Comparison (One full turn of 360° , pressure to zero.
plus 170° )
13) Remove all pre-tensioning jacks.
Fig. 3
14) Compare the angle between the
reference marks (X and Y). The
tightening angle must be 530°. If there
is a large difference, you must
investigate the cause and do the
procedure again.
Note: If one nut can be turned less than
the others, it can show that the
related elastic stud does not have
sufficient tension.
The possible causes are:
D The sealing rings (3) are defective.
D The piston (1) cannot move.
D The HP hose has a leak.
15) Do step 1) to step 14) again.
16) Make sure that all round nuts (4) are
turned equally to an angle of 530_.

Intentionally blank
Cylinder Cover
Grind Sealing Face

Tools:
1 Cutting device 94270
1 Profile cutter 94270A
1. General
The sealing face in the cylinder cover for the primary injection valve is a metallic seal.
Thus, this sealing face must be clean and have no damage.
2. Sealing Face − Machining

You use the cutting device (94270, Fig. 1) to repair sealing faces that are dirty, or
have light damage.
1) Apply Molykote G paste to the running surface (4).
2) Apply tacky grease on the profile cutter (94270A). This will make sure that
shavings do not fall into the combustion chamber.
3) Make sure that the two set screws (5) are tight.
4) Carefully put the cutting device (94270) and the profile cutter (94270A) into the
valve bush (2) in the cylinder cover (3).
5) Attach the guide flange (1) to the valve bush (2) with the two screws (5).
6) Put a ring spanner on the top of the cutting device (94270).
7) Push down lightly with your hand on the cutting device (94270) and use the ring
spanner to turn the profile cutter (94270A).
8) Remove only the sufficient quantity of material to get a satisfactory seating area.
4 2
94270
6
2
94270A
Fig. 1 WCH03101

Intentionally blank
Sealing Face for Pilot Injection Valve Position − Grind

Tools:
1 Grinding device 94270−02 2 Stud bolts 94270F
1 Stencil 94270−2D
1. Procedure
1) Make sure that the stop sleeve (4) is
attached to the spindle (1) of the device
(94270−02).
94270−02
I 2) Make sure that the O−rings (2) are
serviceable.
3) Use the applicable grade of emery
cloth related to the quantity of metal
you want to remove.
4) Put the stencil (94270−2D) on the
emery cloth.
5) Use a pencil or a ball pen to make the
inner shape (5).
WCH00864
6) Cut out accurately the shape.
I 7) Attach the shape (5) to the device
I-I (94270−02) with the clamp (6) and the
1
the Allen screw (7).
4 94270−02
8) Torque the Allen screw (7) to 8.0 Nm.
9) Apply a thin layer of oil to the
O−rings (2).
2 10) Attach the device (94270−02) to the
cylinder cover with the stud bolts
(94270F) as shown.
3 11) Attach an electric drill to the spindle (1).
12) Operate the electric drill at a maximum
of 500 rpm.
94270−2D
Note: During step 12, do not grind more
than 1.0 mm from the bottom of
the bore (3).
94270F 13) Apply a light pressure and start
grinding.
94270−02 14) Regularly remove the unwanted

material from the device (94270−02)
and the bore (3).
15) Make sure that the circular marks
5 around the sealing face of the bore (3)
are concentric.
6
7 16) Change the emery cloth for a smoother
grade, then do step 3) to step 15) again
until you get a smooth finish.
Fig. 1 17) Clean the bore (3).

Intentionally blank
Sealing Face for Fuel Injection Valve Position − Grind

Tools:
1 Grinding device 94270−01
1. Procedure
(94270−01).
I 2) Make sure that the O−rings (4) are
serviceable.
94270−1
x you want to remove.
emery cloth.
1 5) Use a pencil or a ball pen to make the
inner shape.
WCH00865
I 6) Cut out accurately the shape.
I-I 7) Attach the shape (5) to the device
2 (94270−01) with the clamp (6) and the
3 94270−1 the Allen screw (7).
8) Torque the Allen screw (7) to 4.0 Nm.
9) Apply a thin layer of oil to the
O−rings (4).
4
10) Attach the device (94270−01) to the
cylinder cover as shown.
11) Attach an electric drill to the spindle (2).
of 500 rpm.
94270−1D 13) Apply a light pressure and start
grinding.
14) Regularly remove the unwanted
and the bore (8).
8
around the sealing face are concentric.
16) Change the emery cloth for a smoother
17) Clean the bore (8).
5
6
7
Fig. 1

Intentionally blank
Sealing Face for the Prechamber − Grind

Tools:
1 Grinding device 94270−03
1. Procedure
(94270−03).
94270−3
you want to remove.
emery cloth.
94270−3D inner shape (3).
5) Cut out accurately the shape (3).
6) Attach the shape (3) to the device
(94270−03) with the clamp (4) and the
the Allen screw (5).
1 7) Attach the device (94270−03) to the
cylinder cover as shown.
2
8) Attach an electric drill to the spindle (1).
of 500 rpm.
10) Apply a light pressure and start
grinding.
and the bore (6).
around the sealing face are concentric.
13) Change the emery cloth for a smoother
WCH00866
6
14) Clean the bore (6).
3
4
5
Fig. 1

Intentionally blank
Injection Valve

Tools:
2 Hexagon head bolts 94270C 1 Bush 94289C
2 Stud bolts 94270D
1. Removal
1
CAUTION
2 Injury Hazard: The weight
of the injection valve is
3 12 kg. Use sufficient
personnel to lift and move
4 heavy items.
1) Remove the HP fuel pipe, refer to

8733−1.
2) At the related terminal box (95.41 to
95.47) disconnect the cable (1, Fig. 1).
3) Make sure that the cooling for the
WCH02387
injection valve is stopped, refer to the
Fig. 1 Operation Manual 8016−1,
paragraph 3.
4) Remove the screws (2) together with
the spring cage (3) from the injection
valve (4).
3 94270C
5) Put the two bolts (94270C, Fig. 2) in
the positions as shown.
6) Turn fully the two bolts (94270C) until
they touch the thread end in the valve
44 mm bush (1).
7) Turn equally the two bolts (94270C) to
lift the injection valve approximately
44 mm.
2 1
8) Remove the injection valve.
9) Remove and discard the five
O-rings (2).
Fig. 2 WCH03113

Injection Valve: Removal and Installation
2. Storage
1) Apply protection to the nozzle tip.
2) Be careful when you move the injection valve.
CAUTION
Injury Hazard: White spirit is a harmful substance. Put on gloves
and safety goggles when you use white spirit.
3) Use white spirit to clean to the injection valve (e.g. Shellsol TD, Shellsol T or
Solvent FP68).
4) Put the injection valve in an applicable package.
5) Put the injection valve in a clean, dry area that has no contamination.

3. Injection valve −
1
installation
WARNING
Injury and Damage Hazard:
Do not use copper paste in
2 this procedure. Copper
paste can be a conductor
of electricity. Injury to
personnel and damage to
3 equipment can occur.
94289C 1) Do a check of the condition of the

sealing face in the cylinder cover. If
necessary, grind the sealing face in the
WCH00903 cylinder cover, refer to 2708−3.
2) If necessary, remove the injection
valve (1, Fig. 3) from its package.
Note: The five O-rings (2) are part of the
spare parts set for the injection
valve.
3) Put the five new O-rings (2) in position
as follows:
a) Put the bush (94289C) in position
as shown.
b) Apply oil to the five O-rings.
94270D
4 c) Put the five O-ringsin their correct
positions.
1
d) Remove the bush (94289C).
4) Carefully put the the injection valve (1)
into the valve bush (5). The dowel pin
4.0 mm
(3) makes sure that the injection valve
is in the correct position.
5) Put the two stud bolts (94270D) in
5 position as shown.
6) Turn equally the nuts (4) to push the
injection valve (1) fully in.
Note: The injection valve is fully
installed when the distance
between the valve bush (5) and the
injection valve (1) is 4.0 mm.
WCH03113
Fig. 3

7) If the spring cage (5, Fig. 4) was

disassembled, make sure that the 24
1 cup springs (2) are installed as shown.
7
Flush 8) Apply Never-Seez NSBT8 to the
6 threads and the seating surface of the
screws (3).
5
9) Tighten equally the screws (3) until the
spring guide (6) is flush with the spring
2
cage (5).
10) Connect the cable (1) that you removed
before to the terminal box (95.41 to
95.47).
3 11) Install the HP fuel pipe, refer to 8733−1
paragraph 4.
WCH02401
Fig. 4

Injection Valve
Checks, Disassemble, Assemble

Tools:
1 Torque spanner 94012 1 Adaptor 94272B
1 Slugging wrench 94269A−46 1 HP hose 94275
1 Hydraulic cylinder 94269B 1 Tool 94289
1 Cable 94275A which includes:
1 Socket wrench insert 94269C−46 1 Bush 94289A
1 Valve holder 94273 1 Bush 94289B
1 OBEL test bench 94272
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Injection Valve − Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Nozzle Tip − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Nozzle Tip − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Pilot Valve − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7 Pilot Valve − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.8 Injection Valve − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. General
The test bench 94272 and calibration fluid must be used for the tasks that follow:
D To do checks
D To disassemble
D To assemble.
The properties of the calibration fluid (e.g. Shell Calibration Fluid S.9365, Univar
Calibration Fluid 1487) are as follows:
D The density at 15_C is 827 kg/m3 (ISO 12185)
D The kinematic viscosity at 40_C is 2.6 mm2/s (ASTM D445)
D The pour point is −27_C (ISO 3016).
If calibration fluid is not available, you can use clean diesel oil (gas oil). If clean diesel
oil (gas oil) is used, install the injection valve immediately after you complete the
checks.
Note: It is not recommended that diesel oil (gas oil) is used if the injection valve
is put into storage after these checks. The injection valve can get
corrosion.
On some injection valves the quantity of leakage flow can be more than others. If the
test bench flow is not sufficient to open the needle, you can use a clean additive-type
crankcase (system) oil of SAE 30 viscosity. For more data, refer to the Operation
Manual 0750, paragraph 2 System Oil).

Injection Valve: Disassemble, Checks, Assemble
94272
2. Preparation
WARNING
Danger. Do not use welding
1 or grinding equipment near
the work area. Fuel and
solvents are flammable.
94273
WARNING
Injury Hazard. Calibration
fluid is a harmful
substance. Always read the
manufacturer’s safety
WCH03003
instructions before you use
calibration fluid.
94275 94275A 1) Read and obey the data in the

instruction manual of the test bench
manufacturer.
I
2) Make sure that the work station is
1 clean.
3) Make sure that the support is removed
from valve holder (94273, Fig. 1) in the
2 receiver (2).
4) Use a brass wire brush to remove
combustion particles from the external
parts of the nozzle.
Remove the
Support 5) Put the injection valve (1) in position in
the valve holder (94273). Make sure
that the injection valve points down.
2
6) Attach the injection valve (1) to the
valve holder with the spring cages (3)
and Allen screws (4).
7) Attach the HP hose (94275) to the
connection piece (94272B).
I
8) Connect the HP hose (94275).
94272B
9) Connect the the cable (94275A) to the
injection valve (1).
4
10) Connect the electrical connection to the
test bench.
3
Fig. 1

3. Procedure
3.1 Checks
WARNING
Injury Hazard: Do not put your fingers near the holes in the nozzle
tip. Fuel can go through your skin and cause injury or kill you.
1) Start the test bench (94272).

2) At regular intervals, use a master pressure gauge to do checks of the pressure
gauges on the test bench. If necessary, adjust the pressure gauges.
3) Set the pressure of the test bench (94272) to 200 bar.
4) Push the INJECT button. Make sure that the injection valve (1) operates
correctly.
5) Do a check of the seating surface between the needle seat and nozzle as
follows:
a) Keep the pressure in the test bench (94272) constant at approximately 400 bar.
b) Monitor the injection valve for 30 seconds. No fuel must come out of the nozzle.
6) Do a check of the opening pressure as follows:
a) Set the pressure to 350 bar, then push the INJECT button. No fuel must come
out of the nozzle
b) Set the pressure to 450 bar, then push the INJECT button. Make sure that fuel
comes out of the nozzle as a spray.
3.2 Results
1) For the correct operation and to use an injection valve again, read the data
below:
D The pressure to operate the injection valve is between 200 bar and 300 bar, refer
to the test above.
D For used injection valves, a pressure decrease of 30 bar is permitted.
D Most of the fuel will come out as a spray from the top set of holes in the nozzle tip
at the specified pressure.
D At the end of an injection, no fuel must come out of the nozzle.
2) If the injection valve does not function satisfactorily, disassemble as given in
paragraph 3.3.
3) Release the pressure in the test bench (94272) and the HP hose (94275A).
You must replace nozzle tips when the holes have become worn. It is not
recommended but possible to replace the nozzle tip with the needle installed. If you
replace the nozzle tip with the needle installed, do the procedure carefully.
Only the injection valve manufacturer (or an authorized company) is permitted to
repair or replace nozzle holders, intermediate plates and nozzle bodies that have
unsatisfactory sealing surfaces.

3.3 Injection Valve −

Disassemble
94272
1) Make sure that the test bench (94272)
and HP hose (94275) have no
pressure.
2) Remove the receiver (2, Fig. 1) from
1 the valve holder (94273).
94275
3) Disconnect the HP hose (94275, Fig. 2)
94269A−46 and the cable (94275A).
94269B 4) Turn the valve holder (94273) through
180° .
2
5) Operate the hydraulic cylinder
94273 (94269B) and the slugging wrench
(94269A−46) to loosen the locknut (1).
6) Remove the locknut (1).
Note: The needle and nozzle body are
WCH03003 machined together so that their
Fig. 2 sealing surfaces have the same
contours. You must keep these
items together. If it is necessary to
replace the needle or the nozzle
body, you must replace the two
items. Do not replace only one
item.

SCREWDRIVER 3.4 Nozzle Tip − Removal

Note: If it is necessary to replace only
the nozzle tip, it is sufficient to
1 remove only the sleeve (5, Fig. 3).
1) Put the screwdrivers into the recess in
the nozzle body (2).
5
2) Use the screwdrivers to carefully
4 2 remove the snap ring (3).
3 3) Remove the sleeve (4).
4) Remove the nozzle tip (1) from the
nozzle body (2).
3.5 Nozzle Tip − Installation

013.493/05a
Note: Make sure that the new nozzle tip
is the correct type for the engine.
1) Clean the parts with clean diesel oil or
kerosine.
2) Use a low-pressure air supply to dry
NOZZLE TIP DATA the parts.
3) Put the new nozzle tip (1) in position on
the nozzle body (2). Make sure that the
dowel pin (5) engages with the hole in
the nozzle tip.
4) If necessary, put the nozzle tip (1) in a
vice.
5) Attach the snap ring (3) to the recess in
the nozzle body (2).
Note: After the nozzle tip is replaced, do
a check of the injection valve in
accordance with paragraph 2 and
paragraph 3.
WCH03497
Fig. 3

3.6 Pilot Valve − Removal

94289 Note: When you do the step below, it is
not necessary to torque the
coupling nut (2, Fig. 4).
1) Remove the nozzle tip, refer to
paragraph 3.4.
94289B
1 2) Attach the coupling nut (2) to the
nozzle body (1).
2
3) Attach the bush (94289B) to the
coupling nut (2).
3
4) Put the T-handle (94289) through the
bush (94289B).
WCH03003 5) Engage the T-handle (94289) with the
pilot valve (3).
Fig. 4
6) Turn the T-handle (94289) in the
direction shown.
7) Carefully remove the T-handle (94289)
and the pilot valve (3).
8) Remove the bush (94289B).
9) Examine all parts for damage and
corrosion. Replace parts that have
damage or corrosion.
3.7 Pilot Valve − Installation

94289 1) Put the bush (94289A, Fig. 5) into the
coupling nut (2).
2) Engage the pilot valve (3) with the
T-handle (94289).
3) Put the T-handle (94289) and pilot
valve (3) through the bush (94289A).
94289A 4) Turn the T-handle (94289) to install the
3
1 pilot valve (3).
2
5) Remove the T-handle (94289) and the
bush (94289A).
6) Remove the coupling nut (2).
7) Install the nozzle tip, refer to
paragraph 3.5.
WCH03003
Fig. 5

3.8 Injection Valve − Assemble

1
WARNING
Injury and Damage Hazard:
Do not use copper paste in
this procedure. Copper
paste can be a conductor
of electricity. Injury to
2 personnel and damage to
equipment can occur.
1) Make sure that the sealing faces of the

injection valve (2, Fig. 6):
D Are clean and dry
D Are in a satisfactory condition
D2 D1 D Have no lubricant.
2) Apply a thin layer of Never Seez
NSBT8 to the threads and seating face
of the locknut (1).
3) Attach the locknut (1) to the injection
valve (2) with your hand.
94269C−46 94012 4) Refer to the formulas shown where:
D TS = the applicable torque setting
for the torque spanner.
D TT = the specified torque setting for
the coupling nut.
1
D D1 = the distance from the center of
the square drive to the center of the
hand grip.
94269C-46 D D2 = the distance from the center of
the square drive to the center of the
adapter.
94012 5) Use the torque spanner (94012) and
the wrench extension (94269C−46) to
torque the locknut to 500 +30 Nm.
6) Do a check of the injection valve, refer
to paragraph 3.1 and paragraph 3.2.
TS = TT x D1
D2 + D1
TS for coupling nut:

500 x 800
= 459.7 Nm
70 + 800
Fig. 6

Intentionally blank
Pilot Injection Valve: Removal, Disassemble, Check,

Tools:
1 Torque spanner 94012 1 OBEL test bench 94272
1 Slugging wrench 94269A−55 1 Connecting piece 94272F
1 Socket wrench extension 94269C−55 1 Valve holder 94273
1 Hydraulic cylinder 94269B 1 HP hose 94275
1 Supporting plate 94270E 1 Cable 94275A
2 Stud bolts 94270F
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Coupling Nut − Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Pilot Injection Valve − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Coupling Nut − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. General
WARNING
Danger: Do not weld or grind materials in the area. The sparks

from welding equipment and grinding tools can cause a fire.
Usually, it is not necessary to do maintenance of the pilot injection valve. For the
intervals to do checks or to replace parts of the pilot injection valve, refer to 0380−1
Pilot injection valve.
You must use the test bench 94272 and calibration fluid for the tasks that follow:
D To do the checks
D To disassemble
D To assemble.
You must read the instructions of the test bench manufacturer before you use it.
At random intervals, do a check of the pressure gauges of the test bench with a
master pressure gauge. Adjust the the pressure as necessary.
Note: Only trained personnel are permitted to do the test procedure.
D The density at 15° C is 827 kg/m3 (ISO 12185)
D The kinematic viscosity at 40° C is 2.6 mm2/s (ASTM D445)
D The pour point is −27° C (ISO 3016).
checks.
corrosion.

Pilot Injection Valve: Removal, Disassembly, Check, Assemble, Installation
2. Preparation
1) Stop the engine, refer to the procedure
in the Operation Manual 4002−2.
2) Let the engine temperature decrease
before you start the removal procedure.
1 3) Set to off the pilot fuel pump.
4) Close the valves from the fuel supply
and pilot fuel supply.
I
5) Make sure that there is no pressure in
the cylinder.
8
WCH02881 6) Make sure that there is no pressure in
fuel rail and servo oil rail.
7) Make sure that the pipes that follow
have no pressure:
D HP pilot fuel pipe (1 or 8, Fig. 1) .
I D Lubricating oil outlet pipe (6)

D Lubricating oil inlet pipe (5)
D Lubricating oil and fuel leakage
10 pipe (4)
9 2 D Control fuel pipe (3).
8 8) Make sure that the fuel supply and the
lubricating oil supply are closed.
9) Make sure that the drain from the pilot
3
injection valve (2) to the sludge tank is
4 open.
5 10) Set to off the power supply to solenoid
valve.
7 6
3. Removal
1) Disconnect the electrical cable (7) to
1 or 8 solenoid valve.
2) Remove the HP pilot fuel pipe), refer to
Fig. 1 8790−1.
3) Remove the Allen screws (8) together
with the spring cages (9).
4) Remove the flange (10).
5)

I 6) Put the plate (94270E, Fig. 2) on the

pilot injection valve (2) as shown.
7) Put the two screws (1) in the plate
94270E
I (94270E). Turn the screws until the
1 they touch the valve holder (3).
1
8) Turn equally the two screws (1) to lift
the pilot injection valve (2)
37 mm
Note: The valve holder (3) stays in the
cylinder cover (4).
2 9) Remove the pilot injection valve (2)

from the valve holder (3).
10) If it is necessary to put the pilot
3
injection valve (2) into storage, do do
step a) and step b) below:
a) Put protection on the pilot injection
valve.
4 b) Put the pilot injection valve in a

clean, dry area that has no
contamination.
11) If it is not necessary to put the pilot
injection valve into storage, continue
from step 12).
12) Do a check of a pilot injection valve (2),
Fig. 2
4. Coupling Nut − Remove

1) Make sure that the test bench (94272,
94272 Fig. 3) has no pressure.
2) Attach the pilot injection valve to the
valve holder (94272F) as shown.
94275
3) Use the wrench (94269A-55) and the
hydraulic cylinder (94269B) to loosen
the coupling nut (1) of the pilot injection
valve.
1
5) Do a check of the injection valve, refer
94269B to the procedure given in paragraph 5.
94269A-55
WCH03003
Fig. 3

5. Pilot Injection Valve −

Check
94275
WARNING
AIR
SUPPLY Danger: Do not put your
fingers near the holes in the
94273 nozzle tip. Fuel can go
2 through your skin and
cause injury or kill you.
1
WARNING
fluid is a harmful
substance. Always read the
manufacturer’s safety
instructions before you use
WCH03003 calibration fluid.

clean.
3 2) Make sure that the receiver (1, Fig. 4)

is removed from the valve
holder (94273).
I 3) Use a brass wire brush to remove
combustion particles from the external
areas of the nozzle.
4) Put the pilot injection valve in position
2 in the valve holder (94273). Make sure
that the pilot injection valve points
down.
1
5) Attach the pilot injection valve (2) to the
valve holder (94273) with the spring
cages and their Allen screws.
connecting piece (94272F).
7) Connect the electrical plug with the test
bench.
8) Start the test bench in accordance with
the manufacturer’s instructions.
I
9) Set the pressure of the test bench to
94272F
500 bar.
10) At regular intervals, use a master
pressure gauge to do checks of the
pressure gauges on the test bench. If
necessary, adjust the pressure gauges.
Fig. 4

11) Push the INJECT button. The pilot injection valve must operate correctly.
12) Do a check of the seating surface between the needle seat and the nozzle as
follows:
a) Keep the pressure of the test bench constant at approximately 350 bar.
b) Monitor the injection valve for 30 seconds. No fuel must come out of the
nozzle.
out of the nozzle.
b) Set the pressure to 400 bar, then push the INJECT button. Fuel must come out
of the nozzle as a spray.
6. Results
1) For the correct function and to use an injection valve again, read the data below:
D The pressure to operate the pilot injection valve is between 300 bar and 400 bar,
refer to the check given in paragraph 5. The pressure to operate a new pilot
injection valve is approximately 350 bar.
D Most of the fuel will come out as a spray from the top set of the holes in the
nozzle tip at the specified opening pressure.

7. Coupling Nut − Install

pilot injection valve are:
1 D Are clean and dry
D Have no lubricant.
2) Apply a thin layer of Molykote paste G
2 to the thread and the seating surface of
the coupling nut (2, Fig. 5).
3) Attach the coupling nut (2) to the pilot
injection valve (1) with your hand.
WCH02881
4) Refer to the formula shown, where:
D2 D1 for the torque spanner.
D TT = the specified torque setting
for the coupling nut (2).
D D1 = the distance from the center
of the square drive to the center of
the hand grip.
94269C−55 94012 D D2 = the distance from the center
the adapter.
5) Use the torque wrench (94012) and the
wrench extension (94269C−55) to
torque the coupling nut (2)
1 to 800 )30 Nm.
6) Do a test of the pilot injection valve,
94269C−55
7) Remove the pilot injection valve from
the test bench.
94012
TS = TT x D1
D2 + D1

800 x 800
= 739.9 Nm
65 + 800
Fig. 5

94270F 8. Installation
1
CAUTION
2
Injury Hazard: Always put
48 mm on gloves and safety
goggles that have a closed
side frame when you do
work with white spirit.
3 White spirit can cause
5
damage to your skin and
4 eyes.
1) Clean the injection valve (2, Fig. 6) with

white spirit e.g. Shellsol TD, Shellsol T
or Solvent FP68.
2) Apply oil to the new O-rings (5).
Note: The O-rings are part of the spare
parts set for the pilot injector
valve.
3) Put the injection valve (3) into the valve
holder (4).
4) Put the stud bolts (94270F) into the
WCH03108 valve holder (4) as shown.
Fig. 6 5) Turn down equally the two nuts (1) until

you get a distance of 48 mm between
the flange (2) and the valve holder (4).
5
FLUSH
1 6) Remove the stud bolts (94270F).
2 7) If the spring cage (2, Fig. 7) was

disassembled, make sure that the cup
springs (3) are installed correctly as
3 shown.
4 8) Apply Never Seez NSBT to the threads
and surfaces that touch on the two
Allen screws (1).
9) Install the two Allen screws (1) together
with the spring cages (4).
10) Tighten equally the two Allen
screws (1) until the top of the spring
guide (2) is flush with the top of the
spring cage (4).
WCH00532 Qty six 11) Connect the electrical connection (5) to
the applicable terminal box.
Qty six
12) Install the applicable pilot fuel pipe,
Qty six refer to 8790−1.
Qty six
Fig. 7

Intentionally blank
Exhaust Valve
Removal and Installation of Exhaust Valve, Replacement

of Elastic Studs
Tools:
1 Stud tool 94008A−M12 1 Connection block 94934
2 Pre-tensioning jacks 94252 1 Hydr. distributor 94934A
1 Valve protector 94262 2 Coupling elements 94934G
1 Suspension device 94265 3 HP hoses 94935
2 Special eye nuts 94265A 1 Hydraulic unit 94942
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Round Nuts − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Exhaust Valve − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Elastic Studs − Examine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Exhaust Valve − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Round Nuts − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Elastic Studs − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Other Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Preparation
1) Drain the cylinder cooling water from
the applicable cylinder, refer to the
|Operation Manual 8017−1.
4 1
2) Close the air inlet to the air spring at
2
2 the control air supply.
3) Remove the applicable hydraulic pipe,
3 refer to 8460−1.
4) Disconnect the cooling water pipe.
5) Disconnect the oil drain pipe.
6) Disconnect the air supply pipe from the
air spring.
7) Remove the applicable holder (3,
Fig. 1).
I I 8) Disconnect the electrical connections
(2) from terminal box (4) and the valve
stroke sensor (1).
9) Use the applicable tools and equipment
to remove the expansion piece (5).
WCH03193
I-I
Fig. 1

Removal and Installation of Exhaust Valve, Replacement of Elastic Studs
2. Removal Procedure
2.1 Round Nuts − Removal

1) Clean the threads of the elastic studs (1, Fig 2) and the area around the round
nuts (2).
2) Put the two pre-tensioning jacks (94252) in position on the applicable elastic
studs (1).
3) Connect the pre-tensioning jacks to the hydraulic unit (94942) as shown.
4) Use the round bar (4) to turn the round nuts (2) back one turn. Make sure that
there is a clearance (3).
5) Do the procedure given in 9403−4, paragraph 1 and paragraph 2 to apply tension
to the elastic studs (1).
6) Remove the round nuts (2).
94252
94252
94934G
94934G
1
2
4 3
WCH03193
009.701/02
94935 94935
94934
94942 94934A 94935

013.622/05
Fig. 2

94265 2.2 Exhaust Valve − Removal

WARNING
of the suspension tool
(94265) is 33.4 kg. Use
applicable equipment and
personnel to move and
install the suspension
device.
94265A 1) Attach the two special eye nuts

(94265A, Fig. 3) to the exhaust
valve (1).
1
2) Attach the engine room crane to the
suspension tool (94265).
3) Attach the suspension tool (94265) to
the special eye nuts (94265A).
remove the exhaust valve (1) from the
Fig. 3 cylinder cover.
Note: Some parts can look different
5) Remove and discard the O-rings (1 and

4, Fig. 4).
1
6) Attach the valve protector (94262) to
the valve seat (3).
2
7) Tighten the three screws (2).
4
3 8) Move the exhaust valve to an
applicable area.
94262
9) If necessary, lower the exhaust valve
on to a wooden underlay.
WCH03194
Fig. 4
2.3 Elastic Studs − Examine

1) Examine the elastic studs for damage.
If it is necessary to replace the elastic
studs, do the procedure given in
paragraph 5 before you install the
exhaust valve.

1
3. Installation
2
3.1 Exhaust Valve − Install
1) Clean all the sealing faces on the
exhaust valve and in the cylinder cover
(1, Fig. 5).
2) Do a check for damage in the cylinder
cover (1) and on the exhaust valve.
WCH03194 3) Clean the gasket (2). Replace the
gasket if necessary.
Fig. 5
4) Put the gasket (2) in the cylinder
cover (1).
5) Attach the suspension tool (94265,
Fig. 3) to the eye nuts (94265A).
the exhaust valve.
1 7) Remove the valve protector (94262).

8) Put a small quantity of oil on the new
2
O-rings (1 and 2, Fig 6).
9) Attach the new O-rings (1, 2).
WCH03194
Fig. 6
1 Note: When you do step 10), make sure

that you do not damage the
2 threads of the elastic studs.
10) Carefully lower the exhaust valve into
the cylinder cover (3, Fig. 8). Make
3 sure that the dowel pin (2) in the
cylinder cover engages with the hole in
the valve cage (1).
11) Remove the suspension tool (94265)
and the special eye nuts (94265A).
WCH03194
Fig. 7

3.2 Round Nuts − Install

1) Clean all the sealing faces on the
exhaust valve and in the cylinder cover.
2) Apply a small quantity of oil to the
threads of the elastic studs (3, Fig. 8).
1 3) Attach the round nuts (2) to the elastic
3
2 studs (3). Tighten the round nuts with
the round bar (1).
4) Use a feeler gauge to do a check for
correct seating of the round nuts (2).
5) Use a felt-tip pen to make a mark on
the round nuts (2) and related marks on
WCH03193
the valve cage. This shows their initial
Fig. 8
position.
6) Put the two pre-tensioning jacks (94252, Fig. 9) in position on the elastic
studs (1).
7) Connect the pre-tensioning jacks to the hydraulic unit (94942) as shown.
8) Do the procedure given in 9403−4, to apply tension to the elastic studs (1) and
tighten the round nuts (2).
9) Look at the marks made before to make sure that the round nuts (2) have turned
to the angle given in 0352−1.
94252
94252
94934G
94934G
1
2
WCH03193
009.701/02
94935 94935
94934
94942 94934A 94935
Fig. 9 013.622/05

4. Completion
I I
1) Clean the sealing faces on the
expansion piece (1, Fig. 10) and the
related sealing faces on the valve cage
and exhaust manifold.
2) Apply a thin layer of a heat-resistant
lubricant to the sealing faces and
related screws.
WCH03087
3) Use the applicable tools and equipment
to put the expansion piece (1) in
position. Make sure that the direction of
I-I flow is correct, i.e. the protection
pipe (2) is in the correct position
1 (nearest to the valve cage).
4) Install all pipes that you removed in
2 paragraph 1.
5) Install the hydraulic pipe, refer to
8460−1.
Direction of Flow
WCH03087 6) Connect the electrical connections (2,
Fig. 10
Fig. 11) to the terminal box (4) and the
7) Attach the electrical cable of the valve
stroke sensor (1) to the valve cage and
the holder (3).
8) Open the air inlet to the air spring at the
control air supply.
9) Fill the cylinder cooling water to the
applicable cylinder.
4 1
2
2
WCH03193
WCH03087
Fig. 11

5. Elastic Studs − Replace

1) Use the stud tool (94008A−M12,
Fig. 12) to remove the elastic stud (1).
2) Remove all grease and clean the
94008A−M12
sealing face of the new elastic stud.
3) Read the data in the documentation of
the jointing compound manufacturer. If
necessary, apply adhesive primer to
make the adhesion on the joint surface
WCH00836 better.
4) For the recommended jointing
JOINTING compounds and adhesive primers, see
COMPOUND the Table 1.
Note: Do not apply adhesive primer or
lubricant to the thread of the
SEALING elastic stud (1).
SURFACE
5) Put the elastic stud (1) into the
applicable position.
1 6) Tighten the elastic stud (1), refer to the
instructions given in 0352−2,
paragraph 2.
003.465/00
Fig. 12
Note: Read the data in the documentation of the manufacturer to mix and apply
the jointing compounds.
Table 1: Jointing Compounds and Hardeners
Jointing Hardener Adhesive Manufacturer

Compound Primer
Elastosil RT 622 B G 790 Wacker-Chemie Gmbh
RT 622 A Geschäftsbereich Silicone
Hanns-Seidel-Platz 4
D-81737 München
Silcoset Silcoset Silcoset Primer AMBERSIL LTD
105 RTV Curing Agent A Wylds Rd
Bridgwater
Somerset
TA6 4DD
England

6. Other Materials
Products of other manufacturers that have the specifications given below, are also
permitted. Materials that:
D Contain no acid, e.g. no acetic acid
D Are resistant to oil, marine diesel oil, heavy fuel oil and water at a permanent
temperature of approximately 100_C.
D Have a short age-curing time, i.e. a minimum of 24 hours in accordance with ISO
standard reference conditions
D Flow easily to fill annular spaces and prevent voids
D Have good adhesion on adhesive-primed metallic surface
D Are easy to prepare and mix
D Have none or minimum surface shrinkage
D The jointing compound must stay in an elastic condition.

Exhaust Valve
Disassemble and Assemble

Tools:
1 Depth gauge 94126
1 Torque wrench
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Valve Drive − Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Valve Spindle − Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Guide Bush − Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Guide Bush − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Valve Spindle − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Valve Drive − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Valve Stroke Sensor − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Damper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Non-return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Exhaust Valve − Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. General
The International Association of Classification Societies recommends a minimum of
two exhaust valves in storage on board. These on-board exhaust valves must be
used to replace unserviceable items.
Only approved personnel, or a Wärtsilä Services Switzerland Ltd or Winterthur Gas &
Diesel Ltd. authorized repair workshop can repair or recondition defective exhaust
valves.
For the inspection and overhaul intervals, refer to the Maintenance Schedule 0380−1
Exhaust valve.
Read the data in 0012−1 General Guidelines for Lifting Tools

Exhaust Valve: Disassemble and Assemble
Fig. 2, Fig. 4, Fig. 8,

Fig. 9, Fig. 10
I Fig. 3, Fig. 9
II Fig. 5, Fig. 11
Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 11
Fig. 1

2. Disassemble
WARNING
Danger: Do not weld or
grind materials in the area.
The sparks from welding
2 equipment and grinding
tools can cause a fire.
1) Make sure that the work area is clean

and has no dust.
2.1 Valve Drive − Disassemble

1) Make sure that the exhaust valve is in a
vertical position on wooden underlay.
2) Remove the six nuts (2, Fig. 2).
3) Attach the applicable equipment to the
Fig. 2 eye bolt (1).
4) Remove the valve drive.
5) Remove the two screws (3, Fig. 3).
1 6) Remove the transmitter housing (2).

2 7) Remove the valve stroke sensor (1).
3
Fig. 3
8) Remove the two screws (2, Fig. 4).

9) Remove the housing (1).
1
2
Turned through 90°

Fig. 4

2.2 Valve Spindle − Remove

1) Remove the circlip (1, Fig. 5).
1
2) Push the piston (6) down.
2 3) Remove the two parts of the valve
6 cotter (2).
5 4) Remove the piston (6) from the valve
3 spindle (5).
5) Remove the cup springs (3).
When you do step 6) below, make sure
4 that the valve spindle (5) does not move.
applicable lifting equipment to lift the
valve cage (4) away from the valve
spindle (5).
7) Lower the valve cage (4) on to its side.
Fig. 5
WCH02863
2.3 Guide Bush − Remove

1) Remove the four screws (2, Fig. 6).
2) Remove the spacer (1).
7 1 2
3) Remove and discard the rod seal
3 4 ring (7).
4) Use two jack-screws or M10 threaded
rods to remove the guide bush (5).
I I 5) Measure the inner diameter of the
guide bush.
6) Compare the value with that given in
0330−1, Clearance Table Exhaust
Valve.
3. Assemble
5 3.1 Guide Bush − Install
1) Clean the bores (6) in the valve
I-I cage (4).
2) Clean the valve bush (5).
3) Replace the O-ring (3).
WCH02863
4) Put oil on the guide bush (5).
5) Put the guide bush (5) in the valve
6 cage (4).
6) Use two jack-screws or M10 threaded
Fig. 6 rods to push the guide bush (5) into the
5 valve cage (4).

3.2 Valve Spindle − Install

10 1) If the valve seat or spindle are new
1 items, you must examine them. Refer
2 to the instructions given in 2751−3,
9 paragraph 5.
8 3
6 2) Measure the dimensions of the valve
7
spindle (7, Fig. 7).
4
5 3) Compare the values with those given in
0330−1, Clearance Table Exhaust
Valve.
4) Examine the piston seal ring (9). If
there is damage, replace the piston
seal ring.
5) If necessary, replace all O-rings .
6) Put oil on the valve spindle (7).
7) Use the applicable lifting equipment to
lift the valve cage (4).
Note: When you do step 8) below, make
sure that you do not damage the
guide bush.
8) Hold the valve spindle (7) in position,
then carefully lower the valve cage (4)
over the valve spindle.
Fig. 7
WCH02863 9) Put oil on the new rod seal ring (7,
Fig. 6).
10) Put the new rod seal ring (7) in position
in the valve bush (5).
11) Before you install a new piston seal ring (9, Fig. 7), do as follows:
a) Put the piston seal ring into very hot water for some minutes.
b) Carefully put the piston seal ring in the correct position on the piston (10).
12) Attach the spacer (5) to the valve cage (4) with the four screws (6).
13) Install the piston (10), the two parts of the valve cotter (2) and the circlip (1).

3.3 Valve Drive − Assemble

1) Attach the lifting equipment to the
6 housing (2, Fig. 8).
2) Lift, then lower the housing (2) on to
1
the valve cage (4).
3) Attach the housing (2) to the valve
cage (4) with the two Allen screws (3).
2
4) Put the top housing (6) in position on
5 3 the housing (2). Make sure that the
spring dowel pin (5) engages with the
4 hole in the valve cage (4).
5) Put oil on the six nuts (1).
Turned Turned 6) Put the six nuts (1) on the elastic bolts.
WCH02863
through 18° through 30° 7) Torque symmetrically the six nuts (1) to
125 Nm.
3.4 Valve Stroke Sensor −

7 Install
8
1) Clean the items that follow:
9 D Valve stroke sensor (10)
10
D Transmitter housing (11)
5
11 D The bore and collar in the
12 housing (9).
2) Put the valve stroke sensor (10) and
the transmitter housing (11) into the
bore.
3) Attach the transmitter housing (11) with
WCH02863 the two screws (12).
Fig. 8

3.5 Damper Setting

You set the damper (1, Fig. 9) only if you
1 replace a valve spindle or valve seat, or
after one of the seating faces was ground.
1) Remove the damper (1).
2) Make sure that the bores in the damper
are clear.
3) Make sure that the exhaust valve is in
the closed position.
4) Use a feeler gauge to make sure that
there is no clearance between the
valve plate and the valve seat.
5) Use the depth gauge (94126, Fig. 9) to
measure the height H from the edge of
the top housing (2) to the bottom of the
damper bore.
6) Make sure that the distance H is
94126
101 ±0.5 mm.
Note: For example, if the measured
3 distance H is 100 mm, you must install one
shim. Each shim has a thickness of
2 T
1.0 mm.
7) Install the correct quantity of shims to
H ± 0.5 mm get the correct distance H.
8) Install the damper (1).
9) Apply Loctite 271 to the threads of the
eye nut.
10) Install the eye nut.
016.599/08
Fig. 9

3.6 Throttle
1) Do a check of the throttle as follows:
a) Remove the screw plug (2,
1 Fig. 10) from the top housing (3).
2
b) Remove the throttle (1).
c) Make sure that the throttle (1) is
3 clear.
d) Put oil on the thread of the
throttle (1).
e) Put the throttle (1) and the screw
WCH02863
plug (2) in the bore of the top
Fig. 10 housing (3).
f) Tighten the screw plug (2).
1 3.7 Non-return Valve

1) Do a check of the non-return valve (1,
2 Fig. 11) as follows:
2) Remove the non-return valve (1) from
the top housing (2).
3) Make sure that the non-return valve (1)
operates correctly.
AIR INLET 4) Install the non-return valve correctly in
to the top housing (2).
WCH02863
Fig. 11
4. Exhaust Valve − Lock

If it becomes necessary to lock the exhaust valve, refer to the procedure given in the
Operation Manual 0520−1, paragraph 3.1.

Exhaust Valve
Valve Seat − Replace / Grind

Tools:
1 Valve seat dismantling device 94261
1 Template 94279
1 Tool, grinding 94291
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Valve Seat − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.1 Recommended Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 Alternative Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Valve Seat − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Valve Seat − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Valve Seat − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
You must replace the valve seat when:
D The seating surface has too much damage, or
D Frequent grinding has worn the valve seat to more than the specified limit.
2. Preparation
1) Disassemble the valve and remove the valve spindle, refer to 2751−2.
3. Valve Seat − Removal

If a valve seat is removed e.g. to replace an unserviceable O-ring, you must:
D Grind the valve seat before installation (paragraph 4), or
D Mark the position of the valve seat in the valve cage before you start the removal
procedure.
2016
5
Winterthur Gas & Diesel Ltd. 1/ 5

1
3.1 Recommended Procedure
2 1) Turn the valve cage (2, Fig. 1) until the
valve seat (1) points up.
2) Carefully put the valve cage on to an
applicable wooden underlay (3).
3) Install the top two halves of the tool
(94261) into the groove of the valve
seat (1).
4) Install the bottom two halves of the tool
cage (2).
WCH02863
3
5) Turn equally the three jack screws (4)
4 to push out the valve seat (1) from the
valve cage (2).
5
1 6) Remove and discard the O-ring (5).
7) Remove the tool (94261).
94261
3.2 Alternative Procedure
2 If it is necessary to remove the valve seat
when the valve cage must stay in the usual
position (i.e. the top of the valve cage points
Fig. 1
up), do the procedure that follows:
1) Use the crane and an applicable lifting
tool to hold the valve cage (2, Fig. 2)
immediately above an applicable
wooden underlay (3).
2) Use applicable wooden chocks to keep
the valve cage (2) in position and
prevent movement.
2 cage (2).
1 (94261) into the groove of the valve
seat (1).
WARNING
WCH02863
3 Injury Hazard: The valve
seat weighs 45 kg. Be
5 2 careful when you do the
step below.
5) Carefully turn the three jack screws (6)

equally until the valve seat (1) falls out
94261 of the valve cage (2).
1 6) Lift and move the valve cage 2 away
from the valve seat (1).
4
7) Remove and discard the O-ring (5).
Fig. 2 8) Remove the tool (94261).

4. Valve Seat − Grind

I Use only the tool (94291, Fig. 3) to grind the
valve seats.
1
1) Read the data in the manufacturer’s
documentation for the tool (94291).
2) Put the valve seat (1) in the correct
position on the tool (94291).
94291
Between 30.0°and 30.2°
WCH03195
Fig. 3
3) Put the gauge (94279) on the valve

seat (1, Fig. 4).
Maximum 3.0 mm
The data on the gauge (94279) shows the
maximum permitted limits for the valve
seat (1).
4) Use the feeler gauge (94122) to
measure the values. If the measured
values are more than the limits shown,
you must replace the valve seat (1).
1 94279
5) If the measured values are less than
the values given, do the procedure that
follows:
a) Use the tool (94991) to grind the
sealing face of the valve seat (1).
WCH03195
Make sure that you get a smooth,
flat surface.
Maximum 7.0 mm
b) Keep the valve seat angle to
Fig. 4 between 30.0° and 30.2°.

