Maintenance Manualmaytau.ut.edu.vn/userfiles/files/RTA84C-Maintenance.PART...RTA84C Maintenance 0001/1.1 Preface The instructions contained in this "Maintenance Manual" are intended

RTA84C

Maintenance Manual“Marine” (UG Version)

Vessel:

Type:

Engine No.:

Book No.:

Wärtsilä Switzerland Ltd 24hrs Support: +41 52 262 80 10

PO Box 414 [email protected]

CH-8401 Winterthur

Switzerland

� 2005 Wärtsilä Switzerland Ltd, Printed in Switzerland

This page is intentionally left blank

0

1

2

3

4

5

6

7

8

9

MM

/ R

TA

/ R

egis

ter

Camshaft and Control Elements

Crankshaft, Connecting Rod and Piston

Cylinder Liner and Cylinder Cover

Bedplate and Tie Rod

General Information

Governor, Injection Pump and Actuator Pump

Scavenge Air Receiver and Auxiliary Blower

Balancer

Piping

Tools


RTA96CBetrieb Group0

1Wärtsilä NSD Switzerland Ltd

General Information Group 0

For Particular Attention 0000/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface 0001/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents 0002/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Numbering and Designation 0008/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� General Guidelines for Maintenance

– Safety Measures and Warnings 0011/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Clearance Table

– Main and Thrust Bearings 0330/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Crosshead Guide 0330/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Cylinder Liner 0330/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Piston Rod Gland 0330/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Exhaust Valve 0330/4.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Top and Bottom End Bearings to Connecting Rod 0330/5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Piston Cooling and Crosshead Lubricating Links 0330/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Working Piston and Piston Rings 0330/7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Working Piston and Piston Rings (Cylinder Liner with Antipolishing Ring) 0330/7. . . . . . . . . . . . . . . . .

– Wheels for Camshaft Drive and Drive for PTO Gear Box 0330/8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– PTO Drive 0330/9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Camshaft and Reversing Servomotor 0330/10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Gearing for Auxiliary Drives 0330/11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Intermediate Shaft for Auxiliary Drives 0330/12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Starting Air Distributor 0330/13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Roller Guides to Fuel Injection and Actuator Pumps 0330/14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Gear Pump for Cylinder Lubricating Pump Drive 0330/15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Balancer Drive Units 2nd Order 0330/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Integrated Balancer 2nd Order 0330/17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Tightening Values of Important Screwed Connections

– Tightening Values of Important Screwed Connections 0352/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Tightening Instructions for Normal Screws 0352/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wärtsilä Switzerland Ltd RTA84C / MM / 2001

BetriebGroup0RTA96C

2 Wärtsilä NSD Switzerland Ltd

� Masses (Weights)

– Individual Components per Piece in kg 0360/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Dimensions and Material Specification

– O-rings and Rubber Rings 0370/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Piston and Rod Seal Rings 0370/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Maintenance Schedule

– Inspection and Overhaul Intervals (Guidelines) 0380/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cross and Longitudinal Section 0803/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Taking Oil Samples for Laboratory Analysis 0900/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2001 / MM / RTA84C Wärtsilä Switzerland Ltd

RTA84CMaintenance 0000/1.1

1Wärtsilä Switzerland Ltd

This manual is put at the disposal of the recipient solely for use in connection with the corresponding type of dieselengine.It has always to be treated as confidential.

The intellectual property regarding any and all of the contents of this manual, particularly the copyright, remains withWärtsilä Switzerland Ltd. This document and parts thereof must not be reproduced or copied without their writtenpermission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.

Before the operator intends to use the engine or before maintenance work is undertaken, the Operating Instructionsor the Maintenance Manual respectively is to be read carefully.

To ensure the best efficiency, reliability and lifetime of the engine and its components, only original spare partsshould be used.It is to be ensured as well that all equipment and tools for maintenance are in good condition.

The extent of any supplies and services is determined exclusively by the relevant supply contract.

