W200

09
Engine removal and installation

0936 Page 1
 W200

Engine removal and installation....................................................................................................3

09.1.Remove and install a complete genset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

09.1.1.Remove the complete genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
09.1.1.1.Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
09.1.1.2.Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
09.1.1.3.Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

09.1.2.Install a complete genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

09.2.Remove and install the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

09.2.1.Remove the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
09.2.2.Install the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
09.2.2.1.Engine mounted rigid on common bedframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
09.2.2.2.Engine resilient on keelson (Diesel only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
09.2.2.3.Engine rigid on the keelson (Diesel only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

09.3.Remove and install the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

09.3.1.Remove the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
09.3.1.1.All coupling types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
09.3.1.2.The elastic elements are of block type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
09.3.1.3.The coupling features an outer rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

09.3.2.Remove the elastic coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

09.3.3.Remove the coupling hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
09.3.4.Install the coupling hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
09.3.5.Install the elastic coupling on the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
09.3.6.Install the alternator on the common bedframe . . . . . . . . . . . . . . . . . . . . . . . . . . 12
09.3.6.1.All coupling types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
09.3.6.2.The elastic elements of block type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
09.3.6.3.The coupling features an outer rim (Stromag type) . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

09.4.Genset alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

09.4.2. Using dial gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Page 2 0936
 W200 & W220 Engine removal and installation 09.

09. Engine removal and installation

09.1. Remove and install a complete genset
09.1.1. Remove the complete genset
09.1.1.1. Connections
1 Secure the genset and lock out the circuit breaker.
2 Disconnect the fuel or gas, starting air, exhaust and,
if fitted, the connection of the air inlet on the turbocharger.
3 Disconnect the various sensor lines.
4 Disconnect the bus bar or the cables from the alternator
and the earth cable.

Caution : Any intervention on the alternator electrical circuit must be

carried out by an authorized person.

09.1.1.2. Hoisting
F
B

A : engine 4 60°
B : centre of gravity
C : alternator 4
A C
1 : bedframe
2 : resilient mounts
3 : jack rings
4 : spacing bars
3
1
2

Fig. 09-1

09.1.1.3. Handling

Note : While handling, make sure that the genset keeps horizontal. If
needed, add on extra shackle on the highest two hanging
points.

0936 Page 3
 09. Engine removal and installation W200 & W220

1 Fix slings onto the jack rings of the bedframe and move
complete genset to storage place (see Fig. 09-1 item 3 and
Fig. 09-2).

Fig. 09-2

2 Use spacing bars SPC8330001, (see Fig. 09-1, item 4).

The weight to handle is approx :
• From 25 to 28 tons (metric) for a W12V200 or V220.
• From 47,5 to 51,5 tons (metric) for a W12V200, according
to the navy application.
• From 33 to 46.5 tons (metric) for a W16V200 according to
the configuration. Exists only in Marine version.
• From 35 to 49 tons (metric) for a W18V200 or V220.

09.1.2. Install a complete genset

1 Check the concrete slab for cleanliness and sufficient
dimension.
2 Install slings like for hoisting (see § 09.1.1.2).
3 Install the resilient mounts at the locations indicated on
the specific drawing.

Fig. 09-3

4 Once the genset is resting on its concrete slab, check that

the top surface of the bedframe is at level.

Page 4 0936
 W200 & W220 Engine removal and installation 09.

5 Measure and adjust the coupling alignment (see below, see

Chap 09.4.).
6 Measure the heights (x) of each resilient mounts (see
Fig. 09-4).
If the height difference (x1) exceeds 2 mm, compensate with shims
and measure the coupling aligment again.

x x1

30

1
150

Fig. 09-4
7 Record the heights of the resilient mounts (see mea-
surement record WMR025).
8 Install bus-bar, earth wire and braiding.
9 Connect the various sensor lines.
10 Connect the fuel or gas, starting air, exhaust and, if fitted,
air inlet line(s) on turbocharger.