5. Valve Seat − Check

1
You do this procedure to make sure that the
sealing face of the valve spindle correctly
touches the sealing face of the valve seat.
4
1) Put a thin layer of engineer’s blue paste
2 on the sealing face of the valve spindle
(4, Fig. 5).
3 2) Put the valve spindle (4) in position in
the valve guide bush.
3) Put the wooden block (2) on the valve
003.457/00
spindle (4).
Note: During step 4) below, do not turn
the valve spindle (4) because this
can cause the sealing faces to
seize.
4) Tap the wooden block (2) with the
4 hammer (1) three of four times.
S = 0.029 mm to 0.048 mm 5) Use the feeler gauge (94122) to do a
check of the clearance between the
sealing faces of the valve spindle (4)
and valve seat (3).
Note: The clearance must be as shown
3 (S= 0.029 mm to 0.048 mm).
6) Remove the valve spindle (4) from the
I guide bush.
7) Do a check of the engineer’s blue
003.455/00 paste. The blue paste must only show
on the inner part of the full
circumference of the valve spindle (see
View I).
I
Engineer’s blue
paste mark
Fig. 5

6. Valve Seat − Installation

1) Clean the bores and the sealing faces
1 of the valve cage (3, Fig. 6) and the
4 valve seat (2).
2
2) Apply oil (or lubricants e.g. Never-Seez
I NBST-8, or Loctite anti-seize
compound) to the bores and sealing
94261 faces of the valve seat (2) and the
valve cage (3).
3 3) Put the same lubricant on the new
O-ring (4).
4) If the valve seat was removed to
replace the O-ring, do the step below:
I
a) Align the marks on the valve seat
(2) with the marks on the valve
2 cage (3).
5) Push the valve seat (2) into the bore of
the valve cage (3).
94122
seat (2).
seat (2).
3 8) Turn equally the three jack screws (1)
to fully push the valve seat (2) into the
valve cage (3).
Sealing Faces 9) Use the feeler gauge (94122) to make
Fig. 6 sure that there is no clearance between
the sealing faces.

Intentionally blank
Exhaust Valve
Grinding the Seating Surface on the Valve Head

Tools:
1 Tool, valve grinding device 94291
1 Template 94292
1
1. General
a = between a Use only the tool (94291, Fig. 1) to grind the
30°8' and 30°10'
valve head.
You must grind valve heads that have
damage or corrosion on the seating surface.
If the rotation wing is missing from the valve
spindle, do not grind the valve head.
2. Valve Head − Grind

1) Read the data in the manufacturer’s
94291 manual for the tool (94291).
2) Put the tool (94291) in an area where
there is no vibration.
Note: If necessary, put the tool on a
rubber mat. This will help to
WCH03196 prevent rough surfaces during the
grinding procedure.
Fig. 1 3) Put the valve spindle in position in the
tool (94291).
4) Put the template (94292, Fig. 2) on the
valve head (1).
Note: The data shown on the gauge
Max 3.0 mm (94292) shows the maximum limits
for the valve head.
measure the values.
6) If the values are less than the limits
1 given, do the procedure that follows:
a) Use the tool (94291) to grind the
surface of the valve head (1).
Remove only the minimum
material necessary to get a
WCH03196 smooth, flat surface.
b) Use an applicable coolant to keep
94292 the valve head (1) cool.
c) Keep the angle of the valve head
(1) to between 30°8' and 30°10'.
Note: You can grind off a maximum of
3.0 mm from the seating surface.
7) Do a check of the valve seat and valve
Max. 6.0 mm
spindle, refer to 2721−3, paragraph 5.
Fig. 2

Exhaust Valve: Grinding the Seating Surface on the Valve Head
8) If the measured values are more than the limits given on the gauge (94292), you
can repair the valve spindle (refer to the data below).
9) If more than 3.0 mm is ground off, do the procedure that follows:
a) Use a build-up welding procedure to repair the valve seating surface.
b) Grind the seating surface of the valve spindle again (see paragraph 2).
3. Corrosion
Corrosion can occur at the bottom of the valve plate when engines operate for long
periods (e.g. in rough weather conditions).
If the corrosion is less than or equal to 6.0 mm (see Fig. 2), the valve spindle can be
repaired.
Note: The repair procedure can only be done in a Wärtsilä Services Switzerland
Ltd or Winterthur Gas & Diesel Ltd. authorized repair workshop.
Valve spindles cannot be repaired when the corrosion is more 9.0 mm, but can
continue to operate until the corrosion has a depth of 13.0 mm.

Starting Air Valve
Removal, Disassemble, Grind, Assemble, Installation

Tools:
1 Assembly tool 94281
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. General
You must remove and disassemble the starting air valve for maintenance if:
D The starting air valve does not operate correctly during the engine start
procedure
D The starting air pipe becomes hotter than on adjacent cylinders during operation.
Read the data in 0380−1 Starting air valve, for the applicable intervals to do checks
on the starting air valve.
2. Preparation
1) Stop the engine.
2) Release the pressure in the starting air system as follows:
a) Close the shut-off valves on the starting air bottles.
b) Turn the handwheel 2.10 of the starting air shut-off valve 2.03 to the position
CLOSED (refer to the Operation Manual, 4003−2 Control Diagram).
c) Open the ball valves 2.06 and 2.21 to release the pressure.

Starting Air Valve: Removal, Disassemble, Grinding, Assemble, Installation
I 3. Removal
1 1) Remove the control air pipe (5, Fig. 1)
from the starting air valve.
2) Disconnect the electrical connection
from the 3/2-way solenoid valve (1).
3) Remove the four screws (6).
5
4) Carefully remove the starting air valve
from the cylinder cover (4).
5) Remove and discard the gasket (3).
6) Put applicable protection over the
4 opening in the cylinder cover (4).
WCH03192
5 6
Fig. 1

4. Disassemble
3 1) Put the starting air valve in a vice.
1 Make sure that the vice jaws do not
damage the starting air valve.
2 2) Remove the two screws (2, Fig. 2).
3) Remove the cover (1) together with the
3/2-way solenoid valve (3).
Fig. 2 WCH0192
Loosened 4) Attach the tool (94281, Fig. 3) to the

Fully Tightened starting air valve.
Position
Position 1
1 5) Tighten equally the two nuts (1).
2 6) Remove the self-locking nut (2).
94281 7) Carefully loosen the two nuts (1) until

there is no spring pressure.
Fig. 3
8 1 9) Remove the piston (7, Fig. 4) from the

valve spindle (5).
2
7 10) Remove the compression spring (6)
from the housing (2).
3
6 11) Remove the valve spindle (5) from the
4 housing (2).
12) Remove and discard the piston rings
(1, 4).
13) Remove and discard the O-rings (3, 8).
5
WCH03192
Fig. 4

5. Grind
1) If the seating faces of the housing (1,
Fig. 5) and the valve spindle (2) have
minimum damage, do as follows:
a) Manually grind the seat faces of
2
the housing (1) and the valve
spindle (2).
I
b) Make sure that you keep the
radius to the values given.
1 WCH03192
2) If the seating faces of the housing (1)
I and the valve spindle (2) have more
than minimum damage, do as follows:
a) Use a machine tool to grind the
WCH03192
seating face of the housing (1)
and valve spindle (2).
91°
b) Manually grind the seating faces
90° of the housing (1) and the valve
WCH03192 spindle (2) to get a good finish.
c) Make sure that you keep the
Fig. 5 radius to the values given.
6. Assemble
8 1
1) Clean all the parts of the starting air
2 valve.
7
2) Put a small quantity of oil on all the
parts.
3
6 3) Put a small quantity of oil on the new
4 O-rings (3 and 8, Fig. 6) and the piston
rings (1, 4).
4) Put the two new O-rings (3, 8) in the
housing (2).
5) Put the new piston rings (1, 4) on the
piston (7).
5 6) Put the valve spindle (5) into the

housing (2).
WCH03192
Fig. 6
7) Put the compression spring (6) into the
housing (2).
8) Put the piston (7) in position on the
valve spindle (5).

Initial Position
1 9) Put the tool (94281, Fig. 7) in position
on the housing.
10) Tighten equally the two nuts (1) until
you get to the second position.
Note: Do not get Molykote paste G on
94281 the thread of the valve spindle (3)
where the insert of the self-locking
Second Position nut (2) will go.
2 11) Apply a thin layer of Molykote paste G
to the thread of the valve spindle (3).
12) Attach the self-locking nut (2) to the
valve spindle (3). Do not torque the
self-locking nut at this step.
WCH03192
13) Fully tighten equally the two nuts (1) of
3 the assembly tool (94412A).
Fully Tightened Position 14) Torque the self-locking nut to 140 Nm.
1
2
16) Tap the top of the valve spindle (7) with
a hammer. The valve spindle must
spring back to its initial position.
Fig. 7
17) Attach the cover (1, Fig. 8) together

4 with the solenoid valve (4) to the
housing (3) with the two screws (2).
1
18) Torque the the M12x35 two screws (2)
2 to the value given in 0352−2.
Fig. 8 WCH03192

7. Installation
I 1) Remove the protection from the
6 cylinder cover (4, Fig. 9).
2) Put a new gasket (3) in the bore of the
cylinder cover (4).
3) Apply a thin layer of oil to the bore of
1 the cylinder cover (4).
2
5 4) Attach the control air pipe (5) to the
bore in the cover (1).
5) Carefully put the starting air valve in the
4 cylinder cover (4). Make sure that the
control air pipe (5) goes into the bore of
I
the cylinder cover correctly.
5
2 6) Apply Never-Seez NSBT-8 to the
threads of the four screws (2).
1
7) Put the four screws (2) in position in the
cover (1).
8) Symmetrically torque the four screws
(2) to 80 Nm.
9) Symmetrically tighten the screws (2) to
3 an angle of 90° .
WCH03192
10) Tighten the connections of the control
air pipe (5).
Fig. 9
3/2-way solenoid valve (6).

Pilot Injection Valve: Removal, Disassemble, Check,

Tools:
1 Torque spanner 94012 1 OBEL test bench 94272
1 Slugging wrench 94269A−55 1 Connecting piece 94272F
1 Socket wrench extension 94269C−55 1 Valve holder 94273
1 Hydraulic cylinder 94269B 1 HP hose 94275
1 Supporting plate 94270E 1 Cable 94275A
2 Stud bolts 94270F 1 Assembly tool 94289E
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Coupling Nut − Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Pilot Injection Valve − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8. Coupling Nut − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
9. Injection Valve Seal − Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. General
WARNING

Usually, it is not necessary to do maintenance of the pilot injection valve. For the
intervals to do checks or to replace parts of the pilot injection valve, refer to 0380−1
Pilot injection valve.
You must use the test bench 94272 and calibration fluid for the tasks that follow:
D To do the checks
D To disassemble
D To assemble.
You must read the instructions of the test bench manufacturer before you use it.
At random intervals, do a check of the pressure gauges of the test bench with a
master pressure gauge. Adjust the the pressure as necessary.
Note: Only trained personnel are permitted to do the test procedure.
D The density at 15° C is 827 kg/m3 (ISO 12185)
D The kinematic viscosity at 40° C is 2.6 mm2/s (ASTM D445)
D The pour point is −27° C (ISO 3016).
checks.
corrosion.

2. Preparation
1 3) Set to off the pilot fuel pump.
4) Close the valves from the fuel supply
and pilot fuel supply.
I
5) Make sure that there is no pressure in
the cylinder.
8
WCH02881 6) Make sure that there is no pressure in
fuel rail and servo oil rail.
7) Make sure that the pipes that follow
have no pressure:
D HP pilot fuel pipe (1 or 8, Fig. 1) .
I D Lubricating / cooling oil outlet

pipe (6)
D Lubricating / cooling oil inlet
10 pipe (5)
2 D Lubricating oil and fuel leakage

9
pipe (4)
8
D Control fuel pipe (3).
8) Make sure that the fuel supply and the
3 lubricating oil supply are closed.
4 9) Make sure that the drain from the pilot
injection valve (2) to the sludge tank is
5 open.
10) Set to off the power supply to the
7 6
solenoid valve.
3. Removal
1 or 8
1) Remove the applicable HP pilot fuel
pipe (1 or 8), refer to 8790−1.
Fig. 1
2) If the valve holder must be removed,
remove the pipes (3, 4, 5 and 6).
3) Disconnect the electrical cable (7) from
the solenoid valve.
4) Remove the two Allen screws (8)
together with the distance pieces (9).

I 6) Put the plate (94270E, Fig. 2) on the

pilot injection valve (2) as shown.
7) Put the two screws (1) in the plate
94270E
I (94270E).
1
1 8) Turn equally the screws until the they
touch the valve holder (3).
9) Turn equally the two screws (1) to lift
37 mm the pilot injection valve (2)
Note: The valve holder (3) stays in the
2 cylinder cover (4).
10) Remove the pilot injection valve (2)
from the valve holder (3).
3
11) If it is necessary to put the pilot
injection valve (2) into storage, do do
a) Put protection on the pilot injection
4 valve.
b) Put the pilot injection valve in a
clean, dry area that has no
contamination.
12) If it is not necessary to put the pilot
injection valve into storage, continue
from step 12).
Fig. 2 13) Do a check of a pilot injection valve (2),
4. Coupling Nut − Remove

94272
1) Make sure that the test bench (94272,
Fig. 3) has no pressure.
94275 2) Attach the pilot injection valve to the
valve holder (94272F) as shown.
3) Use the wrench (94269A-55) and the
hydraulic cylinder (94269B) to loosen
the coupling nut (1) of the pilot injection
1
valve.
94269B 5) Do a check of the injection valve, refer
to the procedure given in paragraph 5.
94269A-55
WCH03003
Fig. 3

5. Pilot Injection Valve −

Check
94275
WARNING
AIR
SUPPLY Danger: Do not put your
fingers near the nozzle tip.
94273 Fuel can go through your
2 skin and cause injury or kill
you.
1
WARNING
fluid is dangerous. Always
read the manufacturer’s
safety instructions before
you use calibration fluid.
WCH03003

clean.
2) Make sure that the receiver (1, Fig. 4)
3 is removed from the valve
holder (94273).
3) Use a brass wire brush to remove
I combustion particles from the external
areas of the nozzle.
4) Attach the pilot injection valve (2) to the
valve holder (94273) with the spring
2
cages and their Allen screws. Make
sure that the pilot injection valve points
1 down.
connecting piece (94272F).
test bench.
7) Start the test bench in accordance with
the manufacturer’s instructions.
8) Set the pressure of the test bench to
500 bar.
I 9) At regular intervals, use a master
94272F pressure gauge to do checks of the
pressure gauges on the test bench. If
necessary, adjust the pressure gauges.
Fig. 4

10) Push the INJECT button. The pilot injection valve must operate correctly.
11) Do a check of the seating surface between the needle seat and the nozzle as
follows:
a) Keep the pressure of the test bench constant at approximately 350 bar.
b) Monitor the pilot injection valve for 30 seconds. No fuel must come out of the
nozzle.
out of the nozzle.
b) Set the pressure to 400 bar, then push the INJECT button. Fuel must come out
of the nozzle as a spray.
6. Results
1) For the correct function and to use a pilot injection valve again, read the data
below:
D The pressure to operate the pilot injection valve is between 300 bar and 400 bar,
refer to the check given in paragraph 5. The pressure to operate a new pilot
injection valve is approximately 350 bar.
D Most of the fuel will come out as a spray from the holes in the nozzle tip at the
specified opening pressure.
I I 7. Holder
1 1) Remove the six Allen screws (1, Fig. 5)
1
from the holder (2).
2) Remove the holder (2), together with
the prechamber (4).
2 3) Make sure that the seals (5, 6) are
serviceable. If the seals are
2 unserviceable, do step a) to step e)
a) Remove the bottom part of the
3 prechamber (7) from the top part.
b) Remove the seals (5, 6).
c) Attach a new seal (5) to the
4 prechamber (4).
d) Attach the bottom part of the
prechamber (7) to the the top part.
5
6 e) Use the assembly tool (94289E)
7 to attach the new seal (6) to the
3.5 mm
prechamber (4).
4
6 4) Apply NeverSeez NSBT 8 to the
threads and surfaces that touch of the
94289E six Allen screws (1).
94289E
5) Attach the holder (2) to the cylinder
cover with the six Allen screws (1).
6) Torque the six Allen screws (1) to
Fig. 5 80 Nm.

8. Coupling Nut − Install

pilot injection valve:
1 D Are clean and dry
D Have no lubricant.
2) Apply a thin layer of Molykote paste G
2 to the thread and the seating surface of
the coupling nut (2, Fig. 5).
3) Attach the coupling nut (2) to the pilot
injection valve (1) with your hand.
WCH02881
4) Refer to the formula shown, where:
D2 D1 for the torque spanner.
D TT = the specified torque setting
for the coupling nut (2).
D D1 = the distance from the center
the hand grip.
94269C−55 94012 D D2 = the distance from the center
the adapter.
5) Use the torque wrench (94012) and the
wrench extension (94269C−55) to
torque the coupling nut (2)
1 to 800 )30 Nm.
6) Do a test of the pilot injection valve,
94269C−55
7) Remove the pilot injection valve from
the test bench.
94012
TS = TT x D1
D2 + D1

800 x 800
= 739.9 Nm
65 + 800
Fig. 5

9. Pilot Injection Valve

Seal − Install
94289E 1 1) Put a new seal (2, Fig. 6) on the
injection valve (1).
2) Use the tool (94289E) to install the
seal (2) on to the injection valve (1).
3) Remove the tool (94289E).
4.25 mm
10. Installation
CAUTION
2 Injury Hazard: Always put
94289E on gloves and safety
goggles that have a closed
side frame when you do
work with white spirit.
White spirit can cause
damage to your skin and
eyes.
1) Clean the pilot injection valve (1) with
white spirit e.g. Shellsol TD, Shellsol T
A B or Solvent FP68.
5 2) Apply oil to the new O-rings (9).
3 Note: The O-rings are part of the spare
parts set for the pilot injection
94270F valve.
4
6 3) Put the pilot injection valve (1) into the
7 valve holder (8).
47 mm 4) Put the stud bolts (94270F) into the

valve holder (8) as shown.
5) Turn down equally the two nuts (6) until
you get a distance of 47 mm between
1 the flange (7) and the valve holder (8).
9
8 6) Remove the stud bolts (94270F).
7) Apply Never Seez NSBT to the threads
and surfaces that touch on the two
Allen screws (3).
8) Attach the two distance pieces (4) to
the pilot injection valve with the two
Allen screws (3).
9) Toque equally the two Allen screws (3)
to 10 Nm.
10) Torque equally the two Allen screws (3)
to 45 Nm.
11) Connect the electrical connection (5) to
the applicable terminal box.
12) Install the applicable pilot fuel pipe,
refer to 8790−1.
WCH03108
WCH03108
13) Install the pipes removed before (see
Fig. 6 Fig. 1).

Intentionally blank
Crankshaft, Connecting Rod and Piston Group 3
Crankshaft: Crank Deflection − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103−1/A1
Vibration Damper
Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−1/A1
Axial Damper: Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3140−1/A1

Turning Gear: Teeth and Screwed Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3206−1/A1
Crankcase: Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−1/A1
Top Platform: Configuration of Lifting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−2/A2
Connecting Rod
Bottom End Bearing − Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−2/A2
Top End Bearing − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−3/A2
Top End Bearing − Bearing Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−5/A2
Crosshead
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−1/A1
Crosshead Pin − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−2/A2
Piston
Top Surface Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403−4/A1
Piston Rings and Ring Grooves: Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425−1/A1

Piston Cooling and Crosshead Lubrication: Inner Pipe − Removal and Installation . . . . . . . . . . . 3603−1/A1
Winterthur Gas & Diesel Ltd. 1/ 3 RT-flex50DF / MM / 2016

Intentionally blank
Crankshaft
Crank Deflection − Measure

Tools:
1 Crankshaft equipment (dial gauge) 94305
1. General
It is sufficient to measure the crank-web deflection in accordance with the intervals
specified in the class rules. It can be necessary to measure the crank-web deflection
in unusual conditions, for example:
D Important change of crank-web deflection results compared to the data before.
D Bearing temperature alarms, or bearing damage.
D After the primary bearing shells were replaced, and again after approximately
100 service hours.
D If the ship has touched the sea bed.
For the examples given above, it is recommended that you speak to Wärtsilä for
support.
2. Preparation
Make sure that:
D The indicator valves are open.
D The ship floats freely in the water as horizontal as possible.
D The crankshaft is in position on all the main bearings.
The data that follow have an effect when
you measure the crank web:
D The engine is cold, or has service
temperature.
D The temperature difference between
2 the lubricating oil sump and the
seawater.
D The loaded condition of the ship (the
1 draught).
D Strong sunshine.
It is recommended that you include these
data in the records.
3. Measure
Fig. 1
013.051/05 WARNING
make sure that no
personnel are near the
Note: Make sure that you turn the

flywheel (1, Fig. 1) and pinion (2) in
the correct direction (The arrows
show the correct direction.)

Measuring Crank Deflection
1) Make sure that the tank heater and lubricating oil separator are set to off for a
minimum of eight hours.
2) Operate the turning gear to move the crank to the BDC 1st position (see Fig. 2).
3) Attach the dial gauge (94305) to the connecting rod. Make sure that the dial
gauge goes into the center punch marks.
4) Turn the rod of the dial gauge to apply tension.
5) Set the dial gauge to zero. The dial gauge must not have a difference of more
than 0.01 mm.
6) Use the turning gear to move the crank to each position shown. At each position,
record the indications on the dial gauge.
Note: You can read from the dial gauge the change in the distance between the
crank webs. The smaller the difference, the better the crankshaft is
aligned.
7) If the difference between the two BDC positions is more than 0.04 mm, you must
do the check again.
VIEW FROM
DRIVING END
CLOCKWISE
DIRECTION
FUEL SIDE TDC EXHAUST SIDE
BDC 1st Position BDC 2nd Position
CRANK DEFLECTION
SIGN ON DIAL GAUGE
94305
+ −
OR
− +
Approximately.
18 mm
Center Punch Mark for
Dial Gauge 94305
Fig. 2

Measuring Crank Deflection
4. Data Analysis
94305 STROKE
nBDC
D
nTDC
Fig. 3
If the measured values are above the maximum permissible limits, do the necessary
measurements to find the cause of the problem. It can be:
Where values are measured, which are above the maximum permitted limits, you
must find the cause (e.g. defective main bearing, engine stay changed because hull
deformation, loose hold-down bolts, defective propeller shaft bearings, equipment
94305 etc).
The limits are applicable for all conditions of ship operation after delivery i.e.:
D The draught and trim of the ship are in the limits for usual operation.
D The engine is hot or cold.
Usual Ship Operation: Crank-web Deflection Limits (mm)
Vertical Horizontal
Cylinder No. 1 Cylinder No. 2 Last cylinder All Cylinders

(Driving end) to Last but One (Free end)
Cylinder
Note 1) Note 2)
0.42 0.30 0.30 0.30 0.14

−0.42 −0.30 −0.30 −0.42 −0.14
1) For engines without a torsional vibration damper, front disc or free end Power
Take Off.
2) For engines with a torsional vibration damper, front disc or free end Power Take
Off.
Speak to Wärtsilä Services Switzerland, if the last data is more than the limits given in
the table above.

Intentionally blank
Vibration Damper
Inspection (Geislinger Vibration Damper)
1. General
Some engine designs can have a Geislinger manufactured vibration damper installed
at the free end of the crankshaft.
The service life of a vibration damper is related to the speed range in which the
engine operates. Sea water (and other types of water) in the lubricating oil can cause
the internal parts to become worn and decrease the effect of the vibration damper.
WCH02925
For View I − I, see Fig. 2
Fig. 1: Vibration Damper (front view)

1 Vibration damper monitor 3 Damper casing
2 Monitor pipe 4 Oil supply pipe

Inspection (GEISLINGER Vibration Damper)
2. Check
2.1 Engine Filters

CAUTION
Damage Hazard: If the oil supply to the damper is stopped, the
engine must be stopped immediately. Damage to the vibration
damper can occur. The oil supply must flow correctly before the
engine is started again.
Note: The vibration damper must not be operated until the cause is found and
the problem is repaired.
If damage occurs to engine bearings because of water contamination in the
lubricating oil, you must examine the vibration damper for damage as soon as
possible.
You must do regular checks of the engine filters for steel or bronze particles. If
particles are found in the housing, you must speak to, or send a message to the
supplier immediately.
If the oil pressure decreases to less than 1.0 bar, do not use the adjustable throttle in
the supply pipe (4, Fig. 1 and Fig. 2). You must investigate the cause of the pressure
decrease
2.2 Inner Spring Tips and Groove Flanks

Note: You must only disassemble the vibration damper if you think there is
damage, or the parts have become worn to more than the specified limits.
You must speak to the manufacturer for instructions.
Note: Only specialists can make adjustments of the vibration damper. The
torsional vibrations and these adjustments must be done at the same
time.
To do a check of the inner spring tips and groove flanks, do the procedure that
follows:
1) Stop the engine.
2) Remove the inspection cover from the vibration damper casing.
3) Examine the inner spring tips and groove flanks. Refer to the manufacturer’s
manual for the limits.
4) Attach the inspection cover to the vibration damper casing.
5) Start the engine.
Before you remove a vibration damper and balance weight, record their positions with
reference to the crankshaft position.
For the torque values of the coupling bolts (5), refer to 0352−1.
For the test run after the first commissioning, the usual checks and servicing intervals,
refer to the manual of the vibration damper manufacturer.
The address for GEISLINGER vibration dampers is given below:
Geislinger GmbH
Geislinger GmbH
A-5300 Hallwang / Salzburg
Austria
Tel: +43 662 66 999 0
Fax: +43 662 66 999 40

Inspection (GEISLINGER Vibration Damper)
I-I
1
2 2
FREE END
OIL
SUPPLY 3
4
000.940/93

WCH02925
Fig. 2: Vibration Damper (section view)

1 Damper casing 4 Oil supply pipe
2 Vibration damper 5 Coupling bolt
3 Cover 6 Vent nozzle

Intentionally blank
Axial Detuner

Tools:
2 Manual ratchets 94016-001 2 RUD eye bolts 94040-M20
1 Manual ratchet 94016-002 1 Lifting tool 94335
1. Preparation
CAUTION
Injury Hazard: The weight of the top housing is approximately
400 kg. Use the correct equipment to lift and move the top housing.
This will prevent injury to personnel.
Note: For data about the axial damper monitor, refer to the Operation Manual
3140−1.
1) Set to off the bearing oil pump.
2) Remove the two pipes (6, Fig. 1) from the axial damper monitor (6) and the
screw-in unions (5).
3) Remove the screws that hold the top cover (4) to the column and the bottom
cover.
4) Use applicable lifting equipment to remove the top cover (1).
5) Remove the two pipes (2) from the top cylinder half (3)
I I-I
1
6
5
4
WCH03505
2
I
3
Fig. 1

Axial Detuner: Disassemble and Assemble
2. Disassemble
2) Remove the eight screws (3) from top cylinder half (2). On engines that have a
vibration damper, loosen fully the eight screws and pull them out as far as
possible.
3
3
Fig. 2

3) Attach the lifting tool (94335, Fig. 3) between the double-I girders.
4) Attach the manual ratchet (94016−002) to the lifting tool (94335).
5) Attach the eye bolts (94040−M20) to the top cylinder half (1).
6) Attach the manual ratchets (94016−001) to the eye bolts (94040−M20) as shown.
I-I 94335
I
94016−002
94016−001
94016−001
94040−M20
1
016.608/08a
I
Fig. 3

Note: The two gaskets (2, Fig. 4) are 2-part items. The gasket (5) is a 1-part item.
Note: When you do step 7), make sure that you do not cause damage to the
gaskets (2, 5 and tension springs (3, 4)
7) Operate the manual ratchets (94016−001) to carefully lift the top cylinder half (1).
8) Operate the manual ratchets (94016−001, and 94016−002) to move the top
cylinder half (1) to the side as shown.
9) Lower the top cylinder half (1) on to an applicable surface.
94335
94016−002
I
1
94016−001
016.609/08a
I
2 2
3 3
5
Fig. 4 4
10) Do a check of the gaskets(2, 5). If the gaskets have damage or contamination, do
a) Turn the gaskets (2, 5) until you can remove the tension springs (3, 4).
b) Remove and discard the gaskets (2, 5).

3. Assemble
1) Apply clean engine oil to the gaskets (2, 5).
2) Attach the new gaskets (2, 5) to the axial detuner.
3) Make sure that the new gaskets (2, 5) can move freely around the axial detuner.
4) Put the tension springs (3, 4) around the 2-part gaskets (2, 5).
5) Operate the manual ratchets (94016−001 and 94016−002, Fig. 4) to lift and move
the top cylinder half into position above the bottom cylinder half.
6) Carefully lower the top cylinder half on to the bottom half of the cylinder. Make
sure that you do not cause damage to the and the tension springs.
Note: Use the two taper pins (3, Fig. 5) to help you to get the top cylinder in the
correct position.
7) Install the four M24 screws (1) to the top cylinder half (4). Refer to 0352−2,
paragraph 1 for the applicable torque value.
8) Install the eight screws M24x190 (2) to the top cylinder half (4). Refer to 0352−1
for the applicable torque value.
Fig. 5

4. Completion
1) Attach the two pipes (2, Fig. 6) to the top cylinder half (4).
2) Attach the top housing (1).
3) Connect the two pipes (3) to the screw-in unions (2).
I I-I
1
5
WCH03505
2
I
3
Fig. 6

Turning Gear
Teeth and Screwed Connections Check
1. General
Before you operate the turning gear (1, Fig. 1) you must do a check of the condition of
the tooth flanks on the pinion (2) and the flywheel (3). Also you must make sure that
lubricant is applied to these components.
For maintenance of the turning gear, refer to the instructions given in the supplier
documentation.
013.051/05
3
Fig. 1

Turning Gear: Checking the Toothing
2. Tooth Checks
2.1 Lubrication Instructions

Apply a very thin, equal layer of lubricant to the tooth flanks of the pinion (2, Fig. 1)
and the flywheel (3). Refer to Table 1 and Table 2.
Table 1: Instructions − Pyroshield
Manufacturer Location Instruction

LE 5182 Apply a thin layer of the
Pyroshield lubricant to the teeth as
shown in the photograph.
Table 2: Instructions − Klüberfluid
Manufacturer Location Instruction

Klüberfluid Increase the temperature of
C−F 3 Ultra the Klüberfluid.
Put an applicable quantity of
Klüberfluid into a container.
Put the container into warm
water until the Klüberfluid is at
approximately 35_C.
Apply the Klüberfluid as
shown in the photograph.
2.2 Lubrication Intervals

1) Look at the tooth flanks. If the highest loaded areas of the tooth flanks do not
have much lubricant, apply the lubricant as given in Table 1 and Table 2.
2) Apply the lubricant each 2000 operation hours, or as necessary.
2.3 Recommended suppliers

Lubrication Engineers Inc.
300 Bailey Avenue
Forth Worth, TX
USA
http://www.lelubricants.com
Email: info@le-inc.com
Klüber Lubrication München KG
Geisenhausenerstrasse 7
81379 München
Germany
http://www.klueber.com
Email:info@klueber.com

Crankcase
Work Platform
Tools:
1 Platform 94142
2 Nut 94142A
1 Support 94143
1. General
WARNING
Injury and Damage Hazard: Do not turn the crankshaft when the
platforms and/or supports are installed. This can cause injury to
personnel and damage to equipment.
You use the platform (94142, Fig. 1) and support (94143) when you do work in the
crank area and between the columns. The platform and support help to prevent
accidents in these areas.
You install the platform (942142) with the nuts (94142A) to the longitudinal beam (2)
and the crank (1).
You install the support (94143) between the columns at the applicable height, on the
steps (4). You put the straps (3) around the steps to hold the support in position.
94143
94142A 1
2 94142
Fig. 1 012.897/05

Intentionally blank
Top Platform
Configuration of Lifting Tools

Tools:
1 Spur-geared chain block 94017 2 Bushes 94335B
(WLL 2000 kg) 2 Screws 94335C
1 Lifting tool 94335
1. General
For the removal and installation of heavy engine components, the lifting tool (94335)
is attached between double I-girders (1). The lifting tool is attached with spring dowel
pins and tightened with the screws (94335C).
Note: The permitted Work Load Limit (WLL) is 1740 kg. The strand angle must
not be more than 30° .
94017
II
I-I
1 WCH00684
2
3
94335C
I
II
I I
018.385/09
94335B 94335 94335
Fig. 1

Intentionally blank
Connecting Rod
Loosening and Tensioning the Connecting Rod Studs

Tools:
1 Feeler gauge 94122 1 Connection block 94934
2 Pre-tensioning jacks 94314 1 Hydr. distributor 94934A
2 Distance bushes 94314A 3 HP hoses 94935
1 Pre-tensioning jacks 94315 1 Hydraulic unit 94942
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Loosening the stud of bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Tensioning the stud of bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Loosening the stud of top end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Tensioning the stud of top end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
1 Note: Read the instructions 9403−4
2 referring to the application of
hydraulic pre-tensioning jacks to
3 screwed connections.
Check if the nuts 2 or 5 turn freely on the
threads.
CAUTION
Never turn the crankshaft
(with the turning gear) as
long as the pre-tensioning
jacks are attached to the
connecting rod studs!
4
5
701.013.378
Fig. 1 013.378/05

2. Loosening the stud of

bottom end bearing
94314
1) Clean the threads of studs 4 and the
area around nuts 5.
94314A 6
2) Put the distance bushes 94314A on the
studs.
y
y
3) Attach and tighten the pre-tensioning
jacks 94314 with open vent screws 7
until there is only little or no clearance
at ’x’ (Fig. 3).
6
4) Screw back the pistons 8 by about ½
turn.
94935
5) Connect the pre-tensioning jacks to
hydraulic unit 94942 as shown in Fig. 2.
6) Actuate the hydraulic unit until
94934 bubble-free oil flows out through the
2000
0
vent screws. Close the vent screws 7.

94934A 7) Actuate the hydraulic unit up to about
1530 bar and keep pressure constant.
94935 Pistons 8 of the pre-tensioning jacks

must never exceed the red limiting
grooves ’BN’ (Fig. 3).
8) Use the round bar ’RS’ and screw back
701.013.428.dxf
013.428/05
the nuts 5 by one turn.
94942
9) Release the pressure to ’0’ at the
hydraulic unit and then remove
Fig. 2 pre-tensioning jacks.
8
x
BN
5 RS
4 94314A
KO
6
013429/05
Fig. 3

3. Tensioning the stud of bottom end bearing

1) Clean the threads of studs 4 and the area around the nuts 5.
2) Apply oil to the stud threads and screw on the nuts.
3) Tighten the nuts with round bar ’RS’ and equally distribute clearance ’y’ between
the bearing halves (bearing protrusion) as shown in Fig. 2.
4) Put the distance bushes 94314A on the studs.
5) Attach and tighten the pre-tensioning jacks 94314 with open vent screws 7 until
there is only little or no clearance at ’x’ (Fig. 3).
6) Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. 2.
7) Actuate the hydraulic unit until bubble-free oil flows out through the vent screws.
Close vent screws.
8) Actuate the hydraulic unit and set the pressure to 950 bar (1st step) and keep
pressure constant.
Pistons 8 of the pre-tensioning jacks must never exceed the red limiting
Tighten the nuts with round bar ’RS’ and check with the feeler gauge through
slot ’KO’ (Fig. 3) that no clearance remains between nut and supporting
surface.
Check with the feeler gauge that no clearance remains between bearing cover and
connecting rod.
(Should clearance remain, loosen the fastening and compare the bearing protrusion with
the nominal value as indicated in 3303−2).
Fig. ’a’ 9) After tensioning to the 1st step mark the
position of the nuts against connecting
rod as shown in Fig. ’a’.
10) Raise the pressure to 1500 bar (2nd
step) and keep it constant.
Tighten nuts down and check correct
seating with the feeler gauge.
009.752/02
Check from the markings applied by how
y much the nuts were turned after
x pre-tightening (1st step).
Tightening angle to be about 30_ (Fig. ’b’).
Fig. ’b’ 11) Should considerable differences to

these nominal values be encountered
then repeat the tensioning process.
12) Release pressure to ’0’ at the hydraulic
unit and then remove pre-tensioning
jacks.
y Finally check the vertical bearing

013.430/05 clearance (see Clearance Table 0330−1
TIGHTENING x ’Top and bottom end bearings to
ANGLE connecting rod’).

I 4. Loosening the stud of

top end bearing
b a
Note: For loosening the studs always
follow the sequence shown in Fig.
4 i.e. a + a and b + b.
a b
94315 1) Clean the threads of studs 1 and the
area around the nuts 2.
I 2) Put the pre-tensioning jacks 94315
diagonally on the studs as shown in
Fig. 4, and completely screw them on
3 with opened vent screw 7 until there is
only little or no clearance at ’x’ (Fig. 5).
y
3) Turn back the pre-tensioning jacks by

about ½ turn (gap ’SA’ in Fig. 5).
4) Connect the pre-tensioning jacks to
3 hydraulic unit 94942 as shown in Fig. 4.
94935 5) Actuate the hydraulic unit until

bubble-free oil flows out through the
vent screws. Close vent screws.
6) Actuate the hydraulic unit up to about
1530 bar and keep pressure constant.
94934 Pistons 8 of the pre-tensioning jacks

must never exceed the red limiting
94934A
7) Use the round bar ’RS’ and screw back
the nuts 2 by one turn.
94935
013.431/05 8) Release the pressure to ’0’ at the
hydraulic unit and then remove
94942 pre-tensioning jacks.
Fig. 4
9) Do the same procedure for the second
pair of the connecting rod studs.
8
x
BN BN
9
2 RS
1
SA KO
3
009.755/02 009.756/02
PRE-TENSIONING JACK PRE-TENSIONING JACK

PLACED FOR LOOSENING PLACED FOR TENSIONING
Fig. 5 Fig. 6

5. Tensioning the stud of top end bearing

Note: For tensioning the studs always follow the sequence shown in Fig. 4 i.e.
a + a and b + b for each step.
1) Clean the threads of studs 1 as well as the area around nuts 2.
2) Apply oil to the stud threads and screw on the nuts.
3) Tighten the nuts with round bar ’RS’ and equally distribute clearance ’y’ between
the bearing halves (bearing protrusion) as shown in Fig. 4.
4) Open the vent screw 7.
5) Put the pre-tensioning jacks 94315 diagonally on studs as shown in Fig. 4, and
completely screw them on until there is only little or no clearance at ’x’ (Fig. 5).
6) Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. 4.
7) Actuate the hydraulic unit until bubble-free oil flows out through the vent screws.
Close vent screws.
8) Actuate the hydraulic unit and set pressure to 1000 bar (1st step) and keep
pressure constant.
Pistons 8 of the pre-tensioning jacks must never exceed the red limiting
Tighten the nuts with round bar ’RS’ and check with the feeler gauge through
slot ’KO’ (Fig. 5) that no clearance remains between nut and supporting
surface.
Check with the feeler gauge that no clearance remains between bearing cover and
connecting rod.
(Should clearance remain, loosen the fastening and compare the bearing protrusion with
the nominal value as indicated in 3303−3).
Fig. ’a’ 9) Do the same procedure for the second
pair of the connecting rod studs.
10) After tensioning to the 1st step mark the
position of the nuts against bearing
cover as shown in Fig. ’a’.
11) Raise the pressure to 1500 bar (2nd
step) and keep constant.
009.758/02 Tighten the nuts down and check correct
y seating with the feeler gauge.
Check from the markings applied by how
x much the nuts were turned after
Fig. ’b’ pre-tightening (1st step).
Tightening angle to be about 15_ (Fig. ’b’).
Should considerable differences to these
nominal values be encountered then repeat
the tensioning process.
12) Release the pressure to ’0’ at the
hydraulic unit and remove
pre-tensioning jacks.
y 013.432/05
Finally check the vertical bearing
x
TIGHTENING clearance, refer to Clearance Table
ANGLE 0330−1 ’Top and bottom end bearings to
connecting rod’.

Intentionally blank
Connecting Rod
Bottom End Bearing − Removal, Inspection and

Installation
Tools:
1 Work platform 94142 1 Spur-geared chain block H3 94017−022
4 Retaining pins 94323 2 RUD-eye bolt M8 94040−M8
1 Lifting tool 94335 2 Manual ratchets 1600 kg H1, H2 94016−007
1 Chain (double sling) 94666I 2 Swivel lugs 94048−M30
2 Eye bolts M6 94040−M6 2 Swivel lugs 94048−M30
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Bearing Cover − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Bottom Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Top Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7. Top Bearing Shell − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8. Bottom Bearing Shell − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9. Bearing Cover − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
WARNING
94335 2. Preparation
crankshaft until the applicable crank is
H3 at TDC.
3) Attach the swivel lugs (94048−M30,
1 Fig.1) to the bearing cover (3).
4) Attach the manual ratchets (H1, H2) to
the column and the eye
H1 H2 bolts (94040−M8) on the bearing
94048−M30 94048−M30 cover (3).
5) Attach the lifting tool (94335) between
3
double-I girders.
6) Attach the chain block (H3) to the lifting
tool (94335).
2
3. Bearing Cover −
Removal
1) Loosen then remove the round nuts (1),
Fig. 1 013.502/05a
refer to 9403−4.
2) Operate the manual ratchets (H1, H2) to carefully lower the bearing cover (3).
Make sure that you do not cause damage to the threads of the elastic studs and
the surface of the crank pin.
3) Do an inspection of the bearing shell (2).
4) If the bearing shell (2) is in good condition, lower bearing cover (3) to the bottom
of the crankcase.