The data, instructions and graphical illustrations etc. in this manual are based on drawings made by WärtsiläSwitzerland Ltd and correspond to the actual standard at the time of printing (year of printing is indicated on titlepage).Those specifications and recommendations of the classification societies which are essential for the design havebeen considered therein. It must be recognized that such data, instructions and graphical illustrations may be sub-ject to changes due to further development, widened experience or any other reason.

This manual is primarily intended for use by the engine operating and maintenance personnel. It must be ensuredthat it will always be at the disposal of such personnel for the operation of the engines and/or for the required mainte-nance work.

This manual has been prepared on the assumption that operation and maintenance of the engines concerned willalways be carried out by qualified personnel having the special knowledge, training and qualifications needed tohandle in a workman-like manner diesel engines of the corresponding size, the associated auxiliary equipment, aswell as fuel and other operating media.

Therefore, generally applicable rules, which may also concern such items as protection against danger, are speci-fied in this manual in exceptional cases only.It must be made sure that the operating and maintenance personnel are familiar with the rules concerned.

This manual has been prepared to the best knowledge and ability of its authors. However, neither WärtsiläSwitzerland Ltd nor their employees assume any liability – under any legal aspect whatsoever, includingpossible negligence – in connection with this manual, its contents, or modifications to it or in connectionwith its use.Claims relating to any damage whatsoever or claims of other nature such as, but not limited to, demands foradditional spares supplies, service or others are expressly excluded.

Wärtsilä Switzerland Ltd

Winterthur

Switzerland

For Particular Attention

1997�


0001/1.1MaintenanceRTA84C

Preface

The instructions contained in this "Maintenance Manual" are intended to help to ensure that the maintenancewhich must be carried out at specific intervals is correctly carried out.It is a precondition that the personnel charged with such important work possesses the necessary training and expe�rience.

Information about the operation of the engine as well as descriptions of the function of the various systems are partof a separate book, the "Operating Manual". In this manual you can find also under sheet 0010/1 and 0040/1 ex�planations to the layout and use of the Operating Instructions as well as of the Maintenance Manual.

More detailed instructions on the operation and maintenance of components from sub�suppliers can be gatheredfrom the instruction leaflets of the respective manufacturers. Outside makes are, for example, such engine compo�nents which are not manufactured in accordance with drawings of Wärtsilä Switzerland Ltd.

The Maintenance Manual is divided into the following main chapters:

� General guidelines for maintenance

� Clearance tables, tightening values of screwed connections, masses (weights), seal rings

� Maintenance schedule

� Design groups

� Tool lists

A few explanations to the above:

The 'General Guidelines for Maintenance' contain, in addition to recommendations on precautionary measures tobe taken, also suggestions for carrying out the work.

The above mentioned tables inform about normal and maximum acceptable clearances, the tightening of impor�tant screwed connections, weights of individual engine components as well as the type and use of various sealingrings.The normal clearances given in the clearance tables sheet 0330/1 correspond to those resulting from manufacturingtolerances or clearances as adjusted on the new engine.The maximum clearances or max/min. dimensions represent values resulting from long periods of operation due towear, which, however, must not be exceeded nor gone below, respectively. For parts where the clearance can becorrected by changing shim thickness, discs or spacers, the normal clearance should always be aimed at and ad�justed. Where this is not possible, the worn parts must be replaced or reconditioned by building�up (chromium plat�ing, resurfacing by welding or by metal spray).If, during an overhaul, clearances or dimensions are found which nearly attain the permissible limits, then it must beleft to the engineer responsible for the operation of the engine to decide whether the parts are replaced. This de�pends, for example, on the duration of the next operating period till the next overhaul and what wear has to be ex�pected based on experience made.

The 'Maintenance Schedule' indicates nominal intervals in which various maintenance operations are to be carriedout. Please note that maintenance intervals are based on experience and are subject to operation of the engine un�der standard conditions.

Detailed instructions are given in the 'Design Groups' on the procedure of maintenance work on certain engineparts.

Tools and devices necessary to carry out maintenance are described in the 'Tool Lists', and are generally suppliedwith the engine.

All information contained in the text and illustrations of this manual are valid at the time of printing.Modifications will be incorporated in the next edition!