0936 Page 5
 09. Engine removal and installation W200 & W220

09.2. Remove and install the engine

09.2.1. Remove the engine
1 Secure the genset and lock out the circuit breaker.
2 Disconnect the fuel or gas, starting air, exhaust and,
if fitted, the connection of the air inlet on the turbocharger.
3 Disconnect the various sensor lines.
4 If there is a coupling housing, remove the screws con-
necting the alternator housing to the engine.
5 Use the lifting tools assy SPC 8300001 to lift the engine.
6 Before hoisting the engine, make sure the lifting tools
assy are correctly positionned (see Fig. 09-5).
7 Fit the tooling above the cylinder head, use the nuts
SPC 8300002.

Tightening torque : 70 Nm
Nut SPC 8300002

A1 A1 A1
B1 B1 B1

A2 A2 A2
B2 B2 B2

A3 A3 A3
B3 B3
1200

B3
8300002 A4 A4 A4
B4 B4 B4

8300001 A5 A5 A5
B5 B5 B5
1500
1200

A6 A6 A6
B6 B6 B6

A7 A7 12V
B7 B7

A8 A8
B8 B8

B9
A9 16V SPC 8300001
18V

Fig. 09-5
8 Tighten the nuts SPC 8300002 of the lifting tools at 70
Nm.

Note : In case of 12V engine with two turbochargers, one extra shackle
must be added on each of the two lifting tools assy on flywheel
side.

Page 6 0936
 W200 & W220 Engine removal and installation 09.

09.2.2. Install the engine

09.2.2.1. Engine mounted rigid on common bedframe
1 Use the lifting tools assy SPC 8300001 to lift the engine.
2 Check the bedframe and engine feet for cleanliness.
3 Gently spray the contact surfaces with anti-corrosion
protective oil “ISOTECT 377" ref. MGE 000068.
4 Put the engine approximately into place.
5 Position and engage two fixation screws into the engine
feet diagonally placed, with their washers.
6 Engage the other screws and washers and lower the en-
gine.
7 When the engine is standing on the bedframe, make
sure to have no clearance between the feet and the bedframe. If
necessary compensate the clearance with adequate shims.
8 Tighten the foot screws at 660 Nm (see Fig.09-06, item A).
9 Spray the flywheel with anti-corrosion protective oil
“ISOTECT 377".
10 Install bus-bar, earth wire and braiding.
11 Connect the various sensor lines.
12 Connect the fuel or gas, starting air, exhaust and, if fitted,
the connection of the air inlet on the turbocharger.
13 Fit the alternator in accordance with chapter 9.3.

Fig. 09-6

0936 Page 7
 09. Engine removal and installation W200 & W220

09.2.2.2. Engine resilient on keelson (Diesel only)

Only one type of resilient mounts is used (see Fig. 09-7).

dimension
A

Item 1

Fig. 09-7

1 Install the resilient mounts on the keelson. For each en-

gine foot, use 4 screws M16 , 4 flat washers, 4 nuts M16 and
4 lock-nuts M16 (see Fig. 09-7, item 1).
2 Put some grease NL GL 2 on top of the jack-screws.
3 Lower the engine on its resilient mounts. Use the lifting
tool assembly SPC 8300001 to lift the engine (mass, see Chap.
09.1).
4 Do not tighten the coupling or the pipes. The engine
must be filled up with its various fluids.
5 Wait for at least 24 hours.
6 Record the heights of the resilient mounts. The theore-
tical height of the mini K55 mounts is 153.6 ± 2 mm (see Fig. 09-7 di-
mension A).
7 Align the engine using the jack-screw. (see Chap 09.4.)
09.2.2.3. Engine rigid on the keelson (Diesel only)
Using resin
The resin supplier, in accordance with the Classification Society, de-
termines the type of resin and the tightening torque.
On normal operating conditions, the temperature of the engine feet
can reach 70°C.
The supporting surface of each engine foot is 1252 mm².
Align the engine (see Chap 09.4.) taking into account the thermal
expansions of the engine and of the reducer.
Follow the resin supplier’s installation procedure (casing,
preparing).
Using steel chocks
Proceed as on Chap 09.2.2.1. (Engine rigid on common baseframe).