Bottom End Bearing − Removal, Inspection and Installation
5) Apply a light tension to the manual

ratchets (H1 and H2, , Fig. 2).
the column and attach it to the top
attachment point as shown.
to move the bearing cover to the
H1 position shown.
EXHAUST SIDE
8) Attach the chain block (H3) to the
bearing cover (1).
FUEL SIDE
H2 the bearing cover (1)

crank approximately 70° to the exhaust
side.
1
13) Remove part of the bottom plate from
the middle platform.
14) Operate the chain block (H3) to move
013.505/05a
the bearing cover (1) through the
column door.
15) Lower the bearing cover (1) on to the
floor plate.
16) Remove the chain block (H3) from the
bearing cover (1).
H3
013.506/05a
Fig. 2

94666I
I 94040−M6 4. Bottom Bearing Shell −
Removal
I
1) Remove the two Allen screws (3,
Fig. 3).
3 2) Attach the two eye bolts (94040−M6) to
the bearing shell.
1
3) Attach the chain (94666I) to the eye
bolts (94040−M30).
2 4) Attach the chain block (H3) to the
chain (94666I).
5) Operate the chain block (H3) to lift the
013.507/05 bearing shell (1) from the bearing
Fig. 3 cover (2).
5. Top Bearing Shell −

Removal
crank to TDC.
3) Put the four retaining pins (94323,
Fig. 4) into the bores of guideways (1).
1 turn the crankshaft to the fuel side until
the guide shoes touch the retaining
94323 pins (94323). Make sure that the guide
shoes touch equally the retaining pins.
If necessary, adjust the retaining pins.
3 5) Attach the manual ratchet (H1) to the
column and the connecting rod.
6) Operate the manual ratchet (H1) to
H1 hold the connecting rod in the position
shown.
X X
2 crankshaft to the fuel side. At the same
time, operate the manual ratchet (H1)
to keep a light tension on the chain.
8) Continue to operate the turning gear
until the distances at X between the
crankshaft and the bottom end bearing
are equal.
013536/05a
Fig. 4


crank (1, Fig. 5) down.
10) Install the work platform (94142), refer
to the instructions given in 3301−1.
11) Hold the bearing shell and remove
Allen screws (2).
12) Remove the bearing shell.
6. Inspection
1) Do an inspection of the bearing shell.
H2
2 2) If you find damage, replace the bearing
94142 shell.
7. Top Bearing Shell −

Installation
1) Clean the seating surface of the
bearing shell.
1
2) Make sure that the bearing shell has no
damage.
Fig. 5 013.537/05a 3) Hold the bearing shell in position on the
connecting rod.
Note: Make sure that the distance
between each end of the bearing
shell and the connecting rod is the
same.
4) Attach the bearing shell to the
94323 connecting rod with the Allen
screws (2).
5) Make sure that the crank pin (1) is in a
2 satisfactory condition.
6) Put oil on the crank (1).
7) Put oil on the surface of the bearing
H1
shell.
X X 8) Remove the work platform (94142).
1 9) Operate the turning gear to move the
crank to TDC. Make sure that distances
at X between the crankshaft and the
bottom end bearing are equal.
10) Continue to operate the turning gear
until the crank pin (1) engages with the
connecting rod (2).
013536/05a
crank to TDC. At the same time,
operate the manual ratchet (H1) to
keep a light tension on the chain.
12) Remove the retaining pins (94323).
Fig. 6 13) Remove the manual ratchet (H1) from

the connecting rod (2).

94666I 8. Bottom Bearing Shell −

I 94040−M6
Installation
I 1) Attach the two eye bolts (94040−M6,
Fig. 7) to the bottom bearing shell (1).
2) Attach the chain (94666I) to the two
3 eye bolts (94040−M30) and the chain
block (H3).
1
3) Lift the bottom bearing shell (1).
2 bottom bearing shell (1) and the
bearing cover (2).
5) Put oil on the surface of the bearing
013.507/05
shell (1).
6) Lower the bearing shell (1) on to the
Fig. 7 bearing cover (2).
same.
7) Remove the chain (94333I).
8) Remove the two eye bolts (94040−M6).
9) Attach the bottom bearing shell (1) to
the bearing cover (2) with the two
screws (3).
9. Bearing Cover −
H3 Installation
1) Attach the chain block (H3) to the eye
H1 bolt on bearing cover (1, Fig. 8).
top attachment point in the column and
the eye bolt on the bearing cover (1).
crankshaft to the position shown.
1 4) Operate the manual ratchet (H1) and
the chain block (H3) to move the
bearing cover through the column door
as shown.
013.506/05a
Fig. 8


to the attachment point in the column
and the eye bolt (94040−M8).
bottom attachment point in the column
and the eye bolt (94040−M8).
7) Carefully remove the chain block (H3).
8) Make sure that the bearing shell (2) is
clean.
H1 9) Operate the manual ratchets (H1, H2)

H2
to lift the bearing cover (1) into position.
94040−M8 94040−M8
10) Put oil on the bearing shell as follows:
1 a) If you start the engine immediately
after completion of this procedure,
use only bearing oil.
2 b) If the engine has stopped for
some days, use a mixture of
high-viscosity oil (steam engine
cylinder oil, ISO VG 1000/1500)
and bearing oil. The ratio is two
013.502/05a
thirds ISO VG 1000/1500 to one
third bearing oil.
Fig. 9 Note: A list of suppliers for ISO VG

1000/1500 high viscosity oils is
given in Table 1.
11) Put the round nuts (1, Fig. 10) on the
elastic studs.
12) Tighten the round nuts (1) equally with
a round bar.
13) Measure the distances (X1, X2)
between the edges of the bearing
shells and the bearing cover.
14) Refer to 0330−1 Group 3303 to get the
1 clearance values (X1, X2) for new
bearing shells.
15) Apply tension to the elastic studs, refer
to 9403−4.
the area.
x1 x2
013.540/05
Fig. 10

Table 1: ISO G 1000/1500 Suppliers
Supplier Type Viscosity at Viscosity at Weight at

40° C mm2/s 100° C mm2/s 15° C g/ml
BP ENERGOL DC 1000 980 49.0 0.913
BP ENERGOL DCW 1000 920 40.0 0.913
CHEVRON CYLINDER OIL 1000 1000 43.1 0.937
EXXON/ESSO CYLESSO 1000 950 44.0
EXXON/ESSO CYLESSO TK 1000 925 46.7
MOBIL EXTRA HECLA SUPER Cylinder Oil 680 39.0 0.905
SHEEL FIONA Oil 1500 1500 37.0 0.958
SHEEL VALVATA OIL 1000 1000 45.4 0.924
TEXACO 650T MINERAL Cylinder Oil 985 44.0 0.919

Intentionally blank
Connecting Rod
Top End Bearing − Removal, Inspection and Installation

Tools:
1 Work platform 94142 1 Lifting tool 94335
4 Retaining pins 94323 1 Stop plate 94370H
1 Lifting plate 94324 2 Manual ratchet 1600 kg H1, H2 94016−007
2 Lifting rings 94332 2 Manual ratchet 3200 kg H3, H4 94016−013
1 Spur-geared chain block 2000 kg H5 94017−022 4 RUD-eye bolts M8 94040−M8
2 Chain 94666I 2 Eye bolts M6 94040−M6
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Crosshead − Lift (Installed Piston) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Crosshead − Lift (Piston Removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Bearing Shell − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Bearing Shell − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Installation with Piston Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Installation with Piston Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. General
WARNING
2. Bearing Shell −
Removal
Note: You can examine the bearing shell
with piston installed or removed.
1) Read and obey the data in 0012−1
General Guidelines for Lifting Tools.

crank (2, Fig. 1) of the applicable
H2 cylinder to BDC.
H1
2) Install the work platform (94142) refer
1
94040−M8 to 3301−1.
94040−M8
94142 3) Attach the eye bolts (94040−M8) to
each side of the connecting rod (3).
the attachment points in the column
2 and the eye bolts (94040−M8).
3
013.626/05a
Fig. 1

1
2.1 Crosshead − Lift (Installed
94332
Piston)
2 Note: During this procedure, the piston
(3, Fig. 2) is installed.
H3 H4 1) Remove the four round nuts (5) of the
connecting rod (7), refer to 9403−4.
3 2) Attach the stop plate (94370H) to the
bearing cover (4) and guide shoe (6).
3) Attach the two eye bolts (94040−M8) to
the guide shoe (6).
FREE END
4) Attach the two lifting rings (94332) to

the cylinder block (1) with the four
screws (2).
5) Torque the four screws (2) to 200 Nm.
I the lifting rings (94332) and the eye
bolts (94040−M8).
4
5
6
013.021/05
94370H
94040−M8
4
6
Fig. 2

7) Operate the manual ratchets (H3 and

H4, Fig. 3) to lift the crosshead above
the bottom holes in the guideways (1).
8) Put the four retaining pins (94323) in
the holes in the guideways (1).
9) Operate carefully the manual ratchets
H3 H4 (H3, H4) to lower the guide shoes on to
the retaining pins (94323).
10) Make sure that the guide shoes touch
equally the retaining pins. If necessary,
adjust the retaining pins.
I
1
I
94323
013.627/05
Fig. 3

2.2 Crosshead − Lift (Piston

Removed)
1) Remove the four round nuts (2, Fig. 4)
from the connecting rod (4), refer to
9403−4.
2) Attach the stop plate (94370H) to the
6 bearing cover (1) and guide shoe (6).
3) Attach the lifting plate (94324) to
crosshead pin with the round nuts from
the piston rod foot.
II 4) Attach the hook of the engine room

crane to the lifting plate (94234).
I the crosshead pin (6) above the bottom
94324
bores in the guideways (5).
1 6) Put the four retaining pins (94323) in
2 the holes in the guideways (5) as
3 shown.
4 carefully lower the guide shoes (3) on
to the four retaining pins (94323).
8) Make sure that the guide shoes (3)
touch equally the retaining
pins (94323). If necessary, adjust the
retaining pins.
9) Remove the hook of the engine room
013.034/05
crane from the lifting plate (94234).
II
5
94323
94324
94370H
94040−M8
1
3
Fig. 4

94335
3. Bearing Shell −
Removal
1) Attach the lifting tool (94335, Fig. 5)
between the double-I girders.
94017−022
to move the connecting rod a small
distance to the fuel side.
the swivel lug (94048−M30) on the
I connecting rod. Make sure that the
connecting rod stays on the fuel side.
I H2 4) Operate the manual ratchet (H2) to
2
move the connecting rod fully to the
1 fuel side.
5) Remove the Allen screws (10) from the
bearing shell (11).
6) Attach the two eye bolts (94040−M6) to
the bearing shell.
7) Attach the chain (94666I) to the eye
bolts (94040−M6) and the manual
ratchet (H1).
Fig. 5 013.632/05a
8) Apply protection to the threads of the
elastic studs on the connecting rod.
This prevents damage to the bearing
shell.
carefully lift the bearing shell a small
distance.
H5
chain (94666I).
the sling (94666I).
12) Carefully operate the chain block to
move the bearing shell through the
column door.
H1
13) Lower the bearing shell on to the
94666I H2 platform.
I
4. Inspection
1) Do an inspection of the bearing shell.
I
2) If you find damage, replace the bearing
shell.
1
94040−M6
013.637/05a
Fig. 6

5. Bearing Shell − Installation
5.1 Installation with Piston Installed

1) Clean the seating surface of the bearing shell (1, Fig. 7).
2) Put oil on the surface of the bearing shell (1) as follows:
a) If you start the engine immediately after completion of this procedure, use only
bearing oil.
b) If the engine has stopped for some days, use a mixture of high-viscosity oil
(steam engine cylinder oil, ISO VG 1000/1500) and bearing oil. The ratio is two
thirds ISO VG 1000/1500 to one third bearing oil.
Note: A list of suppliers for ISO VG 1000/1500 high viscosity oils is given in
Table 1.
3) Clean the seating surface of the connecting rod and make sure that there is no
damage.
4) Make sure that the surface of crosshead pin is in a satisfactory condition.
5) Install the eye bolts (94040−M6) to the bearing shell.
6) Attach the chain (94666I) to the manual ratchet (H5) and the eye bolts
(94040−M6).
7) Operate the chain block (H5) to lift the bearing shell (1) to the height of the
column door.
8) Attach the manual ratchet (H1) to the chain (94666I).
9) Operate the chain block (H5 and the
manual ratchet (H1) to carefully lower
H5 the bearing shell (1) into the connecting
rod.
10) Install the two screw screws (2, Fig. 5).
same.
11) Remove the four eye bolts (94040−M6,
H1 Fig. 7).
94666I H2 12) Remove the protection from the elastic
studs on the connecting rod.
I
I 13) Remove the chain block (H5) and the
chain (94666I).
eye bolts (94040−M8).
move the connecting rod a small
1 distance.
94040−M6 eye bolt (94040−M8) on the connecting
013.637/05a
rod.
Fig. 7 to move the connecting rod to the
vertical position.


H4, Fig. 8) to lift the guide shoes a
small distance.
19) Remove the four retaining pins
H3 (94323).
H4
elastic studs are aligned with the
holes in the crosshead pin.
to lower the guide shoes on to the
1 elastic studs.
I 21) Remove the items that follow:

D Manual ratchets (H3, H4)
I D Retaining pins (94323)
94323 D Stop plate (94370H)
D Eye bolts
D Two lifting rings (94332).
elastic studs (2).
2 a round bar.
24) Measure the distance (X1, X2) between
the edges of the bearing shells (1) and
25) Refer to 0330−1, Group 3303 to get the
clearance values (X1, X2) for new
bearing shells.
013.627/05
26) Install the four round nuts (3) to the
1
2
3
X1 X2
013.629/05
Fig. 9
Fig.8

5.2 Installation with Piston Removed

1) Clean the seating surface of the bearing shell (1, Fig. 10).
2) Put oil on the surface of the bearing shell (1) as follows:
a) If you start the engine immediately after completion of this procedure, use only
bearing oil.
b) If the engine has stopped for some days, use a mixture of high-viscosity oil
(steam engine cylinder oil, ISO VG 1000/1500) and bearing oil. The ratio is two
thirds ISO VG 1000/1500 to one third bearing oil.
Note: A list of suppliers for ISO VG 1000/1500 high viscosity oils is given in
Table 1.
3) Clean the seating surface of the connecting rod and make sure that there is no
damage.
4) Make sure that the surface of crosshead pin is in a satisfactory condition.
5) Install the eye bolts (94040−M6) to the bearing shell.
6) Attach the chain (94666I) to the manual ratchet (H5) and the eye bolts
(94040−M6).
7) Operate the chain block (H5) to lift the bearing shell (1) to the height of the
column door.
9) Operate the chain block (H5 and the
manual ratchet (H1) to carefully lower
the bearing shell (1) into the connecting
H5 rod.
10) Install the two screw screws (2, Fig. 5).
same.
11) Remove the four eye bolts (94040−M6,
Fig. 10).
H1
H2 12) Remove the protection from the elastic
94666I
studs on the connecting rod.
I 13) Remove the chain block (H5) and the
I chain (94666I).
eye bolts (94040−M8).
move the connecting rod a small
distance.
1
94040−M6 eye bolt (94040−M8) on the connecting
013.637/05a
rod.
Fig. 10
to move the connecting rod to the
vertical position.

18) Operate the engine room crane to to lift

the guide shoes (1, Fig. 11) a small
distance.
19) Remove the four retaining
pins (94323).
elastic studs are aligned with the
holes in the crosshead pin.
lower the guide shoes (3) on to the
elastic studs.
II 21) Remove the items that follow:
D The hook from the engine room
I crane
94324
D Retaining pins (94323)
D Stop plate (94370H)
D Eye bolts
1
D Lifting plate (94324).
elastic studs (2).
a round bar.
24) Measure the distance (X1, X2) between
the edges of the bearing shells (1) and
013.034/05
25) Refer to 0330−1, Group 0303 to get the
clearance values (X1, X2) for new
II bearing shells.
26) Install the four round nuts (3) to the
94323
1
2
3
I
X1 X2
94324
94370H
94040−M8 4
013.629/05
Fig. 11 Fig. 12

Table 1: ISO G 1000/1500 Suppliers
Supplier Type Viscosity at Viscosity at Weight at

40° C mm2/s 100° C mm2/s 15° C g/ml
BP ENERGOL DC 1000 980 49.0 0.913
BP ENERGOL DCW 1000 920 40.0 0.913
CHEVRON CYLINDER OIL 1000 1000 43.1 0.937
EXXON/ESSO CYLESSO 1000 950 44.0
EXXON/ESSO CYLESSO TK 1000 925 46.7
MOBIL EXTRA HECLA SUPER Cylinder Oil 680 39.0 0.905
SHEEL FIONA Oil 1500 1500 37.0 0.958
SHEEL VALVATA OIL 1000 1000 45.4 0.924
TEXACO 650T MINERAL Cylinder Oil 985 44.0 0.919

Connecting Rod

Tools:
1 Work platform 94142 1 Lifting tool 94335
4 Retaining pins 94323 1 Stop plate 94370H
1 Lifting plate 94324 2 Manual ratchet 1600 kg H1, H2 94016−007
2 Lifting rings 94332 2 Manual ratchet 3200 kg H3, H4 94016−013
1 Spur-geared chain block 2000 kg H5 94017−022 3 Eye bolts M8 EB1, EB2, EB3 94040−M8
1 Holder 94331
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. General
WARNING
H2 make sure that no
H1 1 personnel are near the
EB1 flywheel, or in the engine.
EB2
WARNING
Injury Hazard: The
2 connecting rod weighs
1142 kg. To prevent injury,
EB3
be careful when you move
the connecting rod.
94331
2. Preparation
1) Read the data in 0012−1 General
2 Guidelines for Lifting Tools.
3 2) Remove the bottom end bearing cover,
refer to 3303−2.
4
Note: If the piston is installed, refer to
3303−2, paragraph 2.1 to lift the
94331 crosshead (1, Fig. 1).
Note: If the piston is removed, refer to
3303−3, paragraph 2.2 to lift the
Fig. 1 013.020/05 crosshead (1).
3) Attach the holder (94331) to the
connecting rod (2) with the nuts(3).
4) Attach the two eye bolts (EB1, EB2) to the connecting rod (2).
5) Attach the manual ratchets (H1, H2) to the attachment points in the column.
6) Operate the manual ratchets (H1, H2) to apply a light tension to the chains.
3. Removal
1) Operate the turning gear to turn the crank of the applicable cylinder to BDC. At
the same time, operate the manual ratchets (H1, H2) to keep a light tension on
the chains.

Connecting Rod: Removal and Installation
2) Attach the lifting tool (94335, Fig. 2).

94335 between reinforced double-I girders,
refer to 3301−2.
tool (94335).
H5 4) Operate the manual ratchets (H1, H2)

to move the connecting rod to the fuel
side.
H1 5) Remove the manual ratchet (H1) from

the bottom attachment point and the
eye bolt (EB1).
H2 top attachment point in the column and
EB1
the eye bolt (EB2).
EB2
8) Remove the eye bolt (EB1).
Fig. 2
94335
crank counterclockwise approximately
45° . At the same time, operate the
manual ratchet (H1, Fig. 3) to get the
connecting rod through the column
H5
door.
10) Remove the applicable bottom plates
from the middle platform.
H1
bolt (EB2).
EB2 EB3
the eye bolt (EB2).
13) Attach the eye bolt (EB3) to the
connecting rod as shown.
Fig. 3 013.036/05a


crank counterclockwise to
approximately 35_ after TDC (see
Fig. 4).
eye bolt (E3).
H1 eye bolt (EB3). Apply a light tension to
the chain.
17) Remove the holder 94331.
EB3
H2 18) Operate carefully the manual ratchets
(H1, H2) and the chain block (H5) to
94331
remove the connecting rod from the
crank pin.
19) Remove the manual ratchet H1.
Fig. 4
94335 20) Operate the chain block (H5, Fig. 5)

and the manual ratchet (H2) to remove
the connecting rod from the engine.
H5
H2
013.037/05a
Fig. 5

4. Installation
1) Make sure that the mark FUEL SIDE
H5 on the connecting rod (3, Fig. 6) points
to the fuel side of the engine.
EB2
2) Put oil on the bearing shell (2) and the
crank pin (1).
FUEL SIDE
bolt (EB2)
EB3 4) Attach the manual ratchet (H2) to the
eye bolt (EB3).
3 H2
Fig. 6
013.037/05a

H5 that you do not cause damage to
the bearing shell or the crank pin.
5) Operate carefully the chain block (H5,
Fig. 7) and the manual ratchet (H2) to
move the connecting rod (3) to the
H1 crank pin (1).
eye bolt (EB3).
EB3
H2 7) Attach the holder (94331) to the
connecting rod.
94331
013.037/05a
Fig. 7


crank clockwise. At the same time,
operate the chain block (H5, Fig. 8) to
hold the connecting block.
H5 eye bolt (EB 2).
10) Remove the manual ratchet from the
eye bolt (EB3).
H1 eye bolt (EB2).
EB2 EB3
013.036/05a
Fig. 8

crank clockwise.
to the eye bolt (EB2).
H5
the eye bolt (EB2).
H1 15) Remove the manual ratchet (H1) from

the the top attachment point in the
column.
H2
EB1
EB2
013.036/05a
Fig. 9


crank clockwise to BDC. Make sure
that the connecting rod stays in the
vertical position (see Fig. 10).
eye bolt (EB1).
H2 18) Remove the eye bolt (EB3).
H1 1 19) Remove the holder (94331).
EB1 EB2
5. Completion
Note: If the piston is installed, refer to
2
3303−2, paragraph 5.1 step 18) to
EB3 step 26) to lower the
crosshead (1).
Note: If the piston is removed, refer to
94331 3303−3, paragraph 5.2 step 18) to
step 26) to lower the
Fig. 10 crosshead (1).
1) Install the bottom end bearing cover,
refer to 3303−2.
2) Measure the clearances, refer to
0330−1.
the work area.

Connecting Rod
Top End Bearing − Bearing Cover Removal and

Installation
Tools:
2 Lifting rings 94332 2 Manual ratchets H1, H2, 94016−007
1 Lifting tool 94335 2 Manual ratchets H3, H4 94016−001
1 Spur-geared chain block H4 94017−021 4 RUD-eye bolt EB1, EB2 94040−M8
1 Work platform 94142 1 Double sling chain 94666I
2 Lifting boss 94333A 2 Suspension chains 94333B
1
1. Piston − Lift and Hold
EB WARNING
94333B make sure that no
I I personnel are near the
94333A flywheel, or in the engine.
2
94142 1) Read and obey the data in 0012−1
3
the crank of the applicable cylinder to
BDC.
3) Attach the work platform (94142,
013.552/05 Fig. 1), refer to 3301−1.
I-I 4) Remove the nuts of the elastic studs on
94333A the piston rod foot, refer to 9403−4.
5) Attach the bosses (94333A) to the
3 piston rod foot (3) with the Allen four
screws (5).
2 6) Attach two eye bolts (EB) to the piston
rod gland support (1).
013.553/05 7) Attach the chains (94333B) to the eye
bolts (EB).
4 8) Remove the work platform (94142).
Fig. 1
crank to the exhaust side sufficiently to
attach the chains (94333B, Fig. 2) to
the bosses (94333A).
dowel pins (7) do not stay in the
7 6 piston rod foot (5).
10) Operate the turning gear to lower the
piston until the elastic studs (6) come
94333B out of the piston rod foot (5).
94333A
5
Fig. 2

Top End Bearing − Bearing Cover Removal and Installation
2. Removal
1
1) Loosen the elastic studs on the top end
94332 bearing and remove their round nuts,
2 refer to 9403−4.
2) Attach the eye bolts (EB1 and EB2,
H1 H2 Fig. 3) to the bearing cover (3).
3) Attach the lifting rings (94332) to
5
cylinder block (1) with screws (2).
the lifting rings (94332) and the eye
bolts (EB1, EB2).
6) Operate equally the manual ratchets
EB1 EB2 (H1, H2) to lift the bearing cover (3).
3 7) Attach protection to the crosshead
4 pin (4) to prevent damage and
contamination.
013.038/05
Fig. 3 013.038/05

94335
between the double-I girders.
9) Attach the work platform (94142), refer
H4 to 3301−1.
top attachment point in the column.
11) Attach the chain (94666I) to the manual
94666I ratchet (H3) and the eye bolts (EB1,
H3 EB2).
EB1, EB2
1 12) Remove the applicable part of the
bottom plate from the middle platform.
FUEL SIDE
94142
013.039/05a
Fig. 4
94335
H4
13) Operate equally the manual ratchets
(H1, H2 and H3, Fig. 5) to lower the
bearing cover (1) until the chains of the
manual ratchet (H3) is vertical.
H3 14) Remove the manual ratchets (H1, H2)
c from the eye bolts (EB1, EB2).
15) Attach the chain block (H5) to the chain
(94666I).
16) Operate the chain block (H4) and the
FUEL SIDE
manual ratchets (H3) to move the

bearing cover out of the column.
17) Lower the bearing cover on to an
applicable surface.
Fig. 5

3. Installation
1) Make sure that the bearing cover is clean and has no damage.
2) Attach the chain (94666I) to the eye bolts (EB1 and EB2) and the chain
block (H4) see Fig. 4 and Fig. 5.
3) Operate the chain block (H4) to lift the bearing cover.
5) Operate the chain block (H4) and the manual ratchet (H3) to move the bearing
cover into the column.
6) Remove the chain block (H4) from the chain 94666I).
7) Operate the manual ratchet (H3) to move the bearing cover above the crosshead
pin.
8) Attach the manual ratchets (H1, H2, Fig. 6) to the eye bolts (EB1, EB2).
9) Remove the manual ratchet (H3) from the chain (94666I).
10) Remove the chain (94666I) from the eye bolts (EB1, EB2).
Note: During step 11), make sure that the bearing cover (3) is level and
vertically aligned with the center of the crosshead pin (4). This prevents
damage to the elastic studs.
11) Operate carefully the manual ratchets (H1, H2) to lower the bearing cover (3) on
to the crosshead pin (4).
1
94332
2
H1 H2
EB1 EB2
3
4 4
013.038/05
013.038/05
Fig. 6

4. Completion
94333B
WARNING
I EB
make sure that no
94333A personnel are near the

Note: During step 2), make sure that you
do not cause damage to the elastic
studs, (1, Fig. 7).
crosshead pin up sufficiently to loosen
the chains (94333B). Make sure that
the dowel pins (2) engage correctly
3) Remove the chains (94333B).
4) Operate the turning gear to lower the
crosshead pin and the piston to BDC.
5) Remove the bosses (94333A), the
013.691/05
chains (94333B) and the eye
bolts (EB).
6) Attach the round nuts to the elastic
studs (1).
I 7) Tighten the round nuts, refer to 9403−4.
2 the area.
1
Fig. 7 013.694/05

Intentionally blank
Crosshead
Clearances
Tools:
1. General
During an overhaul or after the installation
of the crosshead, you must do as follows:
FUEL SIDE 1) Measure and record the clearances
5 shown in Fig. 1 and Fig. 2.
1 2) Compare the clearances with those
given in 0330−1 Clearance Table
Crosshead Guide.
A
2. Clearance Checks
2.1 Guide Shoe and Guide Way

1) Make sure that the related crosshead
4 B
pin (4) is in a position so that the guide
shoes (1) and (5) touch the guide ways
(3) (on the fuel side or exhaust side).
2) Measure the clearance (C) between the
guide shoe (1) and the guide way (3).
Note: The clearance (C) is applicable for
the full length of the guide way (3)
and measured at the position
3 2
D C WCH03529 shown in Fig. 2.
Fig. 1
2.2 Crosshead
1) Measure the lateral clearance (D) at
each position of the crosshead as
follows:
a) Use an applicable hardwood
wedge (or an item that is almost
30° BEFORE OR the same) to push the crosshead
AFTER TDC axially to one side. Make sure that
you apply the pressure only to the
90° BEFORE OR guide shoe.
AFTER TDC
C
30° AFTER OR 2.3 Guide Shoe and Top End
BEFORE BDC Bearing
1) Measure the full lateral clearance (A)
between the top end bearing (2) and
the the guide shoes (1, 5).
2.4 Radial Clearance

1) Measure the radial clearance (B)
WCH03529
between the guide shoe (5) and the
Fig. 2 crosshead pin (4) at all positions of the
crosshead.

Intentionally blank
Crosshead
Crosshead Pin − Removal and Installation

the
Tools:
1 Deviation pipe 94117A 2 Manual ratchet 800 kg, H4, H5 94016-001
1 Work platform 94142 2 Manual ratchet 1600 kg, H2, H3 94016-007
1 Lifting plate 94324 1 Manual ratchet 3200 kg, H1 94016-013
2 Lifting rings 94332 2 RUD eye bolt EB 94040-M30
1 Lifting tool 94335 Shackle 94018
1 Wire rope sling 94666 1 Spur−geared chain block (H6) 94017−22
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Crosshead Pin − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Guide Shoes − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Guide Shoes − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Crosshead Pin − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Clearance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1. Preparation
WARNING

2) Operate the turning gear to move the applicable crank to BDC.
3) Lock the turning gear to prevent an accidental engine start.
4) Install the work platform (94142), refer to 3301−1.
5) Attach the deviation pipe (94117A) to the column.
6) Remove the inner piston cooling pipe, refer to 3603−1.
7) Prepare the piston, refer to 3303−5 paragraph 1.
8) Remove the top bearing cover, refer to 3303−5 paragraph 2.

1 2. Crosshead Pin −
Removal
94666
1) Attach the sling (94666, Fig. 1) to the
H1
attachment points (1) in the column.
94324 2) Attach the lifting plate (94324) and
3 shackles to the crosshead pin (2) with
94324 the round nuts (3) removed from the
piston rod foot.
2
3) Attach the sling (94666) to the manual
ratchet (H1) and to one of the shackles
3 94142 on the lifting plate (94324).
Fig. 1 013.237/05
4) Attach the eye bolts (EB, Fig. 2) to the

connecting rod (2) as shown.
the attachment points in the column
and the eye bolts (EB). Apply a light
tension to the manual ratchets.
1
to lift the crosshead pin (1) as far as
H2
H3 possible.
EB EB
2
013.238/05
Fig. 2

7) Put the wooden chock (1, Fig. 3) in the

bottom corner of the column as shown.
to move the crosshead to the exhaust
94666 side a small distance. Make sure that
the connecting rod cannot move back
to the fuel side.
EXHAUST SIDE
the related eye bolt (EB).
H2 10) Operate the manual ratchet to move
the connecting rod until on to the
wooden chock (1).
1
Fig. 3 013.239/05
12) Operate the manual ratchet (H1, Fig. 4)

to lower the crosshead pin (1) to the
same height as the column door frame.
H1
Fig. 4 013.240/05

I 13) Attach the lifting rings (94332, Fig. 5) to

the cylinder block (6) with the
screws (5).
15) Attach the eye bolts (EB) to the guide
shoes (1, 4).
16) Connect the manual ratchets (H4, H5)
to the lifting rings (94332) and the eye
bolts (EB).
to hold the weight of the guide
shoes (1, 4) from the crosshead pin.
18) Remove the bolts (2, Fig. 6), tab
washers (5) and holding plates (3)
from the guide shoe (1).
013.241/05
I-I
6 94332
5
1
H5 2
H4
3
5
1
4
EB EB
3
2 94324 Fig. 6 WCH03529
013.242/05
Fig. 5

19) Move the crosshead pin (1, Fig. 7) to

H4 the driving end as shown.
the guide shoe (2).
DRIVING END
013.243/05
21) Move the crosshead pin (1) to the free

end.
H5
the guide shoe (3).
1
FREE END
013.244/05
Fig. 7


94335 between the double-I girders.
tool (94335).
H6 25) Turn the crosshead pin 90_.
crosshead pin.
H1 crosshead pin from the column.
I
94324 3. Guide Shoes − Removal
1) Record the positions of the guide
shoes. The shims of the guide shoes
can have different dimensions. This will
help you during the installation
procedure.
I
to the eye bolt (EB) at the free end.
3) Lower the guide shoe to the door
Fig. 8 frame.
013.245/05a
94117A
5) Turn the guide shoe (1) in the center of
the cylinder.
I I-I
H4
H5 H4 H5
94666
H1
DRIVING END
H1
EB
1 1
013.246/05
013.247/05 013.248/05
Fig. 9
I

6) Attach the chain block (H6, Fig. 10) to

the guide shoe.
H6 7) Operate the manual ratchet (H1) and
guide shoe from the engine.
8) Do step 2) to step 6) for the guide shoe
attached to the manual ratchet (H5).
H1
4. Guide Shoes −
Installation
Note: When you the steps below, make
sure that you install the guide
shoes in their original positions.
1) Attach the chain block (H6) and the
manual ratchet (H1) to the guide shoe.
2) Apply a light tension to the chains of
the manual ratchets (H6, H1)
Note: When you step 3) to step 5), keep
Fig. 10 013.249/05a the tension on the two manual
ratchets.
manual ratchet (H1) to move the guide
shoe through the door frame.
to the eye bolt on the guide shoe. Apply
tension to the chain.
5) Remove carefully the chain block (H6).
to lift the guide shoe.
8) Do step 1) to step 7) for the other guide
shoe (use the manual ratchet (H4) .
H6
5. Crosshead Pin −
Installation
1) Clean the crosshead pin (1, Fig. 11)
and the guide and bearing surfaces.
H1
2) Make sure that the surfaces of the
I
1 crosshead pin are clean and have no
94324 damage.
3) Apply bearing oil to the crosshead
pin (1) and all guide and bearing
surfaces.
4) Attach the chain block (H6) and the
manual ratchet (H1) to the crosshead
pin (1).
manual ratchet (H1) to move the
crosshead pin (1) through the door
frame.
013.245/05a
Fig. 11 6) When the crosshead pin is in the
column, remove the chain block (H6).

7) Turn the crosshead pin (1, Fig. 12) 90° .

H4
8) Move the crosshead pin (1) to the
driving end.
9) Lower and align the guide shoe (2) with
the crosshead pin (1).
2 10) Move the crosshead pin (1) fully

through the guide shoe (2).
11) Lower and align the guide shoe (3) with
the crosshead pin (1).
1
12) Align the crosshead pin (1) with the two
DRIVING END
guide shoes (2, 3).

13) Attach the two holding plates (5) to the
to the guide shoe (2, 3) with new tab
washers (6) and bolts (4).
1 14) Make sure that there is no clearance

between the holding plates (5) and the
4
crosshead pin (1).
2, 3 15)
6
5
013.243/05
H5 WCH03529
NO CLEARANCE
1
FREE END
013.244/05
Fig. 12


to the eye bolt on the connecting rod.
move the connecting rod (1) sufficiently
to remove the wooden chock (2) and
H1 attach the eye bolt (EB).
18) Remove the wooden chock (2).
19) Attach the eye bolt (EB) to the
connecting rod (1).
H2
3 20) Attach the manual ratchet (H3, Fig, 14)
1 to the eye bolt (EB).
EB
Note: During the step below, slowly
2
move the connecting rod (1) to the
middle of the column.
21) Gradually tighten the manual ratchet
(H2). At the same time, keep tension
on the chain of the manual
ratchet (H3).
22) Continue with the step above until the
connecting rod (1) aligns with the
crosshead pin (3).
013.239/05 Note: During the step below, make sure

that the elastic bolts in the
connecting rod align with the
Fig. 13 holes in the crosshead pin.
23) Carefully lower the crosshead pin (3)
on to the connecting rod (1).
24) Remove the lifting tools.
25) Remove all the manual ratchets and
the chain block.
3 26) Remove the protection from the
H2 crosshead pin (3).
H3
27) Install the inner piston cooling pipe,
refer to 3603−1 paragraph 3.
EB
1
013.238/05
Fig. 14

6. Clearance Checks
1) Do the clearance checks, refer to 3326−1.
7. Completion
1) Install the round nuts to the elastic studs on the connecting rod, refer to 9403−4.
2) Install the top bearing cover, refer to 3303−5 paragraph 3.
3) Attach the piston to the crosshead, refer to 3303−5 paragraph 4.
4) Set to on the lubricating oil pump.
5) Make sure that the crosshead and the bottom end bearings of the connecting rod
have sufficient lubrication.

Piston

Tools:
1 Working platform 94142 1 Spacer 94344A
2 Nuts 94142A 2 Chains 94344B
1 Support 94143 2 Distance holders 94345
1 Dismantling tool 94208 1 Piston supporting device 94350
1 Lifting hook 94209 1 Inserting cone 94342
2 Lifting bosses 94333A 1 Lifting tool 94341
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Preparation
WARNING
make sure that no
1) Read the data in 0012−1General

Guidelines for Lifting Tools.
4) Make sure that all tools and equipment
94143 are clean.
5) Remove the cylinder cover, refer to
2708−1.
94142 6) Look at the area of the piston ring
stroke. If there is unwanted material,
Fig. 1 WCH03299
refer to the procedure in 2124−3.
7) Clean the top part of the cylinder liner.
8) Install the piston supporting device
94350 on the gallery.
9) Install the work platform (94142) and
the support (94143), refer to 3301−1.
1 10) Attach the tool (94208, Fig. 2) to the
antipolishing ring (1) with the three
94208
screws.
11) Attach applicable equipment to to the
engine room crane and the tool
(94208).
Fig. 2
remove the antipolishing ring (1).

Piston: Removal and Installation
2. Removal
1) Remove the work platform (94142) and
2 the support (94143).
crank (1, Fig. 3) approximately 90° to
BDC.
3) Remove the four round nuts (2, Fig. 3)
from the piston rod foot (1), refer to
9403−4.
Fig. 3 WCH00082
4) Remove the four inner bolts (5, Fig. 4)

from the support (6). Do not remove the
support (6).
6
5) Attach the two eye bolts (EB) to the
5 support (6).
6) Attach the lifting bosses (94333A) to
EB the piston rod foot (4) with the Allen
screws (3).
7) Attach the two suspension chains
(94344B) to the eye bolts (EB) and the
94344B lifting bosses (94333A).
that the bolts of the piston rod foot
do not catch.
94333A 94344B
3 crank to BDC until the chains are tight.
4
Fig. 4


crank to BDC.
10) Put the spacer (94344A, Fig. 5) on the
crosshead pin (1).
94344A
Fig. 5 WCH03082

crosshead up sufficiently so there is no
tension on the chains (94344B, Fig. 6).
94344B
12) Remove the chains 94344B the eye
bolts (EB) and the lifting bosses
(94333A)..
Fig. 6 WCH03082
13) Attach the two distance holders (94345,

Fig. 7) to the piston rod foot (1) with the
four screws.
94345
1
Fig. 7

14) Before you move the crank to TDC,

1 make sure that:
D The four inner bolts (1, Fig. 8) are
94345
removed.
D The distance pieces (94345) are in
line with the gland box.
Fig. 8
Note: When you do step 15), the piston

moves up and the the distance
pieces (94230) move the gland box
up.
move the piston to TDC.
1 16) Clean the three holes (1, Fig. 9) in the
piston crown.
Fig. 9 WCH03082
1
17) Make sure that the tool (94341, Fig. 10)
94341 is clean.
18) Remove the six bolts (1) and the three
2 brackets (2).
19) Apply Molykote paste G−n to the
threads of the six bolts (1).
Fig. 10
I 20) Attach the crane hook (4, Fig 11) to the
lifting tool (94341).
21) Carefully lower the tool (94341) on to
the piston crown. Make sure that the
94341 1 grooves for the brackets (2) align with
the holes in the piston crown (3).
2
3 Note: To help you align the brackets (2),
first attach one bracket to the
tool (94341).
22) Attach the three brackets (2) to the
I tool (94341) with the six bolts (1). Make
WCH03299 sure that the brackets fully engage in
4 23) Torque the six screws (1) to 85 Nm.
Fig. 11

24) Make sure that the piston support

94350 tool (94350, Fig. 12) is in the correct
position on the top platform.
1
3 25) Loosen the four screws (3).
26) Move fully out the two supports (1).
27) Lift and lock the plates (2) in the
2 vertical position.
28) Apply protection to the crosshead pin
and the top end bearing to prevent
damage and contamination.
29) Operate the crane to carefully lift the
Fig. 12 piston from the cylinder. Make sure that
the piston rod foot does not touch the
support of the piston rod gland box.
94341 30) Lower and align the piston between the
supports (1, Fig. 13) until the piston rod
foot is below the plates (2).
31) Close the plates (2).
32) Push fully in the two supports (1).
33) Tighten the four screws (3).
34) Lower the piston on to the supports (1).
35) Remove the crane hook from the
1 tool (94341).
36) Remove the distance holders (94230)
94350
from the piston rod foot.
38) To disassemble the piston, refer to
2 3403−3.
WCH03413
39) Do a check of the top surface of the
piston, refer to 3403−4.
40) Do a check of the piston rings and
grooves, refer to 3425−1.
41) Measure the bore of the cylinder liner,
1
refer to 2124−1.
42) If necessary, dress the lubricating
grooves and scavenge air ports, refer
to 2124−3.
2
43) Refer to the Maintenance Schedule for
other work on each piston 0380−1.
Select the related data.
94230
Fig. 13
WCH03082

3. Installation
1) Make sure that the items that follow are
clean and in a satisfactory condition:
1
D All parts of the piston rod gland
D The piston ring grooves and the
piston rings
D All surfaces of the piston.
94209 2) Make sure that the O-rings in the piston
rod gland are in a satisfactory
condition.
3) Apply oil to the bore and O-rings of the
94342
piston rod gland.
4) Apply oil to the piston rings, piston skirt,
piston rod and running surface of the
3 2 cylinder liner.
5) Install the piston rings, refer to 3425−1.
6) Put oil on the surfaces of the cone
(94342, Fig. 14).
Fig. 14 7) Put oil on the bore and the O-rings of
the piston rod gland.
correctly installed on the piston rod.
9) Attach the sling (94209) to the engine
room crane.
10) Operate the crane to put the
94341 tool (94342) in position on the cylinder
liner (3). Lock the tool in position with
the three bolts (2).
1 11) Make sure the distance holders (94345,
Fig. 7) are installed on the piston rod
foot (1).
2 12) Make sure that the spacer (94344A,
Fig. 15) is in position on the crosshead.
13) Attach the tool (94341) to the piston
crown, refer to step 17) to step 23)
above.
94344A 14) Attach the engine room crane to the

tool (94341).
crank to TDC.
16) On the piston support tool (94350)
loosen the screws (3, Fig. 12).
17) Turn and lock the two plates (2) up
before the piston touches them.
18) Lift the piston together with the piston
rod gland from the tool (9350)
Fig. 15 19) Lift the piston together with piston rod
WCH03299 gland from the tool (94350).
20) Move the piston (1, Fig. 15) into
position above the cylinder liner (2).

21) Make sure that each clearance in the

piston rings is opposite the clearance in
the piston ring above/below.
that you do not damage the
cylinder liner (2) or the support for
4 the piston rod gland.
22) Carefully lower the piston 1, Fig. 15)
3
into the cylinder liner (2) until the piston
rod foot touches the spacer (94344A).
EB
24) Remove the distance pieces (94230)
from the piston rod.
94344B 25) Attach the lifting bosses (94333A,
Fig. 16) to the piston rod foot (2).
26) Attach the two eye bolts (EB) and the
lifting bosses (94333A) to the piston
rod foot (2).
27) Attach the two eye bolts to the support
ring (4).
EB
28) Attach the two chains (94333B) to the
94333A four eye bolts (EB).
94344A piston to BDC until the two chains
1 (94333B) have tension.
30) Continue to operate the turning gear to
move the crank to BDC until you can
remove the spacer (94344A).
31) Remove the spacer (94344A).
that the bolts on the crosshead (1)
align with the holes in the piston
rod foot.
WCH03082
crosshead to TDC.
in the correct position for the dowel pin
(5) to engage with the support (4).
34) Make sure that the chains (94333B)
I I-I have no tension.
5 35) Remove the chains (94344B), the eye
bolts (EB) and the lifting
bosses (94333A).
36) Attach the piston rod gland to the
support (4) with the four new locking
plates and four M16x60 bolts (3).
I
WCH02292 37) Bend the locking plates to lock the four
bolts (3).
Fig. 16

38) Put oil on the four elastic studs (2,

1 Fig. 17).
39) Attach the four round nuts (3) to the
2 elastic studs (2).
40) Tighten the four round nuts (3), refer to
9403−4.
Fig. 17

tool (94209, Fig. 18).
42) Remove the three bolts (2).
1
remove the tool (94209) from the
cylinder liner (3).
94209
94342
3 2
44) Make sure that the cylinder liner and

Fig. 18 the anti-polishing ring (1, Fig.19) are
clean and in a satisfactory condition.
45) Put oil on the surfaces of anti-polishing
ring (1).
46) Connect the crane to the lifting
1 tool (94209).
94208
47) Attach the tool (94208) to the
tool (94208).
48) Operate the crane to lower the
anti-polishing ring (1) into the cylinder
liner.
Fig. 19 49) Remove the lifting tool (94209) and the
tool (94208).

4. Completion
1) Install the cylinder cover, refer to 2708−1.
2) Set to on the bearing lubrication pump.
3) Look through the scavenge ports on the fuel side. Make sure that the running
surface of the cylinder liner stays dry.
Note: A defective O-ring in the piston rod gland can cause an increase of the
dirty oil level in the scavenge air space.
4) Do a function check of the cylinder lubrication, refer to 7218−1, paragraph 1.2.
5) Remove all tool and equipment from the work area.

