W200 & W220

05
Maintenance tools

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 W200 & W220

Maintenance Tools ..................................................................................................................................3

05.1.General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

05.2.Tooling calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

05.3.Lifting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

05.4.Instructions for use and maintenance of hydraulic clamping tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

05.4.1.Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05.4.2.Types of problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05.4.3.Reminder of instructions for use and safe practice . . . . . . . . . . . . . . . . . . . . . . . . . 5
05.4.4.Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05.4.5.Tool storage and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05.4.6.Instructions for the maintenance of hydraulic jacks . . . . . . . . . . . . . . . . . . . . . . . . 7
05.4.6.1.Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
05.4.6.2.Removal procedure (see Fig. 05.02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
05.4.6.3.Reassembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
05.4.7.Instructions for the choice and use of connecting rod hydraulic jacks . . . . . . . . . . . . . . . 10
05.4.7.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
05.4.7.2.How to identify each type of connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
05.4.7.3.How to choose the right jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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05. Maintenance Tools

05.1. General Information
The maintenance of an engine requires some special tools developed
during the engine design.
Some of these tools are supplied with the engine and others are
available through your Wärtsilä Network.
The tools required for a particular installation may vary greatly, de-
pending on the use and service area .
Standard tool sets are therefore selected to perform basic operations .
A list of dedicated tools is available in Chapter 8.00 of the Spare Parts
Catalogue.

05.2. Tooling calibration

Tools such as torque wrenches and pressure gauges, identified in the
Spare Parts Catalogue are elements of precision requiring a periodic
calibration.
Periodic calibration will have to be carried out by an approved
organism (according to the rules in force in the country).

Note : It is very important to use dedicated tools for all the mainte-
nance operations listed in chapter 04.

05.3. Lifting tools

The lifting tools identified in the Spare Parts Catalogue have been cer-
tified "EC Standard" and have been submitted to load tests.
Each tool is dedicated to a quite specific use and must not be used for
other purposes.
Any degradation of the tools involves their reject.

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05.4. Instructions for use and maintenance of hydraulic

clamping tools
Note : Check the maintenance schedule (chap 04) to know the opera-
tions and select the tools needed to perform them.

05.4.1. Introduction
Hydraulic clamping tools greatly facilitate heavy and physically tiring
assembly work. The method consists in applying hydraulic pressure
to the surface of a ram in a cylinder, also known as an hydraulic
tensioner, and in transforming this pressure into a tensile force on the
stud (e.g. cylinder head stud). Nonetheless, the use of these tools re-
quires to respect carefully a number of safety instructions for the pre-
vention of accidents.
In exceptional cases, unexpected problems may arise because of very
frequent use, ageing of materials or material homogeneity, damage
during transport or set-up, ingress of impurities or other damage, un-
suitable hydraulic fluid or improper operation and overloading.

05.4.2. Types of problems

With highly loaded components, such as hydraulically pre-stressed
screwed assemblies or dynamic tools using high pressures and forces
during the clamping operation, three types of problem in particular
may cause accidents, injuries or damages to the machine if these jobs
are performed without respecting safety instructions :
a) Breaking of highly loaded components when the pressure is in-
creased (tightening or loosening, inspection) e.g. with engine
bolts, tie rod nuts, press rams. As pressure builds up, the elastic
energy resulting from the applied load is abruptly released in such
a manner that the broken parts are driven in the direction of the
force, i.e along the line of the bolt or press axis. These problems
only occur when the pressure is increased, i.e during pumping or
when the tightening device submitted to full pressure is addition-
ally stressed by strong juddering.
b) Needle-like or fan-like hydraulic oil leakages which can cause
eye or skin injuries up to a distance of one meter. These streams of
hydraulic oil are caused by leaks due to torn sealing devices, burst
hoses or broken valves.
c) Breakage of piston and connecting rod bolts while the engine
is running may cause major damage to the engine.
The causes may be tightening without regard to the corresponding
instructions, application of incorrect pressure, failure to connect a
hose, failure to click a hose coupling in place, failure to tighten a nut
fully, incorrect press mounting, omitting to check the torque value at
the end of an operation (number of turns of nut not recorded).

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05.4.3. Reminder of instructions for use and safe

practice
a) Before any use :
1 Clean the working area so that the tool and engine compo-
nent mating surfaces are free from foreign bodies.
2 Check the oil level of the pump and make sure that the
right type of oil is used and top up if necessary.
3 Check the condition of hoses and hose couplers :
• Tightening of end fittings
• Cleanliness of couplers
• External appearance of the hose

Note : Scrap the equipment if doubtful.

4 Check that tensioner rams are returned to their lowest po-

sition (top surface of the ram lower than that of the cylinder head
jack body or flush with that of the connecting rod jack body ).
Otherwise, the rams may be re-aligned when the hydraulic line
assembly is connected, with the discharge valve open.
5 Check that the external surface of the ram, in zone A
where there is the greatest fatigue is in perfect condition. Scrap
the hydraulic tensioner if the slightest deformation is found in
zone A of the ram.

Fig. 05-01

6 Check the validity of the manometer calibration.

b) During use :
1 Position jacks, hoses, etc precisely,making sure that
the nut is centered and moves freely.
2 Check that the circuit has been bled (see Chap. 05.4.4).
3 Check if the hydraulic circuit is sealed.
No leaks are allowed. If leaks are found, recondition the faulty parts,
then bleed the circuit.
4 Do not exceed the recommended pressures.