Page 8 0936
 W200 & W220 Engine removal and installation 09.

09.3. Remove and install the alternator

09.3.1. Remove the alternator
09.3.1.1. All coupling types
1 Secure the genset and lock out the circuit breaker.

Caution : Any intervention on the alternator electrical circuit must be

carried out by an authorized person.

2 Disconnect the various sensor lines.

3 Disconnect the bus bar or cables from the alternator and
the earth braiding.
4 If there is a coupling housing, remove the screws
connecting the alternator housing to the engine.
Proceed following the different coupling types.

09.3.1.2. The elastic elements are of block type

1 Unscrew the coupling from the flywheel.
2 Use the lifting points of the generator. Before any han-
dling, check the mass of the machine in the builder
documentation
09.3.1.3. The coupling features an outer rim
1 Either pull the alternator far enough to set free the
whole length of the elastic element(s). In the other case, unscrew
the coupling outer rim from the flywheel and pull the alternator to
set free the centring.
2 For this purpose, use the lifting points which, as well as
the mass, are given in the drawing specific to the alternator.

09.3.2. Remove the elastic coupling

Dismount the flange from the hub, i.e. :
• Paulstra AXO4 coupling : remove 12 screws HM 24×80
with their flat washers M24 and 4 positioning pins Ø 20
using pin extractor SPC 8370008 and jack SPC 8370004.
• Centa Centaflex coupling : remove 24 screws HM 24×45.
• Reich Arcusaflex coupling : remove 24 screws HM 24X...
• Stromag PVP 666_1 coupling : remove 20 screws CHC
M 27×100 and 4 positioning pins Ø 22 using pin extractor
SPC 8370008 and jack SPC 8370004.
• Vulkan Rato DG coupling : remove 24 screws HM 22×70.
Removing also the other series of 24 screws HM 20×90
makes it possible to radially extract the elastic elements
without moving the engine or the driven machine.
• Vulkan Vulastik L40D0 coupling : remove 16 screws CHC
M 24.

0936 Page 9
 09. Engine removal and installation W200 & W220

09.3.3. Remove the coupling hub

Two possible press fits exist for the hub : M6m6 if the coupling is a
Stromag PVP 666_1, P7m6 adjustment for all others.
M6m6 adjustment
It is possible to extract the hub after heating it with two oxyacety-
lene torches, or better with two propane torches : the extractor is
made of SPC 8370004, 8610023, 8610024 and the plate + threaded
rods assembly 52005796.
P7m6 adjustment
It is not possible to extract the hub : it will be necessary to cut a
notch, just over the key, with a grinder to force it open with wedges
and extract it (see Fig. 09-8).

Note : It is necessary to limit the depth of the notch to avoid any shaft
da-
mage.

Shaft end

Fig. 09-8

09.3.4. Install the coupling hub

1 Put an indelible mark on the outer (non fonctional)
face of the hub, in order to support its reassembly.
2 Disassemble the hub from the flange or from the elastic ele-
ment(s).
3 Carefully clean the rotor shaft end with an universal sol-
vent (Care Clean or equivant).
4 Carefully de-burr the key with an oil stone.
5 Check that the key perfectly fits both in the hub and on the
shaft.

Page 10 0936
 W200 & W220 Engine removal and installation 09.

6 Set the key on the shaft with Loctite “648 block press”,
ref. 184741595 or screw it if so foreseen.
7 Smear the shaft and the key with a lubricant oil, ref.
MGE000063 or equivalent.
8 Install the lifting strap SPC 8710001 (see Fig. 09-9 item 2)
on the hub (see Fig. 09-9 item 1).
2 1

Fig. 09-9

9 Warm up the hub in an furnace with revolving heat at

180°C (if Stromag coupling) or 250°C (if another coupling
type) for 3 1/2 hours (according to installation - make sure the
steel does not get blue).