Intentionally blank
Piston
Changing the Compression Shims

Tools:
1 Working platform 94142
2 Lifting bosses 94333A
2 Suspension chains 94333B
1. Compression shim − Removal and Installation

1
RC
94333B
I I
94333A 2
I-I
4 94333A
94142
3
2
5
013.553/05
Fig. 1 013.552/05
Note: Pay attention to:

D General Guidelines for Lifting Tools 0012−1.
D Utilization of Working Platform 3301−1.
WARNING
that no personnel are near the flywheel.
1) Turn crank of the cylinder concerned to B.D.C.

2) Install working platform 94142, refer to the instruction in 3301−1.
3) Loosen the nuts of the waisted studs for the screwing of piston rod foot 3 and
crosshead pin 4, as described in 3403−1.
4) Attach the lifting bosses 94333a with their Allen screws 5 on the piston rod foot.
5) Screw two RUD-eye bolts ’RC’ into piston rod gland support 1 and hang both
suspension chains 94333B on them as shown in Fig. 1.
6) Remove the working platform 94142.
7) Turn the crank up to exhaust side until the suspension chains 94333B can be put
into lifting bosses 94333A, as shown in Fig. 2.

Piston: Changing the Compression Shims
The crank may be turned max. 30_

towards T.D.C.
Pay attention to the warning plate provided
on the holders!
94333B CAUTION
94333A Carefully turn the crank
down until waisted studs 7
are out of piston rod foot 3
(Fig. ’3’).
Be careful, that the two
dowel pins 8 in crosshead
pin 4 do not jam in the pis-
ton rod foot.
8) Loosen and remove the screws
fastening compression shim 6.
9) Use the two eye bolts to remove the
compression shims 6.
For installation a new compression shim,
note that there are two different
compression shims, see below. Use an
applicable one for installation. Do the
installation in a reverse sequence to the
removal.
Fig. 2 013.691/05 Note: Please note the correlation
between setting screw ’ST’ on
measuring gauge 94225 (see
2124−1) and the mean thickness of
built-in compression shims.
I
RC
94333B
I
013.693/05
7 II
94333A
3
II
COMPRESSION SHIMS:
7 8
6 ONLY FOR ENGINES
WITHOUT ADDITION
HP CROSSHEAD
LUBRICATION PUMP
ONLY FOR ENGINES

Fig. 3 013.692/05
WITH ADDITION
HP CROSSHEAD
LUBRICATION PUMP
013.694/05

Piston

Tools:
1 Suspension device 94341 1 Hydr. distributor 94934A
2 Pre-tensioning jacks 94346 2 Coupling elements 94934G
1 Piston supporting device 94350 3 HP hoses 94935
2 Jacking screws 94364 1 Hydraulic unit 94942
1 Connection block 94934 1 Torque wrench
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. General
2) Remove the piston, refer to 3403−1.
Note: You disassemble a piston to clean the chamber in the piston head, do an
overhaul of the ring grooves etc.
Note: When you do step 3), apply tension to the elastic bolts in the sequence
given in Fig. 1.
3) Apply tension to the elastic bolts (1) to loosen the eight round nuts, refer to
9403−4, paragraph 1 and paragraph 2.
4) Remove the 12 round nuts (1).
c a
b d
d b
a c
c a
b d
Fig. 1: Sequence to Apply Tension to the Elastic Bolts

Piston: Disassemble and Assemble
2. Disassemble
CAUTION
Damage Hazard: When you
disassemble the piston,
I make sure that you do not
damage the pipes or
nozzles on the spray plate.
1) Put the two jacking screws (94364A,

Fig. 2) fully into the two tap holes in the
top of the piston rod (3). Make sure that
the jacking screws touch the piston
head (2).
I
2) Tighten equally the two jacking screws
I-I until there is a clearance between the
piston head (3) and the piston rod (2).
3 94364 3) Make sure that the tool (94341) is

clean.
1 4) Remove the six bolts (1) and the three
2 brackets (2).
Fig. 2 5) Apply Molykote paste G−n to the

WCH030092
threads of the six bolts (1).

1 lifting tool (94341, Fig 3).
94341 7) Attach the crane hook to the lifting tool
(94341).
2 8) Carefully lower the tool (94341) on to

the piston crown. Make sure that the
grooves for the brackets (2) align with
Note: To help you align the brackets (2),
first attach one bracket to the
tool (94341).
9) Attach the three brackets (2) to the
tool (94341) with the six bolts (1). Make
94341 sure that the brackets fully engage in
10) Torque the six screws (1) to 85 Nm.
3 11) Operate the engine room crane to lift
the piston crown (3).
12) Move the piston crown (3) to an
WCH03299
applicable area.
4
13) Remove the jacking screws (94364A)
Fig. 3 from the top of the piston rod.

1 CAUTION
Damage Hazard: If it
becomes necessary to
remove the the elastic
studs, do not use a pipe
wrench. This could cause
damage to the bolt shank.
14) Remove the piston skirt (5, Fig. 4) from

the piston rod (6) as given in step a) to
step c):
a) Remove the two bolts (7).
8 WCH03092
b) Use the jacking screws (94364C)
to remove the piston skirt (5) from
2 the piston rod (6).
3 Note: When you lift the piston skirt
(5) make sure that the spring
4 dowel pin (1) does not catch.
c) Lift the piston skirt (5) away from
the piston rod (6).
5 15) Remove the 12 bolts (8).
8
16) Use the two jacking screws (94364B) to
remove the spray plate (4) from the
piston rod (6).
7
17) If necessary, remove the pipes (3) and
nozzles (2).
18) Do a check of the top surface of the
6 WCH03092
piston head, refer to 3403−4.
Fig. 4

3. Assemble
1
Note: Do not install pipes or nozzles that
2 have damage.
I
1) Apply LOCTITE No. 0270 to the thread
3 of the pipe (2, Fig. 5).
2) Use the applicable tool to install the
4 pipe (2) to the spray plate (4).
I 3 3) Use a center punch to lock the pipe (2)
Center in position.
Punch 4) Apply Loctite No. 0270 to the thread of
here the nozzle (1).
Fig. 5
5) Put oil on the new O-rings (3).
6) Install the two new O-rings (4) on the
spray plate (4).
7) Install a new O-ring to the piston rod.
8) Attach the spray plate (5, Fig. 6) to the
piston rod (6) with the 12 screws (8).
9) Torque the 12 screws (8) as follows:
a) Symmetrically torque the 12
94341 screws to 12 Nm.
b) Symmetrically torque the eight
screws to an angle of 30° . This is
equal to to a torque value of
1
22 Nm.
that the dowel pin (3) engages in
2 the related hole in the piston
WCH03299 I-I skirt (5).
1
10) Attach the piston skirt (5) to the piston
rod (6) with the two screws (7).
3 lower the piston head (1) on the piston
skirt (5). Make sure that the dowel pin
(3) engages with the hole in the piston
I
head (1).
I
4
5
8
Fig. 6 WCH03092
6

12) Refer to Fig. 1 for the sequence to

apply tension to the elastic studs.
13) Apply tension to the 12 elastic studs (1,
Fig. 7).
14) Tighten the round nuts (1) on the
elastic bolts (2).
15) Install the piston, refer to 3403−1,
paragraph 3.
1
2
Fig. 7

Intentionally blank
Piston
Top Surface Check

Tools:
1 Template 94366A
1 Template 94366B
1. General
Each time you remove a piston, you must do a check of the top surface of the piston
head for damage (burn scars).
The causes of burn scars are as follows:
D Poor combustion
D Worn nozzles
D Heavy local carbon particles on top of the piston head etc.
Note: You can also do this check with the piston installed.
94366B 2. Procedure − Piston

Removed
1) Put the template (94366B, Fig. 1) in
position on the top piston ring.
10 mm 2) Turn the template (94366B) around the
axis of the piston head.
measure the depth of the burn scar(s).
Piston 4) Remove the template (94366B).

018.587/09 Ring Note: You can also use a depth gauge to
measure the depth of the burn
Fig. 1 scar(s).
5) If the burn scars are less than 10 mm,
do step a) and step b):
a) Use an applicable tool to grind the
burn scars.
b) Use emery paper to make sharp
edges smooth.
6) If the burn scars are more than 10 mm,
do step a) to step c):
a) Remove the piston head, refer to
3403−3, paragraph 1 and
paragraph 2.
b) Do the procedure to surface weld
and repair the piston head to its
original thickness.
c) Assemble the piston (refer to
3403−3, paragraph 3).
Note: Before you start the engine, find
the cause of the burn scars.

Piston − Top Surface Check
94366A
1 3. Procedure − Piston
Installed
WARNING
make sure that no
10 mm personnel are near the
flywheel, or inside the
009.901/02
Fig. 2 engine.

piston to BDC.
2) Look at the piston head through the
scavenge ports (1, Fig. 2) to find burn
scars.
3) Put the template (94366A) through the
related scavenge port.
4) Use the feeler gauge 94122 to
measure the depth of the scar(s).
Note: You can also use a depth gauge to
measure the depth of the burn
scar(s).
5) Remove the template (94366A).
6) If there are more burn scars, put the
template (94366A) through the related
scavenge port (1) and do step 2) to
step 4) again:
7) If the burn scars are less than 10 mm,
do step a) and step b):
a) Use an applicable tool to grind the
burn scars.
b) Use emery paper to make sharp
edges smooth.
8) If the burn scars are more than 10 mm,
do step a) to step d):
a) Remove the piston, refer to
3403−1 paragraph 1 and
paragraph 2.
b) Remove the piston head, refer to
3403−3, paragraph 1 and
paragraph 2.
c) Do the procedure to surface weld
and repair the piston head to its
original thickness.
d) Assemble the piston (refer to
3403−3, paragraph 3).
Note: Before you start the engine, find
the cause of the burn scars.

Piston Rings
Piston Rings and Ring Grooves − Rate of Wear

Tools:
1 Inside micrometer 94101 1 Permascope MP0 94356
1 Feeler gauge 94122 (with instruments to
1 Piston ring tool 94338 measure chrome-ceramic
layers)
1 Calliper gauge
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Piston Ring − Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Chrome-ceramic Layer − Measure (Piston Installed) . . . . . . . . . . . 2
2.2 Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Service Life − Calculate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Piston Ring Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Piston Ring Clearance (Piston Installed) . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Piston rings − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Piston Ring Clearance (Piston Removed) . . . . . . . . . . . . . . . . . . . . . 6
3.4 Used Piston Rings − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 New Piston Rings − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Piston Rings − Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. General
Use the data in paragraph 2.1 and paragraph 2.3 to make an analysis of the of the
condition of the cylinder liner, piston and piston rings.
The rates of wear are related to the type of fuel used, the engine load profile, ambient
conditions etc, during engine operation.
Visual inspections show very important conditions of cylinder liners and piston rings
after a short time. For more data to monitor the cylinder liner and piston ring
conditions, refer to the Operation Manual 0750−1 Lubricating Oils.
When you measure and record the piston ring grooves, the data is used to calculate
the wear.
Refer to 0380−1, Piston Rings for the scheduled intervals.

Piston Rings and Grooves − Rate of Wear Three Piston Rings
2. Piston Ring − Rate of Wear
2.1 Chrome-ceramic Layer − Measure (Piston Installed)

WARNING
1) Read the data in the suppler documentation for the Permascope MP0 (94356).
2) Calibrate the Permascope MP0 (94356). Use the calibration foils and the top
flank of a spare top piston ring to get a correct setting.
3) Operate the turning gear to move the piston almost to BDC (so that you can see
the piston rings).
4) Clean the surface of the piston ring (1, Fig. 1) at the locations P1 to P9.
5) Put the sensor of the Permascope MP0 (94356) against the middle of the piston
ring (1).
6) Record the value on the digital display of the Permascope MP0 (94356).
7) Compare the measured data with the limits given in 0330−1, Clearance Table,
Piston and Piston Rings. If the recorded data is not in the limits given, you must
do an overhaul of the piston head.
Locations to Measure the Thickness of the

Chrome-ceramic Layer on the Piston Ring
Minimum Recommended
P9 P1 P9 P1
1 94356
P7 P3
WCH01216
P5 P5
Fig. 1

2.2 Rate of Wear

The rate at which the the chrome-ceramic layer becomes worn is related to the
operation conditions. If a piston ring that has some wear of the chrome-ceramic layer
is found (see Fig. 2), do an overhaul of the unit as soon as possible.
Chrome-ceramic
Layer is Worn
Fig. 2
With regular procedures to measure the chrome-ceramic layer, you can calculate the
rate of wear for each piston ring.
You can continue to use the piston rings if the remaining chrome-ceramic layer is
more than the limits that follow:
D Top piston ring, more than 0.05 mm
D Middle and bottom piston rings, more than 0.02 mm
If the thickness of the chrome-ceramic layer is less than the limits given, you must
replace the applicable piston ring.

2.3 Service Life − Calculate

Use the formula below to calculate the rate of wear of a piston ring:
(D1−D2) x 1000
WR =
T2−T1
Where:
D WR = Rate of Wear (mm/1000 hrs)
D T2 = Time (hrs)
D T1 = First recorded operation hours (hrs)
D D1 = First recorded thickness of the chrome-ceramic layer (mm)
D D2 = Second recorded thickness of the chrome-ceramic layer (mm).
See Table 1 for examples of results.
Table 1: Rate of Wear − Examples
D1 D2 T1 T2 WR
0.382 0.367 0 (new) 1500 0.01
0.351 0.340 3500 5000 0.0073
Use the formula below to calculate the remaining piston ring service life:
(D2−Dmin) x 1000
LT =
WR
Where:
D LT = Remaining in-service time (hrs)
D D2 = second recorded thickness of chrome-ceramic layer (mm)
D Dmin = Minimum thickness of the chrome-ceramic layer (mm) (see paragraph
2.2)
D WR = Calculated rate of wear (mm/1000 hrs)
Table 2: Example for Remaining Service Life
D1 D2 Dmin T1 T2 WR LT
0.382 0.367 0.05 0 (new) 1500 0.01 31700
0.351 0.340 0.05 3500 5000 0.007333 39545

3. Piston Ring Grooves

Do a check of all dimensions and record them (see 0330−1 Piston and Piston Rings).
These records are important for an analysis of the running gear and must include the
data that follow:
D All dimensions
D The date of the overhaul
D The operation hours of the different components
D The operation hours of the engine.
3.1 Piston Ring Clearance

2 X2 (Piston Installed)
WARNING
1
Possible Shape make sure that no
On Piston Groove personnel are near the
X2
piston (2, Fig. 3) down.
2 Note: Push the feeler gauge fully into the

groove in the piston head. This will
make sure that the feeler gauge
1 will touch the inner diameter of the
groove.
2) Measure the clearance X1 at Point A. If
there is unwanted material on the
chrome-ceramic layer, you can push
94122 the feeler gauge only to that point.
X1 3) Measure the clearance at X2.
4) Do step 2) and step 3) above at
2 between two and four different
locations around the piston (2).
X1
The sum of each value from X1and X2 will
give the total piston ring clearance.
1 A
The maximum clearance is at point A. For
the maximum wear data, refer to 0330−1,
Piston and Piston Rings.
Unwanted Material On 5) If the clearance at point A is more than
Chrome-ceramic Layer the permitted value, do step a) and
2 step b)
a) Replace the piston rings.
1 WCH02244
b) Repair the piston head.
Fig. 3 Note: For the repair of piston heads,
speak to the nearest Wärtsilä
Service Center.

3.2 Piston Rings − Removal

CAUTION
Damage Hazard: Do not open the piston rings too far. This will
cause damage to the piston rings.
Note: If the same piston rings will be installed again, record their positions.
1) Use the tool (94338, Fig. 4) to remove the top, middle and the bottom piston
rings (1). Make sure that you do not damage the chrome-ceramic surface.
2) Clean the piston grooves.
3) Clean piston, piston rings and the grooves in the piston head.
94338
I-I
I 1
I
Fig. 4 WCH02956
3.3 Piston Ring Clearance (Piston Removed)

Note: You can use a calliper gauge, an inside micrometer set (94101, paragraph
3.3.1), or a piece of piston ring (paragraph 3.3.2) to measure the grooves
in the piston head.
3.3.1 Procedure with Calliper Gauge or Inside Micrometer Set

1) Use the calliper gauge (1, Fig. 5) or inside micrometer set (94101) to measure
the height of the groove at point A and point B. Measure the height of the groove
at a minimum of four locations around the circumference of the piston head.
2) Record the value from the calliper gauge (1) or inside micrometer set (94101).
3) If the clearance at point A or point B is more than the permitted value, you must
repair the piston head.
B
A
WCH02244
1
Fig. 5 Possible Shape On
Worn Piston Groove
Note: If the clearance at point A and, or point B is more than the permitted
value, you must repair the piston head. For the maximum values, refer to
0330−1, Piston and Piston Rings.

3.3.2 Alternative Procedure with Piston Ring Piece

1) Measure the thickness of the piece of piston ring (1, Fig. 6).
X1
2
1
94122
Fig. 6 WCH02244
2) Put the piece of piston ring (1) into the piston ring groove.
3) Use the feeler gauge (94122) to measure the clearance (X1) between the face of
piston ring and the groove.
Note: You must measure the height of the groove at a minimum of four
locations around the circumference of the piston head (2).
4) Use the data that follow to calculate the piston ring clearance:
C = GH − RT
Where:
D C = Clearance (mm)
D GH = the measured height of the piston ring groove (mm)
D RT = the nominal piston ring thickness (mm).
Note: If the clearance at X1 is more than the permitted value, you must repair
the piston head. For the maximum values, refer to 0330−1 , Piston and
Piston Rings. For the repair of piston heads, speak to the nearest
Wärtsilä Service Center.
Do not install a piston head that has clearances near the maximum value. This is
because the service life will be too short.

3.4 Used Piston Rings − Installation

For the ring types and their locations, see Table 3.
Table 3: Standard Piston Ring Locations
Ring Type Material Application
Top Piston Ring

1 x GTP1CC17 (gas tight) chrome-ceramic layer For new and fully
honed cylinder liners
Middle Piston Ring and used cylinder
1 x SCP2CC15 (straight cut) chrome-ceramic layer liners in good
condition
Bottom Piston Ring
1 x SCP2CC15 (straight cut) chrome-ceramic layer
CAUTION
Note: Only install piston rings that are in a satisfactory condition. Make sure
that the mark TOP, on the piston ring, points up.
Note: The piston rings must be installed in the same position as before. Use
your recorded notes.
Note: Make sure that you use tool (94338, Fig. 7) to install the piston rings.
1) Install the bottom piston ring (4) to the piston head.
2) Install the middle piston ring (3) to the piston head.
3) Install the top piston ring (1) to the piston head. Make sure that the ring
clearance (5) is opposite the ring clearance (2) of the middle piston ring (3).
5
1
4
WCH02956 WCH02682
3
Fig. 7

3.5 New Piston Rings − Installation

CAUTION
Note: Make sure that the mark TOP, on the piston ring, points up.
Note: For the ring types and their locations, refer to Table 3.
Note: Make sure that you use tool (94338, Fig. 8) to install the piston rings.
1) Measure and record the thickness of the chrome-ceramic layer on each piston
ring. This will help you monitor the rate of wear during operation.
2) Install the bottom piston ring (4) to the piston head.
3) Install the middle piston ring (3) to the piston head.
4) Install the top piston ring (1) to the piston head. Make sure that the ring
clearance (5) is opposite the ring clearance (2) of the middle piston ring (3).
5) Refer to the Operation Manual, 0410−1 for the running-in procedure for new
piston rings.
5
1
4
WCH02956 WCH02682
3
Fig. 8
4. Piston Rings − Storage

Keep the piston rings in their original packages in a dry area. Make sure that the
piston rings are in a horizontal position on a flat surface.
To prevent damage, be careful when you prepare the piston rings for installation and
during movement.

Intentionally blank
Inner Pipe − Removal and Installation

Tools:
1 Lifting tool 94337
1 Centering piece 94337A
1 Flange 94337B
1. Removal
WARNING
1) Operate the turning gear to move the applicable crank approximately 30_ after
TDC.
2) Remove the oil inlet pipe (1, Fig. 1) from the piston cooling and crosshead
lubrication.
3) Attach the lifting tool (94337) to the inner pipe (2) and the engine room crane (3).
I
3
1
I
94337
II
013.399/05
Note: For View II,

see Fig. 2.
013.400/05
013.398/05
Fig. 1

Piston Cooling and Crosshead Lubrication: Removal and Installation of Inside Pipe
4) Loosen the screws (6, Fig. 2).

II 1
5) Loosen the screws (2).
2 6) Lower the ring holder (3) together with

3 sleeve (1).
crank to BDC.
5
8) Remove the inner pipe (4) together with
the sleeve (1) and the ring holder (3).
III
9 6
7
013.414/05
III
013.415/05
10 9 6 4
2. Oil Inlet Pipe

If the engine must operate with the
connecting rod removed do as follows:
1) Install the flange (94337B, Fig. 3) to the
inlet pipe (11).
11
5
4
1
3
94337B
Fig. 2 013.416/05
Fig. 3 013.417/05

Piston Cooling and Crosshead Lubrication: Removal and Installation of Inside Pipe
I 3. Installation
B applicable crank to BDC.
A
2) If necessary, remove the flange
8 (94337B, Fig. 3) from the inlet
1 pipe (11).
7
3) Attach the lifting tool (94337, Fig. 1) to
6
the inner pipe and the engine room
5 crane (3).
94337A 013.419/05 4) Push the ring holder (6, Fig. 4) and
sleeve (7) over the inner pipe (8).
5) Attach carefully the inner pipe (8) in the
connection piece (3). Hold the inner
pipe in position with the screws (2). Do
1 not tighten the screws at this step.
I 6) Operate the turning gear to carefully
move the crank approximately 30_ after
TDC.
7) Push the ring holder (6) and the sleeve
(7) into the bore of the cylinder
block (1). Hold the ring holder and the
sleeve with the screws (5). Do not
tighten the screws at this step.
8) Lightly tighten the screws (2, 5). Make
sure that you can move the inner
4 2
pipe (8) and the ring holder (6).
3
9) Use the centering piece (94337A) to
align the ring holder (6) and the inner
pipe (8) until you get the clearance A is
013.418/05
0.30 mm to 0.39 mm.
10) Tighten the screws (2, 5). Make sure
that there is a clearance B is between
0.08 mm to 0.20 mm as shown. Also,
do the check again to make sure that
the clearance A is 0.30 to 0.39 mm.
11) Install the oil inlet pipe 1 (Fig. 1).
Fig. 4

Intentionally blank
Driving Wheels and Shut-off Valve for Starting Air Group 4
Driving Wheels
Running and Backlash Clearances and Tooth Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−1/A1
Starting Air Shut-off Valve: Clean and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325−1/A1

Intentionally blank
Drive Wheels
Running and Backlash Clearances and Tooth Condition

Tools:
1 Feeler gauge 94122 1 Dial gauge
1 Micrometer 1 Lead wire Ø 1.5 mm
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Gear Tooth Backlash Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Feeler Gauge 94122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 Dial Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.3 Lead Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. General
On new engines during the running-in period, you must do a visual check of the gear
wheels after approximately one and two operation hours. You must do the same
checks on used engines that have new gear wheels installed.
2. Checks
WARNING
that no personnel are near the flywheel, or inside the engine.
1) Operate the turning gear to move the crankshaft while you do an inspection of all
teeth.
2) Set to on the service pump.
3) Make sure that oil flows freely from all nozzles.
4) Set to off the service pump.
5) Make sure that all screws are correctly locked.
6) After the running-in period, do a check of the drive wheels each three months as
given above. If faults show during this period, repair them.
7) If you hear unusual noises in the area of the gear train, you must find the cause.
Replace defective drive wheels as soon as possible to prevent damage to
adjacent drive wheels.
8) Do the inspection given above one time each year when the drive wheels have
operated correctly for between 6000 hours and 8000 hours,
To do checks of the clearances and tooth marks, you must tighten the tie rods and
elastic studs of the main bearing.

3. Gear Tooth Backlash

f1 Checks
f2 Refer to 0330−1, Driving Wheels for Supply
Unit (Group 4103) for data about the gear
tooth backlash values.
There are three procedures to measure the
backflash.
10 3.1 Feeler Gauge 94122

Drive Wheel 1) Measure the clearance between the
c
tooth flanks (10, Fig. 1). Do this
procedure at a minimum of four
positions around the circumference of
WCH02402
the gear wheel.
Gear Wheel
3.2 Dial Gauge

15 mm 1) Put the dial gage in a position where
Equal Distances you can read the backlash value when
the gear wheel moves.
15 mm 2) Make sure that the drive wheel does
b1 not move.
b3 move the gear wheel a sufficient
distance.
a1
10 4) Measure the backlash when one tooth
a3 of the gear wheel moves between the
b profiles of two gear wheel teeth.
c
WCH02402 a 3.3 Lead Wire
Note: Use a new lead wire of 1.5 mm
diameter (Pb 9.99 fine) each time
you measure the backlash.
1) Attach three lengths of lead wire
Lead Wire (approximately 200 mm) in the
positions shown with Scotch tape.
2) Put marks (0 to 9) on the tooth profiles
0
as shown.
1
2
gear wheel. Make sure that the lead
3
wire goes once through the teeth of the
4 gear wheel and drive wheel.
5
The lead wire (c) shows the full backlash (f).
6 The lead wires (a) and (b) show the
7 parallelity of the tooth profile.
8 The obliquity Df is the difference between
9 the values of the wires on the drive flanks
WCH02402 (1) between e.g. a1 − b1.
4) Remove the lead wire.
Fig. 1

5) Use the micrometer to measure the lead wire.

6) Calculate as follows:
D The full tooth backlash: f = f1 + f2
D The obliquity: Df = a1 − b1 or a3 − b3.
The permitted difference of the tooth profile parallelity is between 0.0% and 0.2%
across the width of the tooth.
4. Performance
After commissioning, do a check of the performance of the gear train as follows:
1) Apply a thin layer of oil resistant engineer’s blue ink to three of the teeth on each
of the gear wheels.
2) Operate the turning gear.
3) Do a check of the marks on the gear wheel teeth and driving wheel teeth. This is
to make sure that the teeth engage correctly and are parallel.

Intentionally blank
Starting Air Shut-off Valve
Clean and Function Check

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Shut-off Valve − Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.1 Initial Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.2 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.3 Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. General
Read the data in 0380−1 Maintenance Schedule for the necessary maintenance and
intervals on the shut−off valve for starting air (shut-off valve).
Read the data in the Operation Manual 4003−2, Engine Control Diagram and 4003−9,
Pipe Diagram − Air Systems.
2. Preparation
1) Engage the turning gear.
2) On the starting air bottles 9.01, close
1 the stop valves.
4
3) Open the vent valves 2.21 and 2.27 to
release the air in the system.
4) Disconnect the electrical connections
AO I from the pressure switch (7) and the
solenoid valves (1).
5) Remove the pipe (3, Fig. 1).
6) Remove the pipe (4).
WCH03534
3 7) Remove the pipe (5).

2
8) Remove the eight screws (6) from the
flange of the inlet pipe (not shown).
9) Remove the eight screws from the
I flange of the outlet pipe (not shown).
10) Remove the shut-off valve from the
1 engine.
1
4 6 11) Do a check of the gaskets installed on
7 the flanges. If the gaskets are
unserviceable, replace them.
3
Fig. 1

Starting Air Shut-off Valve: Clean and Function Check
3. Disassemble
1) Remove the six screws (6, Fig. 2) from the cover.
2) Turn the handwheel (3) fully in. This will move the cover from the spindle (5).
3) Remove the handwheel (3) and the cover.
4) Remove the spring (8) together with the valve (9) and the spindle (5).
5) Remove the valve (9).
6) Remove the two screws (12) from the valve guide (10).
7) Remove the stopper (11) together with the spring (14) and valve body (15).
8) Remove the silencer (23) and its gasket.
9) Remove the two bolts (4) from the control valve (2).
10) Remove the screw plug (19), together with the spring (20), valve (21) and
piston (22).
11) Remove the control valve (2) from the cover.
4. Servicing
1) If necessary, clean the items of the control valve (2) that follow:
D Valve (21)
D Piston (22)
D Spring (20).
2) If necessary, clean the items from the shut-off valve that follow:
D Springs (8) and (14)
D Stopper (11)
D Valve body (15)
D Valve guide (10)
D Valve (21)
D Spindle (5).
3) If you find corrosion on the springs (8, 14 and/or 20) you must replace them.
4) Do a check of all gaskets and O-rings that you removed for damage. If you find
damage, replace the applicable gaskets and/or O-rings.
5) Do a check of the piston joint ring (18). If you find damage, replace the piston
joint ring.
6) Do a check of the valve seat (16). If necessary, grind the sealing surfaces.

20 21 22 23
4
19
1.0 mm
2
1
2 3
13 14 15 16 17 18
12 4
11
WCH03534
5
Fig. 2 10 9 8 7 6

5. Assembly
1) Make sure that all the bores are clear.
2) Remove grease from the surface of the spindle (5, Fig. 2).
3) Apply a thin layer of Molykote paste to the stopper (11), the spring (14) and the
valve body (9).
4) Put the O-ring (12) and valve body (15) into the housing.
5) Put the stopper (11) and spring (14) into the valve guide (10), then attach the
valve guide to the housing with the two M12x50 screws (13).
6) Torque the two M12x50 screws (13) to the value given in 0352−2, paragraph 1.
7) Apply Molykote paste to the bore of spindle nut (17). Put the spindle nut on the
spindle (5).
8) Apply Loctite 0243 to the threads of the spindle nut (17).
9) Put the spindle (5) and spindle nut (17) into valve (9).
10) Attach the valve (9) together with spindle (5) and piston joint ring (18) to the
housing.
11) Apply Molykote paste to the inner cylinder of the cover (6).
12) Put the spring (8) on to the spindle (5) in the cover (6).
13) Attach the cover (6), spring (8) and spindle (5) to the housing with the six M24x70
screws (7).
14) Torque the six M24x70 (7) to the value given in 0352−2, paragraph 1.
15) Install the handwheel (7).
16) Attach the control valve (2) to the cover (6) with the two M24x90 bolts (4).
17) Torque the two M24x90 bolts (4) to the value given in 0352−2, paragraph 1.
18) Put the piston (22), valve (21), spring (20) and screw plug (19) in position in the
control valve (2).
Note: When you do the step below, look through the hole in the control
valve (2).
19) Make sure that the clearance between the valve (21) and the piston (22) is
1.0 mm.
20) Attach the silencer (23) to the control valve (2).
21) Put the assembled shut-off valve in position on the engine.
22) Attach the outlet flange (not shown) to the valve guide (4, Fig. 3) with the eight
M24x50 screws.
23) Torque the eight M24x50 screws to the value given in 0352−2, paragraph 1.

1 24) Attach the inlet flange and pipe (not

4 5 6 7 8 shown) to the shut-off valve with the
eight M24x50 bolts (9).
25) Torque the eight M24x50 screws to the
value given in 0352−2, paragraph 1.
AO I 26) Connect the check pipe (10) to the pipe
connection.
27) Connect the control air pipe (9) to the
WCH03534
pipe connection.
3 28) Connect the drain pipe (3) to the pipe
2 connection.
2.0 mm to I
5.0 mm 13
13
10 11 6. Shut-off Valve − Test
12
6.1 Initial Position

WARNING
9 Injury Hazard: During this
test, do not select START.
Injury to personnel can
occur.
Fig. 3 WARNING
Injury Hazard: During this
test, do not go near open
bores. High-pressure air
can come out of the bores
and cause injury.
Note: You must only do this test on a fully assembled engine that is ready to
start.
1) Make sure that the stop valves on the starting air bottles 9.01 are closed.
2) Operate the handwheel to move the shut-off valve to the position CLOSED.
3) Close the vent valve 2.21.
4) Disengage the turning gear.
6.2 Test Procedure

1) Close vent valve 2.27 in the main starting air pipe.
2) Slowly open the stop valve on the starting air bottles 9.01.
3) Slowly open the screw plug (5). Make sure that no air flows out.
Note: If air flows out, tighten the screw plug (5). The shut off valve is not
airtight.
4) Remove the screw plug (5).
5) Slowly turn the handwheel to move the shut-off valve to the position OPEN.
6) Make sure that air flows from the bore of the screw plug (5). When air flows, the
manual function of the shut-off valve operates correctly.

7) Operate the handwheel to move the shut-off valve to the position AUTOMAT..
8) Make sure that no air flows from the bore of the screw plug (5, Fig. 3). When no
air flows, the automatic function of the shut-off valves operates correctly.
6.3 Automatic Mode

1) Make sure that the shut-off valve is in the position AUTOMAT..
Note: When you do the step below, air will flow through the pipe. This activates
the control valve (1), which shows that the valve body and valve operate.
2) Open the test valve 2.06 to activate the control valve (1). The shut-off valve
operates automatically.
3) Make sure that air flows from the bore of the screw plug (5).
4) Close the test valve 2.06.
5) Make sure that no air flows from the bore of the screw plug (5).
6) Operate slowly the handwheel to move the shut-off valve to the position
OPENED. Make sure that you can feel the spindle (8) touch the spindle guide (9).
7) Turn back the handwheel sufficiently to get a clearance of between 2.0 mm and
5.0 mm. One third of a turn of the spindle is equal to 2.0 mm.
Note: If there is no clearance after frequent servicing of the valve seat and
valve, replace these items during the next overhaul.
7. Completion
1) Use the handwheel to move the shut-off valve to the position CLOSED.
2) Install the screw plug (5).

Supply Unit, Injection and Exhaust Valve Control Group 5
Supply Unit
Servo Oil Pump and Servo Oil Pump Drive − Removal and Installation . . . . . . . . . . . . . . . . . . . . . 5552−1/A1
Camshaft and Bearing Shells − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−2/A1
Gear Wheel on Camshaft − Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−3/A1
Supply Unit Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−4/A1
Lubrication of Supply Unit During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5552−5/A1
Pilot Fuel Supply Unit: Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−1/A1

Pilot Fuel Pump: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−2/A1
Fuel Pump: Removal, Disassemble, Assemble, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−1/A1
Fuel Pressure Control Valve: Removal, Check, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A1
Fuel Pressure Control Valve: Manual Release Valve − Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−1/A2
Fuel Overpressure Safety Valve: Checks and Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−2/A1
Flow Limiting Valve: Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5562−3/A1
Exhaust Valve Control Unit: Removal, Disassemble, Assemble and Installation, . . . . . . . . . . . . . 5612−1/A1
Regulating Linkage
Adjustment: Heinzmann StG 10-01 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5801−1/A1
Winterthur Gas & Diesel Ltd. 1/ 5 RT−flex50DF / MM / 2018−02

Intentionally blank
Supply Unit
Servo Oil Pump and Servo Oil Pump Drive − Removal and
Installation
Tools:
2 Sling 94657
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Pinion − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Shaft − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Shaft − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.4 Pinion − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Servo Oil Pump − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
Data about operation, maintenance and servicing of the servo oil pumps are given in
the related documentation of the servo oil pump manufacturer.
Do the related maintenance in 0380−1 Maintenance Schedule, Supply Unit.
For more data, refer to the Operation Manual 5551-1 Servo Oil Pump.
2. Preparation
1) Stop the engine.
2) Close the stop valve downstream from
the automatic filter (refer to the
Operating Manual 5551−1).
from the applicable servo oil pump (2,
Fig. 1).
4) Remove the HP servo oil pipes, refer to
8447−1, paragraph 1 and paragraph 2.
2
5) If necessary, remove the HP fuel pipes,
1 refer to 8752−1 paragraph1 and
paragraph 2.
6) Remove the drain pipes (not shown).
7) Remove the inlet pipes (not shown).
Fig. 1
012.976/05

Supply Unit: Servo Oil Pump and Servo Oil Pump Drive Removal and Installation
94657
3. Removal
CAUTION
2, 3
of the servo oil pump is
1
the correct equipment to
lift and move the servo oil
pump. This will prevent
injury to personnel.
1) Put the sling (94657, Fig. 2) around the

servo oil pump (1) two times.
room crane.
3) Operate the engine room crane to put
sufficient tension on the sling (94657)
4 to hold the weight of the servo oil
pump.
4) Remove the four nuts (2) and
Note: Some parts can look different. washers (3).
5) Remove the servo oil pump (1) and the
Fig. 2
O-ring (not shown).
6) Move the servo oil pump (1) to an
applicable area.
7) Lower the servo oil pump (1)to the
floor.
8) Remove the sling (94657) from the
servo oil pump.
9) Do step 1) to step 8) to remove the
other servo oil pump.
10) If necessary, remove the pinion, refer to
paragraph 3.

3.1 Pinion − Removal

Note: The bores for the bearing bushes
(7, Fig. 3) in the housing (5) and
the pump supports (1) are matched
items and thus, are not
interchangeable.
1) Record the marks (4, Fig. 3) on the
housings (5) and the pump
supports (1).
I 2) Remove the four screws (2).
3) Remove the pump support (1).
2
4) Remove the shaft (3) together with the
1 pinion (6) from housing (5).
I 3.2 Shaft − Removal

012.977/05
1) Put protection on the pinion (6).
I-I 2) Put the pinion (6) and shaft (3) in a
vice.
5 6 7 1 3) Use a hammer and copper rod (9) to hit
the shaft until the shaft and snap
ring (8) are removed from the
pinion (6).
3 3.3 Shaft − Installation

1) Attach the shaft (3) in position in the
pinion (6) with the snap ring (8).
2) Remove the pinion (6) and shaft (3)
from the vice.
3.4 Pinion − Installation

4
1) Put the shaft (3) and pinion (6) in
position in the housing (5).
2) Attach the pump support (1) to the
3 8 6 9 housing (5) with the four screws (2).
PROTECTION
Fig. 3

I 4. Nozzles
4.1 Removal
Note: To remove the nozzle (9, Fig. 5)
you must first remove the
5 6 7 8 applicable servo oil pump and
1 pinion.
2 Note: The nozzle (4) can be removed
easily after removal of cover (6).
1) Remove the two Allen screws (10) and
the cover (11).
2) Remove the nozzle (9).
3) Remove the the 10 screws (5).
4) Remove the cover (6) and its gasket.
I 5) Make sure that the gasket is

serviceable. Replace the gasket if
4 3 necessary.
6) Remove the nozzle (4).
7) Remove and discard the two
I-I O-rings (3).
4.2 Installation
1) Clean the nozzles (9, 4).
2) Put the nozzle (9) in position.
3) Apply Loctite No. 243 to the threads of
the two Allen screws (10).
9 4) Attach the cover (11) with the two Allen
II screws (10).
5) Put two new O-rings (3) on the
nozzle (4).
9
6) Put the nozzle (4) in position. Make
sure that the pin (7) engages with the
II - II hole in the casing.
II 7) Attach the cover (6) with the 10
10 screws(5).
11
Fig. 5

94657 5. Servo Oil Pump −

Installation
2, 3
CAUTION
1 Injury Hazard: The weight
of the servo oil pump is
the correct equipment to
lift and move the servo oil
pump. This will prevent
Note: During installation, do a check of

the clearances, refer to 0330−1
Clearance Table, Supply Unit.
1) Put a new O-ring in the pump support.
2) Apply a small quantity of oil to the
4 O-ring.
3) Put the sling (94657) around the servo
oil pump (4, Fig. 6) two times.
Fig. 6 room crane.
the servo oil pump (4) in position.
6) Attach the servo oil pump (4) to the casing with the four washers (2) and nuts (3).
7) Do step 1) to step 6) to install the servo oil pump (1).
6. Completion
1) Attach the oil inlet pipes to the servo oil pumps (1, 4).
2) Attach the drain pipes to the servo oil pumps (1, 4).
3) Install the HP servo oil pipes, refer to 8447−1 paragraph 4 and paragraph 5.
4) Install the HP fuel pipes, refer to 8752−1 paragraph 4.
5) Connect the electrical connections that you removed before.
6) Set to on the main bearing oil pump.
7) Set to on the servo oil service pump.
9) Set to off the servo oil service pump.

Intentionally blank
Supply Unit
Camshaft and Bearing Shells − Removal and Installation

Tools:
Devices (roller lifting tools) 94430 1 Centring device 94566B
(related to the number of cylinders) 1 Limiter 94566C
1 Support 94566 1 Assembly template 94567
1 Support 94566A 1 Torque amplifier 94020
1 Limiter 94566C
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Bearing Covers − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Bearing Shells − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Camshaft − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Camshaft and Bearing Shells − Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Bearing Covers − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Preparation
1) Stop the engine and main lubricating
pump.
3) Remove the cover (1).
94430
4) There are two alternatives as follows:
a) Remove the fuel pumps, refer to
1 5556−1 paragraph 1 and
2 paragraph 2 or,
b) Lift the rollers, refer to the
procedure given in the Operation
Manual 5556−2, Fuel Pump −
Cutting Out and Cutting In.
Fig. 1 012.979/05

Supply Unit: Removal and Fitting of Camshaft and Bearing Shells
5) Remove the servo oil pump (1, Fig. 2)

and the nozzle (2), refer to 5552−1.
2 1
012.980/05
Fig. 2
6) Make sure that the bearing covers at

positions No. 2, No 3 and No. 4 (Fig. 3)
and the housing (1), have marks to
identify them as a set.
Note: The bearing at position No. 2 has
the two thrust bearing ring
halves (3).
I
1
1 2 3 4 5
012.981/05
I-I
1
Fig. 3

2. Bearing Covers −
Removal
Note: 7−cylinder and 8−cylinder engines
have six bearings.
Note: The position of the torque
amplifier in Fig. 4 is for reference.
6 1) Attach the limiter (94566C) with the
94566C screws (6) (from the cover) to the
housing below fuel pump No. 1.
5
1 2) Put the screwdriver bit (2) on to the
4 screw (1).
3) Attach the torque amplifier (4) and the
013.067/05 applicable extension (5) to the
3 2
screwdriver bit (2) in the position
shown.
4) Operate the torque wrench (3) to
remove the screw (1).
4 5) Do step 2) to step 4) for the bottom
screw.
6) Remove the bearing cover.
C
7) Do step 2) to step 6) for the remaining
screws (1) of the bearing covers.
3 5 94566C
3 5 94566C
Fig. 4

I
3. Bearing Shells −
Removal
1) Put the template (94567, Fig. 5) on the
94567 top bearing shell.
2) Put the wooden underlay (1) in position
below the camshaft (2) as shown.
3) Use the wooden underlay (1) as a lever
to move the camshaft (2) up a small
distance.
I 4) Move the template (94567) and the top

bearing shell down.
5) Remove the template (94567).
I-I
6) Put a mark on the top bearing shell to
identify its position.
7) Remove the related bearing shell.
2
94567
94567
1
012.983/05
Fig. 5
4. Camshaft − Removal
1 1) On the supports (94566 and 94566A,
Fig. 6, remove the screws (3).
2
2) Remove covers (2, 4) from the
supports (94566, 94566A).
3) Loosen the screws (1, 5).
3
94566A
Fig. 6 94566

Note: When you attach the supports

(94566 and 94566A, Fig. 7), use the
screws from the bearing cover and
2 3 I
the screws from the housing
cover.
4) Attach the supports (94566, 94566A) to
the housing (1).
5) Make sure that the camshaft (3) stays
in position before you remove the last
bearing cover.
6) Attach the covers (2 and 3, Fig. 5).
7) Remove the remaining bearing covers,
refer to the procedure given in
94566A 94566 I 1 paragraph 2, step 3) to step 9).
8) Make sure that the camshaft (3) and
the gear wheel (2) do not move.
I-I
012.984/05
9) Carefully move the camshaft and the

gear wheel on to the two supports
(94566, 945666A).
10) Put the chock (4) in position to hold the
camshaft and gear wheel (2, 3).
Note: When you do step 11), make a
mark on the bearing shells to
identify their positions.
11) Remove the remaining bearing shells.
4 2, 3
Fig. 7

I-I 5. Camshaft and Bearing

Shells − Installation
1) Make sure that all items are clean and
I 2 do not have damage.
1 2) Apply oil to the bearing shells, the ring
halves and the camshaft.
3 3) Put all bottom bearing shells (2, Fig. 8)

into the housing (3) in their correct
positions. Refer to the marks you made
94566/64566A before.
I 4) Put the camshaft (1) and gear wheel in
3 position on the two supports (94566,
94566A).
94566B
5) Carefully move the camshaft/gear
4 wheel (1) into the housing (3). Make
94567 sure that the bearing shells (2) stay in
position and do not fall.
6) Put the bearing shells (4) in position.
012.994/05 Make sure that the holes in the bearing
shells align with the dowel pins (6) in
the bearing covers (7).
5
7) To align the bearing shell (4), put the
6 centering tool (94566B) in position in
the related hole for the elastic screw.
7
8) Apply oil to the threads and seating
surfaces of screws (5).
II II - II
3
5
1
4
II
II
6
7
012.981/05
Fig. 8
Fig. 8

6. Bearing Covers −
Installation
Note: The position of the torque
amplifier in Fig. 9 is for reference.
Start the procedure to tighten the
6 screws (1) at bearing No. 1.
1) Attach the limiter (94566C) with the
94566C screws (6) (from the cover) to the
5 housing below fuel pump No. 1.
1
4 2) Put the screwdriver bit (2) on to the
screw (1).
013.067/05 3) Attach the torque amplifier (4) and the
3 2 applicable extension (5) to the
screwdriver bit (2) in the position
shown.
BEARING COVER NO. 1
Note: The ratio between the torque
4 wrench (3) and the torque amplifier
(4) is 1:5.
6 4) Torque the screw (1) as follows:

C a) Adjust the torque wrench (3) to
290 Nm. The torque value for the
screws (1) is 1450 Nm.
b) Put the torque wrench (3) on the
torque amplifier (4).
c) Torque the screw (1) to the value
013.067/05
of 290 Nm on the torque
amplifier (4).
3 5 94566C
5) Make sure that there is no clearance
at X (Fig. 10).
4 6) Do step 7) to step 13) for the bottom
screw of bearing No. 1.
7) Do step 10) to step 13) for the
remaining screws (1) of the bearing
covers.
3 5 94566C
Fig. 9
Fig. 10
X

7. Completion
1) Make sure that the radial and axial
clearances are in the limits given in
refer to 0330−1, Supply unit.
2) If the axial clearances are not in the
specified range, loosen the screws on
one of the bearing covers, Fig. 8.
3) Make sure that the dowel pin (6) is in
the bearing cover (7).
4) Put the bearing cover in position and
torque the screw again (refer to
paragraph 4, step 10) to step 14).
5) Install the nozzle (2, Fig. 11) and the
servo oil pump (1), refer to 5552−1
2 1 paragraph 4.2 and paragraph 5.
012.980/05
Fig. 11
6) Apply sealing compound to the sealing

94430 surfaces of the cover (1, Fig. 12).
7) Attach the cover (1) to the casing with
the screws (2).
1 8) Cut in the fuel pumps and remove tools
2 94430, refer to the procedure given in
the Operation Manual 5556−2.
9) Set to on the oil pump.
WARNING
make sure that no
012.979/05 10) Operate the turning gear to turn the

engine.
11) Make sure that lubricating oil flows to
Fig. 12 all lubricating points and bearings.

