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WinGD X72 Maintenance Manual
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Maintenance Manual
X72
Issue 002 2019-09
Winterthur Gas & Diesel Ltd.
Schützenstrasse 3
T
el. +4
1 (0)52 264 8844
Winterthur Gas & Diesel AG
P
.O. Bo
x 4
14, 840
1
Fax +4
1 (0)52 264 8866
Winterthur Gas & Diesel S.A.
Winterthur
, Switzerland
www
.wingd.com
2
Table of Contents
Modification Service
3
Removal
4
Group0 General Information Group 0
7
Table of Contents
7
General
8
Spare Parts
8
Group7
9
Removal
11
Cylinder Liner and Cylinder Cover Group 2
12
General Safety Precautions
17
Clearance Table
27
Default Chapter
28
Clearance Table
28
Crankshaft and Thrust Bearing
28
Crankshaft and Main Bearing
30
Crosshead Guide
32
Cylinder Liner
34
Piston Rod Gland
36
Exhaust Valve
38
Exhaust Valve
39
Top and Bottom End Bearings to Connecting Rod
40
Piston Cooling and Crosshead Lubricating Link
42
Piston and Piston Rings
44
Driving Wheels for Supply Unit
46
Fuel and Servo Pump Units
48
Fuel Pump
50
Integrated Electric Balancer
52
Tightening Values of Important Screwed Connections
55
0352−1/A1
62
0352−2/A1
68
0360−1/A1
73
Removal
76
Tension Check
90
Removal
99
General
119
Removal
120
Cylinder Liner and Cylinder Cover Group
123
2124−1/A1
125
Removal and Installation
127
Measure the Bore
125
2124−2/A1
127
Remove Unwanted Material, Dress the Lubricating Grooves and Scavenge Ports
135
2124−3/A1
138
2138−1/A2
140
Replace, Assembling, Wear Measurement
145
Default Chapter
146
Procedure One
146
Piston Rod Gland − Removal
146
Piston Rod Gland − Disassemble
147
Wear Measurement
147
Piston Rod Gland − Assemble
149
Piston Rod Gland − Installation
151
Procedure Two
152
Piston Rod Gland − Removal
152
Piston Rod Gland − Assemble
154
Piston Rod Gland − Disassemble
154
Wear Measurement
154
Piston Rod Gland − Installation
155
Cylinder Cover
157
Removal and Installation of Cylinder Cover and Water Guide Jacket
157
Injection Valve − Sealing Face Machining
171
General
171
2722−1/A1
173
Removal
173
Caution
174
(Injection Valve with FAST)
177
Injection Valve
180
Removal
181
Starting Valve: Removal, Disassemble, Grinding, Assemble, Installation
186
2728−1/A1
187
Exhaust Valve − Removal and Installation
189
2751−1/A1
191
Exhaust Valve
189
Disassemble and Assemble
195
2 Exhaust Valve − Disassemble
197
2751−2/A1
197
Valve Drive − Disassemble
197
Valve Spindle − Remove
197
Guide Bush − Removal
198
3 Exhaust Valve − Assemble
198
Guide Bush − Installation
198
Valve Spindle − Installation
199
Valve Drive − Assemble
199
Damper Setting
200
Valve Stroke Sensor − Installation
201
Throttle
201
Non-Return Valve
201
Oil Supply to Valve Guide
201
2751−3/A1
205
Valve Head − Grind the Seating Surface
209
2751−4/A1
209
Crankshaft, Connecting Rod and Piston Group
211
Crankshaft: Measuring Crank Deflection
211
3103−1/A1
213
Vibration Damper
217
Silicone Fluid Sample
217
3130−1/A1
217
Inspection − GEISLINGER Vibration Damper
221
3130−2/A1
221
Removal
225
3140−1/A1
226
Turning Gear: Teeth and Screwed Connections − Check
228
3206−1/A1
229
3303−2/A1
233
Connecting Rod
233
Removal
233
3303−3/A1
241
Removal and Installation
249
Top End Bearing − Removal, Inspection and Installation
241
3303−4/A1
249
Top End Bearing Cover − Removal, Inspection and Installation
259
3303−5/A1
259
Crosshead
263
Clearance Checks
263
3326−1/A1
263
Crosshead Pin − Removal, Installation, Clearance Checks
265
3326−2/A1
265
3403−1/A1
275
Piston
275
Removal and Installation