Wärtsilä Switzerland Ltd 1997



Table of Contents

General information Group 0

For particular attention 0000/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface 0001/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine numbering and designation 0008/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General guidelines for maintenance 0011/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety measures and warnings

Clearance tables

Main and thrust bearings 0330/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crosshead guide 0330/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner 0330/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rod gland 0330/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve 0330/4.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top and bottom end bearings to connecting rod 0330/5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston cooling and crosshead lubricating links 0330/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working piston and piston rings 0330/7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working piston and piston rings (cylinder liner with antipolishing ring) 0330/7. . . . . . . . . . . . . . . . . . . . . . . . . Wheels for camshaft drive and drive for PTO gear box 0330/8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO drive 0330/9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft and reversing servomotor 0330/10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearing for auxiliary drives 0330/11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate shaft for auxiliary drives 0330/12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting air distributor 0330/13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller guides to fuel injection and actuator pumps 0330/14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump to cylinder lubricating pump drive 0330/15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancer drive units 2nd order 0330/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated balancer 2nd order 0330/17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening values of important screwed connections 0352/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening instructions for normal screws 0352/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Masses (weights) of individual components per piece in kg 0360/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and material specification of O�rings and rubber rings 0370/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and material specification of the piston and rod seal rings 0370/2. . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance schedule 0380/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and overhaul intervals (guidelines)

Engine cross section and longitudinal section 0803/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Taking oil samples for laboratory analysis 0900/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bedplate and tie rod Group 1

Bedplate & thrust bearing Checking the foundation bolts 1112/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main bearing Loosening and tensioning of bearing jack bolts 1132/1. . . . . . . . . . . . . . . . . . . . Removal and fitting of a main bearing 1132/2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wärtsilä Switzerland Ltd UG / 9.01

RTA84CMaintenance0002/1.2

Thrust bearing Checking the axial clearances 1203/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and fitting of thrust bearing pads 1224/1. . . . . . . . . . . . . . . . . . . . . . . . .

Tie rod Checking the tie rod pre�tension and tensioning the tie rod 1903/1. . . . . . . . . . .

Cylinder liner and cylinder cover Group 2

Cylinder liner Measuring bore wear 2124/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and fitting 2124/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing wear ridges, re�dressing the lubricating grooves 2124/3. . . . . . . . . . . . as well as the edges of the scavenge ports

Lubricating quills and Function check 2136/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . accumulators

Piston rod gland Dismantling and assembling as well as measuring the wear 2303/1. . . . . . . . . . .

Cylinder cover Removing and fitting 2708/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic loosening and tensioning of cylinder cover studs 2708/2. . . . . . . . . . . Mechanical loosening and tightening of cylinder cover studs 2708/3. . . . . . . . . . Manual overhaul of sealing face for the fuel injection valve in the 2708/4. . . . . . cylinder cover

Fuel injection valve Checking, dismantling, assembling and setting (L'ORANGE test stand) 2722/1. Checking, dismantling, assembling and setting (O.M.T. test bench) 2722/1. . . . . Cleaning and overhaul of injection nozzle 2722/2. . . . . . . . . . . . . . . . . . . . . . . . . . Lapping of nozzle holder contact surface 2722/3. . . . . . . . . . . . . . . . . . . . . . . . . .

Starting valve Removing, fitting, dismantling, grinding�in and assembling 2728/1. . . . . . . . . . .

Relief valve for Dismantling, assembling and testing (with L'ORANGE test stand) 2740/1. . . . . cylinder cover Dismantling, assembling and testing (with O.M.T. test bench) 2740/1. . . . . . . . .

Exhaust valve Removal and fitting of the exhaust valve 2751/1. . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling 2751/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing and grinding the valve seat 2751/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grinding the seating surface on the valve head 2751/4. . . . . . . . . . . . . . . . . . . . .