Supply Unit
Camshaft Gear Wheel − Removal and Installation
1. Removal
1) Remove the camshaft (4, Fig. 1), refer to 5552−2.
2) Put the camshaft (4) on to a wooden underlay.
3) Remove the screws (3).
4) Use two M10 jack-screws to remove the camshaft (4) from the gear wheel (2).
5) Remove the screw (5).
6) Use the two M10 jack-screws to remove the gear wheel (2) from the shaft (1).
2. Installation
1) Make sure that all parts are clean and in a satisfactory condition.
2) Apply oil to the surfaces of the gear wheel (2) and the shaft (1).
3) Push carefully the gear wheel (2) on to the shaft (1).
4) Attach the gear wheel (2) to the shaft (1) with the screw (5).
5) Apply oil to the surfaces of the camshaft (4) and the gear wheel (2)
6) Carefully attach the camshaft (4) to the gear wheel (2) with the screws (3).
7) Torque symmetrically the screws (3) to 200 Nm.
8) Make sure that there is no clearance between the gear wheel (2) and the
shaft (1).
9) Do the Running and Backlash Clearances and Tooth Condition procedure, refer
to 4103−1.
1 3 4
013.058/05
5
Fig. 1

Intentionally blank
Supply Unit

Tools:
1 Lifting tool (complete with eye bolts 94557 Devices 94430
2 Manual ratchets 94016−013 (related to number of cylinders)
2 Chain 94202L
1. Preparation
1) Read the data in 0012−1 General
Guidelines for Lifting Tools
2) Remove the HP fuel pipes, refer to
8752−1.
3) Remove the HP servo oil pipes, refer to
8447−1.
1 4) Remove screws (1, Fig. 1) and the
2 cover (2).
5) Cut out the fuel pumps, refer to the
Operation Manual 5556−2.
Fig. 1

Removal and Fitting of Supply Unit
2. Removal
94202L 1) Remove the dowel pins (3, Fig. 2).
94202L
H1 H2 2) Remove the screws (7).
3) Attach the two chains (94202L) to the
engine room crane.
the chains (94202L) and the lifting tool
(94557).
5) Attach the two eye bolts (EB) to
94557 housing of the supply unit as shown.
move the lifting tool above the eye bolts
(EB).
7) Attach the lifting tool (94557) to the two
eye bolts (EB).
7 EB EB 8) Operate the manual ratchets (H1, H2)
to apply a light tension on the chains.
1 9) Remove the screws (8) together with
3
the distance sleeves.
6
I 10) Remove the screws (2, 4 and 6).
11) Operate carefully the engine room
5 crane to lift the supply unit from the
engine.
4 2
12) Move carefully the supply unit away
013.043/05 from the engine.
13) Lower the supply unit on to an
3
applicable surface.
I
Fig. 2 013.042/05

Removal and Fitting of Supply Unit
3. Installation
1) In paragraph 2, do step 3) to step 8) to attach the lifting tool (94557, Fig. 2) to the
supply unit (1).
2) Clean the sealing surfaces of the supply unit (1).
3) Apply a non-hardening sealing compound to the sealing surfaces of the supply
unit (1).
4) Operate the engine room crane to move the supply unit (1) into position on the
housing.
5) Install the screws (2, 4, 6 and 7). Do not tighten the screws at this step.
6) Install the dowel pins (3).
7) Tighten the screws (2, 4, 6 and 7).
8) Do a check of the backlash, refer to 0330−1 Driving Wheels for the Supply Unit
4. Completion
1) Install the HP fuel pipes, refer to 8752−1.
2) Install the HP servo oil pipes, refer to 8447−1.
3) Attach the cover (1, Fig. 1) to the supply unit with the screws (.
4) Cut in the fuel pumps, refer to the Operation Manual 5556−2.
5) Start the lubricating oil pump.
6) Do a check to make sure that oil flows to the bearings and nozzles (10).
7) Apply a non-hardening sealing compound to the cleaned sealing surfaces of
cover 3 and then fit the latter.

Intentionally blank
Supply Unit
Lubrication of Supply Unit during Maintenance

Tools:
1 Lubricating tool 94844 1 Adapter
1 Reduction nipple 1 Adapter
1. General
The engine has a manual lubrication system. This system prevents damage to the
bearings and bushes of the supply unit (5, Fig. 1) during dry-running of the engine.
Clean system oil is used for the lubrication.
2. Procedure
1) Clean the surface of the supply unit casing.
2) Remove the blind flange from the lubricating tool (94884).
3) Attach a flange with a G1/2” thread to the lubricating tool (94884).
4) Remove the applicable pipe from the supply unit (5).
5) Make sure that the ball valve (10) is closed.
6) Attach the adapter (1) to the flange (8) on the lubricating tool (94844).
7) Attach the flexible hose (2) to the adaptor (1) with the hose clip (7).
8) Attach the reduction nipple (4) to the supply unit (5).
9) Attach the adapter (3) to the reduction nipple (4).
10) Attach the lubricating tool (94844) to an applicable position approximately 2.0 m
above the supply unit as shown.
11) Attach the flexible hose (2) to the adaptor (3) with the hose clip (6).
12) Remove the inspection covers from the supply unit (5).
13) Fill the lubricating tool (94844) with system oil.
14) Open the ball valve (10).
15) Make sure that the system oil flows on to the bearings and camshaft (9).
WARNING
16) After a period of 15 minutes, operate the turning gear.

Note: If the turning gear operates for long periods, keep the system full to make
sure that the bearings and camshaft (9) have sufficient lubrication.
17) Make sure that the bearings and camshaft (9) have sufficient lubrication.
18) Install the inspection covers to the supply unit (5) that you removed before.
19) Close the ball valve (10).
20) Remove the lubricating tool (94844), flexible hose (2) and adaptors (1, 3).
21) Remove the reduction nipple (4).
22) Install the pipe that you removed before to the supply unit (5).

Lubrication of Supply Unit during Maintenance
I-I
94844
10
I
2
I
8
II - II
2
3
4
II 6
II
9
5
WCH03859
Fig. 1

Pilot Fuel Supply Unit
Lubrication
1. General
If you operate the engine in gas mode continuously, it is recommended that you have
one more pilot fuel supply unit as a replacement.
The supply unit is an electric motor that has a flexible coupling to the pump and a
duplex filter.
2. Maintenance
Lubricate the flexible coupling in accordance with the maintenance schedule.
1) Remove the service cover (4).
2) Turn the flange until you see the grease nipple.
3) Lubricate the flexible coupling.
4) Install the service cover (4).
CAUTION
Injury Hazard: The weight of the pilot fuel supply unit is
approximately 367 kg. Use the correct equipment to lift and move
the pilot fuel supply unit. This will prevent injury to personnel.
Note: To get access to duplex filter (2), you must remove the cover on the pilot
fuel pump (3).
After the period given in the Maintenance Schedule, replace the pilot fuel supply unit.
6 5 4 3 2 WCH03121
Fig. 1
Key to Fig. 1
1 High pressure fuel pipe 4 Service cover for flexible coupling
2 Filter unit 5 Flexible coupling
3 Pilot fuel pump 6 Electric motor

Intentionally blank
Pilot Fuel Pump

Tools:
1 HP oil pump 94931 1 HP hose 94935
1 Pressure gauge 94934A 1 Assembly tool 94573
1. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Removal
1) Stop the engine.
2) Make sure that the pilot fuel pump (5, Fig. 1) has stopped.
3) Disconnect the electrical connection from the electric motor (1).
4) Close the stop valve (3).
5) Remove the pilot fuel pressure pipe (4).
6) Remove the pilot fuel return pipe (2).
7) Remove the fuel inlet pipe (9).
8) Hold the weight of the pilot fuel pump (7).
9) Remove the four Allen screws (6).
10) Remove the pilot fuel pump (5) from the electric motor (1).

Pilot Fuel Pump: Removal and Installation
1 2 3 I
I 4
WCH03857
II
2
7 6 5
Fig. 1 4 9
11) On the assembly tool (94573, Fig. 2), turn fully back the special nut (2).
12) Apply Molykote G−Rapid Plus to the surfaces (4).
13) Attach the adapter piece (6) to the shaft of the pilot fuel pump (1).
14) Torque the adapter piece (6) to 45 Nm.
15) Turn the special nut (2) until touches the spherical disc (3). Do not tighten the
special nut.
16) Connect the HP oil pump and hose to the assembly tool (94573).
17) Operate the HP oil pump tp increase the pressure to between 1600 bar and 1800
bar. Make sure that the coupling half floats on the oil film.
18) Operate the HP oil pump to keep the pressure constant.
19) Turn back 5.0 mm the special nut (2). Make sure that the hydraulic force pushes
the coupling half against the spherical disc (3).
20) Make sure that the coupling half is loose.
21) Release the pressure from the HP oil pump.
22) Remove the gear coupling.

94573
1
2
I I
WCH03848
I-I
4
Fig. 2
2. Installation
1) Push as far as possible the special nut (2, Fig. 3) on the shaft of the pilot fuel
valve (1). Make sure that the couping is at 90° to the shaft of the pilot fuel valve.
2) Measure the distance from the special nut (2) to the end face of the pump (1).
Make sure that the distance is approximately 107.5 mm.
3) On the assembly tool (94573) turn fully back the special nut (2).
4) Apply Molykote G−Rapid Plus to the surfaces (3).
5) Attach the adapter piece (4) to the shaft of the pilot fuel pump (1).
6) Torque the adapter piece (4) to 45 Nm.
7) Turn the special nut (2) until it touches the spherical disc (7).
8) Attach the HP hose (9) to the HP oil pump (8)
9) Attach the hose (9) to the closing valve (5).
10) Operate the HP oil pump to get a pressure of between 1600 bar and 1800 bar.
11) Make sure that the coupling floats on the oil film.

12) Push the special nut (2) forward until the distance from the end face of the pilot
fuel pump is 61.5 mm.
13) Release the pressure in the HP oil pump (8).
14) Remove the hose (9) from the closing valve (5).
15) Remove the assembly tool (94573) from the pilot fuel pump (1).
1 I-I
2
3
WCH03848
I I 4 5
107.5 mm
6
7
61.5 mm
8
2
9
WCH03848
Fig. 3
16) Attach the pilot fuel pump to the electric motor temporarily with the four bolts and
nuts (8, Fig. 1).
17) Measure the distance X through the opening in the connection piece (1, Fig. 4).
18) Remove the electric motor (6) from the connection piece (1).
19) Push the flange on the motor shaft until you get a distance of X=3.0 mm.
20) Lock the hubs with an M8 screw (5).
21) Fill the coupling with grease.
22) Attach the electric motor (6) to the connection piece (1) with the bolts/nuts (7).
23) Make sure that the distance between the hubs is 3.0 mm.

Note: Some parts can look different. I-I

6 7 1
X
II
I I
WCH03848
II 4
2
III
3
II - II
X−3.0 mm 3.0 mm
5
WCH03848
III
Fig. 4
24) Attach the sleeves together with the screws and nuts (2) (Fig. 4).
25) Torque the screws (3) and nuts (2) to 36 Nm.
26) Make sure that the sleeves (1) turn freely an axial distance of ±1.5 mm.
3. Completion
1) Apply NeverSeez NSBT8 to the threads and surfaces that touch of the pilot fuel
pressure pipe (4, Fig. 6).
2) Attach the pilot fuel pressure pipe (4) as shown.
3) Torque the two coupling nuts (5) to 30 Nm.
4) Install the pilot fuel return pipe (2).
5) Install the fuel inlet pipe (10).
6) Connect the electrical connection to the electric motor (1).

1 2 3 4 I
I 5
5
9
WCH03857
II
2
8 7 6
Fig. 6
4 10

Fuel Pump
Removal, Disassemble, Assemble, Installation

Tools:
1 Fitting and dismantling device 94551 1 Checking gauge 94556
1 Cover 94552 2 Screwdrivers
1 Spacer 94555 2 M12 jacking screws
Applicable lifting gear
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Fuel Pump − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Guide Pin − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Guide Piston and Roller − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Toothed Rack − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Pump Cylinder − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Non-return Valve − Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Fuel Pump − Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Pump Cylinder − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Pump Cover − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Toothed Rack − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Regulating Sleeve − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.6 Pump Plunger and Bottom Housing − Installation . . . . . . . . . . . . . 9
4.7 Plunger Position − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Fuel Pump − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fuel Pump: Removal, Disassemble, Assemble, Installation
1. Preparation
WARNING
Fire Hazard. Do not weld or grind materials in the area. Sparks
can cause a fire to occur.
WARNING
Injury Hazard. Put on gloves and eye protection. Fuel can come
out as a spray and cause injury.
WARNING
CAUTION
Damage Hazard: Do not operate the engine with a fuel pump
removed. This will decrease the supply of oil, i.e. there could be a
decrease of lubrication to the other fuel pumps. Damage to
equipment can occur.
CAUTION
Injury Hazard: The weight of the fuel pump is approximately
162 kg. Use the correct equipment to lift and move the fuel pump.
This will prevent injury to personnel.
Note: Read the data in 0012−1 General Guidelines for Lifting Tools.
1) Stop the engine,refer to the Operation Manual 0310−1.
2) Set to off the fuel supply
3) Set to off the main oil supply.
4) Make sure that the fuel return valve is open, refer to the Operation Manual, Control
Diagram 4003−2 and Pipe Diagram 4003−11.
5) Close the fuel inlet valve, refer to the Operation Manual, Control Diagram 4003−2
and the Pipe Diagram 4003−11.
6) Make sure that the pressure in the supply unit decreases to zero.
7) Set to off the power supply to the fuel pump actuators.
8) Make sure that there is no pressure in the fuel system.
9) Make sure that the temperature of the fuel has decreased to ambient.
10) Clean the work area and make sure that there are no dust particles.
11) Set to off the power supply to the actuators.
12) Make sure that the valves to the fuel pumps are closed.
13) Remove the fuel inlet and outlet pipes.
14) Remove the applicable HP fuel pipe(s), refer to 8752−1.

2. Fuel Pump − Removal

4
1) Remove the connecting element (3,
3 Fig. 1) between the regulating rack (4)
and the actuator (2).
1 2) Operate the turning gear until the cam
base touches the roller (5, Fig. 2).
2
4) Use the two M12 jacking screws to lift
the fuel pump until the pin disengages.
5) Attach the cover (94552, Fig. 2) to the
pump cover (5).
lift and move the fuel pump.
7) Move the fuel pump to an applicable
Fig. 1
work bench.
8) Put the fuel pump on its side on the
wooden surface. Make sure that you do
not cause damage to the toothed rack
(7) or and the roller (6).
9) Remove the lifting equipment from the
94552 fuel pump.
5
Fig. 2

3. Disassemble
94551 3.1 Guide Pin − Removal

1) Attach the fuel pump to the work
bench. Make sure that the top of the
fuel pump points down.
2) Attach the tool (94551, Fig. 3) as
shown.
3) Turn the spindle of the tool (94551) to
move the guide piston (3) in sufficiently
to remove the guide pin (2).
1 4) Turn the screw (1) to remove the guide
pin (2).
013.671/05
Fig. 3 3 2
EB
8
1 3.2 Guide Piston and Roller −
Removal
2
7
3
guide piston (4, Fig. 4)
4 2) Remove the guide piston (4) from the
housing.
3) Remove the circlip (1).
4) Push out the pin (2).
5) Remove the roller (3) together with the
pressure discs (8) and the bush (7).
7) Remove the snap ring (5).
5
6
Fig. 4
008.649/00

8) Remove the Allen screws (3, Fig. 5).

1 9) Remove the bottom housing (1) from
top housing.
2 10) If necessary, replace the bush (2) as
follows:
a) Remove the bush.
3
b) Apply Loctite No. 648 to the
thread of the bush.
c) Torque the new bush to 200 Nm.
Fig. 5 013.673/05
3.3 Toothed Rack − Removal

1
1) Disassemble the bottom spring carrier
(1, Fig. 6) together with the pump
2 plunger (3).
3 2) Put the pump plunger (3) in a dry, clean

5 area to prevent damage.
4 3) Remove the compression spring (2).
4) Remove regulating sleeve (4) together
with the top spring carrier (5).
013.674/05
Fig. 6

5 6
6) Remove the circlip (4) and the stop
ring (5).
7) Remove the flange (6) together with the
rod seal ring (3).
1 8) Push out the toothed rack (1).
4 3 2
Fig. 7 013.679/05
3.4 Pump Cylinder − Removal

1
1) Turn the pump cover (2, Fig. 8) to point
2 up.
10
2) Use applicable equipment to hold the
9 3
pump cover (2) to the work bench.
8 4
3) Remove the screws (1).
5
7 4) Remove the pump cover (2), valve
6 block (4), valve body (8) and
compression spring (9).
6) Remove the intermediate disc (10).
7) Remove the screw (6).
8) Remove the pump cylinder (7).
Note: The pump cylinder (7) and pump
plunger (3, Fig. 6) must stay
Fig. 8
008.653/00
together as a set.

1
3.5 Non-return Valve − Removal
1) Put the two applicable screwdrivers in
2 the nut of the valve block (1, Fig. 9).
2) Use the two screwdrivers as levers to
4 push out the valve block (1). Make sure
that you do not cause damage to the
3 nut of the valve block.
Note: The non-return valve must be
replaced as a unit only, i.e. valve
Fig. 9 block (1), valve body (2),
compression spring (4) and
intermediate disc (3).
5
3) Remove the circlip (6, Fig. 10).
6
Fig. 10 019.235/10 4. Fuel Pump − Assemble
4.1 Preparation
1) Clean all parts.
2) Do a check the condition of all parts. If
necessary, replace damaged parts.
3) Use a low-pressure air supply to make
sure that all bores in the housings and
pump cylinder (1, Fig. 11) are clear.
4) Replace all O-rings and rod seal rings.
33 1
32 2
4.2 Pump Cylinder −
Installation
5 3 1) Attach the top housing (3) vertically to
the work bench.
2) Align the groove in the pump cylinder
with the bore for the screw (2) in the
top housing (3).
Fig. 11 008.654/00
3) Carefully put the pump cylinder (1) into
the top housing (3).
4) Attach the pump cylinder (1) to the top
housing (3) with the screw (2).
Note: Make sure that there is a clearance
between the screw (2) and the
base of the groove.

1
4.3 Pump Cover − Installation
2 1) Make sure that all the joint faces are
11 clean and in a satisfactory condition.
10 3
2) Lubricate the O-rings (5, Fig 12).
9 4
3) Attach the O-rings (5) to the valve
5
8 block (4).
6 4) Put the valve body (9) and
compression spring (10) into the valve
7 block (4).
5) Put the valve block into the top
housing (7).
6) Attach the intermediate disc (11) to the
valve block (4) with the circlip (3).
7) Install the pump cover (2).
Fig. 12 8) Apply Never-Seez NSBT-8 to then
008.653/00
threads and seating surfaces of the
screws (1).
9) Torque symmetrically in equal steps the
4.4 Toothed Rack − Installation

1) Make sure that the pump cover (4,
1 Fig. 13) points down.
2) Attach the top housing (5) to the work
11 2
bench.
3) Put a new rod sealing ring on the
10 flange (9).
3
8 9 4) Make sure the toothed rack (3) moves
freely.
5) Put the rod sealing rings (6) in each
flange (9).
94555
6) Attach the two flanges (9) to the
housing (2) with the two screws (5).
7) Attach the stop ring (8) and the
4 circlip (7).
4.5 Regulating Sleeve −

7 6 5 013.680/05 Installation
1) Move the toothed rack (3) to the
position shown.
Fig. 13
2) Put the spacer (94555) on the toothed
rack (3) as shown.
3) Put the regulating sleeve (11) into the
top housing. Make sure that the
toothed rim points down.
4) Make sure that the guide pin (10) goes
into the groove in the regulating
sleeve (11).

1 4.6 Pump Plunger and Bottom

8
Housing − Installation
6 7 2
1) Install the top spring carrier (5, Fig. 14)
and the compression spring (2).
3
5 2) Put the plunger (3) into the bottom
3 4 spring carrier (6).
3) Apply clean diesel oil to the pump
plunger (3).
4) Put the pump plunger (3) and the
bottom spring carrier (6) in position in
the top housing (7). Make sure that the
two drivers of the pump plunger (3)
engage with the regulating sleeve (4).
008.656/00 5) Apply oil to the new O-ring (8).
6) Put the O-ring (8) on the top
housing (7).
013.674/05
Fig. 14
7) Put the bottom housing (1, Fig 15) on

to the top housing (4).
8) Tighten equally the Allen screws (5).
(This compresses the compression
1 spring (6).)
9) Make sure that the toothed rack (3)
2 moves freely.
6
4
3
Fig. 15 013.673/05

94556 4.7 Plunger Position − Check

94555 1) Move the toothed rack (1, Fig. 16) to
1
the position shown.
2) Put the spacer (94555) in the position
shown.
I I
3) Remove the screw plug (not shown)
from the check bore (2).
4) Install fully the gauge (94556) into the
check bore (2).
008.657/00
5) Remove the spacer (94555).
I-I 6) Make sure the toothed rack (1) cannot

move. If the toothed rack cannot move,
94556 the pump plunger is correctly installed.
7) Remove the gauge (94556).
8) Put copper paste on the thread of the
screw plug.
2
9) Install the screw plug to the check
bore (2).
008.658/00
Fig. 16 94555 1
10) Lubricate the new O-ring (6, Fig. 16).
EB 11) Put the new O-ring (6) on the guide

8 piston (4).
1 12) Put grease on the snap ring (5).
2 13) Attach the snap ring (5) to the guide
7
piston (4).
3
14) Lubricate the pump plunger.
4
15) Install the bush (6), pressure discs (7)
and the roller (3) to the guide bush (4).
16) Install the pin (2) and the circlip (1).
17) Put the guide piston (4) in the housing.
18) Do a check of the axial clearances,
refer to 0330−1 Fuel pump.
guide piston (4).
20) Attach the applicable lifting tools to the
5 eye bolts (EB).
6
008.649/00
Fig. 17

21) Operate the applicable lifting tools to

put the guide piston (3, Fig. 18) into the
housing. Make sure that the groove is
opposite the bore for the guide pin (2).
22) Remove the eye bolts (EB).
013.671/05
3 2
Fig. 18
23) Attach the tool (94551, Fig. 19) as

shown.
24) Turn the handle (3) to push down the
4
guide piston (2) until you can install the
guide pin (1). If the guide pin touches
the guide groove, turn the pressure
94551 piece (4) to align the guide pin.
25) Remove the tool (94551)
3
013.671/05
2 1
Fig. 19

94552 26) Make sure that the toothed rack (5,

Fig. 20) can move.
1
27) Put new O-rings (4) on the bottom
housing (2).
5. Fuel Pump − Installation

supply unit housing and the fuel pump.
Make sure that these seating surfaces
5 are in a satisfactory condition.
29) Lubricate the guide parts.
30) Attach the tool (94552) to the pump
cover (1).
lift and move the the fuel pump into the
supply unit.
2
WARNING
4 Injury Hazard: Before you
make sure that no
32) Operate the turning gear until the cam

3
base touches the roller (3).
Fig. 20
33) Lubricate the threads and seating

surfaces of the four screws (1, Fig. 21).
34) Put the four screws (1) in position.
4
3 four screws (1) to 600 Nm.
36) Connect the regulating linkage (3) on
1 the actuator (2) to the connecting
2 element (4).
37) Make sure that the setting of the
regulating linkage is correct, refer to
5801−1.
Fig. 21

6. Completion
1) Install the applicable HP fuel pipe(s), refer to 8752−1.
2) Install the fuel inlet and outlet pipes.
3) Make sure that the valves to the fuel pumps are open.
4) Set to on the power supply to the actuators.
5) Open the fuel inlet valve, refer to the Operation Manual, Control Diagram 4003−2
and the Pipe Diagram 4003−11.
6) Make sure that the fuel return valve is closed, refer to the Operation Manual,
Control Diagram 4003−2 and Pipe Diagram 4003−11.
7) Set to on the main oil supply.
8) Set to on the fuel supply.
9) Operate the turning gear to move the cam. Make sure that there are no leaks or an
unusual temperature increase.
7. Storage
1) Make sure that the storage area is clean and dry.
2) Put the fuel pump in a vertical position.
3) Apply clean oil to the fuel pump.
4) Put Vaselinet in the open inlet and outlet holes of the fuel pump.
5) Put plastic stoppers into the open spaces.
6) Put a cover (material or plastic) on the fuel pump for protection.
7) Keep the pump in a vertical position.

Intentionally blank
Fuel Pressure Control Valve
Removal, Check, Installation

Tools:
1 HP oil pump 94931 1 HP hose 94935
1 Hydraulic distributor 94934A 1 PCV test block with tube 94556
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. PCV Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Setpoint Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Storage on Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. General
To prevent failure of the pressure control valve (PCV), Wärtsilä recommends that you
only do the procedures that follow:
D Do a check and adjust the PCV
D Replace the PCV.
For the maintenance intervals of the PCV refer to the Maintenance Schedule 0380−1,
Group 5.
For faults in the high pressure fuel system and defective pressure control valve, refer
to the Operation Manual, 0515−1, paragraph 5.
2. Preparation
WARNING
Injury hazard. Put on gloves and eye protection. Hot fuel can
come out as a spray and cause injury.
WARNING
Fire hazard. Do not weld or grind materials in the area. Sparks can
cause a fire.
1) Stop the engine.

2) Make sure that the pressure in fuel rail is zero, refer to the Operation Manual
Local Control Panel, 4002−2, paragraph 3.3.
3) Make sure that the work area is clean.

Fuel Pressure Control Valve: Removal, Check, Installation
1
3. Removal
8 1) Make sure that the fuel rail (4, Fig. 1)
7 2
has no pressure.
6
from the solenoid valve (2).
3) Remove the fuel return pipe (5) from
5 the PCV (1).
4) Remove the four screws (8).
3
5) Remove the PCV (1) from the valve
block (3).
4 6) Do a check of the lip seal (9). Replace
the lip seal if necessary.
DRIVING END
WCH02900
WCH02366
Fig. 1

I 1 4. PCV Check
II
5 2
4.1 Preparation
4 1) Put the protection (4, Fig. 2) around the
PCV test block (94556).
2) Put the test block (94556) in a bench
94935 vice.
94556
3) Make sure that the sealing surfaces of
the PCV and the test block (94556) are
WCH02281 clean and have no damage.
4) Put the PCV in position on the test
94931 block (94556).
94934A
5) Put oil on the threads of the four
screws (1).
3 6) Put the four screws (1) in position in the
PCV.
7) Tighten the screws (1) in the sequence
given in View I as follows:
a) Tighten the screws with your
I
hand.
b) Torque the screws to 80 Nm.
c) Torque the screws to 190 Nm.
a 8) Attach the flexible tube (94556C) (part

c
of the test block 94556) to the PCV
d b outlet (2). Put the other end of the
flexible tube into an applicable
II container (3).
9) Connect the HP oil pump (94931),
hydraulic distributor/pressure gauge
(94934A) and HP hose (94935) to the
test block (94556).
CAUTION
6
Safety Valve adjust the safety valve.
DO NOT Damage to the PCV can
ADJUST occur.
Fig. 2 10) Identify each of the two pressure

control set screws.
11) On the setpoint adjustment valve
(SAV) (6), loosen the locknut.
12) Loosen fully the SAV (6) to minimum.

4.2 Adjustment Procedure

CAUTION
Damage Hazard. Do not connect the solenoid valve. Damage to
the PCV can occur.
1) Operate the HP oil pump (94931, Fig. 2.

2) Tighten the SAV (6) to get a value of 100 bar.
Note: If oil flows into the groove (5) the PCV has a leak, or the O-ring in the tool
(94556) has damage.
4) Continue to tighten the SAV (6) and do checks for leaks at the same time.
5) Adjust the SAV (6) until the PCV opens at 1050 bar.
6) On the SAV (6), tighten the lock nut.
7) On the HP oil pump (94931), open the relief valve to decrease the pressure to
zero.
4.3 Setpoint Check

1) On the HP oil pump (94931), close the relief valve.
2) Operate the HP oil pump (94931).
3) Make sure that the PCV opens at 1050 ± 30 bar.
4) If the PCV opens at less than 1020 bar or more than 1080 bar, do the procedure
in paragraph 4.2 again.
Note: If the PCV does not open at less than 1300 bar or opens at less than 1020
bar (when the SAV (6) is fully closed), the PCV has a malfunction. You
must find and repair the malfunction before you install the PCV.
5) On the HP oil pump (94931), open the relief valve to decrease the pressure to
zero.
6) Disconnect the flexible tube from the PCV outlet (2).
7) Disconnect the HP hose (94935) from the tool (94556).
8) Remove the four screws (1) from the PCV.
9) Remove the PCV from the bench vice.
10) Remove the protection from the PCV test block (94556).

I 1
5. Installation
8
2 1) Make sure that the seating surfaces of
7
6 the PCV (1, Fig. 3) and the valve block
(3) are clean and have no damage.
2) Put the PCV (1) in position on the valve
block (3).
5 3) Put oil on the threads of the four
screws (8).
3 4) Put the four screws (8) in position in the
PCV.
4 5) Torque the screws (8) in the sequence
given as follows:
a) Tighten the screws with your
DRIVING END
hand.
b) Torque the screws to 80 Nm.
c) Torque the screws to 190 Nm.
6) Install the fuel return pipe (5) to the
WCH02900
PCV (1).
solenoid valve (2).
I
6. Storage on Board
The spare parts must be carefully protected
against corrosion as follows:
1) Make sure that the PCV has no dirt, oil
a c and grease.
d b
2) Apply liquids (e.g. Tectil 506, ISOTEC
337 or equivalent liquids) to the
applicable surfaces.
Fig. 3
3) Plug all blind holes and tapped holes.
Note: Items must be protected from
unsatisfactory conditions (cold,
high humidity, etc.) and kept in a
sealed container.

Intentionally blank
Manual Release Valve − Clean
1. General
If the pressure control valve does not close correctly, do the procedure given in
paragraph 2.
2. Procedure
2.1 Disassemble
Note: It is not necessary to remove the PCV (1, Fig. 1) from the fuel rail (2) to do
this procedure.
Note: For the full PCV overhaul instructions, speak to or send a message to
WinGD.
1) Stop the engine
2) Make sure that the PCV (1) is open.
Note: If HFO is used, the drain port will be hot when the PCV is open.
3) Operate the pressure release button more than two times to release pressure.
1
6
2
O−ring Pusher
WCH02900
Rubber Cap
DRIVING END
Pressure
Release Button
Hole
Solenoid Tube
Lever
Internal Pin
Spring Plunger
Drain Port
Fig. 1

Fuel Pressure Control Valve: Manual Release Valve − Clean
4) Carefully remove the rubber cap

(Fig. 2).
Rubber
Cap
Solenoid
Plastic
Collar 5) Record the installed position of the
plastic collar.
Nut 6) Remove the nut, plastic collar and
solenoid.
Solenoid
Tube
Hole
7) Remove the solenoid tube.
8) Use your finger to push the lever. Make

sure that you can feel two different
Lever spring tensions.
Note: If the valve closes and you can get
rail pressure, it is not necessary to
continue the procedure. Refer to
paragraph 2.3, step 5) to step 9) to
assemble the PCV.
Block
CAUTION
M6 Allen Injury Hazard: Make sure
Screws that there is no pressure in
the fuel rail or the drain
side of the system. High
pressure fuel can cause
9) Remove the four Allen screws from the

block.
10) Remove the block.
Fig. 2

Fuel Pressure Control Valve: Manual Release Valve − Clean
11) Carefully remove the pusher (Fig. 3).

Note: It is possible that the pusher will
stay on the PCV body.
12) Remove the plunger and spring from
the PCV.
Block 2.2 Clean and Apply NeverSeez

1) Remove the grease from all
components (pusher, plunger, spring
and O−ring).
2) Apply a thin layer of NeverSeez to all
components (plunger, spring and
Pusher O−ring pusher.
3) Put NeverSeez into the hole in the
solenoid tube (see Fig. 1 and Fig. 2).
4) Push the internal pin in and out with
your hand to apply the NeverSeez.
2.3 Assemble
1) Put the plunger and spring into the
pusher assembly.
2) Put the O−ring and pusher in position in
the block.
3) Attach the valve block to the PCV with
the four M6 Allen screws.
O−ring 4) Torque the for M6 Allen screws to
15 Nm.
5) Attach the solenoid tube to the valve
block.
Plunger
6) Put the solenoid in position on the
valve block.
7) Put the thick part of the collar against
the solenoid.
Spring
8) Attach the nut to the solenoid. Tighten
the nut.
Rubber
Cap
Note: During step 9), hold in the pusher

with your hand to help you attach
the rubber cap (Fig. 3).
Flat−blade 9) Use a small flat−blade screwdriver to
Screwdriver attach the rubber cap over the plastic
collar.
Fig. 3

Intentionally blank
Fuel Overpressure Safety Valve
Checks and Setting

Tools:
1 OBEL test bench 94272 2 Hydraulic distributors 94934A
1 Valve holder 94272A 2 HP hoses 94935
1 HP oil pump 94931
1. General
Maintenance of the relief valve (1, Fig. 1) is not usually necessary, but you must do a
function check at regular intervals. Refer to the Maintenance Schedule 0380−1 Fuel
Overpressure Safety Valve for the frequency to do the function test. Unserviceable
relief valves must be sent to the manufacturer, or a Wärtsilä Switzerland Ltd.
authorized repair workshop for inspection and repair.
The International Association of Classification Societies (IACS) approval is given for:
D The type of test
D The type of certificate
D The frequency of the test.
The results of the test must be recorded in the Inspection Report.
Note: The two bores (2) identify the relief valve as a new item.
AF80
1
Applicable pressure that

opens the relief valve is
stamped here.
015.499/07
Fig. 1 3 2
2. Removal
1) Stop the engine (refer to the Operation Manual 0310−1).
2) Make sure that the fuel rail has no pressure.
3) Use a spanner (AF80) to remove the relief valve (1) from the valve block (4).
4) Remove and discard the O-rings (3).

Fuel Overpressure Safety Valve: Checks and Setting
3. Relief Valve Test
3.1 Test and Calibration Fluid − Physical Conditions

You use the test bench (94272) and the test and calibration fluid (e.g. Shell
Calibration Fluid S.9365) to test the relief valve. Table 1 gives the mandatory data for
the test and calibration fluid.
Table 1
ASTM D445
Kinematic Viscosity at 40_C 2.6 mm2/s
Density at 15_C 827 kg/m3 ISO 12185
Pour Point −27_C ISO 3016
3.2 Preparation
Note: Read the data in the instructions from the manufacturer about the
specifications of the test bench.
1) Put the relief valve (1, Fig. 2) in the valve holder (94272A).
2) Tighten the relief valve (1).
3) Connect the valve holder (94272A) to the HP oil pump (94931) or the hydraulic unit
(94942).
3.3 Sealing Pressure Check

1) Operate the HP oil pump (94931) to increase the pressure to 1150 bar.
2) Keep the pressure constant for one minute.
3.4 Operation Pressure Check

1) Operate the HP oil pump to increase the pressure until the relief valve (1) opens.
2) Make sure that the relief valve opens at between 1200 bar and 1350 bar.
3) Operate the valve (3) to release the pressure in the HP hoses (94935).
4) Remove the relief valve (1) from the valve holder (94272A).
5) Close the valve (3).

Fuel Overpressure Safety Valve: Checks and Setting
94934A
94935
94272A
013.484/05
94272
94931 3 94934A
013.486/05
Fig. 2
4. Installation
1) Apply Never-Seez NSBT-8 to the thread of valve housing (4, Fig. 3).
2) Attach new O-rings (3) to the relief valve (1).
3) Put the relief valve into the intermediate piece of the fuel pressure control
valve 3.06.
4) Torque the relief valve (1) to 300 Nm.
AF80
1
Applicable pressure that

opens the relief valve is
stamped here.
015.499/07
Fig. 3 3 2

Intentionally blank
Flow Limiting Valve
Replacement
Tools:
2 Eye bolts (M10) 94045-M10
1 Surface plate 94585A
1 Blind flange 94585B
1. General
It is not usually necessary to do maintenance on the flow limiting valve (FLV) , but
during operation the piston and cylinder in the FLV can become worn. This causes
fuel leakage. Refer to 0380−1 Maintenance Schedule Flow limiting valve for the
intervals to replace the FLV.
2. Preparation
WARNING
WARNING
Injury Hazard: You must put on gloves and safety goggles when
you do work on hot components. Fuel and oil can come out as a
spray and cause injury.
WARNING
Injury Hazard: Do not operate the turning gear. Fuel can come out
of the opening in the fuel rail and cause injury.
1) Stop the engine, refer to the Operation

Manual, 0310−1.
2) Cut out the injection, refer to the
Operation Manual, 0510−1.
3) Let the engine temperature decrease.
1 4) Let the pressure in the fuel rail
3
decrease to zero.
5) Make sure that the fuel injection system
2 has no pressure.
6) Make sure that all tools and equipment
are clean and in good condition.
7) Remove the HP injection pipes from
the FLV (2, Fig. 1), refer to 8733−1
paragraph 1 and paragraph 2.
8) Remove the leakage pipes (1, 3) from
the FLV (2).
WCH03116
9) Apply protection to the openings on the
Fig. 1 FLV.
10) Apply protection to the open ends of
the pipes (1, 3).

Flow Limiting Valve: Replacement
3. Removal
4 1
CAUTION
of the FLV is approximately
35 kg. Use the correct
equipment to lift and move
the FLV. This will prevent
WCH03116
3 2
1) Remove the four bolts (1, Fig. 2) and
the four bolts (4).
Fig. 2
2) Install the two M10 eye bolts
(94045-M10) to the FLV.
3) Lift the FLV.
4) Carefully remove the lip seal (3). Make
sure that you do not cause damage to
the lip seal.
5) Put the lip seal (3) in a safe area.
6) Make sure that the dowel pins stay in
the fuel rail.
7) Lower the FLV on to an applicable
clean surface.
8) Clean all seating surfaces of the blind

flange (94585B, Fig. 3).
9) Make sure that the lip seal is installed
94585B in the blind flange (94585B).
10) Attach the blind flange (98585B) to the
WCH03115 fuel rail with the four M12x60 screws.
11) Torque the four M12x60 screws to
60 Nm.
Fig. 3 WCH03114

4. FLV − Align and

5 Installation
4
4.1 Valve Block − Align
1) Make sure that the lip seal (3, Fig. 2) is
removed from the FLV.
1a 1 2) Clean the surface plate (94585A,
Fig. 4).
3) Attach the FLV to the surface plate
(94585A). Do not tighten the screws (4,
1b 2
3 7 5) at this step.
Fig. 4 94585A 4) Loosen the eight bolts (3).
5) Make sure that the eight bolts (3) have
Never Seez applied to the threads.
eight bolts (3) to 120 Nm.
9) Remove the FLV from the surface plate
(94585A).
4.2 Installation
CAUTION
4 1 of the FLV is approximately
35 kg. Use the correct
equipment to lift and move
the FLV. This will prevent
1) Remove the blind flange (94585B,
Fig. 3) from the fuel rail.
3 2
WCH03116 2) Clean the inlet bores of the FLV (2,
Fig. 5 Fig. 5).
3) Attach the M10 eye bolts (94045-M10)
to the FLV (2).
4) Lift the FLV (2).
5) Carefully put the lip seal (3) in position
in the FLV (2).
6) Lower carefully the FLV (2) on to the
fuel rail.
7) Apply Never Seez NSBT to the four
M12 screws (4) and the four M10
screws (1).
8) Torque the four M12 screws (4) to
60 Nm.
9) Torque the four M10 screws (1) to
35 Nm.

10) Connect the leakage pipes (2) and 3,

Fig. 6) to the FLV (1).
11) Install the HP injection pipes, refer to
8733−1.
1 12) After you start the engine,do a check
3 for leaks.
WCH03116
Fig. 6

Exhaust Valve Control Unit
Removal, Disassemble, Assemble and Installation

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 Oil Filter − Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.3 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.4 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. General
Refer to 0380 Exhaust valve control unit for the intervals necessary to do checks of
the piston and slide rod.
2. Preparation
WARNING
Danger: Do not weld or grind materials in the area. The sparks from
welding equipment and grinding tools can cause a fire.
1) Stop the engine, refer to the Operation Manual 0310−1.