Note : In the same time, the end of the rotor shaft can be chilled with
liquid nitrogen or, if not available, with a CO2 fire extin-
guisher.

10 Check its expansion by using control tool SPC 8660036

(see 09-10 item 1).

Fig. 09-10

0936 Page 11
 09. Engine removal and installation W200 & W220

Note : Perform the check quickly to prevent thermal expansion of the

tool.

Caution : Assemble the hub on the rotor shaft in the right way.

11 Maintain the hub using the washer and screw

(DLT318113). Tighten to the torque 500 Nm.
12 Cover it to let it gently cool down.
13 Check the cooling to cover the hub to let it gently cool
down.

09.3.5. Install the elastic coupling on the alterna-

tor
1 If the coupling assembly features a flange
• Rebuild the flange on the hub (if positioning pins are to be
used, cool them down first using liquid nitrogen - if no
nitrogen is available, use carbon dioxide from a fire
extinguisher for example).
• Tighten the screws at 660 Nm.
• Protect the flange with anti-corrosion oil Isotect 377, ref.
MGE00077.
2 If the alternator features a coupling housing
• Dismount the protecting grating on it.
3 Visually check that the Shore hardness marked on
the coupling blocks is the required one.
4 Use a file to eliminate the rubber traces on the
connection surfaces and de-burr them.
5 Install the elastic elements (blocks or annular elements).
6 If the elastic element(s) are of annular type, tighten them
as indicated in the following table :
Stromag Vulkan Reich
PVP666_1 Vulkardan RATO DG Arcusaflex
screw M27 L40D8 AC11...
+75+0
1500 Nm 1400 Nm 675 Nm 710 Nm

09.3.6. Install the alternator on the common

bedframe
09.3.6.1. All coupling types
1 Check the alternator for free rotor rotation.
2 Check the axial clearance “J” of the rotor :
• ABBLSA 54 0.06 ≤ J ≤ 0.1
• ABBLSA 56 0.09 ≤ J ≤ 0.23

Page 12 0936
 W200 & W220 Engine removal and installation 09.

• Newage 824E 0.013 ≤ J ≤ 0.413

• Newage 824F 0.088 ≤ J ≤ 0.5
• others see builder’s instructions.
3 Use the lifting tools assy of the alternator to handle it. The
drawing of the alternator gives the lifting points and mass.
4 Keep the alternator slinged as long as the jack screws are
not in contact with the bedframe.
5 Check the cleanliness of the bedframe and the alternator
feet.
6 Lightly spray the contact surfaces with anti-corrosion
protective oil “ISOTECT 377" ref. MGE000077.
7 Proceed according to coupling type.

0936 Page 13
 09. Engine removal and installation W200 & W220

09.3.6.2. The elastic elements of block type

Fig. 09-11

1 Remove the coupling blocks.

2 Place the alternator on the base frame.
3 Use the jack screws of the alternator to handle it.
4 The alternator features a coupling housing :
• Place four screws to connect to the flywheel housing and
use them to pull the alternator in place :
– V12 Phase 1 : both screws HM 16×120, (see Fig. 09-12 item 1)
are fitted with a sleeve Ø16×37 mm high and an
ondulating washer (see Fig. 09-12 item 2 & 3),
the other 23 fitted screws are HM 16×100 with the same
ondulating washer (see Fig. 09-12 item 3 & 4).
– General case : four screws sleeve, HM 16×120 , (see
Fig. 09-12 item 1), are fitted with a sleeve Ø16×37 mm
high and an ondulating washer (see Fig 09-12 item 2 & 3),
the other 21 HM screws are 16×100 fitted with the same
ondulating washer (see Fig 09-12 item 3 & 4).

3
2
1

4
3

Fig. 09-12

Page 14 0936
 W200 & W220 Engine removal and installation 09.

• Screw the alternator flanges to the bedframe and flywheel

then to the housing, do not tighten.
5 If the alternator features coupling housing.
• Screw the alternator flanges to the bedframe, do not tighten.
6 Lift up the alternator with its jacking screws until the
rotor shaft is approximately at the same level as the engine
crankshaft (see Fig. 09-13).
7 Check visually the good pre-positionning of the flywheel
housing centring and the coupling centring.