Crankshaft, connecting rod and working piston Group 3

Crankshaft Measuring crank deflection 3103/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibration damper Taking a silicone oil sample 3130/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (on crankshaft and camshaft)

Axial detuner Dismantling and assembling 3146/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turning gear Oil change and checking the worm wheels 3206/1. . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Utilization of working platform 3301/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rod Loosening and tensioning the connecting rod studs and bolts 3303/1. . . . . . . . . Inspection, removing and fitting of bottom end bearing 3303/2. . . . . . . . . . . . . . Inspection, removing and fitting of top end bearing 3303/3. . . . . . . . . . . . . . . . . . Removing and fitting 3303/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rod (1�part) Loosening and tensioning the connecting rod studs 3303/1. . . . . . . . . . . . . . . . . . Inspection, removing and fitting of bottom end bearing 3303/2. . . . . . . . . . . . . . Removing and fitting 3303/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wärtsilä Switzerland Ltd9.01 / UG


Crosshead Checking clearances 3326/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and fitting a crosshead 3326/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working piston Removal and fitting 3403/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the compression shim 3403/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling 3403/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking piston top surface 3403/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston rings Checking piston ring wear 3425/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking piston ring wear (cylinder liner with antipolishing ring) 3425/1. . . . .

Camshaft and control elements Group 4

Camshaft driving wheels Checking the running and backlash clearances as well as 4103/1. . . . . . . . . . . . . condition of the teethRemoval and fitting the intermediate gear wheel; 4103/2. . . . . . . . . . . . . . . . . . . Replacing a gear rimReplacing the 2�part gear wheel on the crankshaft 4103/3. . . . . . . . . . . . . . . . . . .

Camshaft Removing and fitting a camshaft section 4203/1. . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and fitting of hydraulic locking elements 4203/2. . . . . . . . . . . . . . . . . . Removing and Fitting of Hydraulic Locking Elements on the Camshaft 4203/3. Removing and fitting of the camshaft coupling 4203/4. . . . . . . . . . . . . . . . . . . . . . Removing and fitting of an SKF shaft coupling 4203/5. . . . . . . . . . . . . . . . . . . . . Removing and fitting the gear wheel on the camshaft 4203/6. . . . . . . . . . . . . . . .

Starting air distributor Dismantling and assembling 4303/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting air shut�off Cleaning and function check 4325/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve and valve forslow turning

Rotation direction safe� Inspection and function check 4506/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . guard

Governor, fuel injection pump and actuator pump Group 5

WOODWARD governor Installing, removing and maintenance 5103/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . PGA 200

Safety cut�out device Maintenance and function check 5307/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injection pump Adjusting and checking the control with V.I.T. 5512/1. . . . . . . . . . . . . . . . . . . . . . Lapping the sealing face for the covers of the suction, delivery 5512/2. . . . . . . . and spill valvesChecking and setting of the relief valve (with L'ORANGE test stand) 5512/3. . Checking and setting of the relief valve (with O.M.T. test bench) 5512/3. . . . . . Tightening a nipple for the plunger guide 5512/4. . . . . . . . . . . . . . . . . . . . . . . . . .

Actuator pump Determining the shim thickness 5513/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge air receiver and auxiliary blower Group 6

Charge air receiver Maintenance of the valve groups, air flaps and cleaning the 6420/1. . . . . . . . . . . charge air receiver

Auxiliary blower Maintenance 6545/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge air cooler Cleaning (water side) with engine at standstill 6606/1. . . . . . . . . . . . . . . . . . . . . . Removing and fitting a cooler element 6606/2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water separator Maintenance of water separator elements 6708/1. . . . . . . . . . . . . . . . . . . . . . . . . .

Wärtsilä Switzerland Ltd 9.01 / UG


Cylinder lubrication, PTO gear box and balancer Group 7

Cyl. lubricating pumps Cleaning 7203/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving shaft to the flow Dismantling and assembling 7212/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control valve of the cy�linder lubrication

PTO gearbox Checking the tooth profile and tooth backlash, aligning the 7403/1. . . . . . . . . . . gearbox housing, checking the running performanceRemoving and fitting gearbox components as well as the inter� 7403/2. . . . . . . . mediate gear wheel

GEISLINGER coupling External inspection for oil leaks and constant venting 7412/1. . . . . . . . . . . . . . .