2) Release the pressure in the servo oil rail, refer the Operation Manual 0520−1
paragraph 2.3.
3) Remove the applicable hydraulic pipe, refer to 8460−1, paragraph 1 and
paragraph 2.

Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation
3. Procedure
1
3.1 Removal
1) Make sure that the servo oil rail (1,
2
DRIVING END Fig. 1) has no pressure.
WCH02965
(3) from the rail valve (4).
3) Remove the return pipe (5) from the
3 exhaust valve control unit (VCU) (2).
7
4 4) Remove the six Allen screws (6) from
6 the VCU (2).
5) Attach applicable lifting equipment to
the two eye bolts (7).
2 lift and move the VCU (2).
5 7) Put protection over the holes in the
servo oil rail (1) to prevent
Fig. 1 contamination.
3.2 Oil Filter − Clean

1) Remove the filter holder (6, Fig. 2).
3) Remove the three oil filters (2)
4) Clean the three oil filters (2).
5) Attach the three oil filters (2) to the filter
holder (6) with the circlip (5). Make sure
that the flow direction is correct.
1 6) Make sure that the O-ring (4) is
I I serviceable. Replace the O-ring if
necessary.
7) Make sure that the seal (3) is
serviceable. Replace the seal if
WCH03550
necessary.
2
5 8) Put the filter holder (6) in the valve
I-I block (1).
4
9) Torque the filter holder to 225 Nm.
Fig. 2

1
3.3 Disassemble
2
1) Remove the six Allen screws (2, Fig. 3)
3 2) Carefully remove the cover (1).
4 3) Remove and discard the O-ring (3).

7
4) Remove the compression spring (4).
5 5) Remove the slide rod (5).
6 6) Loosen the pan-head screw (10).
8) Remove and discard the O-ring and
back-up ring (8).
WCH03550
3.4 Assemble
1) Make sure that the piston (6) moves
FLUSH freely.
2) Put oil on the new O-ring and backup
ring (8).
8 3) Put the new O-ring and backup ring (8)
in position on the flange (9).
9
10 4) Attach the flange (9) to the VCU (7)
with the pan-head screw (10). Make
sure that the flange is flush with the
Fig. 3
bottom of the VCU (8).
5) Put the slide rod (5) in the VCU (8).
6) Put the compression spring (4) in the
VCU (8).
7) Put oil on the new O-ring (3).
8) Put the new O-ring (3) in position in the
cover (1).
9) Attach the cover (1) to the VCU (8) with
the six Allen screws (2).
10) Torque the six M10x40 screws (2) to
the value given in 0352−2.

3.5 Installation
WARNING
1
Injury Hazard: White spirit
2
I is a dangerous substance.
Injury to personnel can
occur Put on gloves and
WCH02965 safety goggles when you
use white spirit.
1) Use white spirit (e.g. Shellsol TD,

7 3 Shellsol T or Solvent FP68) to clean
4 the seating surfaces (10, Fig. 4) of the
6 of the VCU (2) and the servo oil rail (1).
2) Put the new O-ring (8) in the groove of
the servo oil rail (1).
3) Attach the applicable lifting equipment
2 to the eye bolts (7).
5
dowel pin (9) engages with the
hole in the bottom of the VCU (2).
I 4) Operate the applicable lifting
equipment to lift and lower the VCU (2)
on to the fuel rail (1).
5) Apply oil to the six Allen screws (6).
6) Attach the VCU (2) to the servo oil
10 rail (1) with the six Allen screws (6)
7) Torque the six Allen screws (6) to
170 Nm.
8) Install the return pipe (5) to the
WCH03550 VCU (2).
9) Connect the electrical connections (3)
to the rail valve (4).
9 8 1
Fig. 4
4. Completion
1) Install the hydraulic pipe, refer to
8460−1, paragraph 4.
5. Storage
The VCU must be kept in a dry area that
has no contamination.
Keep the VCU in its original protection. Lift
and move the VCU carefully to prevent
damage.

Regulating Linkage
Adjustment
Tools:
2 Spacers 94555A
1. General
After the installation of a new fuel pump (1, Fig. 1) or actuator (2), do a check of the
regulating linkage. If necessary, adjust the regulating linkage (refer to paragraph 2).
Maintenance of the connection between the fuel pump and the actuator is not
necessary.
Fig. 1
WCH02905

Regulating Linkage: Adjustment
2. Regulating Linkage − Adjust

1) Disconnect the electrical connection from the actuator (4, Fig. 2).
2) Loosen the screw (6).
3) Remove the screw (2) and its self-locking nut.
4) Lift the lever (9).
5) Make sure that the regulating linkage moves freely.
6) Apply grease to the linkage joints.
7) Put the two spacers (94555A) in position on each side of the toothed rack (1).
8) Move the output shaft (3) to move the pointer (5) to the mark 50.
9) Put the lever (9)on the sleeve (8).
10) Tighten the screw (6).
11) Attach the connecting element (10) to the lever (9) with the screw (2) and the
self-locking nut.
12) Remove the spacers (94555A).
36 mm
94555A
I
36 mm
GREASE
1 2
3
I
1
4
10 5
WCH02905
6
7
2 9 8
Fig. 2

Scavenge Air Receiver and Auxiliary Blower Group 6
Scavenge Air Receiver: Clean and do Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6420−1/A1

Scavenge Air Receiver (TC at Exhaust Side): Clean and do Checks . . . . . . . . . . . . . . . . . . . . . . . . . 6420−2/A1
Auxiliary Blower: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545−1/A1
Auxiliary Blower (TC at Exhaust Side): Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545−2/A1
Scavenge Air Cooler: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606−1/A1
Scavenge Air Cooler (TC at Exhaust Side): Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 6606−2/A1
Water Separator: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708−1/A1
Water Separator Removal and Installation (TC at Exhaust Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708−2/A1

Intentionally blank
Scavenge Air Receiver
Scavenge Air Receiver − Clean and do Checks
1. General
For the intervals to clean the scavenge air receiver (1, Fig. 1), refer to 0380−1,
Scavenge air receiver. You must also clean and do a check of the scavenge air
receiver after each piston overhaul.
II FREE END I-I

I
1
WCH03010
I I
II
For View II - II, see 2

Fig. 3 and Fig. 4.
3
Fig. 1

2. Relief Valve − Check

WARNING
Injury Hazard! Do not disassemble the relief valve. Parts can eject at
high speed and cause injury. If there is damage or a malfunction,
speak to the manufacturer of the relief valve or Wärtsilä
Switzerland Ltd.
1) Do a check of the relief valve during each engine overhaul as follows:

a) Do a visual check for damage and corrosion. If necessary, replace the relief
valve (1, Fig. 2).
b) Do a check of the seal wire (3) and the lead seal (2). If the seal wire and lead seal
are broken, you must replace the relief valve.
I
II - II
1 1 2
II
WCH03554
II
Fig. 2

3. Flaps
3.1 Removal
1) Remove the screws (8, Fig. 3) and the tab washers (9).
2) Remove the two flat bars (10) and the stop plate (7).
3) Remove the screws (5) and tab washers (6).
4) Remove the guide (2), spacer (1) flap (4) and axle (3).
3.2 Installation
1) Put the axle (3), spacer (1), guide (2) and flap (4) in position.
2) Put a flat bar (10), stop plate (7), the other flat bar (10) new tab washers (9), and
screws (8) in position. Do not tighten the screws at this step.
3) Put the screw (5) and new tab washers (6) in position. Do not tighten the screws
at this step.
4) Make sure that the axle (3) and the flap (4) can move freely.
5) Tighten the screws (8, 5).
6) Bend the tab washers (6, 9) to lock the screws (8, 5).
II - II III - III
IV
III
IV
Access to air flaps
from free end along WCH00688
bottom plates.
III
IV - IV 7 8, 9 10 2
018.183/09
5, 6 4
Fig. 3

4. Scavenge Air Receiver − Clean and do Checks

1) Open the cover (3, Fig. 1).
2) Lock the cover (3) in position with the pin (2). This prevents unwanted movement.
3) Clean the scavenge air receiver.
4) Do the checks that follow:
Note: The level switches LS4071A and LS4075A (2, Fig. 4) monitor the water
level in the condensate collectors (6). For more data, refer to the
Operation Manual 4003−4 Pipe Diagram Water Systems.
a) At regular intervals, look at the sight glasses (3) of the condensate collector (6)
to make sure that water flows.
b) If necessary, clean the filters (7) and the drain pipes (4, 5). For more data, refer
to the Operation Manual 8345−1.
c) Do a check of the flaps (8) for damage, free movement and dirt. If necessary,
clean or replace the flaps, refer to paragraph 3.
5) Remove the pin (2, Fig. 1) to unlock the cover (3).
6) Close the cover (3).
II - II
3
WCH03025
4
5
7 6
Fig. 4

Scavenge Air Receiver (TC at Exhaust Side)
1. General
For the intervals to clean the scavenge air receiver (1, Fig. 1), refer to 0380−1,
Scavenge air receiver. You must also clean and do a check of the scavenge air
receiver after each piston overhaul.
II I
I
1
WCH03363
II
2
5
4 3
For View II − II, see Fig. 3
Fig. 1

Scavenge Air Receiver − Clean and Checks
2. Relief Valve − Check

WARNING
Injury Hazard! Do not disassemble the relief valve. Parts can eject at
high speed and cause injury. If there is damage or a malfunction,
speak to the manufacturer of the relief valve or Wärtsilä Services
Switzerland Ltd.
1) Do a check of the relief valve during each engine overhaul as follows:

a) Do a visual check for damage and corrosion. If necessary, replace the relief
valve (1, Fig. 2).
b) Do a check of the seal wire (3) and the lead seal (2). If the seal wire and lead seal
are broken, you must replace the relief valve.
I
II - II
1 1 2
II
WCH03554
II
Fig. 2

3. Flaps − Removal and Installation
3.1 Removal
1) Remove the screws (7, Fig. 3) and the tab washers (8).
2) Remove the two flat bars (9) and the stop plate (6).
3) Remove the screws (4) and tab washers (5).
4) Remove the guide (1), spacer (10) flap (3) and axle (2).
3.2 Installation
1) Put the axle (2), spacer (10), guide (1) and flap (3) in position.
2) Put a flat bar (9), stop plate (6), the other flat bar (9), new tab washers (8), and
screws (7) in position. Do not tighten the screws at this step.
3) Put the screw (4) and new tab washers (5) in position. Do not tighten the screws
at this step.
4) Make sure that the axle (2) and the flap (3) can move freely.
5) Tighten the screws (4, 7).
6) Bend the tab washers (5, 8) to lock the screws (4, 7).
II - II
III
6 7, 8 9 1
IV
III
4, 5 3
IV 10
Fig. 3 WCH03363

4. Scavenge Air Receiver − Clean and do Checks

1) Open the covers (2 and 5, Fig. 1).
2) Lock the covers (2, 5) in position with the pins (3, 4). This prevents unwanted
movement.
3) Clean the scavenge air receiver.
4) Do the checks that follow:
Note: The level switches LS4071A and LS4075A (2, Fig. 4) monitor the water
level in the condensate collectors (6). For more data, refer to the
Operation Manual 4003−4 Pipe Diagram Water Systems.
a) At regular intervals, look at the sight glasses (3) of the condensate collector (6)
to make sure that the water flows.
b) If necessary, clean the filters (7) and the drain pipes (4, 5). For more data, refer
to the Operation Manual 8345−1.
c) Do a check of the flaps (8) for damage, free movement and dirt. If necessary,
clean or replace the flaps, refer to paragraph 3.
5) Remove the pin (2, Fig. 1) to unlock the cover (3).
6) Close the cover (3).
3
WCH03025
Fig. 4 7 6 4
5

Auxiliary Blower
Maintenance
Tools:
2 Manual ratchet (WLL 1600 kg) 94016−007
4 Slings (WLL 1000 kg) 94657
1 Support (WLL 800 kg) 94658
1. General
Two auxiliary blowers (1, Fig. 1) are attached to the scavenge air receiver (2). For
more data about the auxiliary blower, refer to the Operation Manual 6545−1 Auxiliary
Blower and Switch Box.
Auxiliary blowers that do not operate for long periods must be started for a short time
two times each month. If this is not possible, turn the impeller with your hand. This is
necessary to prevent corrosion to the bearings. For the Inspection and Overhaul
intervals, refer to 0380−1, Group Auxiliary blower.
I 1
2
1
WCH03556
Fig. 1

Auxiliary Blower: Maintenance
94657 2. Removal
94658 94657
2.1 Preparation
1) Read and obey the data given in
I
0012-1, General Guidelines for Lifting
1 Tools.
2) Stop the engine.
3) Set to off the power supply.
94016−007 from the electric motor (2, Fig. 2).
2
2.2 Removal
94657
WARNING
of the support (94658) is
approximately 62 kg. The
WCH03034
weight of the spur-geared
chain block (94018-001) is
3 2 approximately 23 kg. Use
approved equipment and /
or sufficient personnel for
I lifting, movement and
installation.
Note: The procedure that follows is for

each of the two electric motors.
4 5 1
1) Attach the two slings (94657) to the
pipe of the support (94658).
the support (94658) on the beam (1) as
shown.
3) Attach the support (94658) to the beam
Fig. 2 (1) with the bolts (4) and nuts (5).
4) Attach two slings (94657) to the electric
motor (2).
5) Attach the two manual
ratchets (94016−007) to the two
slings (94657) on the support (94658).
6) Attach the two manual
ratchets (94016−007) to the two
slings (94657)on the electric motor (2).
7) Operate the two manual
ratchets (94016−007) to apply sufficient
tension to the slings (94657) to hold the
mass of the electric motor (2).
8) Remove the screws that attach the
electric motor (2) to the casing (3).

Auxiliary Blower: Maintenance
CAUTION
94016−007 Damage Hazard: Do not put
94658
the electric motor on the
floor without an applicable
support because damage to
the impeller can occur.
9) Operate the two manual

ratchets (94016−007, Fig. 3) to
From carefully remove the electric motor (2)
Crane from the casing (3).
94657 10) Operate the two manual
ratchets (94016−007) to move the
electric motor to the right.
3
2
two slings (94567).
Note: When you do step 12), hold the
mass of the electric motor (2).
12) Carefully remove the two manual
WCH03034
ratchets (94016−007).
13) Use the engine crane to move the
electric motor to an applicable area.
Note: For data about the procedure to
Fig. 3
clean the impeller (and to replace
the ball bearing) refer to the
documentation of the auxiliary
blower manufacturer.
3. Installation
1) Attach the two slings (94657) to the electric motor (2) and the engine room crane.
2) Operate the engine room crane to lift the electric motor (2) until you can attach
the manual ratchets (94016−007) to the two slings (94567).
3) Attach the manual ratchets (94016−007) to the two slings (94567).
Note: When you do step 4), hold the mass of the electric motor (2).
4) Carefully remove the engine room crane from the two slings (94567).
5) Operate the two manual ratchets (94016−007) to move the electric motor (2) into
the casing (3).
6) Attach the electric motor (2) to the flange with the screws removed before.
7) Connect the electrical connection to the electrical motor (2).
8) Refer to the Operation Manual to operate the auxiliary blower.
9) Make sure that the electric motor (2) operates in the correct direction.

Intentionally blank
Auxiliary Blower (TC at Exhaust Side)
Maintenance
Tools:
2 Covers (5 cylinders) 94656A
2 Covers (6 to 8 cylinders) 94656B
1. General
The two auxiliary blowers (2 and 3, Fig. 1) are attached to the scavenge air
receiver (1). For more data about the auxiliary blower, refer to the Operation Manual
6545−2 Auxiliary Blower and Switch Box.
Auxiliary blowers which are do not operate for a longer period must be started for a
short time two times each month. If this is not possible, turn the impeller with your
hand. This is necessary to prevent damage or corrosion to the bearings. For the
Inspection and Overhaul, refer to 0380−1, Group 6545.
If the auxiliary blowers do not operate, install the two covers to the flange connection
at the inlet pipe of the auxiliary blower (one for each auxiliary blower) as shown
below:
D 94656A for 5-cylinder engines
D 94656B for 6-cylinder to 8-cylinder engines.
3 2
94656A WCH03295 94656A

94656B 94656B
Fig. 1

Intentionally blank
Scavenge Air Cooler

Tools:
2 Manual ratchet (H1, H2) (WLL 800 kg) 94016−001 1 Support RIGHT 94663B
1 Manual ratchet (H3) (WLL 250 kg) 94016A−001 2 Lugs 94663C
4 Swivel lugs 94048−M16 2 Safety chains 94663D
1 Support 94661 2 Chains 94666I
1 Support LEFT 94663A
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL SIDE
1. Preparation
1 1) Read the data in 0012−1 General
Manual 0310−1.
2 3) Stop the cooling water pump.
4) Close the butterfly valves (1, Fig. 1) of
7 the scavenge air cooler (SAC) (3).
6 5) Drain the water from the SAC (3).
3
5 6) Remove the drain and vent pipes (5, 6).
7) Remove the inlet and outlet
pipes (2, 7).
4
WCH00708
Fig. 1

Scavenge Air Cooler: Removal and Installation
FIXED EXPANSION
SIDE SIDE 2. Removal
1) Remove the screws (4, Fig. 2)11 on the
1 fixed side.
2 2) Remove the cover (1) on the expansion

side.
3) Attach the three swivel lugs
(94048−M16) to the front of the SAC.
5 4 STEP 3 4) Attach the left and the right supports

(94663A, 94663B) to the receiver with
its four screws (each).
5) Tighten the screws on the supports
(94663A, 94663B).
6) Attach the chain (94666I) to the outer
swivel lugs (94048−M16) in the front of
H1
the SAC.
94666I
beam and the chain (94666I).
8) Attach the manual ratchet (H3) to an
H3 applicable strong-point in the engine
room and the center swivel lug
94048−M16 WCH03084
(94048−M16) in the cover (5).
Fig. 2 9) Operate the manual ratchet (H1) to get
sufficient tension to hold the mass of
the SAC.
Note: During step 10) operate the manual
ratchet (H1) to keep tension on the
Engine Room chain.
Crane
10) Operate the manual ratchet (H3) to pull
the SAC approximately 750 mm from
the receiver.
750 mm
94666I 11) Attach the two lugs (94663C, Fig. 3) to
the SAC.
12) Attach the two safety chains (94663D)
to the lugs.
I
H3 13) Operate the manual ratchet (H3) to
carefully move the SAC from the
platform area to below the engine room
I crane.
chain (94666I).
the chain (94666I).
94663C the middle swivel lug (94048−M16).
17) Remove the applicable bottom plates
94663D 94663A and rails from the platform. This lets
94663B you move the SAC through the platform
Fig. 3 during a later step.

Engine Room H2 18) Operate the engine room crane to

Crane carefully pull out the SAC (Fig. 4).
19) Attach the swivel lugs (94048−M16, ) to
the rear of the SAC (1).
20) Attach the chain (94666I) to the two
I swivel lugs (94048−M16) on the rear of
the SAC (1).
chain (94666I).
II 22) Operate the manual ratchet (H2) to lift
the SAC a small distance.
WCH03084
WARNING
Injury Hazard: The mass of
the SAC is approximately
I 1142 kg. To prevent injury,
be careful when you move
the SAC.

the engine room crane until the rear of
94666I the SAC is fully on the supports
(94663A, 94663B) (view II, i.e the SAC
94048−M16 is moved 70 mm in front of guide end of
the left and right supports (94663A,
94663C 94663B)).
94663D 24) Operate the engine room crane and the

manual ratchet (H2) to hold the full
weight of the cooler.
25) Remove the two lugs (94663C), the
safety chains (94663D) and the left and
II the right supports (94663A/ B).
70 mm
Fig. 4


manual ratchet (H2, Fig. 5) to move the
SAC fully away from the platform.
H2
Engine Room the front of the SAC. At the same time,
Crane operate the manual ratchet (H2) to
lower the rear of the SAC.
28) Continue with step 27) until the SAC is
in a vertical position.
lower the SAC through the platform on
to an applicable surface.
31) Remove the engine room crane from
the chains (94666I).
H2
32) Remove the chains (94666I) and the
four swivel lugs (94048−M16) from the
SAC.
H2
WCH00708
Fig. 5

3. Installation
Engine Room
Crane 1) Clean the sealing surfaces of the SAC,
the scavenge air receiver and the
frame.
2) Attach the four swivel lugs
(94048−M16, Fig. 4) and the two
chains (94666I) to the SAC.
94666 to the chain (94666I).
4) Attach the support (94661) to the
scavenge air receiver.
shackle on the support (94661).
WCH00708
H3 support (94661).
Fig. 6 7) Attach the engine room crane to the
two chains (94666I).
the SAC into the vertical position.
manual ratchet (H2) to get the SAC into
the vertical position shown.
the engine room crane to get the SAC
into the horizontal position shown.
rear chain (94666I).
Engine Room 12) Attach the two supports (94663A and
Crane 94666I
94048−M16 94663B, Fig. 7) to the left and the right
H2 side of the receiver.
13) Attach the two lugs (94663C) and the
two safety chains (94663D) as shown.
94661 14) Apply a high-temperature and
non-hardening jointing compound to
the sealing surfaces.
Note: During step 15), keep the SAC
horizontal.
94663D 94663A
94663B 15) Operate carefully the manual ratchet
H3
(H3) to pull the SAC into the receiver
until the rear of the SAC is directly
Fig. 7 below the manual ratchet (H2).
16) When the rear of the SAC is on the
supports (94663A, 94663B), remove
the manual ratchet (H2).

17) Continue to operate the engine room

crane and the manual ratchet (H3).
H1
to the front chain (94666I).
hold the weight of the SAC.
94 20) Remove the engine room crane from

the front chain (94666I).
94666I 21) Continue to operate the manual ratchet

(H3) to pull the SAC into the scavenge
air receiver as shown.
WCH03084
Fig. 8 to the front chain (94666I).
23) Apply a high-temperature and
non-hardening jointing compound to
the sealing surfaces.
Note: During step 23) operate the manual
ratchet (H2) to control the height
H1 H2 of the SAC.
the SAC fully into the scavenge air
receiver. At the same time, operate the
I II manual ratchet (H1) to keep a light
tension on the chain.
946
25) Install the bottom plates and rails that
you removed before.
26) Remove the manual ratchets (H1, H2,
H3).
WCH00708
H3 27) Remove the left and right supports

(94663A/B) and the safety chains
(94663D).
28) Remove the lugs (94663C).
I II
29) Remove the chains (94666I) and the
swivel lugs (94048−M16) from the
SAC.
30) Attach the SAC (4) to the scavenge air
1 receiver with the screws (2).
31) Attach the cover (1) to the rear of the
SAC (4).
4 2 STEP
Fig. 9

FUEL SIDE
4. Completion
1 1) Install the inlet pipe (7, Fig. 10)
2) Install the outlet pipe (2, 7).
3) Install the drain pipe (5).
4) Install the vent pipe (6).
2
5) Open the butterfly valves (1) of the
7 SAC (3).
6) Release the air from the SAC.
6
3 7) Start the cooling water pump.
5
9) Make sure that no scavenge air flows
4 between the SAC (3) and the SAC
housing.
10) Stop the cooling water pump.
WCH00708
Fig. 10

Intentionally blank
Scavenge Air Cooler A44−SD (TC at Exhaust Side)
Removal and Installation 7 Cyl.

Tools:
1 Manual ratchet (WLL 3200 kg) (H1) 94016−013 1 Support LEFT 94663A
2 Chain block (WLL 3000 kg) (H2, H3) 94018−006 1 Support RIGHT 94663B
2 Eye bolts 94040−M30 2 Safety chains (for SAC A44−SD) 94663F−IL
4 Swivel lugs 94048−M30 1 Support 94661−1L
1 Support 94661 2 Plates (for SAC A44−SD) 94664−IL
1 Lifting plate 94663−1L 1 Wire rope sling (WLL 3000 kg) 94666
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Preparation
FREE END
WARNING
6 2760 kg. To prevent injury,
1
use only the applicable
5
equipment to move the
SAC.
2
4 1) Read the data in 0012−1 General
Manual 0310−1.
3) Stop the cooling water pump.
3
4) Close the butterfly valves (4, Fig. 1) of
Data for SAC A46-SF the scavenge air cooler (SAC).
Fig. 1
5) Drain the water from the SAC.
6) Remove the drain pipe (3).
7) Remove the vent pipe (1).
8) Remove the inlet pipe (5).
9) Remove the outlet pipe (6).
10) If necessary, remove the applicable
bottom plates, rails or platform element.
11) Remove the auxiliary blower.

Scavenge Air Cooler: Removal and Installation 7 Cyl.
2. Removal
DRIVING END
FREE END
I II
3) Remove the collar (9).
I II 4) Remove and discard the O-ring (6).
5) Remove the screws (3) and the four
9 1 clamps (4).
2
8 6) Remove the collar (2).
7 3 7) Remove the flange (1).
6 4 8) Remove and discard the O-ring (5).
WCH03311
5
Fig. 2
9) Put the two chain blocks (H2 and H3,

Fig. 3) in position on the rail (1).
I H2 H3 1 10) At the free end:
2 FREE
a) Attach the two swivel lugs
END
(94048−M30) to the front of the
SAC.
b) Attach the eye bolt (94040-M30)
to the center of the SAC.
c) Attach the support (94661-IL) to
H1 the gallery beam with its screws.
94661−IL 11) At the driving end:
a) Attach the two swivel lugs
(94048−M30) to the front of the
WCH00115
SAC.
b) Attach the wire rope sling (94666)
to the two outer swivel lugs
I
(94048-M30).
94048−M30 94048−M30
hole in the support (94661-IL).
94666 13) Attach the wire rope sling (94666) to
94016−013
the manual ratchet (H1).
14) Operate the manual ratchet (H1) to get
sufficient tension to hold the mass of
the SAC.
94040−M30 15) Attach the chain block (H3) to the eye
bolt (94040-M30).
16) Operate the chain block (H3) to get
Fig. 3
sufficient tension.


H3 FREE to pull the SAC a distance of
END approximately 750 mm. At the same
time, use the chain block (H3) to keep
the SAC horizontal.
H1 18) Attach the left and right supports
1
(94663A-IL, 94663B-IL) to the
receiver (1) with the screws.
19) Torque the screws of the supports
I
(94663A-IL, 94663B-IL) to 145 Nm.
20) Attach the two plates (94664-IL) to the
SAC with its screws.
94663A−IL WCH00115
21) Make sure that the length of the safety
94663B−IL chains (94663F−IL) is 1998 mm (for a
SAC A44−SD).
I
WARNING
750 mm 2760 kg. To prevent injury,
keep the the two safety
chains attached to the
plates.
22) Attach the safety chains (94663F−IL) to

94664−IL the plates (94664−IL).
WCH03310
94663F−IL
94663F−IL
017.659/08
1998 mm
Fig. 4


I H2 H3 1 2 to pull out the SAC a maximum
distance of 195 mm (View II) to the
guide end of the supports (94663A−IL,
94663B−IL).
H1 24) At the driving end, attach the lifting
plate (94663−IL) to the swivel lugs
(94048−M30).
25) Attach the lifting plate (94663−IL) to the
I II chain block (H2).
26) Operate the two chain blocks (H2, H3)
to hold the weight of the SAC.
WCH03309 27) Remove the plates (94664−IL), safety
chains (94663F−IL), manual ratchet
(H1) and the support (94661−IL).
28) Move the SAC until the chain block
I-I (H3) touches the end-stop (2) in the
H2 rail (1).
94663−IL
94048−M30
WCH03309
II
94663A−IL
195 mm
94663B−IL 94663F−IL
Fig. 5

29) Operate the chain blocks (H2 and H3,

H2 H3
Fig. 6) to lower carefully the SAC (2).
30) Attach the hook (1) of the engine room
crane to the wire rope sling (94666)
1 31) Operate the engine room crane to lift
the SAC (2) a small distance.
94666
94040−M30 32) Remove the chain block (H3) from the
eye bolt (94040-M30).
2 WCH00115
Fig. 6
H2 1 H3
33) Operate the engine room to pull out the

SAC until the chain block (H2, Fig. 7) is
adjacent to the platform lug (1).
WCH00115
94663−IL
Fig. 7
H2 H1 34) Attach the manual ratchet (H1, Fig. 8)

to the platform lug (1) and the lifting
plate (94663−IL).
lifting plate (94663−IL).
94666
lower the SAC to the vertical position.
WCH00115
Fig. 8
94663−IL

37) Remove the manual ratchet (H1,

Fig. 9).
H1
38) Remove the lifting plate (94663−IL).
move and lower the SAC to an
applicable area.
40) Remove the lifting plate (94663−IL),
swivel lugs (94048−M30), wire rope
sling (94666) and eye bolt
(94040−M30).
94663−IL
Fig. 9
94048−M30 3. Installation
94666 1) Make sure that all the surfaces of the
SAC and the related surfaces in the
receiver are clean and have no
damage.
2) Apply a layer of silicon compound to
94040−M30 each side of the SAC and the related
surfaces in the receiver housing.
94040−M30
3) Attach the swivel lugs (94048−M30,
94048−M30 Fig. 10), and the eye bolts
(94040−M30) to the SAC.
Fig. 10
4) Make sure that the supports
(94663A−IL, 94663B−IL) are installed
to the left and right side of receiver
frame.
5) Attach the wire rope sling (94666) to
94666 the swivel lugs (94048−M30).
H1 6) Attach the hook (1, Fig. 11) of the
engine room crane to the wire rope
sling (94666).
the SAC to the position shown.
8) Attach the lifting plate (94663−IL) to the
bottom swivel lugs (94048−M30).
94663A/B 94663−IL
Fig. 11


H2 H1 to the lifting plate (94663−IL).
the SAC as shown.
94666 bolt (94040−M30).
the lifting plate (94663−IL).
chain block (H2) to move the SAC to
the horizontal position.
WCH00115
94663−IL
H2
WCH00115
94663−IL
Fig. 12

H2 H3 chain block (H2, Fig. 13) to move the
SAC adjacent to the opening.
1 bolt (94040−M30).
16) Operate the chain block (H3) to hold
94666 the weight of the SAC.
94040−M30
17) Remove the hook (1) of the engine
room crane.
18) Operate the chain blocks (H2, H3) to lift
the SAC to the applicable height.
WCH00115
Fig. 13

H1 H2 H3 19) Attach the support (94661-IL, Fig. 14)

to the applicable platform support at the
driving end.
support (94661-IL).
21) Move the SAC on to the supports
94661−IL
I (94663A, 94663B). Make sure that the
distance between the front of the SAC
and the end on the support is a
minimum of 195 mm.
WCH00115
22) Remove the lifting plate (94663−IL).
94666
I 94663A 23) Attach the wire rope sling (94666) to
94663B the swivel lugs (94048−M30) on the
SAC.
wire rope sling (94666).
Note: During step 25), operate the chain
block (H3) to lift the end of the
SAC a small distance. This keeps
94663A−IL
most of the SAC weight off the
94663B−IL
supports (94663A/B).
195 mm Fig. 15) to move the SAC into the
receiver until the rear of the SAC is 750
Fig. 14 mm from the opening.
26) Remove the chain blocks (H2, H3) from
the platform rail.
H1 H2 H3 27) Operate the manual ratchet (H1) to pull
the SAC fully in.
28) Remove the left and right supports
(94663A/B).
29) Remove the support (94661−IL).
I 31) Remove the swivel lugs (94048−M30)
and the eye bolts (94040−M30).
Fig. 15
750 mm

1) Put a new O-ring (6, Fig. 16) in

position.
DRIVING END
FREE END
I II
2) Put the collar (9) in position.
3) Put the flange (8) in position.
4) Attach the flange (8) to the SAC with
II the M16x60 screws (7).
I
5) Torque the M16x60 screws (7) to the
9 1 value given in 0352−2.
2
8 6) Put a new O-ring (5) in position.
7 3 7) Put the collar (2) in position.
6 4
8) Put the flange (1) in position.
9) Attach the flange (1) to the SAC with
the M16x60 screws (3).
WCH03311
5
10) Torque the M16x60 screws (3) to the
value given in 0352−2.
Fig. 16
FREE END 4. Completion

1) If necessary, install the bottom plates,
rails and platform elements.
2) Install the drain pipe (3, Fig. 17).
6 1 3) Install the vent pipe (1).
5
4) Install the inlet pipe (5).
2 5) Install the outlet pipe (6).

4 6) Install the auxiliary blower.
7) Open the butterfly valves (4).
8) Release the air in the SAC.
9) Start the cooling water pump.
3
Data for SAC A46-SF 11) Make sure that no scavenge air flows
between the SAC and its housing.
Fig. 17 12) Stop the cooling water pump.

Intentionally blank
Water Separator

Tools:
1 Manual ratchet (WLL 800 kg) 94016−001 (H3) 1 Lifting plate 94667A
2 Manual ratchet (WLL 250 kg) 94016−005 (H1, H2) 1 Support 94667B
2 Shackles (WLL 1000 kg) 94018A (S1, S2) 1 Lifting lug 94667C
1 Lifting plate 94667 1 Angle support 94667D
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1. Preparation
CAUTION
Injury Hazard: The cover of
the water separator weighs
applicable equipment to
install the cover.
I
1) Read and obey the data in 0012−1
2) Remove the applicable supports and
bottom plates for access.
1
3) Remove the cover (1, Fig. 1).
4) Open the inspection cover (3) to get
access to the water separator.
5) Lock the inspection cover (3) in the
open position with the pin (2).
WCH00709
3
2
WCH03010
Fig. 1

Water Separator: Removal and Installation
2. Removal
1) Remove the 18 screws (2, Fig. 2).
2) Remove the 18 intermediate rings (1).
I-I II - II
II
III III
I
WCH00709
II I
1
4
III - III
6 5
Fig. 2

3) Attach the lug (94667C, Fig. 3) and the

support (94667B) as shown.
support (94667B) and the lug
(94667C).
out the water separator until you can
attach the lifting plate (94667A).
6) Attach the lifting plate (94667A).
7) Attach the shackle (S2) to the lifting
plate (94667A).
S2
94667A shackle (S2).
94667C
94667B H3
Fig. 3

out the water separator until you can
attach the plate (94667, Fig. 4) as
shown.
10) Attach the shackle (S1) to the eyelet of
H1 H2 the plate (94667) in the position shown.
11) Remove manual ratchet (H2), the
support (94667B) and the lug
(94667C).
94667
S1
S2
94667A
94667C
H3
94667B
WCH00709
Fig. 4


to hold the weight of the water
H1 H2
separator.
H1 H2
out the water separator. At the same
time, operate the manual ratchet (H1)
to release the tension.

H2 H1 end attachment point (1).
16) Attach the shackle (S1) to the middle
eyelet of the plate (94667).
S1
94667
Fig. 5


H2 H1 to fully remove the water separator. At
the same time, operate the manual
ratchet (H2) to release the tension.
S1
94667
18) Turn water separator 90_.
Engine Room 19) Attach the engine room crane to the

Crane middle eyelet of the shackle (S1).
20) Operate the engine room crane to hold
the weight of the water separator.
move the water separator to an
applicable area.
94667 23) Remove and discard the rubber cords

Middle (3 and 5, Fig. 2).
Eyelet
Fig. 6
3. Installation
I I 1) Make sure that the seating surfaces on
the water separator and the frame are
clean and in good condition.
2) Make sure that the guide bars (1,
WCH00709
Fig. 7) and the areas where the rubber
cords go are clean and in good
condition.
II
3) Put a new rubber cord (2) around the
rod (3). Bond together the ends of the
rubber cord.
II 4) Lubricate the two guide bars (1) and
the rubber cord (2).
3 2 1
Fig. 7

5) Attach the plate (94667, Fig. 8) and the

shackle (S1) to the water separator.
Engine Room
Crane 6) Attach the engine room crane to the
shackle (S1) on the middle eyelet of the
plate (94667).
the water separator.
S1 8) Turn the water separator 90_ to align it

94667 with the frame.
9) Attach the two manual ratchets (H1,
94667 H2) to the attachment points and the
Middle
shackle (S1).
Eyelet
to hold the weight of the water
separator.
11) Remove the engine room crane from
the water separator.
H2 H1
S1
94667
Fig. 8

H2, Fig. 9) to move the water separator
H2 H1 to the frame.
13) Make sure that the manual ratchet (H2)
has the weight of the water separator.
S1
94667
Fig. 9

14) Remove the manual ratchet (H1,

Fig. 10) from the end attachment
H1 H2
point (1).
15) Attach the manual ratchet to the
attachment point (2).
Fig. 10
H1 H2

H2, Fig 11) to move the water
separator into the frame as shown.
Fig. 11
17) Attach the plate (94667A, Fig. 12) to

H1 H2 the water separator.
18) Attach the shackle (S2) to the plate
(94667A).
19) Attach the support (94667D) to the side
of the water separator.
20) Make sure that the manual ratchet (H1)
has the weight of the water separator.
S2
94667A
94667
94667D
WCH00709
Fig. 12


attach it to the shackle (S2). as shown
in Fig. 13.
H1 H2 22) Remove the shackle (S1) and the plate
(94667).
S1
94667
Fig. 13
WCH00709
Note: During step 23), operate the

manual ratchets (H1, H2) to keep
tension on the manual ratchets
(H1, H2).
H1 H2 23) Use the tool (94667D, Fig. 14) to push
the water separator to the position
shown.
25) Remove the shackle (S1) and the plate
(94667).
26) Use the tool (94667D, Fig. 15) to push
94667D fully in the water separator.
27) Remove the support (94667D).
WCH00709
Fig. 14
94667D
Fig. 15 WCH00709

28) Put a new rubber cord (3, Fig. 16) in

the position shown. Bond together the
ends of the rubber cord.
I 29) Make sure that the rubber cords (3, 4)
are seated correctly.
30) Put oil on the threads of the 18 M16x55
screws (2).
31) Put the 18 intermediate rings (1) and
the 18 M16x55 (2) screws in position.
I 32) Torque the 18 M16x55 screws (2) to
1 the value given in 0352−2.
Fig. 16
CAUTION
Injury Hazard: The cover
weighs approximately
53 kg. Use applicable
equipment to install the
cover.
33) Attach the cover (1, Fig. 17) to the

scavenge air receiver.
WCH00709
Fig. 17

4. Completion
x
1) Install the supports and bottom plates
that you removed before.
2
2) Remove the pin (1, Fig 18) to unlock
1 the inspection cover (2).
3) Close the inspection cover (2).
4) Install the pin (1) in the stowage
position.
WCH03010 5. Condensate Drain

Make sure that the drains are not blocked,
Fig. 18 refer to the Operation Manual 8345−1.
You must make sure that water flows correctly. Refer to 0380−1 for the intervals to do
regular checks.
Make sure that the orifices (1, 2 and 3, Fig. 19) in the drain pipes are kept in a clean
condition.
EXHAUST DRIVING
SIDE END
WCH00702
Fig. 19

Water Separator (TC at Exhaust Side)
Removal and Installation − 7 Cylinder Engine

Tools:
2 Manual ratchet (H3) 800 kg 94016-001 1 Lifting tool 94667G
2 Chain blocks (H1, H2) 1500 kg 94018−003 1 Limiter 94667H
1 Lifting and removal gear (bracket) 94667E 1 Holder 94667I
1 Disassembling tool 94667F
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Preparation
CAUTION
DRIVING END

of the front cover is
1 approximately 61 kg. Use
the applicable equipment
to remove the cover.
1) Read and obey the General Guidelines

2 for Lifting Tools 0012−1.
WCH03354 2) Use an applicable chain block to
remove the front cover (1, Fig. 1) from
the scavenge air receiver (3).
3) Remove the cover (4) from the driving
FREE END
end of the scavenge air receiver (3).

4) Remove the platform (2) and the
applicable bottom plates.
5) Open the inspection cover (5) to get
access to the water separator.
3
6) Lock the inspection cover (5) in the
open position with the pin (6).
WCH03355
Fig. 1

Water Separator: Removal and Installation 7 Cyl.
2. Removal
Note: The water separator has two parts. To remove the front or rear water
separator, remove the screws (7, Fig. 2) and the plate.
1) Remove the 32 screws (9).
2) Remove the 32 intermediate rings (8).
I-I II - II
II I
III III
IV IV I
II
I
III - III I
10
1
7
8
2
IV - IV
WCH03360
5 4 3
Fig. 2

H1 H2 1 3) Attach the the two chain blocks (H1

and H2, Fig. 3) to the rail (1).
4) Attach the bracket (94667E) to the
water separator (2).
5) Attach the holder (94667I) as shown.
I
holder (94667I) and the bracket
94667I (94667E).
bracket (94667E).
WCH03564 8) Operate the chain block (H2) to apply a
light tension.
660 mm
CAUTION
I Injury Hazard: The weight
of the complete water
separator (front and rear
94667H 94667G part) is 439 kg. To prevent
injury, be careful when you
lift and move the water
separator.
94667E
2 9) Operate the manual ratchet (H3) to pull
out the water separator (2) a
Fig. 3 approximately 660 mm.
10) Attach the lifting tool (94667G) to the
water separator (2).
11) Attach the limiter (94667H) to the
receiver housing and the lifting tool
(94667G).
94667H 94667G H1 H2 to pull out the water separator
approximately 1030 mm . At the same
time, operate the chain block (H2) to
keep the height of the water separator
constant.
13) Remove the lifting tool (94667G) from
the front of the water separator.
H3 14) Attach the lifting tool (94667G) to the
middle of the water separator.
tool (94667G).
WCH03564
16) Remove the limiter (94667H).
1030 mm
Fig. 4


H1 H2 to fully remove the water separator. At
the same time, operate the chain
blocks (H1, H2) to keep the height of
the water separator constant.
18) Remove the manual ratchet (H3), the
lifting tool 94667G) and the holder
(94667I)
H3
WCH03564
Fig. 5
H1 H2
19) Make sure that the chain block (H1,
Fig. 6) has the full weight of the water
separator.
20) Remove the chain block (H2).
I 21) Use the chain block (H1) to move the
water separator to an applicable area.
22) Operate the chain block (H1) to lower
the water separator on to the platform.
23) Remove the chain block (H1) and the
WCH03564 lifting tool (94667G).
24) If it is necessary to divide the water
separator, do step a) and step b):
I a) Remove the two screws (1).
b) Divide the water separator into its
two parts.
3. Installation
1
Fig. 6 1) If the water separator was divided, do
step a) and step b):
a) Push the two parts of the water
separator together.
b) Attach the two parts of the water
separator together with the two
screws (1).