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5 Check that the pressure gauge works correctly. Re-

move the gauge if a malfunction is found, then have it appraised
and reconditioned by the relevant departments if necessary.
6 Check that couplers are properly connected. Safety
sleeves normally return to their initial position when
couplers are perfectly connected.

Caution ! During pumping (pressure increase phase), no one must stand

in line with the bolt or the press.
Remain at a safe distance from high-pressure presses and
hoses (turn your face away, do not touch parts with your
hands) until full pressure is reached.

7 Gradually increase the pressure to the required value

with the hydraulic pump.

Caution ! Never exceed the indicated pressure!

8 When loosening, a loosening pressure of a maximum of 5%

above the tightening pressure may be needed. If the nut still can-
not be loosened, another problem (for example, seized due to
rust) has to be corrected.
9 Do not strike loaded presses, nuts, bolts, etc. forcefully.
10 The effect of the tightening operation has to be
checked (nut rotation).
11 High-pressure hoses must neither be bent nor guided
in excessively tight curves around edges.
12 Damaged components must neither be re-used nor re-
paired.
13 After tightening, pump rams must be returned to their
lowest position. To this end, fully open the discharge valve of the
pump (to prevent a high flow-back resistance).

05.4.4. Bleeding
Bleed each unit of the hydraulic line in turn, up to the end of the line
(pressure gauge).

05.4.5. Tool storage and maintenance

Correct maintenance and storage is necessary to keep hydraulic tools
in good working order and to ensure they are safe to use. The
following requirements must be observed :
a) ambient temperatures from 10 to 30°C are the most suitable
so that plastic parts (seals, HP hoses) do not age prematurely and
the hydraulic fluid is maintained at the right viscosity.
b) Keep tools away from dust, foreign bodies, chemicals or
fluids to prevent corrosion and chemical or mechanical damage
to precision finished surfaces and parting planes.

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c) High-pressure hoses must not be excessively bent.

d) When overhauling, use only original spare parts as ensuring a
correct operation often depends on seemingly trivial things (e.g.
correct hardness of rings-seals).
e) At regular intervals, check the accuracy of pump pressure
gauge readouts.

05.4.6. Instructions for the maintenance of

hydraulic jacks
05.4.6.1. Introduction
Any leakage at the jack level requires its disassembly and then its re-
conditioning. This work entails bleeding of all tooling involved .

05.4.6.2. Removal procedure (see Fig. 05.02)

1 Separate the spacer (item 1) from the jack.
2 Connect the jack to the hydraulic pump.
3 Put the jack in a pan to collect the oil from th jack.
4 Pressurise the jack until the piston (item 3) is fully ex-
tended (major visible leaks).
5 Disconnect the jack and disassemble the piston (item 3)
and the body (item 2) : hold the body and hit the piston on the bot-
tom of the pan to separate the assembly.
6 Remove the O-ring (item 4) and the anti-extrusion ring
(item 5) from the piston.
7 Remove the O-ring (item 6) and the anti-extrusion ring
(item 7) from the body (item 2).
8 Visually check working surfaces. Remove :
• any burrs using an oilstone
• signs of wear by rubbing down in a circular movement
(use fine emery cloth).

Note : The jack shall be scrapped if the working surfaces are deeply
scored.

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4
3

1 7

Fig. 05-02

05.4.6.3. Reassembly procedure

a) Assembly of the sealing kit :

Note : Anti-extrusion rings (item 4) are always installed opposite the

pressure side (outer side).

1 First of all, install the anti-extrusion rings. Make sure

that they are perfectly seated in their grooves.
2 Make sure that O-rings (item 5) are not twisted when fit-
ted.

Note : Smear the friction surfaces (item 3) with hydraulic oil.

Piston side

5
4

Fig. 05-03

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Cylinder side
4 3 5

Fig. 05-04

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05.4.7. Instructions for the choice and use of con-

necting rod hydraulic jacks
05.4.7.1. Introduction
There are three types of connecting rods.
The aim of this operating instruction is to :
• define the hydraulic jack type to be used according to the
connecting rod stud dimensions
• define if the spacer type delivered with the connecting rod
jacks is necessary according to the nut type
• define the way to mount the hydraulic jacks on the con-
necting rods.

05.4.7.2. How to identify each type of connecting rod

Check the dimensions of the nuts and the studs according to the fol-
lowing pictures.

Stud Nut

Fig. 05-05a

M27 type connecting rod M30 type connecting rod

M27 cylindric nut M30 chamfered nut M30 cylindric nut

Fig. 05-05b

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Note : See chapter 07 to find the hydraulic jacks references and

tightening pressure.

05.4.7.3. How to choose the right jack

a) First case with M30 chamfered nuts

Jack M30/65mm spacer

Spacer 65mm high

Fig. 05-06

Caution : Only use the 65 mm high spacer.

b) Second case with M30 cylindrical nuts

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Jack M30/65mm+5 mm spacer

Spacer 5mm high

Fig. 05-07

Precaution : Only in this case, it is necessary to use a 5 mm high spacer, in

addition to the 65 mm spacer, in order to reach a 70 mm height.

c) Third case with M27 cylindrical nuts

Straight coupling 90 degrees coupling

Fig. 05-08

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Fig. 05-09

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