Balancer 2nd order Fitting, removing, tensioning the roller chain 7708/1. . . . . . . . . . . . . . . . . . . . . . . fitted at the free end Fitting, removing the flexible coupling and a camshaft section

Integrated balancer of Removal and fitting of balancer shafts 7722/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd order

Piping Group 8

Hydraulic piping for Removing and fitting the pipes and refacing the sealing faces 8460/1. . . . . . . . . the exhaust valves drive

Fuel pressure piping Fitting and dismantling, reconditioning the sealing faces 8733/1. . . . . . . . . . . . .

Tools Group 9

Tools Explanation 9403/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydr. jacks and pumps Arrangement and application 9403/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydr. pre�tensioning jacks Storing, servicing and maintenance 9403/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General application instructions 9403/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tool list Standard tools, recommended tools, 9403/5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tools obtainable on loan



Engine Numbering and Designation

87.7056

90.7034

1 2 3 4 5 6

1 2 3 4 5 6 7 8

ÅÅÅÅÅÅDriving End Free End

Auxiliary Blower Auxiliary Blower

Cylinder Numbering

Main Bearing NumberingThrust Bearing Pads

Exhaust SideFuel Pump Side

Clockwise RotationAnti�clockwise

Turbocharger 1Turbocharger 2

Rotation

1990



General Guidelines for Maintenance

Safety Measures and Warnings

The maintenance work which is required to be carried out on the engine at regular intervals is described in theMaintenance Schedule sheet 0380/1 of this manual and is to be understood as a general guide. The maintenance

intervals are dependent on the mode of operation, on the power as well as on the quality of the fuel used. Furtherdetails are set out in the maintenance schedule.Experience will show whether the intervals may be extended or need to be shortened.Strict compliance with the below mentioned recommendations regarding safety measures and maintenance work

is mandatory; the recommendations are not exhaustive.

1. General safety precautions

- It is the operator's duty to assure that all personnel is familiar with all safety, health as well as environmentprotection rules released for operating and maintaining a diesel engine plant. In particular greatest atten�tion has to be given to the functioning, handling and dangers of cranes and lifting devices.

- The safety officer has to make sure that all precautions have been taken in order to avoid dangerous situa�tions.

- The operator has to nominate a person responsible for assigning work tasks to every person who is partici�pating on maintenance work.

- Make sure that fluids or gases draining or escaping cannot cause accidents, fires or explosions duringmaintenance work. Keep the engine and the surroundings clean. Cleanliness increases the quality of thework and helps to prevent accidents.Before beginning maintenance work on the diesel engine the corresponding systems which are influencedby the maintenance work must be relieved of pressure and/or drained if necessary. A protocol must beestablished evidencing these activities.

- Certain media, i.e. fuels etc., are highly inflammable, therefore all precautionary measures have to betaken that they do not get in contact with fires, glowing or hot parts. Smoking in the engine room is strictlyforbidden.Special attention has to be paid to the rules of fire fighting.Make absolutely sure that in case of fire alarm no fire extinguishing gases can be released into the engineroom while people are still inside. Emergency escapes are to be marked and personnel is to be instructedof what to do in case of fire.

- Oils and other media can cause slippery surfaces. In order to avoid injury all surfaces which can be steppedon must be kept clean and dry.

2. Precautionary measures before beginning of maintenance work

Before starting any maintenance work on the engine (particularly on the running gear), take the followingprecautionary measures:

- Close the shut�off valves on the starting air bottles.

- Close all the shut�off valves in the control air supply unit and open the drain cocks in the two air bottles.

- Open the drain valves placed in the pipes before and after the (automatic) shut�off valve for starting airand leave them in this position until maintenance work is completed.

- Open all indicator cocks on the cylinder covers and leave in this position until maintenance work is com�pleted.

- Engage turning gear (gear pinion must be in engaged position) and lock the lever.

- Where the engine has been stopped due to overheated running gear or bearings, wait at least 20 minutes

before opening the crankcase doors.

- The crankcase doors must always be locked with all the closing dogs whenever the engine is running evenif this is only for a short time in order to make temperature checks (e.g. after changing bearings during anoverhaul, etc.).