Caution : It is forbidden to lift or lower the alternator with the adjusted

shims, Vibracon type.

Fig. 09-13

8 Grease the bearing of the alternator (see the users manual

of the generator manufacturer).

0936 Page 15
 09. Engine removal and installation W200 & W220

9 Push the crankshaft and the rotor against their external

thrust thanks to a metal bar (see Fig 09-14) each towards its
free end, from A area of Fig. 09-15 for the engine and from B area
for the alternator if there is a coupling housing (see Fig 09-15).

Fig. 09-14

Fig. 09-15

10 Put crankshaft and rotor in the middle of their respective

axial clearances.

Page 16 0936
 W200 & W220 Engine removal and installation 09.

11 Measure the distance X between flywheel and flange on

alternator rotor shaft :
• Case of Paulstra coupling type Axo4V14 (design thickness
60 mm) :
– If X is comprised between 59 and 60.4 mm, do not use any
shims.
– I f X is comprised between 60.4 and 62 mm, use one or
two shims (0.6 and 1.0 mm).
– otherwise contact your network dealer.
• Install 13 new coupling blocks onto the flange to the rotor
(the 14 th coupling block will be mounted at the end of the
procedure see chap. 09.4.2).
• Tighten them according to Fig 09-16 .

Couple de serrage à 20 daNm

Couple de serrage à 14 daNm

Fig. 09-16

• Case of Centa Centax TT coupling (design thickness 155

mm) :
If X is comprised between 154 and 156 mm, install the four
blocks onto the flange on the rotor or contact your net-
work dealer.

0936 Page 17
 09. Engine removal and installation W200 & W220

Fig. 09-17
• Tighten them according to the table below :

Torque (Nm)
Screw (see Fig. 09-17) TA 3 TA 4
As delivered 250 850
Lubricated with engine
215 730
lube-oil

12 Install the screws to the flywheel, do not tighten.

13 Pushing again the crankshaft and the rotor as de-
scribed step 9, adjust the distance to 0.5±0.1 between the
flywheel face and the external face of the segment (this operation
is not useful with genset with flange between the engine and the al-
ternator).

Fig. 09-18

14 Proceed with Chap 09.4. : Alignment.

Page 18 0936
 W200 & W220 Engine removal and installation 09.

09.3.6.3. The coupling features an outer rim (Stromag

type)

Fig. 09-19

1 Remove the outer rim.

2 Mount this outer rim on the engine flywheel equipped with
a centring.
3 Tighten it according to the torque specified in the draw-
ing (Stromag PVP : 240 Nm + Loctite 243 ref. 184741040).
4 Approach the alternator towards the engine.
5 Use the jack rings of the alternator to handle it.
6 Coat the rubber notches of the elastic element with
silicone oil, in order to ease the sliding of the elastic element in its
housing.

Note : Avoid any silicone oil contact with painted surfaces.

7 Position the notches of the elastic element so that they

match with the outer rim.
8 Keep the alternator towards the engine till its feet match
with their locations on the bedframe.
9 Check that the rubber element is fully integrated within
its outer rim and check the coupling length to ensure that the rub-
ber is not rubbing against the flywheel.
10 Proceed with Chap 09.4. : Alignment.

0936 Page 19
 09. Engine removal and installation W200 & W220

09.4. Genset alignment

On Diesel engines only, open the needle valves for easier cranking
(see Fig 09-20 item 1, if the engine is equipped with needle valves).

Fig. 09-20
09.4.1. Using a laser device
Rotalign from Prüftechnik or similar.
1 Unless the coupling is Reich Arcusaflex, a Stromag PVP or
a Vulkan Vulastik-L or similar, the coupling must be loosely con-
nected to the flywheel.
2 Mount the sender on the flywheel, the receiver on the
flange or the coupling hub.

