WinGD X92 - Page 170

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Maintenance2124−3/A1

Winterthur Gas & Diesel Ltd.

2/ 3

94299

WCH02352

r = 8 mm

Unwanted material

TDC

2 mm to 3 mm

1 mm

Fig. 1

2015

Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports

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Table of Contents7
General Information Group11
For Particular Attention11
Preface11
Engine Numbering and Designations11
General Guidelines for Maintenance: Safety Measures and Warnings11
Clearance Table11
0000−1/A111
For Your Attention13
Spare Parts13
Fuel Supply18
General Safety Precautions21
Safety Notes24
General Safety Warnings and Cautions25
General31
Crankshaft and Thrust Bearing38
Clearance Table38
Crankshaft and Main Bearing40
Crankshaft and Main Bearing41
Clearance Table42
Crosshead Guide42
Cylinder Liner44
Piston Rod Gland46
Piston Rod Gland47
Exhaust Valve48
Top and Bottom End Bearings to Connecting Rod50
Piston Cooling and Crosshead Lubricating Link52
Piston and Piston Rings54
Driving Wheels for Supply Unit56
Fuel and Servo Pump Units58
Fuel Pump60
Tightening Values of Important Screwed Connections63
0352−1/A171
0352−2/A176
0360−1/A179
Maintenance Schedule Inspection and Overhaul Intervals (Guidelines)83
Engine Cross Section93
Bedplate and Tie Rod Group95
Bedplate and Thrust Bearing: Checking the Foundation Bolts95
1112−1/A198
Main Bearing99
1132−1/A199
Main Bearing Removal and Installation101
1132−2/A1101
1132−2/A2117
Thrust Bearing137
Axial Clearance Checks137
1203−1/A1137
Thrust Bearing Pads − Removal and Installation139
1224−1/A1140
Installation143
1715−1/A1147
1715−1/A2149
1903−1/A1151
Cylinder Liner and Cylinder Cover Group154
Cylinder Liner154
Measuring Bore Wear155
2124−1/A1155
Removal and Installation157
2124−2/A1157
Removing the Wear Ridge, Re-Dressing Lubricating Grooves169
2124−3/A1171
Removal and Installation (with Optional Tool)173
Removal Procedure173
2138−1/A2174
Installation175
2303−1/A1178
Cylinder Cover187
2708−1/A1187
2722−1/A1195
Storage and Handling195
Injection Valve: Disassemble, Checks, Assemble (Injection Valve with FAST)198
Preparation198
Procedure198
Checks198
Results199
Disassemble200
Injection Valve200
Nozzle Tip − Replace201
Removal201
Installation202
Assemble203
Injection Valve − Assemble203
2728−1/A1205
Exhaust Valve209
Exhaust Valve − Removal and Installation209
2751−1/A1211
Disassemble and Assemble213
2751−2/A1215
Exhaust Valve − Disassemble215
Valve Drive − Disassemble215
Valve Spindle − Remove215
Guide Bush − Removal216
Exhaust Valve − Assemble216
Guide Bush − Installation216
Valve Spindle − Installation217
Valve Drive − Assemble217
Damper Setting218
Valve Stroke Sensor − Installation219
Throttle219
Non-Return Valve219
Oil Supply to Valve Guide219
Valve Seat − Replace / Grind221
Recommended Procedure222
2751−3/A1223
Valve Seat − Grinding223
Grinding the Seating Surface on the Valve Head227
2751−4/A1227
General227
Crankshaft, Connecting Rod and Piston Group229
Crankshaft: Measuring Crank Deflection229
3103−1/A1231
Vibration Damper235
Inspection (GEISLINGER Vibration Damper)236
Disassembly and Assembly239
Axial Detuner: Disassembly and Assembly240
3140−1/A1240
Turning Gear: Teeth and Screwed Connections − Check246
Lubrication Intervals246
3301−1/A1247
Connecting Rod249
Bottom End Bearing − Removal, Inspection and Installation249
3303−2/A1249
Connecting Rod257
Bottom End Bearing − Removal, Inspection and Installation257
3303−2/A2257
Top End Bearing − Removal, Inspection and Installation269
3303−3/A1269
Bearing Lubrication276
3303−4/A1277
Installation280
Top End Bearing Cover − Removal, Inspection and Installation283
3303−5/A1283
Crosshead295
Crosshead Pin − Removal / Installation / Clearance Checks295
3326−1/A1295
Clearance Checks307
Crosshead Pin − Removal / Installation / Clearance Checks309
3326−2/A1309
Piston323
Removal and Installation323
3403−1/A1323
Installation326
Disassemble and Assemble329
3403−3/A1329
Top Surface − Check333
3403−4/A1333
Piston Rings335
Piston Rings: Wear of Piston Rings and Ring Grooves336
3425−1/A1336
Rate of Deterioration337
Service Life − Calculate338
Piston Ring Grooves339
Piston Ring Clearance (Piston Installed)339
Piston Rings − Removal340
Piston Ring Clearance (Piston Removed)340
Used Piston Rings − Installation342
New Piston Rings − Installation343
Piston Rings − Storage343
Group 4344
Drive Wheels345
Running and Backlash Clearances and Tooth Condition345
General345
4103−1/A1345
4325−1/A1349
Test Procedure353
Automatic Mode354
Supply Unit, Injection and Exhaust Valve Control Group355
Servo Oil Pump − Removal and Installation357
5551−1/A1357
Bearing Bushes362
Installation363
Supply Unit369
Camshaft and Bearing Shells − Removal and Installation369
5552−1/A1369
Camshaft Removal372
Camshaft and Bearing Shells − Removal and Installation (Independent Lubrication System)375
Fuel Pump387
Disassemble, Assemble387
5556−1/A1387
Fuel Pump Removal388
Removal of a Seized Pump Plunger405
5556−2/A1405
Fuel Pressure Control Valve: Removal and Installation410
5562−1/A1410
Cleaning the Filter411
Order Number415
Relief Valve417
5562−2/A1417
Relief Valve Test418
Injection Control Unit: Removal and Installation422
5564−1/A2423
Fuel Pump Actuator Connection to Fuel Pump427
5583−1/A1427
Faults in High Pressure Fuel System431
Defective Fuel Pump Actuator431
Fault Identification431
5583−1/A2432
Removal and Installation435
Scavenge Air Receiver and Auxiliary Blower436
Group 6436
6420-1/A1437
Auxiliary Blower: Maintenance442
Removal442
Preparation442
Removal − Driving End442
6545-1/A1443
Removal − Free End444
Installation446
Function Check446
6606-1/A1447
Cleaning Instructions455
General455
6606-1/A2456
6708-1/A1459
Installation463
Cylinder Lubrication Group467
Cylinder Lubricating System470
Function Check471
Cylinder Lubrication Pump471
Checks471
7218−1/A1472
Cylinder Lubricating System − Bleed472
Cylinder Lubrication Pump472
Oil Pipes472
Duplex Filter473
Clogged Filter Element − Replace473
Filter Element − Clean473
Cylinder Lubricating System473
Exhaust Waste Gate (Low-Load Tuning)477
Maintenance477
Installation482
8460−1/A1483
8733−1/A1489
HP Injection Pipe: Removal, Grinding and Installation490
8752−1/A1493
HP Fuel Pipe: Removal and Installation494
Hydraulic Pre-Tensioning Jacks and Pumps Arrangement and Application503
Group 9503
9223−1/A1506
9308−1/A1509
Standard Tools513
Recommended Special Tools513
9403−2/A1515
Storing, Servicing and Maintenance517
General Instruction529

WinGD X92 - Page 170

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