- In the case of a fire in the engine having been extinguished by means of CO2, the spaces affected must bewell ventilated before work can be carried out within them.

Wärtsilä Switzerland Ltd 7.04


3. Special safety measures

- Prior to turning the crankshaft with the turning gear, make sure that no person is inside the engine and noloose parts, tools or devices can get jammed. Also bear in mind that the coupled propeller turns too (dan�ger in surroundings).

- At all times when somebody is inside the engine casing another person must stand by in order that he cangive the necessary aid if something unexpected happens to the person inside the engine. The person who isinside the engine casing must be equipped with all safety gears which are required to prevent suffocationwithin the limited space and atmospheric conditions.

- The allowed load capacity of the engine room crane, the lifting tools, ropes and chains must be sufficientfor the parts to be lifted (see sheet 0360/1) pay attention to the weight distribution and attachment of thelifting tackle in order that the part which must be lifted cannot tip over or crash down.

- Sharp edges, mating faces etc. as well as ropes are to be protected by wooden pieces, leather or specialedge guards which are placed between the part and the rope or chain.

- Always wear safety goggles when working with hydraulic tools.

- For your own safety keep away from under hanging loads never undersling hanging parts with your fin�

gers or hands and never embrace lifting ropes with your hands.

- For reasons of safety, openings resulting from removed engine components must be closed.

- Removed parts must be secured in the engine room.

Remark: For further notes regarding safety precautions and warnings (general remarks) see also OperatingManual sheet 0210/1.

4. Recommendations for performing work

- Carry out all work carefully, observing utmost cleanliness!

- For maintenance work on the engine use the tools and devices intended for the particular job, which, as arule, are supplied with the engine (please refer to the tool list at the end of this manual).

- Tools and devices should be made ready prior to use, make sure they are in perfect condition.

- Calibrate gauge tools before using and at periodical intervals.

- Check hydraulic tools periodically for tightness and perfect functioning.

- Protect running faces and sealing faces of removed parts by suitable means to prevent damages.

- Close all openings which form when certain parts are removed e.g. pipes, oil holes any opening etc. toprevent dirt from entering the engine. (This includes also the pipes which are removed).

- Check all repaired, overhauled or replaced parts for perfect functioning before starting the engine.

- Check all pipes, which have been removed, for tightness after they are refitted.

- Clearances of moving parts must be checked periodically. Should the maximum permissible values (seeclearance and wear table) have been reached or have even been exceeded, these parts must be replaced.

- Arrange to replace all parts taken from spares stock. When ordering new parts refer to Code Book, men�

tion code numbers and description.

- When tightening studs, nuts or screws, take the utmost care not to damage their thread. They must bescrewed in by hand until metal to metal contact is achieved. Always use the specified lubricants on thethreads.

- Adhere to tightening values wherever they are indicated. Use the specified lubricant on the threads (seesheets 0352/1 and 0352/2).

Wärtsilä Switzerland Ltd7.04


- Locking devices of bolts, nuts, etc. must be fitted correctly and secured properly. Use locking plates andlocking wires only once.

- For threads of screws and studs which are getting very hot, (i.e. exhaust pipe or turbocharger fastenings)apply a high temperature resistant lubricant before assembly, to prevent a heat seizure.

- Used rubber rings must always be replaced by new ones when an overhaul of any engine component takesplace; they must conform in dimension and quality to the specifications on sheet 0370/1.The fitting of piston seal rings and rod seal rings requires the greatest of care to prevent damage, overexpansion or deformation. Before fitting the rings heat them first in boiling water.