Fig. 09-21

3 Enter the geometrical data (position of the alternator

feet) in the device.

Page 20 0936
 W200 & W220 Engine removal and installation 09.

4 Crank the engine 90° to 120°.

5 Read on the device the adjustment to the alternator feet
position.

Fig. 09-22

6 If the recorded values are not within the tolerances

of measurement record WM025, the alternator must be
moved vertically and horizontally.
Compensate the height with shims under the generator feet or with
the vibracons (screw jacks).

Note : With a flanged alternator, the possible movement is limited to

the tolerances of the centering of the engine and the
generator.

Caution : With a flanged alternator , the drive-end bearing will follow the
movement of the engine crankcase, it will be lifted by the ther-
mal expansion of the latter. The correction is to make on the
position of the shaft free end bearing (alternator free end).

7 If instead of an alternator, the engine drives a reducer or

a compressor, compute the height at which the input shaft of
this reducer or compressor shall be set relatively to the crank-
shaft, knowing the :
• heights of the axes over the machines feet.
• temperatures of both machines (engine cooling water and
reducer or compressor cooling oil).
• thermal expansion of the engine block (0.15 mm if LT
water is at 40 °C, 0.19 mm if LT water is at 50°C).
• thermal expansion of the reducer (11x10-6 mm/mm/°C
for steel and 24 for aluminium).

0936 Page 21
 09. Engine removal and installation W200 & W220

Fig. 09-23

8 To adjust the vertical position, use the Vibracons

(if foreseen) or shims, whose part numbers are : SPC6420002,
SPC6420001 (ABB and Leroy-Somer) and SPC6420003 (Newage).
These shims exist in thickness 0.1, 0.2, 0.3, 0.4, 0.5, 1.2 and 3.0 mm.
6420001 6420002 6420003

Fig. 09-24

Page 22 0936
 W200 & W220 Engine removal and installation 09.

9 Oil the required shims using protection oil Isotect 377 and
position them (see item 2, fig. 9-25).
10 Loosen the jacking screws (see item 1 Fig. 09-25 ).
11 Oil, then install the fixation screws (see Fig 09-25 item 3)
or bolts (item 4) for the first base frame generation of the alterna-
tor and tighten them at 500 Nm.
Above view

1 A

4
2
35 3

Fig. 09-25

12 If there is a coupling housing, tighten the screws

according to the prescribed torque (200 Nm) (see Fig. 09-25,
09-26).
13 Check the alignment again and correct it if necessary.
14 On Diesel engines only, close the needle valves if they
have been opened.
15 Dismount the dial gauges and their holders.
16 If the coupling is a Paulstra Axo4V14, install the 14th
AX04V14 coupling block.

PAULSTR A
CENTAX TT 140
AX04V14
Delivered screw:
280 Nm

Lubrificated
2,3 screws*: 250 Nm

Tightening * with oil engine

torque
110+8/+11
Nm

Fig. 09-26

0936 Page 23
 09. Engine removal and installation W200 & W220

17 If the coupling is made out of blocks, tighten the screws

to the flywheel.
18 Check that no tool is left inside the coupling housing.
19 Re-install the protecting grating and/or flywheel cover.
20 Check the deflection of crank n° 1 of the crankshaft.
21 Complete measurement records WMR005 (for crank
n° 1 only) and WMR025.
22 Connect the bus bar or braiding from the alternator and
the earth cable.
23 Run the genset for at least one hour. When the engine is
warm check the alignment again.

Page 24 0936
 W200 & W220 Engine removal and installation 09.

09.4.2. Using dial gauges

1 Use measurement record WMR025.
2 Unless the coupling is Reich Arcusaflex, a Stromag PVP or
a Vulkan Vulastik-L, or similar the coupling must be loosely con-
nected to the flywheel.
3 Fasten two dial gauges to the alternator flange or hub, one
measuring the axial offset (see Fig 09-27 item 1 - use at least
Ø 12-mm rods for sufficient stiffnesses) and one measuring the
radial offset (see Fig 09-27 item 2 - tool referenced SPC 8660035).
For Stromag PVP couplings, a specific tool has been designed
(see Fig 09-27 - item 3).Tools referenced SPC 8660035.