275
Removal
277
Disassemble and Assemble
281
3403−3/A1
281
3403−4/A1
285
Top Surface Check
285
Wear of Piston Rings and Ring Grooves
287
3425−1/A1
288
Piston Rings − Rate of Wear
288
Chrome-Ceramic Layer − Piston Installed
288
Rate of Wear
289
Service Life − Calculate
290
Piston Rings: Wear of Piston Rings and Ring Grooves
288
Piston Ring Grooves
291
Piston Ring Clearance (Piston Installed)
291
Piston Ring Clearance (Piston Removed)
292
Piston Rings − Removal
292
Used Piston Rings − Installation
294
New Piston Rings − Installation
295
Piston Rings − Storage
295
Group 4
297
General
299
Replacing the Gear Wheel on the Crankshaft
304
Running and Backlash Clearances and Tooth Condition
299
4103−2/A1
305
4325−1/A1
309
Group 5
315
5556−1/A1
319
Removal of a Seized Pump Plunger
337
5556−2/A1
337
Removal, Check, Installation
341
Removal
342
Preparation
343
Adjustment Procedure
344
Setpoint Check
344
Fuel Pressure Control Valve: Removal, Check, Installation
342
5562−1/A1
342
5562−1/A2
347
Removal
351
5562−2/A1
352
Installation
353
5562−3/A1
355
Removal
357
5581−1/A1
361
Camshaft and Bearing Shells − Removal and Installation
361
Removal
363
5583−1/A1
367
Fuel Pump Actuator
367
Connection to Fuel Pump
367
General
367
Removal
371
Servo Oil Pump − Removal and Installation (with Hawe SOP)
372
Servo Pump Unit
371
Exhaust Valve Control Unit: Removal, Disassemble, Assemble, Installation
379
Default Chapter
380
Assemble
380
Disassemble
380
5612−1/A1
381
Installation
381
Completion
381
Relief Valve
382
Group 6
383
6420-1/A1
385
Scavenge Air Receiver − Checks and Cleaning
385
Maintenance
389
Default Chapter
389
General
389
2 Procedure One
390
Preparation
390
Removal
390
6545-1/A1
391
Installation
392
3 Procedure Two
393
Preparation
393
Removal
393
Installation
394
6606-1/A1
397
1 General
397
6708-1/A1
415
6735-1/A1
421
Integrated Electric Balancer (Ielba) Bearing Replacement and Adjustment
423
Group 7
423
Cylinder Lubrication System
425
Cylinder Lubrication System
426
Cylinder Lubricating System
427
Cylinder Lubricating System − Operate
427
Function Check
427
Flex Lube Pump
427
Checks
427
Manual Release − One Lube Pulse
427
7218−1/A1
428
Cylinder Lubricating System − Bleed
428
Flex Lube Pump
428
Oil Pipes
428
Duplex Filter
429
Clogged Filter Element − Replace
429
Filter Element − Clean
429
Cylinder Lubricating System
429
Integrated Electric Balancer, Bearing Replacement and Adjustment
431
1 General
432
7758−1/A1
433
2 Preparation
433
3 Counterweights − Lock
433
Top Counterweight
433
Bottom Counterweight
433
4 Bearings − Replace
434
Bearing − Engine Side
434
Removal
434
Bearing − Outer Side
437
5 Check
439
Bearing Clearance
439
Measure Backlash
439
Adjust Bearings
441
6 Final Steps
443
7762−1/A1
445
Piping
449
Exhaust Waste Gate (Low-Load Tuning)
449
8155−1/A1
451
SCR Valve − Removal and Installation
451
HP Servo Oil Pipe: Removal, Grind the Sealing Faces and Installation (with HAWE SOP)
462
8460−1/A1
469
8733−1/A1
473
8752−1/A1
477
Removal
477
Crank Angle Sensor Unit, Tools
491
9223−1/A1
491
9308−1/A1
495
Removal
495
9403−2/A1
501
Configuration and Application
501
9403−3/A1
503
General Instructions
515
9403−4/A1
516
9403−5/A1
520
Standard Tools
521
Recommended Special Tools
553
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WinGD X72 Specifications
General
Bore
720 mm
Cylinder Configuration
Inline
Number of Cylinders
5
Fuel Type
Heavy fuel oil (HFO)
Engine Type
Two-stroke diesel
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