2) Make sure that the seating surfaces on

the water separator, and the frame (1,
I II Fig. 7) are clean.
3) Make sure that the guide bars (2) and
the areas where the rubber cords go
WCH03360 I are clean.
4) Put new rubber cords (3) around the
rods (4). Bond together the ends of the
rubber cords.
5) Lubricate the the guide bars (2) and the
rubber cords (3).
1
WCH03360
3 2
II
4 4
Fig. 7
6) Attach the lifting tool (94667G, Fig. 8)

to the water separator (2).
94667G
tool (94667G).
8) Operate the chain block (H1) to lift the
water separator to the applicable
H1 H2 height.
WCH03564
Fig. 8

9) Move the water separator to the

H1 H2 scavenge air receiver.
10) Attach the bracket (94667E, Fig. 9) to
the front of the water separator.
bracket (94667E).
12) Attach the tool (94667F) to the rear of
H3 94667E the water separator.
13) Attach the holder (94667I) as shown.
rear of the water separator and the
94667I 94667F
holder (94667I).
Fig. 9
H1 H2 15) Operate the manual ratchet (H3,

Fig. 10) to pull the water separator into
the frame to the position shown. Make
sure that the water separator level
stays level.
H3
Fig. 10
H1 H2
16) Continue to operate the manual ratchet
(H3, Fig. 11) until the lifting tool
(94667G) is adjacent to the frame.
lifting tool (94667G).
18) Remove the lifting tool (94667G) from
H3
the middle of the water separator.
the water separator fully in.
94667G
Fig. 11

H1 H2 20) Remove the manual ratchet (H1, H2

and H3, Fig. 12)
Fig. 12
21) Put a new rubber cord (4, Fig. 13) in

the position shown. Bond together the
ends of the rubber cord,
22) Make sure that the rubber cords (1, 4)
are seated correctly.
I
23) Put oil on the threads of the 18 M16x55
screws (3).
24) Put the 32 intermediate rings (2) and
WCH03360
the 32 M16x55 (3) screws in position.
25) Torque the 18 M16x55 screws (3) to
I
the value given in 0352−2.
WCH03360
1
Fig. 13

CAUTION
Injury Hazard: The front
cover weighs
DRIVING END

applicable equipment to lift
and move the cover.
1
26) Attach the front cover (1, Fig. 14) and
the rear cover (4) to the scavenge air
receiver.
2
WCH03354
4. Completion
1) Install the platform (2) and the
applicable bottom plates that you
removed before.
FREE END
2) Remove the pin (6) to unlock the
inspection cover (5).
3) Close the inspection cover (5).
4) Install the pin (6) in the stowage
position.
3
WCH03355
Fig. 14

Cylinder Lubrication Group 7
Cylinder Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7218−1/A1

Intentionally blank
Cylinder Lubricating System

1. Cylinder Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Cylinder Lubrication System − Operate . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Cylinder Lubrication Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Cylinder Lubricating System − Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Cylinder Lubricating Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Oil Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Duplex filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Clogged Filter Element − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Filter Element − Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Cylinder Lubrication System

For more data about the cylinder lubrication system, refer to the Operation Manual,
7218−1.
1.1 Cylinder Lubrication System − Operate

For more data, refer to the Operation Manual, 4002−2, paragraph 3.2 and paragraph
3.21.
1) In the LDU-20, get the MAIN page.
2) In the navigation menu, select Cylinder Lubrication.
3) In the CYL. LUBRICATION page, field Manual lub. Cyl. #, select the applicable
cylinder number.
4) If necessary, change the number of lube pulses (in the range 0 to 200) in field
Num. Of Inj..
Note: You can operate the 4/2-way solenoid valve (8, Fig. 1) to release manually
one lube pulse.

Note: Some parts

can look different.
DRIVING END
WCH02910
2
3
4
I
5
10 9 8
7 6
2
Fig. 1

1.2 Function Check

WARNING
1) If necessary, bleed the cylinder lubricating system, refer to paragraph 3.

2) Make sure that the applicable piston is in the TDC position. If the piston is not in
the TDC position, do step a) to step c):
a) Engage the turning gear.
b) Use the turning gear to get the applicable piston in the TDC position.
c) Disengage the turning gear.
3) Set to on the cylinder lubrication system for the related cylinder, refer to
paragraph 1.1.
Note: During usual operation, the ECS controls the cylinder lubrication.
4) Manually release a lube pulse as follows:
a) Use a pin or a screwdriver (6, Fig. 1) to push the plunger (7) of the 4/2-way
valve (8).
5) Look through the scavenge air ports in the cylinder liner (1) while the lubricating
system operates.
6) Make sure that the lubricating oil flows on to the cylinder liner wall, refer to the
Operation Manual 7218−1, paragraph 8.2 and 8.3.
7) Make sure that the oil that flows has no air. If necessary, bleed the cylinder
lubricating oil pump (10) and the oil pipes (2).
8) Set to off the cylinder lubrication system for the related cylinder.
2. Cylinder Lubrication Pump

For data about the cylinder lubricating pump (10), refer to the Operation Manual
7218−1, paragraph 5.
2.1 Checks
1) Examine the cylinder lubricating pump (10) for damage and leaks.
2) Do a function check of the cylinder lubricating system, refer to paragraph 1.2.

3. Cylinder Lubricating System − Bleed

Bleed the cylinder lubricating pump (10, Fig. 1) and the oil pipes each time you do
maintenance on the cylinder lubrication system.
3.1 Cylinder Lubricating Pump

Note: When you bleed the cylinder lubrication system, always start at the first
cylinder at the free end. The hydrostatic pressure in the cylinder
lubricating system helps you to bleed the cylinder lubricating pump (10).
To bleed the cylinder lubricating pump (10), do step 1) to step 7):
1) Make sure that the cylinder lubricating pump (10) is set to off.
2) Loosen the vent screw (9).
3) Keep the vent screw (9) open until oil that flows has no air.
4) Tighten the vent screw (9)
5) Clean the external surface of the cylinder lubricating pump (10).
6) If necessary, bleed the oil pipes (2) (to the lubricating quills), refer to
paragraph 3.2.
7) Do a function check of the cylinder lubrication system, refer to paragraph 1.2.
3.2 Oil Pipes

To bleed the oil pipes 2, do step 1) to step 8) below:
1) Set to on the cylinder lubricating system, refer to paragraph 1.1.
2) Use an open-ended spanner to hold the screw-in union (4) in position.
3) Loosen the nut (5) of the screw-in union (4) a maximum of two turns.
4) Keep the nut (5) of the screw-in union (4) open until oil that flows has no air.
5) Tighten the nut (5) of the screw-in union (4).
6) Clean the external surface of the lubricating quill.
7) If necessary, bleed the cylinder lubricating pump (10), refer to paragraph 3.1.
8) Do a function check of the cylinder lubricating system, refer to paragraph 1.2.

4. Duplex filter
For data about the duplex filter (1, Fig. 2) refer to the Operation Manual 7218−1,
paragraph 2.
4.1 Clogged Filter Element − Replace

1) Close the ball valve (6).
2) Remove the cover from the rail unit.
3) Move the lever (5) to select the clean filter element.
4) Remove the three nuts (3) on the applicable filter chamber (4), then remove the
cover (2).
5) Replace the clogged filter element.
Note: As an alternative, you can clean the clogged filter element, refer to
paragraph 4.2.
6) Attach the cover (2) to the filter chamber (4) with the three nuts (3).
7) Clean the external surface of the duplex filter (1).
8) Install the cover you removed before to the rail unit.
9) Open the ball valve (6).
4.2 Filter Element − Clean

For data about the procedure to clean the filter element, refer to the documentation of
the filter element manufacturer.

Note: Some parts

1 can look different.
FREE END
WCH03020
2
FREE END
6
4
3 2
WCH03018
Fig. 2

Piping Group 8
Exhaust Waste Gate (Low-load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8135−1/A1

HP Servo Oil Pipe: Removal, Grind, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8447−1/A1
Hydraulic Pipe for Exhaust Valve Drive: Removal, Grind, Installation . . . . . . . . . . . . . . . . . . . . . . . . 8460−1/A1
HP Injection Pipe: Removal, Grind, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8733−1/A1
HP Fuel Pipe: Removal, Grind, Installation (TC at Aft End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8752−1/A1
HP Pipe Pilot Fuel: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8790−1/A1

Intentionally blank
Exhaust Waste Gate (Low-Load Tuning)
1. General
The Low-load Tuning (LLT) uses a specially designed turbocharger system and
specified engine parameters. These parameters are related to fuel injection and
exhaust valve control and get the best decreased part-load BSFC in LLT.
Spring pressure keeps the actuator (3, Fig. 1) closed. A pressure of 5.5 bar opens the
control actuator
2. Maintenance
Special maintenance of the butterfly valve (7) is not necessary. For a general
inspection, refer to the instructions in the documentation of the manufacturer.
1) To do a function check, refer to the Operation Manual 8135−1 and the
Maintenance Schedule 0380−1 Exhaust Waste Gate (LLT).
7 1
5 5
6
2
3
WCH02971
Fig. 1
Key to Illustrations:
1 Expansion piece 5 Exhaust manifold
2 Control rod 6 Exhaust by-pass line
3 Control actuator 7 Butterfly valve
4 Turbocharger

Intentionally blank
HP Servo Oil Pipe
Removal, Grind, Installation

Tools:
1 Grinding tool 94841 Emery cloth As necessary
1 Stencil 94841A 1 Hand drill
1. Preparation
2) Make sure that the servo oil service pump is set to off.
3) Put an oil tray under the applicable intermediate piece (3, Fig. 1).
4) Put an oil tray under the connecting blocks of the applicable HP servo oil
pump (2).
5) Remove the stirrup bolts (1) from the applicable HP servo oil pipe.
IV
I
II 1
3
For views I − I to V,
II see Fig. 2 and Fig. 5
2
V
1 III
WCH02974
WCH02974
Fig. 1

HP Servo Oil Pipe: Removal, Grind, Installation
IV 6) On the flange (1, Fig. 2), loosen the

I-I screws (2).
7) Push down the flange (1) to get air in
the HP servo oil pipe (3).
6 1 8) On the flange (7), loosen the
SF screws (8).
5 2
9) Push up the flange (7) to let the servo
4 3 oil drain from the HP oil pipe (3).
1 10) On the flange (9) loosen the
WCH02974 2 screws (10).
3 WCH02974 11) Push down the flange (9) to get air into
the servo oil pipe (11).
II - II 3
4 12) Loosen the screw plug (19) to drain the
7 oil from the HP servo oil pipe (11).
18
17 8 13) On the flange (6), loosen the screws
(5).
V 16 V
14) Push down the flange (6) to get air in
the servo ol pipe (4).
9
15) Loosen the screw plug (19) to drain the
15 14 10
HP servo oil pipe (12).
13
11
2. Removal
12
WCH02974
2.1 HP Servo Oil Pipes (11, 12)
1) Remove the screws (21) from the
V-V flange (20).
2) Move the flange (20) away from the
servo oil pump.
3) Remove the screws (10) from the
flange (9).
4) Push down the flange (9).
5) Carefully remove the HP servo oil
pipe (11).
6) Remove the non-return valve (22).
VI VI
7) Apply protection to the sealing
faces (SF) to prevent damage.
22
1) Remove the screws (2, 5) from the
III - III flange (1, 6).
2) Push down the flange (1, 6).
21
3) Remove the screws (15), then remove
the intermediate piece (16).
19 4) Remove the screws (8, 17).
5) Push the flange (7, 18) up.
Fig. 2 11 or 12 20 WCH02974

6) Carefully remove the HP servo oil pipe

(3 and 4, Fig. 2).
7) Apply protection to the sealing
faces (SF) to prevent damage.
3. Sealing Faces − Grind

1
To get a smooth finish on the HP servo oil
pipe (1, Fig. 3), do step 1) to step 25).
1) Loosen the claw (3).
2) Apply protection to the opening of the
HP servo oil pipe (1).
2 3) Use the applicable grade of emery
you want to remove.
inner shape.
3
6) Remove the four screws (T2) and the
grinding tool (94841).
WCH02974
threads and faces of the four
screws (T2).
Template 8) Remove the cover (T1).
9) Put the emery cloth you cut out into the
Emery 10) Put the grinding tool (94841), emery
Cloth
cloth and the cover (T1) in position on
the hydraulic pipe (1).
1 94841
11) Torque symmetrically the the four
screws (T2) to 2.0 Nm.
Hand Drill 12) Put the hydraulic pipe (1) in a vice, as
vertically as possible.
13) Adjust the speed of the hand drill to
between 200 rpm and 500 rpm.
14) Align the hand drill and the grinding
tool (94841) accurately with the
hydraulic pipe (1) as shown.
T1 screws (T2) to 2 Nm.
T2
1 16) Put the hydraulic pipe (1) in a vice, as
SF horizontally as possible.
Emery between 200 rpm and 500 rpm.
Cloth
94841
WCH02974
Fig. 3

18) Align accurately the hand drill and the grinding tool (94841, Fig. 3) with the
19) Use light pressure and start grinding.
20) Regularly remove the unwanted material from the grinding tool (94841).
21) Make sure that the circular marks around the sealing face of the pipe are concentric.
22) Change the emery cloth for a smoother grade, then do step 3) to step 21) again until
you get a smooth finish.
23) Replace the emery cloth with a polishing cloth as a last step to polish the HP servo oil
pipe.
24) Clean the HP servo oil pipe (1).
25) If necessary, do step 3) to step 24) for the other servo oil pipes.
4. Adjustment
1 1) Make sure that the claw (4, Fig. 4) is
correctly attached to the HP servo oil
pipe (1).
2) Do a check of the O-ring (3). If the
O-ring is unserviceable, remove and
discard it.
2
3) Make sure that there is a distance of
5.5 mm between the end of the HP
servo oil pipe (1) and the claw (4).
Note: You can adjust the claw (4) with an
open-ended wrench.
4
5.5 mm
WCH02974
Fig. 4

IV I-I
5. Installation

6 1
1) Remove all of the protection from:
2 SF
5 D The sealing faces (SF) in the valve
housing (22, Fig. 5) and the HP servo
4 3
oil pipes (11, 12)
1
WCH02974 2 D The intermediate piece (16)
WCH02974
D The servo oil pump.
3
2) Apply oil to the the threads of all the
II - II 3 screws (2, 5, 8, 10, 13, 17, 21).
4
7 3) Attach the intermediate piece (16) to
18
8 the flat bar with the screws (15). Do not
17
tighten the screws at this step.
V 16 V 4) Put the non-return valve (23) in the
correct position.
9 5) Torque the non-return valve (23) to
10 40 Nm.
15 14
6) Carefully put the HP servo oil pipe (11,
13
11 12) in the intermediate piece (16).
Make sure that the pipe (11) that has
12 the non-return valve (23) is in the
WCH02974
correct position.
7) Torque symmetrically the eight screws
(21) (four screws for each HP servo oil
V-V pipe) to 40 Nm.
8) Torque symmetrically the four screws
(10) and the four screws (13) to 40 Nm.

1) Remove the protection from the sealing
faces (SF) of the HP servo
oil pipes (3, 4).
2) Carefully put the HP servo oil pipes (3,
VI VI 4) in position in the intermediate piece
(16) and the valve housing.
23
3) Torque symmetrically the screws (8,
22 17) to 40 Nm.
4) Torque symmetrically the screws (2, 5)
to 40 Nm.
III - III
5) Tighten the screws (15) on the
21 intermediate piece (16).
6) Tighten the screw plug (19).
19 7) Install the stirrup bolts (3, Fig. 1).
Fig. 5 11 or 12 20 WCH02974

Intentionally blank
Hydraulic Pipe for Exhaust Valve Drive

Tools:
1 Grinding tool 94841 Emery cloth (as necessary
1 Template 94841A 1 Hand drill
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Sealing Faces − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 2
III III
For View III − III see Fig. 3 and Fig. 7
I
7
I
II II 6
WCH02976
For View II − II see
Fig. 2, Fig. 4 and
Fig. 7
Fig. 1
1 Flange 5 Exhaust valve control unit (VCU)

2 Top housing 6 Flange
3 Screw plug 7 Hydraulic pipe
4 Drain screw

Hydraulic Pipe: Removal, Grind, Installation
1. Preparation
WARNING
Injury Hazard: The servo oil system has high pressure. Replace a
defective hydraulic pipe only when the engine has stopped.
WARNING
Injury Hazard: You must put on gloves and safety goggles when
you do work on hot components. When drain screws and plugs are
opened, servo oil can come out as a spray and cause injury.
1) Stop the engine (see the Operation Manual 4002-2).

2) Set to off the servo oil service pump.
3) Set to off the main bearing oil supply.
4) Make sure that there is no pressure in the servo oil system (refer to the data
given in the Operation Manual 0520-1, paragraph 2.3.
II - II
5) Put an oil tray under the drain screw (5,
1 Fig. 2).
7 2 6) Carefully loosen the screw plug (4).
7) Carefully loosen the drain screw (5) to
drain the oil from the servo oil system.
8) Put an oil tray under the applicable
6 3 hydraulic pipe (1).
9) Loosen the screws (7) on the flange (2)
to drain the applicable hydraulic
pipe (1) through the check bore (3) in
the housing of the exhaust valve
control unit (VCU) (6).
11) Torque the drain screw (5) to 200 Nm.
WCH02976
5 4
Fig. 2

3 III - III SF 2. Removal

CAUTION
Damage Hazard: Make sure
that you do not damage
the sealing faces or the
hydraulic pipe.
1) Remove the screws (3, Fig. 3) from the

flange (2).
2) Carefully move the flange (2) away
WCH02976 from the top housing (1).
2 1
Fig. 3
II - II 3) Remove the screws (4, Fig. 4) from the

flange (2).
4) Carefully move the flange (2) away
1
from the VCU (3).
CAUTION
4 of the hydraulic pipe is
2 approved equipment or
sufficient personnel to lift
and move the hydraulic
pipe.
5) Carefully remove the hydraulic pipe (4).

SF
3 6) Apply protection to the sealing
WCH02976
faces (SF) to prevent damage and
Fig. 4
contamination.


To get a clean and smooth finish on the
hydraulic pipe (1, Fig. 5), do step 1) to
Template step 20):
1) Put the template (94841A) on the back
of the emery cloth.
2) Use the applicable grade of the emery
Emery Cloth you want to remove.
inner shape.
94841 4) Cut out accurately the shape.
1
5) Remove the four screws (T2) of
Hand Drill
threads and faces of the four
screws (T2).
7) Remove the cover (T1).
8) Put the emery cloth you cut out into the
9) Put the grinding tool (94841), emery
T1 cloth and the cover (T1) in position on
T2
1 the hydraulic pipe (1).
SF
screws (T2) to 2.0 Nm.
Emery 11) Put the hydraulic pipe (1) in a vice, as
Cloth vertically as possible.
94841
between 200 rpm and 500 rpm.
WCH02976
13) Align the hand drill and the grinding
tool (94841) accurately with the
Fig. 5
14) Use light pressure and start grinding.
material from the grinding tool (94841).
16) Make sure that the circular marks around the sealing face of the hydraulic pipe
(1) are concentric.
17) Change the emery cloth for a smoother grade, then do step 1) to step 16) again
18) Replace the emery cloth with a polishing cloth as a last step to polish the
hydraulic pipe (1).
19) Clean the hydraulic pipe (1).
20) If necessary, do the step 1 to step 19) for the other hydraulic pipes.

4 4. Adjustment
1) Remove the protection from the
1 hydraulic pipe (4, Fig. 6).
2) Make sure that the claw (3) is correctly
attached to the hydraulic pipe (4).
3) Do a check of the O-rings (1, 2). If the
O-rings are unserviceable, replace
3 them.
5.5 mm between the end of the
hydraulic pipe (4) and the claw (3).
2
5.5 mm open-ended wrench.
Fig. 6
III - III 5. Installation

1 2 5.5 mm CAUTION
SF
the sealing faces (SF) or
the hydraulic pipes. Do not
apply lateral force to the
hydraulic pipe and the
flanges.
WCH02976 1) Remove all of the protection from the

sealing faces (SF, Fig. 7) in the top
housing (3) and the VCU (6).
2) Apply oil to the threads of the
4 3
screws (2, 5).
5.0 mm
3) Carefully put the hydraulic pipe (1) in
position in the top housing (3) and the
VCU (6).
II - II 1 4) Torque symmetrically the four
5.0 mm between the flange (4) and the
top housing (3).
6) Torque symmetrically the four
5
7 5.0 mm between the flange (7) and the
6 VCU (6).
5.0 mm Note: After 1000 operation hours, do

step 4) to step 7) again.
Fig. 7 SF
WCH02976

Intentionally blank
HP Injection Pipe
Removal, Grind, Install

Tools:
1 Grinding tool 94870 1 Grinding tool / countersunk screw M4 94870B
1 Screw-on sleeve 94870A 1 Locknut 94870C
1 Template 94870D 1 Hand drill
1. Preparation
1) Stop the engine (refer to the Operation
Manual 0310−1).
1 2) Set to off the fuel booster pump.
I II 3) Make sure that there is no pressure in

the fuel rail.
2 1
4) Set to off the trace heating (if installed).
5) If necessary, remove the trace heating
cable.
6) Disconnect the plug of trace heating
II cable (2, Fig.1).
7) Remove the insulation from the
III applicable HP injection pipe.
WCH02981
8) Put an oil tray under the applicable HP

injection pipe (1).
9) Carefully loosen the screws (5).
10) Lift the applicable flange (7) to drain the
fuel from the HP injection pipe (1).
II - II
I II 2. Removal
4
CAUTION
3 Damage Hazard: Make sure
1 that you do not damage
the sealing faces or the HP
II injection pipes.
1) On the injection valve (4), remove the

four screws (3).
2) On the flange (7) remove the four
III IV - IV SF screws (5).
IV
3) Carefully remove the applicable HP
4 5 injection pipe (1) from the injection
7
1 valve (4) and the flow limiting valve (6).
IV 4) Apply protection to the sealing faces
(SF) and the open ends of the HP
injection pipe (1).
WCH02981
6
Fig. 1 SF

HP Injection Pipe: Removal, Grind, Install

Use a medium to coarse grade emery cloth
94871D (30 CAMI to 80 CAMI) to remove deep
notches of more than 0.1 mm.
Use a fine or ultra-fine grade emery cloth
(100 CAMI to 600 CAMI) to get a smooth
016.738/08
Emery Cloth finish.
Do the procedure that follows:
you want to remove.
2) Put the template (94870D, Fig. 2) on
the back of the emery cloth.
94870B 3) Use a pencil or a ball pen to make the
the inner shape.
Graded Face
5) Make the shape into a cone. Make sure
that the graded surface is the inner
1
side.
6) Attach the emery cloth to the cone of
the grinding tool (94870B) with the
016.739/08
countersunk screw.
7) Put the HP injection pipe (1) in a vice.
2 94870C 94870A
8) Remove the claw (2) from the HP
injection pipe (1).
1 9) Attach the locknut (94870C) to the
threads on the end of the HP injection
pipe (1). Turn the locknut until it is fully
attached to the HP injection pipe.
016.739/08
10) Attach the screw-on sleeve (94870A) to
94870B Hand Drill the locknut (94870C).
11) Lock the screw-on sleeve in position
with the locknut (94870C).
1 SF 94870B 12) Attach the grinding tool (94870B) to the
hand drill.
13) Put the grinding tool (94870B) into the
screw-on sleeve (94870A). Make sure
that emery cloth touches the HP
injection pipe (1).
Fig. 2 14) Adjust the speed of the hand drill to a
maximum of 1500 rpm.
15) Operate the hand drill for 3 seconds to 5 seconds.
16) Remove the grinding tool (94870B) from the screw-on sleeve (94870A).
17) Use a low-pressure air supply to remove unwanted material from the HP injection
pipe.
18) Do a quality check of the sealing surface (SF). If necessary, do step 1) to
step 17) again.
19) Replace the emery cloth with a smoother grade, then do step 1) to step 17)
again.
20) Replace the emery cloth with a polishing cloth as a last step to polish the HP
injection pipe.

HP Injection Pipe: Removal, Grind, Install
4. Installation
I CAUTION
1 II
3
I that you do not damage
the sealing faces or the HP
2
1 injection pipes.
1) If necessary, attach the electrical trace

II heating cable. To the HP injection pipe
(1, Fig. 3).
2) If necessary, replace the O-rings (4, 6,
10, 12).
III 3) Apply oil to the claws (7, 11), sealing
WCH02981
faces (SF) and to the ends of the
threads on the HP injection pipe (1).
4) Make sure that the claws (7, 11) are
II - II correctly attached to the HP injection
pipe (1).
Note: Use only an open-ended wrench to
7 4 adjust the claws (7, 11).
5 5) Remove all of the protection from the
6
sealing faces in the injection valve (3)
and the flow limiting valve (9).
10.5 mm 6) Make sure that there is a distance of
5.7 mm
5.7 mm between the ends of the HP
injection pipe (1) and the claws (7, 11).
7) Apply Never-Seez NSBT8 to the
SF threads of the screws (2, 13).
8) Carefully put the HP injection pipe (1)
in position in the injection valve (3) and
the flow limiting valve (9).
III 9) Torque symmetrically the four

IV - IV
IV 12
13 11 8
14 10.5 mm between the flange (14) and
10 10.5 mm the flow limiter valve (9).
IV 11) Torque symmetrically the four screws
5.7 mm (13) to 40 Nm.
WCH02981 12) Make sure that there is a distance of
9 10.5 mm between the flange (7) and
9 SF the injection valve.
Fig. 3 13) Install the insulation to the HP injection
pipe 1.

Intentionally blank
HP Fuel Pipe

Tools:
1 Grinding tool 94870−1 1 Locknut 94870G
1 Screw-on sleeve 94870E 1 Template 94870H
1 Grinding tool / countersunk screw M8 94870F 1 Hand drill
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Sealing Faces − Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
V
I
1
I
VII
III 2
II
III
WCH02982
IV
V
II IV VI
VI
WCH02982
Fig. 1
Note: The different views are

shown in Fig. 2, Fig. 3, Fig. 8
and Fig. 9

HP Fuel Pipe: Removal, Grind, Installation
1. Preparation
WARNING
Injury Hazard: The fuel system has high pressure. Replace a
defective HP fuel pipe only when the engine has stopped. You
must obey the data given in the Operation Manual 0520-1.
WARNING
Injury Hazard: Always put on gloves and safety goggles when you
do work on hot components. When screws and plugs are opened,
steam or fuel can come out and cause injury.
CAUTION
Damage Hazard: Make sure that you do not damage the sealing
faces or the HP fuel pipes. Do not apply lateral force to the HP fuel
pipes and the flanges.
1) Stop the engine (refer to the Operation

I-I Manual 0310−1).
2) Set to off the fuel supply pump.
3) Set to off the trace heating.
4) If necessary, remove the insulation
from the applicable HP fuel pipe.
3
5) Put an oil tray under the applicable fuel
2 pump.
6) Loosen the screws (4, Fig. 2) a
maximum of three turns.
1
Note: The fuel will drain through the fuel
leakage pipe (7).
7) Move the flange (5) up.
8) Loosen the four screws (1) a maximum
VI of three turns.
II - II
9) Move the flange (2) down to get air into
6 the HP fuel pipe (3).
7 4
5
Fig. 2

I-I
2. Removal
1) Remove the applicable pipe clamps (1
and 2, Fig. 1).
SF
2) Remove the four screws (5, Fig. 3)
from the flange (4).
3
3) Carefully move the flange (4) up.
2
4) Loosen the two screws (10) on the
applicable intermediate piece (6).
1 5) Remove the four screws (1).
6) Carefully move the flange (2) down.
CAUTION
IV - IV VII of the HP fuel pipe is
3 approximately 15kg. Use
3 approved equipment or
4 4 sufficient personnel to lift
5 and move the HP fuel pipe.
6
6 7) Carefully remove the HP fuel pipe (3).
SF 8) Apply protection to the sealing faces
(SF) to prevent damage and
contamination.
10
9) Remove the four screws (8) from the
7 7
flange (7).
8 10) Carefully move the flange (7) down.
9 9
11) Remove the four screws (10 from the
flange (11).
12) Carefully move the flange (11) up.
13) Carefully remove the HP fuel pipe (9).
14) Apply protection to the sealing faces
II - II (SF)to prevent damage and
9 contamination.
10
11
Fig. 3 SF


Use a medium to coarse grade emery cloth
(30 to 80 CAMI) to remove deep notches of
94870H more than 0.1 mm.
Use a fine or ultra-fine grade emery cloth
(100 to 600 CAMI) to get a smooth finish.
To get a clean and smooth finish on the pipe
do the procedure that follows:
Emery Cloth 1) Put the template (94870H, Fig. 4) on

the back of emery cloth.
016.738/08
you want to remove.
1 94870F inner shape.
Graded Face 5) Make the shape into a cone. Make sure
that the graded surface is the inner
side.
6) Attach the emery cloth to the cone of
the grinding tool (94870F) with the
countersunk screw (1).
2
7) Put the HP fuel pipe (3) in a vice.
8) Remove the claw (2) from the HP fuel
016.739/08 pipe (3).
9) Attach the locknut (94870G) to the
3 94870G 94870E threads on the end of the HP fuel
pipe (3). Turn the locknut until it is fully
attached to the HP fuel pipe.
10) Attach the screw-on sleeve (94870E) to
the locknut (94870G).
11) Lock the screw-on sleeve in position
with the locknut (94870G).
3 12) Attach the grinding tool (94870F) to the

hand drill.
13) Put the grinding tool (94870F) into the
screw-on sleeve (94870E). Make sure
016.739/08 that emery cloth touches the HP fuel
pipe (1).
94870F Hand Drill
14) Adjust the speed of the hand drill to a
Fig. 4 maximum of 1500 rpm.
15) Operate the hand drill for 3 seconds to
5 seconds.
16) Remove the grinding tool (94870F)
from the screw-on sleeve.
17) Use a low-pressure air supply to
remove unwanted material from the HP
fuel pipe.

18) Do a quality check of the sealing surface (SF). If necessary use new emery cloth
of the same grade and do step 3) to step 17) again.
19) Replace the emery cloth with a smoother grade, then do step 3) to step 17)
again.
20) Replace the emery cloth with a polishing cloth as a last step to polish the HP fuel
pipe.
1 SF Note: If you find large notches, you must
make the HP fuel pipe (1, Fig. 5)
shorter. Make sure that there is a
minimum distance of 0.5 mm
016.739/08
between the countersunk screw
and the sealing face (SF) on the
HP fuel pipe.
Fig. 5 Minimum 0.5 mm
21) Remove the screw-on sleeve (94870E,
Fig. 4).
22) Attach the claw (2) to the HP fuel
pipe (3).
SF
1
4. Installation
10.0 mm
1) Do a check for damage of the O-rings
(1 and 3, Fig. 6). If necessary, replace
4 2 the O-rings.
2) Remove all the protection from the
sealing faces (SF).
3 3) Make sure that the claw (4) is correctly

attached to the HP fuel pipe (2).
open-ended wrench.
WCH02982
10.0 mm between the end of the HP
fuel pipe (2) and the claw (4).
5) Make sure that the O-rings (1, 3) are in
2 the correct position.
6
10.0 mm
WCH02982 SF
Fig. 6

I-I 6) Apply Never-Seez NSBT to the threads

of all the screws (1, 5, 9 and 11, Fig. 7).
CAUTION
4 SF Injury Hazard: The weight
of the HP fuel pipe is
3
approved equipment or
2 sufficient personnel to lift
and move the HP fuel pipe.
1 CAUTION
Injury Hazard: Make sure
the sealing faces (SF) or
the HP fuel pipe. Do not
apply lateral force to the
IV - IV HP fuel pipe and the
3 VII
3 flanges.
5 5 7) Carefully put the HP fuel pipe (3) in the
6 intermediate piece (7) and the valve
43 mm housing (4).
7
8) Torque symmetrically the four
screws (1, 6) to 30 Nm.
9) Make sure that the flanges (2, 5) are
10 not tilted and in the correct position.
8 8 10) Torque symmetrically the four
9 screws (1, 6) to 55 Nm.
10 10 11) Make sure that there is a distance of
43 mm between the shoulder of the
flange (5) and the intermediate piece
(7).
43 mm between the shoulder of the
flange (13) and the fuel pump cover
II - II (12).
13) Attach the applicable pipe clamps (1
9 and 2, Fig. 1).
11
13
43 mm
12
Fig. 7 WCH02982

HP Pipe Pilot Fuel

1. Preparation
WARNING
Injury Hazard: The pilot fuel system has high pressure. Replace a
defective HP pilot fuel pipe only when the engine has stopped. You
must obey the data given in the Operation Manual 0520-1.
WARNING
Injury Hazard: Always put on gloves and safety goggles when you
do work on hot components. When screws and plugs are opened,
steam or fuel can come out and cause injury.
CAUTION
Damage Hazard: Make sure that you do not cause damage to the
sealing faces or the pilot fuel pipes. Do not apply lateral force to the
HP pilot fuel pipes and the flanges.

2) Set to off the fuel supply pump.
3) Make sure that the pilot fuel supply unit (2, Fig. 1) is set to off.
4) Make sure that the pressure in the Pilot Fuel Supply Unit is zero, refer to the
Operation Manual, 4002−2, paragraph 3.10 Pilot Fuel Pressure.
For View I − I, see Fig. 3
Pilot Fuel
Pipe
I
2
I
1 Pilot Fuel
Pipe
WCH03189
Fig. 1
1 Rail unit 2 Pilot fuel supply unit

HP Pipe Pilot Fuel: Removal and Installation
2. Removal
2.1 Pilot Fuel Pipe (1, 9)

1) Put an oil tray under the applicable pilot
fuel pipe (1 or 9, Fig. 2).
2) Open the screw plug (6). If there is no
9 1 fuel, The pilot fuel pipes (1, 9) are fully
drained.
8 2 4) On the applicable pilot injection valve
(3 or 7), loosen the coupling nut (2
7 3 or 8).
6
5) On the distributor block (11), carefully
loosen the applicable coupling nut (10
or 14).
II
6) Carefully remove the applicable HP fuel
pipe (1 or 9).
5
7) Put the HP fuel pipe (1 or 9) in a clean,
dry area.
4
II 1) Put an oil tray under the applicable pilot
fuel pipe (4 or 5).
2) On the applicable distributor blocks (11)
14 10 loosen the applicable coupling nuts (12
or 13) a maximum of two turns.
11
3) Loosen the applicable coupling nuts
(12 or 13) a maximum of three turns.
Note: Make sure that the fuel drains into
13 12 the oil tray.
5 4 4) Fully loosen the the applicable coupling

nuts (12 or 13).
WCH03189
5) Carefully remove the pilot fuel pipe (4
or 5) from the distributor block (11).
6) Remove and discard the O-rings (10,
Fig. 3).
7) Attach protection to all openings and
11 sealing faces to prevent contamination.
III
III
11 11
13 12 13
4 4
5
Fig. 2

HP Pipe Pilot Fuel: Removal and Installation
IV
3. Installation
IV V 3.1 Pilot Fuel Pipe (4, 5)

11 1) Remove all protection from the
openings and sealing faces.
11 V 2) Apply oil to the applicable coupling nuts
(12 and 13, Fig. 2).
5 4 3) Make sure that the sealing faces (SF,

Fig. 3) have no damage.
4) Put new O-rings on the applicable pilot
fuel pipe (4 or 5).
V-V 5) Attach the applicable pilot fuel pipe (4
or 5) to the distributor blocks (11).
SF 6) Make sure that the coupling nuts (12 or
13) are correctly attached.
5.6 mm
6 7) Make sure that there is a distance of
5.6 mm between the end of the pilot
O-ring fuel pipe (4 or 5) and the claw (6).
8) Use an applicable torque wrench to
12 or 13 torque the coupling nuts (12 or 13) to
26 Nm.
O-ring
4 or 5 1) Remove all protection from the
openings and sealing faces.
2) Apply oil to the applicable coupling nuts
WCH03453 (2 or 8 and 10 or 14, Fig. 2).
3) Make sure that the sealing faces (SF,
Fig. 3) have no damage.
4) Put new O-rings on the applicable pilot
fuel pipe (1 or 9).
I - I (see Fig. 2) and IV - IV
5) Attach the applicable pilot fuel pipe (1
or 9) to the pilot injection valve (3 or 7,
Fig. 2) and the distributor block (11).
O-ring 6) Make sure that the coupling nuts (2 or

8 and 10 or 14) are correctly attached.
2 or 8 7) Make sure that there is a distance of
10 or 14 5.6 mm between the end of the pilot
fuel pipe (1 or 9) and the claw (2 or 8
O-ring and 10 or 14).
1 or 9
8) Use an applicable torque wrench to
torque the coupling nuts (2 or 8 and 10
WCH03453
or 14) to 26 Nm.
5.6 mm
SF
Fig. 3

Intentionally blank
Crank Angle Sensor Unit, Tools Group 9
Crank Angle Sensor Unit: Proximity Sensor − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9223−1/A1

Cylinder Pressure Sensor: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9258−1/A1
Tools: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−1/A1
Hydraulic Jacks and Pumps: Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−2/A1

Storage, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−3/A1
General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−4/A1
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−5/A1

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1 to 39
Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 40 to 41

Intentionally blank
Crank Angle Sensor Unit
Proximity Sensor − Replace
1. General
For the function of the Crank Angle Sensor Unit, read the data in the Operation
Manual 9223−1. For the Inspection and Overhaul Intervals, refer to 0380−1 Crank
Angle Sensor Unit.
2. Proximity Sensor − Replace

WARNING
make sure that no
1) Operate the turning gear to get a

tooth (3, Fig. 1) of the flywheel (6)
opposite the applicable proximity
sensor (5).
2) Put a mark on the cable (2) to identify
6 its position.
3) Disconnect the applicable electrical
connection from the proximity
sensor (5).
4) Loosen the locknut (4).
WCH02993 5) Remove the proximity sensor (5) from
1 the holder.
6) Attach a new proximity sensor (5) to
the holder.
7) Make sure that the proximity sensor (5)
touches the tooth (3).
8) Loosen the proximity sensor (5) to get
a clearance of 4.0 mm between the
tooth (3) and the bottom of the
proximity sensor.
5 9) Carefully tighten the locknut (4) with

your fingers.
4
10) Connect the electrical connection (2) to
the proximity sensor (5). Refer to the
mark made before to identify the
2 correct cable.
flywheel (6) in a clockwise direction.
12) Make sure that the CCM−20 pick-up
sequence is A, B and C.
13) When the crank-angle mark (1) passes
3
the proximity sensor (5), the LED REF
shows.
Fig. 1 4.0 mm

Intentionally blank
Cylinder Pressure Sensor

Tools:
1 Disassemble and assemble tool 94022H
1. General
For data about the balance control of the cylinder pressure, refer to the Operation
Manual, 4002−1, paragraph 3.10.
For the signal failure test, refer to the Operation Manual 4002−2, paragraph 3.5
Cylinder Balancing (Diesel Mode) and 3.6 Cylinder Balancing (Gas Mode).
2. Removal
1) Make sure that there is no pressure in cylinder cover (2, Fig. 1).
2) Disconnect the electrical connection from the pressure sensor (1) (PT3601).
3) Attach the tool (94022H) to the casing of the sensor (1).
4) Carefully remove the sensor (1).
5) Put the sensor (1) in a clean, dry area.
3. Installation
1) Apply oil to the thread of the sensor (1).
2) Attach the tool (94022H) to the sensor (1).
3) Fully install the sensor (1).
4) Torque the sensor (1) to 25$5 Nm.
5) Connect the electrical cable to the sensor (1).
6) On the Local Control Panel, look for the the signal failure list. Make sure that a
pressure sensor (PT3601−07C) shows.
I-I
94022H
I
1
I
WCH03568
Fig. 1
WCH03408

Intentionally blank
Tools
Description
1. General
The tools necessary for the maintenance of the engine are divided into the two
groups that follow:
D 9403−5 Standard Tools
D 9403−5 Recommended Special Tools.
When you send an order for tools or replacements, you must include the data that
follows:
D The engine type
D The tool number
D The tool description.
Data about the configuration, maintenance and storage of the hydraulic
pre-tensioning jacks are given in 9403−2, 9403−3 and 9403−4.
An independent tool set is supplied for some components from sub-suppliers. These
tools must be kept in an isolated storage area away from the engine tools.
Some tools have special screws and devices. These tools have stowage positions for
the special screws and devices. When the tool is not used, the special screws and
devices must stay in their stowage positions.
When oil must be added to the hydraulic pumps, the related oil quality specification
from the pump manufacturers must be obeyed. Use lubricating oils that have the
viscosities SAE 30 to SAE 40. In unusual conditions, it is also possible to use cylinder
lubricating oil.
2. Standard Tools
These tools are necessary for the usual maintenance on the engine. Some of these
tools are not necessary for specified maintenance.
3. Recommended Special Tools

These tools and devices let you do some of the maintenance tasks easily and in a
decreased time when compared to the standard tools. You can send an order for the
recommended special tools with the engine order, or on a specified date.