Fig. 09-27

4 If the alternator features a coupling housing, place the

dial gauges and their holders so as not touch the
reinforcements in the coupling housing.
5 As a general principle during the coupling alignment, the
shaft shall be turned only in counter clockwise direction. The dial
gauges turn with the shaftline.
6 Mark the flywheel with four marks 90° apart, the 0° of them
facing a mark on the flywheel housing.
7 Set the dial gauges to zero in top position (see Fig 09-27
position 1), with a 2 mm possible sinking and always use the same
position to zero the dial gauges.

0936 Page 25
 09. Engine removal and installation W200 & W220

Fig. 09-28

8 Crank the engine from position 1 to positions 2 to 5 suc-

cessively and record the offsets (measurement record WMR025).
9 If position 5 is not at {0, 0}, the dial gauge(s) has (have)
moved : fix it (them) better and resume recording.
10 Compute the required correction to the alternator feet
positions.
11 If the recorded values are not within the tolerances
of measurement record WM025, the alternator must be moved in
accordance. Compensate the height with shims under the
generator feet or with the vibracons (screw jacks).

Note : With a flanged alternator, the possible movement is limited to

the tolerances of the engine and generator.

Caution : With a flanged alternator, the drive-end bearing will follow the
movement of the engine block, it will be lifted by the thermal
expansion of the latter. The correction is to make on the posi-
tion of the shaft free end bearing (alternator free end).

12 If instead of an alternator, the engine drives a reducer or

a compressor, compute the height at which the input shaft of this
reducer or compressor shall be set relatively to the crankshaft,
knowing the :
• heights of the axes over the machine feet.
• temperatures of both machines (engine cooling water and
reducer or compressor cooling oil).
• thermal expansion of the engine block (0.15 mm if LT
water is at 40 °C, 0.19 mm if LT water is at 50°C).
• thermal expansion of the reducer (11x10-6 mm/mm/°C
for steel and 24 for aluminium).
13 To adjust the vertical position, use the Vibracons, if pro-
vided or shims, whose part numbers are: SPC6420002

Page 26 0936
 W200 & W220 Engine removal and installation 09.

SPC6420001 (ABB and Leroy-Somer) and SPC6420003 (Newage).

These shims exist in thickness 0.1, 0.2, 0.3, 0.4, 0.5, 1.2 and 3.0 mm,
(see Fig. 09-29).

Fig. 09-29

14 Oil the required shims using protection oil Isotect 377 and
position them (see item 2 Fig. 09-30).

Fig. 09-30

15 Loosen the jacking screws (see item 1 Fig. 09-30).

16 Oil, then install the fixation screws (see item 3) or the
bolts (item 4) for the base frame of first generation
Fig. 09-30) of the alternator and tighten them at 500 Nm.
17 If there is a coupling housing, tighten the screws
according to the prescribed torque (200 Nm).
18 Check the alignment again and correct it if necessary.
19 On Diesel engines only, close the needle valves if they
have been opened.
20 Dismount the dial gauges and their holders ref.
SPC 8660035 (see Fig. 09.-31 rep. 1, step 1).
21 If the coupling is a Paulstra Axo4V14, install the
last coupling block (14th), (see Fig. 09.-31, step 2).

0936 Page 27
 09. Engine removal and installation W200 & W220

22 If the coupling is made out of blocks, tighten the screws

to the flywheel.
23 Check that no tool is left inside the coupling housing.
24 Re-install the protecting grating and / or flywheel cover.
25 Check the deflection of crank N°1 of the crankshaft (see
measurement recod WMR 005, chap. 06).
26 Complete measurement records WMR005 (for crank
N° 1 only) and WMR025.
27 Connect the bus bar or cables from the alternator and the
earth braiding.
28 Run the genset for at least one hour. Once the engine
is warm, check the alignment again.

Fig. 09-31

Page 28 0936