Intentionally blank
Hydraulic Jacks and Pumps
Configuration
Tools:
1 HP oil pump (2800 bar) 94931 9 Pre-tensioning jack 94145
2 Hydraulic unit (2500 bar) 94942 10 Hydr. jack 500 kN (50 t) 94936
3 High pressure hose (2600 bar) 94935 11 Double pre-tensioning jack 94114B
4 Connection block 94934 12 Hose 94935C
5 Hydraulic distributor 94934A 13 Valve holder 94272A
6 Coupling element 94934G 14 Adapter piece 94934F
7 Connection piece 94215B 15 Hydraulic distributor 94934H
8 Pre-tensioning jack 94215A (with pressure gauge 0 to 25 bar)
16 Connection nipple 94934I
1 14 5 3 2
A 5
H
15 6 3 4
3
16
WCH00724
C
3 3
B 7
8 9
016.623/08
Fig. 1
A Apply tensioning / loosen tie rods, elastic studs C Apply tension / loosen the foundation bolts and
to exhaust valve cages, top and bottom end engine stays
bearings to connecting rod, piston rod screwing
and elastic studs to piston crown
B Apply tension / loosen elastic studs to the
cylinder cover

Hydraulic Jacks and Pumps: Arrangement and Application
1 14 5 3 2 3
E
D
3 3
10
6 11
5 4 5 4
018.664/09
3
F G
12
Fig. 2 013.539/05
5 13
D Apply tensioning / loosen tie rods, elastic studs G Set-up of pre-tensioning jacks 94215a (i.e.
to exhaust valve cages, top and bottom end collection the hydraulic oil)
bearings to connecting rod, piston rod screws
and elastic studs to piston crown. Apply
tensioning / loosen the elastic studs to the main
bearing.
E Removal and installation of main bearing shells H Checks of non-return valve in the lubricating quill
for pulse lubrication.
F Setting and checks of the fuel overpressure
safety valve

Storage, Servicing and Maintenance
1. General
The pre-tensioning jacks are part of the engine tool kit. When the pre-tensioning jacks
are not in use, make sure that:
D The dust plugs are installed in the open connections
D Grease is applied to the applicable areas
D The pre−tensioning jacks are in their toolboxes
D The toolboxes stay in a clean dry area away from contamination.
It is recommended that you keep a sufficient number of new back-up and O-rings of
the specified quality and dimensions.
Refer to Table 1 for the correct positions for the O-rings and back-up rings during
installation.
Put the back-up rings in hot water before installation.
To prevent damage, install carefully the back-up rings and O-rings. Do not use tools
with sharp edges.
Table 1
Tool Position of Pre-tensioning Jack Part Back-up Ring O-ring

Number (not cut)
Dimension (mm)
o∅ x i∅ x t i∅ x s
94114B Elastic studs − main bearing Piston 95.4 x 86 x 1.7 88.27 x 5.33
Cylinder 66.2 x 60 x 1.4 59.92 x 3.53
94145 Foundation bolts and engine stays Piston 92 x 82.6 x 1.7 81.92 x 5.33
Cylinder 79.2 x 73 x 1.4 72.62 x 3.53
94180A Tie rods (with M80x6 thread diameter) Piston 183 x 170.8 x 2.5 164.47 x 6.99
Cylinder 127.4 x 118 x 1.7 116.84 x 5.33
94215A Elastic studs − cylinder cover Piston 110 x 100.6 x 1.7 97.79 x 5.33
Cylinder 93.4 x 84 x 1.7 85.09 x 5.33
94252 Elastic studs − exhaust valve Piston 152 x 138.8 x 2.5 135.89 x 6.99
Cylinder 105.4 x 96 x 1.7 94.62 x 5.33
94314 Elastic studs − bottom end bearing Piston 115 x 105.6 x 1.7 104.14 x 5.33
Cylinder 94.4 x 85 x 1.7 85.09 x 5.33
94315 Elastic studs − top end bearing Piston 105 x 95.6 x 1.7 94.62 x 5.33
Cylinder 76.2 x 70 x 1.4 69.44 x 3.53

Hydraulic Pre-tensioning Jacks: Storage, Servicing and Maintenance
Table 1 (continued)
Tool Position of Pre-tensioning Jack Part Back-up Ring O-ring

Number (not cut)
Dimension (mm)
o∅ x i∅ x t i∅ x s
94340 Elastic studs for the piston rod − piston 58 x 51.8 x 1.4 50.39 x 3.53
screw connection cylinder 47.2 x 41 x 1.4 40.87 x 3.53
94346 Elastic studs for the piston head piston 50.5 x 44.3 x 1.4 44.04 x 3.53
cylinder 46.2 x 40 x 1.4 40.87 x 3.53
O-ring Back-up ring t
o∅ i∅
o∅ i∅
Fig. 1 002.696/98 011.032/03

2. Overview of Pre-tensioning Jacks

Table 2 Tool 94114B − Double Pre-tensioning Jack (Main Bearing − Elastic Studs)
1 Piston 7 O-ring
2 Double cylinder 8 Back-up ring
3 Round nut 9 O-ring
4 Holder 10 Adapter
5 Vent screw 11 Closing valve
6 Back-up ring
94114B−KJ Kit with back-up and O-rings
for double pre-tensioning Jack
4 94114B−KJ
5
6
3
7
9
2
8
4
5
018.674/09
Fig. 2
11 10

Table 3: Tool 94145 − Pre-tensioning Jack (Foundation Bolt and Engine Stay)
1 Piston 6 Back-up ring

2 Cylinder 7 O-ring
3 Vent screw 8 Back-up ring
4 Adapter 9 O-ring
5 Connection piece
94145−KJ Kit with back-up and O-rings

for pre-tensioning Jack
3 94145−KJ
4
6
1
7
2
Fig. 3 013.471/05

Table 4: Tool 94180A − Pre-tensioning jack (Tie Rod − M80x6)

2 Cylinder 7 O-ring
4 Adapter 9 O-ring
5 Connection piece 10 Eyelet
94180A−KJ Kit with back-up and O-rings
for double pre-tensioning Jack
10 5
3 94180A−KJ
4
1
6
2
7
Fig. 4 WCH03123

Table 5: Tool 94215A − Pre-tensioning Jack (Elastic Stud − Cylinder Cover)

2 Cylinder 7 O-ring
4 Adapter 9 O-ring
5 Connection piece 10 Holder
94215A−KJ Kit with back-up and O-rings
10
3 94215A−KJ
4
1
6
2 7
013.472/05
Fig. 5

Table 6: Tool 94252 − Pre-tensioning Jack (Elastic Stud − Exhaust Valve Cage)

2 Cylinder 7 O-ring
4 Adapter 9 O-ring
94252−KJ
5
3
4 6
10
1 7
2
Fig. 6 013.475/05

Table 7: Tool 94314 − Pre-tensioning Jack (Elastic Stud − Bottom End Bearing)

2 Cylinder 7 O-ring
4 Adapter 9 O-ring
5 Connection piece 10 Distance bush
94314−KJ
5
3 6
4
1 7
10 8
Fig. 7 013.474/05

Table 8: Tool 94315 − Pre-tensioning Jack (Elastic Stud − Top End Bearing)

2 Cylinder 7 O-ring
4 Adapter 9 O-ring
94315−KJ
5
6
10
3
4 7
2 9
Fig. 8 010.039/02

Table 9: Tool 94340 − Pre-tensioning Jack (Elastic Stud − Piston Rod Foot)

2 Cylinder 7 O-ring
4 Adapter 9 O-ring
5 Connection piece
3
4
94340−KJ
1 6
013.476/05
Fig. 9

Table 10: Tool 94346 − Pre-tensioning Jack (Elastic Stud − Piston Crown)

3 Cylinder 7 O-ring
5 Adapter 9 O-ring
6 Connection piece
3
94346−KJ
4
1
6
2 7
Fig. 10 016.651/08

Intentionally blank

General Instructions
Hydraulic Pre-tensioning Jacks for:
Version 1: Version 2:
Foundation bolt and engine stay 94145 Main bearing 94114B
Elastic studs − cylinder cover 94215A Tie rod 94180A
Elastic studs − exhaust valve 94252
Connecting rod − top end bearing 94315
Piston rod −screw connection 94340
Elastic studs − piston head 94346
Elastic stud − bottom end bearing 94314
1. General
There are two versions of hydraulic jack preparation:
D Version 1 − the piston (2 is attached directly on to the elastic bolt / elastic stud (6)
(see Fig. 1).
D Version 2 − the nut (10) is used to apply tension to the elastic bolt / elastic stud
(see Fig. 2).
1) You must make sure that the threads of elastic bolts and hydraulic jacks are
smooth and clean.
2) You must make sure that you add lubricant to the elastic bolts and hydraulic
jacks, refer to 0352-1.
3) Connect the hydraulic components to the hydraulic jacks, refer to 9403−2.
4) Fully tighten the high pressure (HP) hoses to make sure that the built−in
non-return valves can operate.
WARNING
Injury Hazard: Always put on gloves, a face shield and safety
goggles when you use hydraulic tools. Hydraulic tools can cause
injury.
5) Do a check of the oil in the HP oil pump or hydraulic unit.

Note: When you must add oil, read the specification of the pump manufacturer.
Use an engine lubricating oil that has a viscosity of SAE 30 to SAE 40. In
unusual conditions, you can also use cylinder lubricating oil.
D For data about the sealing rings on the hydraulic jacks, refer to 9403−3.
D To install elastic studs, refer to 0352−2.

Hydraulic Pre-tensioning Jacks: General Instructions
2. Loosen
2.1 Version 1 − Preparation
1) Make sure that the vent screw (1, Fig. 1) is open.
2) Put the hydraulic jack on to the elastic stud (6).
3) Turn the hydraulic jack until it is tight. Make sure that there is no clearance at X.

1) Make sure that the vent screw (1) is open (see Fig. 2).
2) Put the hydraulic jack over the elastic stud (6).
3) Use the round bar to lightly tighten the round nut (7).
2.3 Procedure
1) Turn back the round nut (7), or the hydraulic jack (see Table 1 below).
2) On the HP oil pump, close the relief valve.
3) Connect the hydraulic jack to the HP oil pump or the hydraulic unit.
4) Put a hose on the vent screw (1)
5) Put a container below the hose to drain the oil.
6) Operate the HP oil pump.
7) Close the vent screw (1) when oil that has no air flows out.
Note: Do not move the piston (2) above the limit of the red groove (3).
8) Operate the HP oil pump to slowly increase the pressure to between
approximately 20 bar to 30 bar more than the value give in Table 1.
9) Keep the pressure constant and use the round bar (8) to loosen the round nut (7)
(see Table 1 below).
10) On the HP oil pump, or the hydraulic unit, decrease the pressure to zero.
11) Remove the hydraulic jack.
Version 1 Version 2
APPLY TENSION LOOSEN APPLY TENSION LOOSEN
9 1
10
2 9 1
3 2
3
x
4
4
8 8
7 5
6 7 5
6
Fig. 1 016.696/08 Fig. 2 016.697/08

3. Apply Tension
1) Turn the round nut (7) fully down (Fig. 1 and Fig. 2). Make sure that there is no
clearance at the slot (5).
2) Put one reference mark (Y) on the nut and one reference mark (X) on the part
below (see Fig. 3 and Fig. 4).
009.752/02
010.031/02
Marks for Y Tightening

X X
Comparison Angle
Fig. 3 Fig. 4

1) Make sure that the vent screw (1, Fig. 1) is open.
2) Put the hydraulic jack on the elastic stud (6).
3) Turn the hydraulic jack until it is tight. Make sure that there is no clearance at X.

1) Put the hydraulic jack over the elastic stud (6).
2) Use the round bar to lightly tighten the round nut (7).
3) If necessary, turn back the hydraulic jack a small distance to get access to the
hole in the round nut (7).
3.3 Procedure
1) On the HP oil pump, close the relief valve.
2) Connect the hydraulic jack to the HP oil pump or the hydraulic unit.
3) Operate the HP oil pump.
4) Close the vent screw (1) when oil that has no air flows out.
5) Slowly increase the pressure to the nominal value, then keep the pressure
constant (refer to Table 1 for the pressure values)
Note: Do not move the piston (2) above the limit of the red groove (3).
7) Use the round bar (8) to tighten the round nut (7) nut.
8) Put the feeler gauge through the slot (5) to make sure that there is no clearance
between the round nut (7) and the seating.
9) Compare the angle between the reference marks (X and Y, Fig. 3 and Fig. 4) on
the round nut and the Comparison value in Table 1. If there is a large difference,
you must investigate the cause and do the procedure again.
10) On the HP oil pump, or hydraulic unit, decrease the pressure to zero.
11) Remove the hydraulic jack.

Table 1: Hydraulic Jacks − Values and Comparison
Position of Group Jack Tightening Comparison Number of Lubricating

Pre-tensioning Value (bar) (_( mm) Turns to Set Agent 1)
Jack the Jack /
Round Nut
Main bearing 1132−1 94114B 1500 − ¾ Oil
Foundation bolt 1715−1 94145 1st step 900 − ¼ No lubricant
then 1500
Engine stays 1715−1 94145 310 − ¼ No lubricant
Tie rods 1903−1 94180 1500 From 100 to 3 Molykote
1500 bar paste G
13.0 to 14.5 mm
Elastic studs − 2708−2 94215A 1500 530_ 1½ Oil
cylinder cover
Exhaust valve 2751−1 94252 1500 155_ 1 Oil
cage
Elastic stud − top 3303−1 94315 1st step 1000 1st to 2nd step ½ Oil
end bearing then 1500 15_
Bottom connect- 3303−1 94252 1st step 950 1 to 2nd step
st 1 Oil
ing rod then 1500 30_
Crosshead and 3326−1 94340 st
1 step 1000 1 to 2nd step
st ½ Oil
guide shoe then 1500 80_
Piston head 3403−3 94340 1500 115_ ½ Oil
Elastic stud − 3303−1 94314 1st step 950 1st to 2nd step ½ Oil
bottom end then 1500 30_
bearing
1) For lubrication on threads and contact surfaces.

Tool List
Standard Tools
94000 Combination wrenches, set compl.
consisting of:
6 wrenches AF36 to AF60
for ordering single wrenches state AF
94000−36 Example: . . . . . 94000−36
94000−60 94000−60 WCH02800
94001 Open end wrenches

94001−65 1 Piece . . . . . AF 65
94001−75 1 Piece . . . . . AF 75
000.384/93
94001−110 1 Piece . . . . . AF 110
94002 Ring slugging wrenches, set compl.

consisting of:
12 wrenches AF27 to AF110
000.382/93
94002−27 Example: . . . . . 94000−27
94002−110 94000−110
94003 Allen keys, set compl.

consisting of:
11 Allen keys AF5 to AF27
for ordering single wrenches state AF 000.381/93
94003−5 Example: . . . . . 94000−5
94003−27 94000−27
94004 Angle screwdrivers

94004−10 1 Piece . . . . . b = 10 mm
94004−12 1 Piece . . . . . b = 12 mm
94004−25 1 Piece . . . . . b = 25 mm
000.380/93
b
94005 Rods
for pre-tensioning jacks
94005−6 3 Pieces . . . . Ø 6 mm
94005−9.5 3 Pieces . . . . Ø 9.5 mm
94005−14 3 Pieces . . . . Ø 14 mm WCH02801

Standard Tools
94006 Socket head keys, set compl.

consisting of:
7 Socket head keys AF11 to AF27
94006−11 Example: . . . . . 94000−11
94006−27 94000−27 000.377/93
94007 Tongs
94007−C8 1 Piece . . . . . Type C 8
94007−C19 1 Piece . . . . . Type C 19
94007−C40 1 Piece . . . . . Type C 40 000.376/93
94007−A10 1 Piece . . . . . Type A 10

94007−A19 1 Piece . . . . . Type A 19
94007−A40 1 Piece . . . . . Type A 40
000.375/93
94008 Withdrawing gears

for taper & cylindrical dowels and pins
94008−M4 1 Piece . . . . . M4
94008−M5 1 Piece . . . . . M5
94008−M6 1 Piece . . . . . M6
94008−M8 1 Piece . . . . . M8
94008−M10 1 Piece . . . . . M10
94008−M12 1 Piece . . . . . M12
94008−M20 1 Piece . . . . . M20
X
for removal of Cyl. cover elastic stud WCH00836
94008A−M56 1 Piece . . . . . M56

X = 146 mm
94010 1 Torque spanner 3/8”

(Range of adjustment 2.5−11 Nm)
94010A Adapter piece 3/8”−½” 010.229/02
94011 1 Torque spanner ½”

(Range of adjustment 12−68 Nm)
010.230/02
94012 1 Torque spanner ¾”

with extension tube and tool box
94012A adapter piece ¾”-½”, 010.231/02
94012B shell type ratchet ¾”-¾”

Standard Tools
94013 1 Torque spanner

WCH02642

013.558/05

94016−001 2 Manual ratchets
WLL 800 kg, 2,5 m stroke

WLL 1600 kg 2,5 m stroke


012.233/04
94016A−001 2 Manual ratchets
94017−021 1 Spur-geared chain block

WLL 2000 kg, 4 m stroke
94017−022 1 Spur-geared chain block

016.621/08
94018−003 2 Spur-geared chain blocks

94018−006 2 Spur-geared chain blocks

WCH02297

Standard Tools
Shackle
94018B 1 WLL 4750 kg
Shackle
94019F 3 WLL 1000 kg
94019G 3 WLL 2000 kg
94019H 3 WLL 3250 kg
94019I 3 WLL 4750 kg WCH03047
94019K 3 WLL 6500 kg
94020 1 Power amplifier

(with transmission factor 1:4)
WCH02642
94021 1 Pipe
to power amplifier
X = 563 mm
X WCH02643
94022 1 Adapter piece 3/8”−¼”

94022A 1 Socket wrench insert
010.233/02
AF 3
94022H 1 Dismantling and assembling tool

for sensor cylinder pressure
X
AF30
X = 313
WCH033226
94023 1 Hex head driver 1”

AF 22 94023
X 94024
94023A 1 Assembly tool AF 13
X = 225 mm
94024 1 Hex head driver ½” 94023A WCH03326

013.556/05
AF 19

Standard Tools
94025 1 Tool box with socket wrench set ½”

000.368/93
94026 1 Tool box with hex. head drivers ½”

000.368/93
94027 4 Extensions
for intermediate wheel assembly
X = 250 mm
X
94032 1 High pressure grease gun

for lubricating grease nipples on
fuel pump regulating linkage
000.370/93
94040 RUD-eye bolts

94040−M8 6 Pieces . . . . M8
94040−M10 6 Pieces . . . . M10
94040−M12 6 Pieces . . . . M12
94040−M16 6 Pieces . . . . M16
94040−M20 6 Pieces . . . . M20
94040−M24 4 Pieces . . . . M24
94040−M30 4 Pieces . . . . M30
013.560/05
94048 Swivel lug

94048−M16 4 Pieces . . . . M16
94048−M30 6 Pieces . . . . M30
WCH00113
94050 1 Tool for pressure measurement B D C F G

for pneumatic elements
94050A 1 Compressed air pump
94050B 1 Pressure gauge 0−4 bar
94050C 1 Pressure gauge 0−6 bar
94050D 1 Pressure gauge 0−16 bar
94050E 2 HP hoses
94050F 1 Adjusting tool
94050G 1 Measuring connection M12x1
94050H 1 Measuring connection M14x1
H A E 002.552/98

Standard Tools
94101 1 Inside micrometer

(Measuring range 50−1000 mm)
with case
94101A 1 Inside micrometer

with case WCH02629
94110 1 Thrust device

for removal and fitting of
main baring cover
X = 590 mm
X
018.664/09
94114B 2 Double pre-tensioning jacks

for elastic studs to main bearing
X = 222 mm
018.664/09
X
94116A 1 Transportation tool

with 2 head screws M6x25
main bearing shell
X = 210 mm X
(WLL 50 kg)
018.662/09
94116B 1 Lifting lug

main bearing cover
X = 72 mm
018.662/09
94116C 1 Trolley
main bearing cover
X = 298 mm WCH02582
(WLL 500 kg)

Standard Tools
94117 1 Assembling and dismantling device
X
main bearing shell
X = 191 mm 018.662/09
94117A 1 Deviation pipe

for removal and fitting of:
− main bearing cover, shell
− crosshead pin X
X = 340 mm
WCH00265
94118A 1 Turning-out device

with 2 head screws M6x25
main bearing shell
018.662/09
X = 215 mm
X
94119B 1 Device
018.662/09
with 3 shackles
main bearing shell
X = 190 mm
94120A 1 Rope (∅ 6 mm)

main bearing shell
X = 1050 mm X 018
(WLL 310 kg)
94122 1 Feeler gauge
000.361/93

Standard Tools
94123 1 Special feeler gauge

for main bearing
X = 620 mm
000.395/93
94126 1 Depth gauge

measuring range 760 mm
000.394/93
94141 1 Support
for removal of main bearing shells
X = 735 mm
X
013.565/05
94142 1 Work platform X

X = 1088 mm
94142A 2 Nuts M20

WCH03524
X = 76 mm X
94143 1 Working support

X = 450−540 mm
WCH03524

Standard Tools
94145 1 Pre-tensioning jack

for foundation bolts and engine stays
X = 130 mm
013/567/05
94155 1 Turning-out device

with screws M20x90
for turning out thrust bearing pads
(with 1-part gear wheel)
X = 161.4 mm 013.568/05
94155A 1 Turning-out device

with screws M20x45
013.569/05
for turning out thrust bearing pads
(with 2-part gear wheel) X
X = 161.4 mm
X
94180 2 Pre-tensioning jacks
for tie rods (M80x6)
X = 232 mm
Y = 243.5 mm
WCH00668

Standard Tools
94201 1 Lifting device

for installation and transporting a
cylinder
94201D 94201A
Liner
X = 927 mm
Weight approx. 120 kg
(WLL 4200 kg)
consisting of:
94201A, B, C, D
94201A 1 Lifting tool
X = 963 mm
Mass approx. 100 kg X
94201B 2 Holders
X = 940 mm 94201C 94201B
Mass approx.19,7 kg
94201C 2 Flange couplings WCH03066
X = Ø176 mm
94201D 1 Shackle
94202L 1 Chain
X = 707 mm
WLL 5000 kg
WCH02588
X
94208 1 Dismantling tool X

for removal of antipolishing ring
X = 442 mm
Y = 37 mm
WCH02873
94209 1 Lifting hook

for removal and installation of
antipolishing ring
X = 1000 mm
WLL 750 kg
X
012.242/04

Standard Tools
X
94213 1 Dismantling tool
X = 83 mm
WCH02256
94214 1 Dismantling and assembling tool

for gas admission valve
consisting of:
94214C 1 Dismantling and
assembling tool
94214D 1 Pusher
94214E 1 Bush
94214F 1 Angle steel 94214C 94214D
94214G 4 Hexagon head screw
M6x12
94214H 6 Hexagon socket head 94214H
cap screw M6x50
94214L
94214I 1 Gasket 94214F
94214M
Sealing between bush 94214G
and for gas admission 94214E
valve
WCH03395
94214K 1 O−Ring
94214L 2 Screws
94214M 2 Nuts
94214A 1 Handle
X = 37.5 mm
X
WCH03331
94214B 1 Pressure reducing valve

X = 172 mm
WCH03331

Standard Tools
94215B
94215 1 Hydraulic tensioning device

for cylinder cover studs,
consisting of:
94215D
94215B 2 Connection pieces
94215D 4 Hoses 94215E
X = 800 mm
94215E 4 Hoses
X = 1000 mm
013.574/05
94215A701.013.574
94215A 1 Pre-tensioning jacks

X = 177 mm
016.765/08
94225 1 Measuring gauge X

for measuring cylinder liner bore
(accessory for it:
inside micrometer tool 94101)
000.419/93
X = 2339 mm
94238 1 Feeler gauge

(10-part)
for checking bearing clearances
000.418/93
Leaf length = 300 mm

Standard Tools

for exhaust valve cage
X = 194 mm
009.952/02
94259 1 Pressure element

for exhaust valve
X = 189 mm
X
016.765/08
94261 1 Valve seat fitting and extracting

device 000.415/93
X = 490 mm
94262 1 Valve protector

(only to be used for transporting a
complete exhaust valve)
X = 450 mm
013.576/05

Standard Tools
94265 1 Suspension device

for cylinder cover and
exhaust valve cage
X = 604 mm
including:
94265A 2 special eye nuts
X = 238 mm
(WLL 2100 kg)
013.577/05
X a a
003.971/96
94269C−46 1 Socket wrench insert

for loosening and tightening of
clamping nut to injection valve
X = 115 mm X
Y = 70 mm
94269C−55 1 Socket wrench insert

for tightening of coupling nut WCH01208
Y
to pilot injection valve
X = 126.5 mm
Y = 65 mm

Standard Tools
94270 1 Cutting device 94270A

for overhauling injection valve seat in
cylinder cover
X = 390 mm
including:
X
94270A 1 Profile cutter WCH02803
94270C 2 Hexagon head bolts

for dismantling and assembly an
injection valve
X = 180 mm
X
WCH02263
94270D 2 Stud bolts

for dismantling and assembly an
injection valve
X = 186 mm
X
WCH02263
94270E 1 Supporting plate

for dismantling and assembly a pilot
injection valve
with two head screws M12x90 with dog
point
X = ∅ 130 mm
WCH02810
94270F 2 Stud bolts

for dismantling and assembly a pilot
injection valve
with two nuts M12
X = 176 mm
WCH02811

Standard Tools
94272 1 Injector test bench

for setting and testing of:
− injection valve
− safety valve
− relief valve
X = 1458 mm
Mass approx. 161 kg X
including:
94269A−46 1 Slugging wrench

for testing on test bench
(AF46 to injection valve)
WCH03069
X = 214.5 mm 94269A−46
94269A−55 1 Slugging wrench

for testing on test bench
nut (AF55 to pilot X 94269A−55
injection valve) WCH01208
X = 219 mm
94269B 1 Hydraulic cylinder

for loosening and X
tightening of coupling nut WCH01208
to injection valve and
pilot injection valve and
94269B
X = 395.5 mm WCH01208
94272A 1 Valve holder

for checking the fuel
overpressure safety X
valve
X =170 mm 94272A
94272B 1 Connecting piece
X
for adjusting the injection

valve
X = 133 mm
X
94272B
94272C 1 Valve holder 94272C
for checking and
adjusting relief valve to X WCH02260
cylinder cover and fuel
rail
X = 68 mm 94272F
94272F 1 Adapter
for pilot injection valve
X = 134.5 mm WCH02804
See next page X

Standard Tools
94272 Continued
94289E 1 Assembly tool

X = 150 mm
Y = 100 mm X
Y
WCH03069
94273 1 Valve holder

to OBEL test bench
for fastening injection
valve
X = 568 mm Y
Y = 546 mm
WCH03070
X
94275
94275 1 HP hose
to OBEL test bench
WCH01208
for testing, loosening and
X
tightening of coupling nut
to injection valve
X = 1000 mm
Max. working pressure 94275A
1500 bar
94275A 1 Cable WCH01208
to OBEL test bench X

Electric connection
between OBEL test
bench and injection valve
X = 1200 mm

Standard Tools
94270−02 1 Grinding device

To grind the pilot injection valve bore
X = 289 mm 94270−2D
X
94270−2D 1 Stencil
WCH03864

X = 358mm 94270−1D
X
WCH00865

X = 172 mm 94270−3D
X
WCH00866
94279 1 Gauge
for checking wear and burn scar on
exhaust valve seat
X
002.563/98
94281 1 Assembly tool

for installation of starting air valve
X = 386 mm
X
WCH03071
94289 1 Bush with dowel pin

for dismantling and assembling
injection valve
X = 80 mm X
WCH00896

Standard Tools
94289A 1 Bush
for assembling injection valve
X = 45 mm
WCH00897 X
94289B 1 Bush
for dismantling injection valve
X = 30 mm
WCH00897 X
94289C 1 Bush
for assembling O-rings of injection
valve
X = 65 mm
WCH00896
94292 1 Template
for checking wear on disc of
exhaust valve spindle
X = 160 mm
X 013.582/05
94305 1 Crankshaft checking equipment

for measuring crank deflection
(in wooden box)
X = 364 mm

for connecting rod studs to
bottom end bearing,
94314
X = 155 mm
94314A 1 Distance bushes 94314A

013.583/05

Standard Tools

for connecting rod studs to
top end bearing,
X = 132 mm
94323 4 Retaining pins

to prop up crosshead guide shoes
when removing or fitting a connecting
rod or a crosshead
X = 75 mm
X
013.584/05
1.013.584
94324 1 Cover and lifting plate

to crosshead
including:
2 shackles 6.5 t
X = 257 mm
(WLL 3400 kg)
X
701.013.58
5
013.585/05

Standard Tools
94331 1 Holder
for removal and fitting of a connecting
rod,
including:
2 Screws M24x380 with washers
2 Discs ∅ 90 mm
X = 726 mm
X
013.586/05
94332 2 Lifting rings

for removal and fitting of:
− main bearing
− bearing cover of top end bearing
− guide shoe
− connecting rod
X = 194 mm
X
(WLL 8000 kg)
013.587/05
94333 1 Lifting device

to piston for removal and fitting of:
− top end bearing cover
− crosshead pin and
− changing compression shim
consisting of:
94333A 2 Lifting bosses
with 4 Allen screws 94333B
M16x45
X = 166 mm
X1
(WLL 1100 kg)

94333B 2 Suspension chains
X1 = 440 mm
X
013.588/05
94333A

Standard Tools
94335 1 Lifting tool

for removal and installation of heavy
engine components 94335B
94335C
X = 964 mm
including: 016.622/0
94335B 2 Bushes
94335C 2 Screws
X

for removal and fitting of inside pipe to
piston cooling and crosshead
lubrication
X = 137 mm
X
013.589/05
701.013.589
94337A 1 Centring piece
for alignment of inside pipe
X = 58 mm
X
701.013.590
013.590/05
94337B 1 Flange
for blanking off oil bore
X = 155 mm
X
013.591/05
94338 1 Piston ring tensioning device

X = 296 mm
Y = 235 mm
WCH02872

Standard Tools

for piston foot fastening and crosshead
screw connection
X = 88 mm
013.594/05

for removal and installation of piston
X = 612 mm X
WCH03301
94342 1 Inserting cone

X = 407 mm

Standard Tools
94344 2 Dismantling tool

rod gland and piston
including:
94344A 1 Holder
X = 312 mm
94344B 2 Chains
94345 2 Distance holders

rod gland and piston
X = 495 mm
X
013.596/05
701.013.596
94345B 1 Clamp ring

X = 52 mm
X
000.402/93
94345C 1 Gauge
for fitting scraper rings
X = 270 mm
X
701.013.597
013.597/05

Standard Tools
94345D 1 Cover plate

for covering bore in cylinder block X
(when piston and gland are removed),
including:
O-ring
4 Screws M16x200 with nuts
X = 432 mm
701.013.59
013.598/05
94345E 2 Assembly tools

for tensioning springs
to piston rod gland and insulation
bandage
X
X = 150 mm
004.284/98
94345F−9 2 Distance pieces, 9 mm

for fitting rings to upper gland group X
X = 297 mm
94345F−11 2 Distance pieces, 11 mm
X = 297 mm
94345F−13 2 Distance pieces, 13 mm 005.65
X = 297 mm
94346 2 Pre-tensioning jacks X

for elastic studs to piston head
X = 66 mm
016.649/08
94350 1 Device
for supporting piston
and removal of piston rod gland
X = 892 mm

Standard Tools
94364 2 Jacking screws M10

for separating piston skirt from piston
rod
X
X = 170 mm
WCH02950
94366A 1 Template
for shape of top of piston crown X
(for use with piston in situ)
X = 549 mm
009.973/02
94366B 1 Template
for shape of top of piston crown X
Y
(with 3 piston rings)
X = 557 mm
Y = 197 mm
009.972/02
94370H 1 Stop plate

for locking top end bearing cover
X = 133 mm
013.601/05
X
94410E 2 Head bolts M30x150

for intermediate wheel assembly 013.699/05
94410F 2 Pins 013.698/05

for intermediate wheel assembly
X = 150 mm X
94430 Device
for cutting out and cutting in of fuel
pump
2 pieces for 5 & 6 cylinder engines
3 pieces for 7 & 8 cylinder engines
including:
94430A 1 Claw X
A
94430B 1 Screw M12x45
B 701.013.6
X =136 mm (for 5 & & cyl. engines)
X =142.5 mm (for 7 & 8 cyl. engines) 013.602/05

Standard Tools
94551 1 Fitting and dismantling device

for removal and fitting of guide pin to
fuel pump
X = 255 mm
008.762/00
94552 1 Cover
with Allen screws M12
for removal and fitting of fuel pump
X = 116 mm 701.013.603
013.603/05
94555 Spacer
for cutting out of individual fuel pumps
1 piece for 5−8 cylinder engines
X = 72 mm X
X1
94555A Spacers
for cutting out of individual fuel pumps
2 pieces for 5, 6 cylinder engines 016.649/08
4 pieces for 7, 8 cylinder engines

X1 = 36 mm
008.765/01
94556 1 Checking device

for plunger position
X = 130 mm

Standard Tools

for transporting a complete supply unit X
of 5 & 6 cylinder engines
X = 922 mm
(WLL 2250 kg)
of 7 & 8 cylinder engines

X = 1182 mm
(WLL 2500 kg)
013.604/05
94566 1 Support
for removal and fitting of camshaft
X = 510 mm
013.605/05
X
94566A 1 Support
for removal and fitting of camshaft
X = 510 mm
013.606/05
X
94566B 1 Centring device

for aligning bearing shells
X = 70 mm
X 013.607/05

Standard Tools
94566C 1 Limiter
for tightening or loosening bearing
covers to supply unit
X = 320 mm X
013.608/05
94567 1 Assembly template

for removal and fitting of bearing shells
to supply unit
X = 68 mm
013.609/05701.013.609
X
94575 1 Adjusting scale

X
(for Heinzmann StG 10-01 Actuator)

for regulating linkage
X = 120 mm 013.610/05
including:
94575A 1 Adjusting pin
(for Heinzmann
X
StG 10-01 Actuator)

X = 51 mm
013.611/05

Standard Tools
94569 1 Blank flange

to fuel pump with
4 Screws M12x50 and
1 O-ring 42.52x2.62 mm
X = 93 mm X
94569A 1 Blank flange

016.650/08
to valve housing at fuel rail with
4 Screws M12x80 X
1
X1 = 92 mm
94583 1 PCV test block with tube

for pressure check of pressure control
valve
X = 954 mm
WCH02283
94585A 1 Surface plate

For alignment of fuel limiting valve
including 2 screws M8x30
X = 400 mm X WCH02590
94585B 1 Blind flange

tool rail unit maintenance, to seal the
injection port in fuel rail,
including 4 screws M12x60
X = 80 mm WCH02595
94585C 3 Screw plug G 3/4“

DIN 908
to close the servo oil unions
94585D 3 Screw plug G 3/8“

DIN 908
to close the servo oil unions

Standard Tools
94585E 4 Capping end

to close the opening in exhaust valve
control unit
WCH0259
8
94589 2 Dismantling tools

for removal lip seal from injection
control unit
X = 310 mm and 638 mm
X
012.308/04
In case of a turbocharger breakdown
Cover to exhaust manifold outlet:
94653A−A165 for ABB A165, X = 600 mm, 12 holes

94653A−A175 for ABB A175, X = 820 mm, 16 holes
Cover to turbocharger inlet:
94653B−A165 for ABB A165, X = 600 mm, 12 holes

94653B−A175 for ABB A175, X = 630 mm, 16 holes
Cover to scavenge air receiver:
94653C−A165 for ABB A165, X = 460 mm, 16 holes

94653C−A175 for ABB A175, X = 820 mm, 16 holes X 000.487/93
Cover to turbocharger outlet:
94653D−A165 for ABB A165, X = 430 mm, 16 holes

94653D−A175 for ABB A175, X = 600 mm, 16 holes
In case of auxiliary blower

breakdown
94656A 2 Covers
to connecting pipe auxiliary blower
X = 430 mm, 14 holes
94656B 2 Covers
to connecting pipe auxiliary blower
X = 465 mm, 14 holes X
WCH03302

Standard Tools
94657 4 Round sling (straight length

1250 mm, with TC at Driving End)
for removal and installation of auxiliary
blower (WLL 1000 kg)
94658 1 Support (with TC at Driving End)

for removal and installaton of auxiliary
blower
X = 1893 mm (WLL 800 kg)
X
WCH03036
Tools for removal and fitting of

scavenge air cooler SAC A46−SD
94661 1 Support
including: 1 Shackle (WLL 2000 kg)
X
4 Screws M12x35
X = 376 mm
Y = 255 mm
Y
WCH00662
94663A 1 Support LEFT

including: 1 Lug
1 Safety chain 94663C (DP)
X
6 Screws M16x40
X
X = 425 mm 94663A
94663B 1 Support RIGHT DP

including: 1 Lug 94663D
1 Safety chain 94663B
6 Screws M16x40
X = 425 mm

94663C 2 Lugs
X = 115 mm
X
94663D 2 Safety chains
X
X =1222 mm (SAC285)
(WLL 1000 kg)
016.822/08
Winterthur Gas & Diesel Ltd. 33/ 42

Standard Tools
94666 1 Wire rope sling Ø 14 mm

with 2 shackles
for removal and fitting of a crosshead pin
and a scavenge air cooler Ø X
X = 800 mm
(WLL 3000 kg at ( 0−45_)
012.316/04
94666I 2 Chains (double sling)

including: 4 Shackles X
X = 554 mm
(WLL 1600 kg at ( 45−60_)
016.468/07
Tools for removal and installation of

scavenge air cooler SAC A44-SD, SAC 261-IL, SAC 265-IL
94661−IL 1 Support
including: 6 Screws M12x45
X = 1220 mm
X
DP WCH00113
94663−IL 1 Lifting plate

including: 1 Shackle (WLL 6500 kg)
X
2 Shackles (WLL 4750 kg)
X = 779 mm
*
(A44: WLL 1400 kg at ( max. 135_)*

WCH00113
94663A−IL 1 Support LEFT

including: 1 Lug
1 Safety chain 94663C−IL (DP)
X
8 Screws M16x40 94663A−IL

X = 600 mm
X
94663B−IL 1 Support RIGHT 94663D DP

including: 1 Lug 94663B−IL
1 Safety chain
8 Screws M16x40
X = 600 mm

Standard Tools
94663C−IL 2 Lugs (only for SAC261, SAC265)

X = 155 mm
94663D−IL 2 Safety chains

X = 1654 mm (SAC265) 94663C−IL
(WLL 1000 kg)
94663E−IL 2 Safety chains X

X = 1222 mm (SAC261)
X
(WLL 1000 kg)
94664−IL X
94663F−IL 2 Safety chains 94663D−IL
X = 1998 mm (SAC A44-SD) 94663E−IL
(WLL 1000 kg) 94663F−IL
WCH03304
016.822/08
94664−IL 2 Plates
including 4 hex. Head screws M20x50
X = 672.5 mm
Tools for removal

and installation of water
separator (TC at DE)
94667 1 Lifting plate

for removal and installation of water
separator
including: DP
X
4 screws M12x25
X = 305 mm WCH00503
94667A 1 Lifting plate

for removal and installation of water DP
separator
including: X
4 screws M12x25
X = 305 mm
94667B 1 Support
for pulling out water separator Y X
X = 1054 mm
Y = 540 mm
DP WCH00663

Standard Tools
94667C 1 Lifting lug

X
for pulling out water separator
X = 100 mm
DP
WCH00663
94667D 1 Support
for installation of water separator
including:
4 nuts M16 Y
X = 1000 mm
X
Y = 400 mm
WCH00663
Tools for removal and fitting of water separator

engines with 1 scavenge air cooler
(underslung SAR design; TC at ES)
94667E 1 Lifting and withdrawing gear kg

including: 1 Shackle
4 Screws M12x25
X = 330 mm
(WLL 400 kg and 6000 N) X DP
N 016.829/08
94667F 1 Disassembling tool

including: 1 RUD-eye bolt
X
4 Screws M12x25
X = 240 mm
(WLL 6000 N)
016.829/08
DP
94667G 1 Lifting tool

including: 1 RUD-eye bolt
1 Shackle
2 Screws M12x65
X = 330 mm
X 016.829/08
(WLL 400 kg)

Standard Tools
94667H 1 Limiter
including: 1 Wire rope ∅10 mm
2 Shackles
2 Screws M16x50
X = 1187 mm
(WLL 6000 N) X 018.229/09
94667I 1 Holder
including: 1 Shackle
4 Screws M12x40 DP
X
X = 216.7 mm
(WLL 6000 N)
018.229/09
94831 1 Blank flange

for blanking off starting air pipe during
emergency operation
X = 200 mm
004.017/96
94841 1 Grinding tool 94841 94841A

for hydraulic pipe
X = ∅ 65 mm, R100.5
94841A 1 Stencil
Y = 65 mm X
Y
WCH02756
94930 1 SW-download package

to UNIC for uni tool
WCH03349
consisting of:
94930A 1 UBS to CAN adapter ca. 1000 80
94930B 1 CAN cable (ca. 2.5 m)
94930C 1 Ethernet adapter cable
(software tool)

Standard Tools
94870 1 Regrinding device

for sealing surfaces on HP fuel
piping (8733−1)
X = 101 mm
including: D
94870A 1 Screw-on sleeve B
(AF 32) A
94870B 1 Grinding tool with C X
countersunk screw M4 X
94870C 1 Lock nut M18x1.5 016.740/08 016.776/08
(AF 27)
94870D 1 Template
X = 35 mm
94844 1 Lubrication device

for supply unit lubrication during
maintenance
X = 600 mm Y
Adaptors: Y1
Y = 28 mm X
Y1 = 45 mm Z
Flexible hose:
Z = 3500 mm
WCH03855
94870−1 1 Regrinding device

for sealing surfaces on HP fuel
piping (8752−1)
X = 151 mm H
including: F
94870E 1 Screw-on sleeve E
(AF 50)
G X
94870F 1 Grinding tool with X
countersunk screw M8
94870G 1 Lock nut M30x2 (AF 46) 016.741/08
94870H 1 Template
X = 75 mm
94890 1 Dismantling and assembling tool

for gas pipe assembly
X = 326 mm
X
WCH03407

Standard Tools
94924 1 Hook spanner

for crank angle sensor
X = 205 mm
94925 1 Hook spanner

for crank angle sensor
X = 242 mm
008.771/00
Hydraulic parts and pump

94931 1 HP oil pump
working pressure max. 2800 bar 94934F
94934F 1 Adapter piece
010.001/02
94934 1 Connection block
005.956/00
94934A 2 Hydr. distributors

with pressure gauges
010.242/02
94934G 2 Coupling elements
013.620/05
94934H 1 Hydr. distributor

with pressure gauge 0...25 bar
WCH00724

Standard Tools
94934I 1 Connection nipple (G¼”)
WCH00724
94935 4 HP hoses 2600 bar X

with closing valves and coupling
sockets
X = 2130 mm 005.954/00
94935C 1 Hose
for set-up of pre-tensioning jacks
Length = 2000 mm
701.013.621
013.621/05
94936 2 Hydraulic jacks 500 kN (50 t)
005.952/00
94942 1 Hydraulic unit

working pressure max. 2500 bar
013.622/05

Recommended Special Tools
94226 1 Tool cylinder liner measuring

complete with extension and case
018.223/09
94291 1 Valve grinding device complete

94291A
for valve spindle and valve seat
94291A 2 Grinding discs

(C-M No. 11373-01-01)
WCH03339 WCH03339
94299 1 Grinding device X

X = ∅ 587 mm
WCH02384
94300 1 Tool cupboard

X = 1120 mm
X
000.500/93

Recommended Special Tools
94349 1 Pressure testing device

for piston
X = 255 mm
X
010.005/02
94356 1 Equipment case

with instruments
for measuring thickness of chrome-
ceramic-layer on piston rings
WCH01216
94929 2 Connecting cables with plugs

for emergency cylinder lubrication
Connector (plug ’C’)
Plug ’B’ with cable lenght = 0.5 m
Plug ’C’ with cable lenght = 2.5 m
WCH01087

MM - WinGD RT flex50DF PDF

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RT-flex50DF

Document ID: DBAD114048

Winterthur Gas & Diesel Ltd. 24hrs Support:

Document ID: DBAD114048

Winterthur Gas & Diesel Ltd. 24hrs Support:

RT-flex50DF Summary for Maintenance Manual

0803-1/A2 2015 EAAD086011 Engine Cross Section New dokument added x

2722-1/A1 2015-09 Injection Valve Information about terminal box addded. x

whole book 2016 Maintenance Manual New Layout x

RT-flex50DF Summary for Maintenance Manual

2140-2/A1 2017-12 Update Exhaust Valve: Pge 7: Para 5, Steps 10 to 12 changed. x

2708-4/A1 2018-02 EAAD087460 Sealing Face for the New procedure x

RT-flex50DF Summary for Maintenance Manual

Date of publication 2018-02

1 Bedplate and Tie Rod

2 Cylinder Liner and Cylinder Cover

3 Crankshaft, Connecting Rod and Piston

4 Driving Wheels and Shut-off Valve for Starting Air

5 Supply Unit, Injection and Exhaust Valve Control

6 Scavenge Air Receiver and Auxiliary Blower

9 Crank Angle Sensor Unit, Tools

General Information Group 0

For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1

Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1

Winterthur Gas & Diesel Ltd. 1/ 1 RT−flex50DF / MM / 2016

For Your Attention

Winterthur Gas & Diesel Ltd. 1/ 1 2016

The Maintenance Manual has the primary data that follow:

Winterthur Gas & Diesel Ltd. 1/ 1 2016

General Information Group 0

For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1

Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1

Bedplate and Tie Rod Group 1

Bedplate and Thrust Bearing: Foundation Bolts − Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112−1/A1

Engine Stays with Friction Shims: Tension − Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A1

Winterthur Gas & Diesel Ltd. 1/ 4 2018−02

Cylinder Liner and Cylinder Cover Group 2

Lubricating Quill: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A1

Injection Valve: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722−1/A1

Pilot Injection Valve: Removal, Disassemble, Check, Assemble, Installation . . . . . . . . . . . . . . . . . 2790−1/A1

Crankshaft, Connecting Rod and Piston Group 3

Crankshaft: Crank Deflection − Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103−1/A1

Axial Damper: Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3140−1/A1

2018−02 2/ 4 Winterthur Gas & Diesel Ltd.

Piston Rings and Ring Grooves: Rate of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425−1/A1

Driving Wheels and Shut-off Valve for Starting Air Group 4

Starting Air Shut-off Valve: Clean and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325−1/A1

Supply Unit, Injection and Exhaust Valve Control Group 5

Pilot Fuel Supply Unit: Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5555−1/A1

Scavenge Air Receiver and Auxiliary Blower Group 6

Scavenge Air Receiver: Clean and do Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6420−1/A1

Winterthur Gas & Diesel Ltd. 3/ 4 2018−02

Water Separator: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708−1/A1

Cylinder Lubrication Group 7

Exhaust Waste Gate (Low-load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8135−1/A1

Crank Angle Sensor Unit, Tools Group 9

Crank Angle Sensor Unit: Proximity Sensor − Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9223−1/A1

Hydraulic Pre-tensioning Jacks

Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−5/A1

2018−02 4/ 4 Winterthur Gas & Diesel Ltd.

General Configuration − Turbocharger at Aft End