Clearance Table

Main and Thrust Bearings

Kurbelwellenlager

a2

b1

B b

a1

dd1 d2

bb

1

f1

f

f

01.708901.7090

i1 i2

ADMISSIBLE DIFFERENCEa1–a2 = MAX. 0.3 mm(WITH JACK BOLTS TENSIONED)

MAIN BEARING

Zulässige Differenza1–a2 = max. 0,3 mm(mit gespannten Druckbolzen)

2.5

Nominal Clearance

normal, newmax. dueto weardimension

Nominal Clearance


B = 870

b = 870

d = 415

b1 = 0.48 - 0.68

d1 + d2 = 15

0.8 f = 150 -0.5-0.6

f 1 = 0.8 - 1.3

1 +i i 2 = 6


0330/2.1 Maintenance RTA84C

Clearance Table

Crosshead Guide

a

d1

c CAbB

d

e

c1

b1

95.7942

Zum Messen der Spiele siehe Angaben in Blatt 3326/1.Das Spiel ’b1’ gilt nur bei angezogenen Zugankern.

FOR MEASURING CLEARANCES SEE INSTRUCTIONS ON SHEET 3326/1.CLEARANCE ’b1’ IS ONLY VALID WITH TIE RODS TIGHTENED.

Brennstoffseite

FUEL SIDE

c1 = 0.03-0.09

d = 1022.4-1023.0

NominalClearance


NominalClearance


= 0.2A = 790

a = 790

B = 990

b = 990

C = 400

1.3

c = 400

2.5

b1 = 0.2-1.0

d1 = 0.6-2.0

e = 0.2-0.4

- 0.03- 0.06

0- 0.10

+ 0.25- 0

- 0.2- 0.25

+ 0.030



Clearance Table

Cylinder Liner

90.7035

CA

B

G

H

a1 (a2)

b1 (b2)

g1 (g2)

h1 (h2)

ap

pro

x. 1

60

� 20

0 m

m

NominalClearance


NominalClearance


A = 1210 00.7

C = 840

B = 1216

+ .5+

00.7

+ .5+

a1 2 = 0.7 �1.1+a

b1 2 = 0.7 �1.1+b

845.90

H = 1030

G = 1040 g1+g2= 1.2 � 1.6

h1+h2= 0.75� 1.05

10.94


Clearance Table

Piston Rod Gland

011.376/03

a

b

b

d

a

c

a1

b1

c1

d1

d1

d1

d1

d1

d1

Ring wear

The differential value between nominaldimension and max. wear is equal forall rings, i.e. also for undersize rings.

Clearance Clearance

Nominal

dimensionnormal, new

max. due

to wear

Nominal


max. due

to wear

a = 31 min. = 25 c = 24 min. = 22.20

a1 = 0.15-0.26 0.50 c1 = 0.05-0.16 0.40

b = 31 min. = 25 d = 5 min. = 3.20

b1 = 0.15-0.26 0.50 d1 = 0.10-0.17 0.40

12.03 Wärtsilä Switzerland Ltd


Clearance Table

Exhaust Valve

93.7092

Ventilspindel

VALVE SPINDLE AIR CYLINDER

Führungsbüchse

GUIDE BUSH

A

e

Luftzylinder

C

D

1/3

L2/3

L

L =

Län

ge

LE

NG

TH

B

f

Diameter Diameter

Nominaldimension

normal, new max. dueto wear

Nominaldimension

normal, new max. dueto wear

A 280 +0.0520

280.208 e 80 -0.19-0.23

79.40

B 280 +0.0520

280.20 f 80 -0.19-0.23

79.40

C 80 +0.0300

80.45

D 80+0.030

081.45

1994


Clearance Table

Top and Bottom End Bearings to Connecting Rod

93.7072

bb

1

B

h1 h2

aa1

A

g1g2

10 m

m

10 m

m

f1

50 m

m

10 m

m

f2

d2 d1

m1m2

n1n2

Clearance Clearance

Nominal


max. due

to wear

Nominal


max. due

to wear

A = 870 f1+f2 = 0.52-0.72

a = 8700

-0.10a1 = 0.45-0.70 1.00 g1+g2 = 15

B = 790 h1+h2 = 0.40-0.80 1.20

b = 7900

-0.10b1 = 0.46-0.72 0.90 m1+m2 = 0.45-0.70

d1+d2 = 0.42-0.62 n1+n2 = 1.10-1.50

12.03 Wärtsilä Switzerland Ltd


Clearance Table

Piston Cooling and Crosshead Lubricating Links

95.7982

cc1 c2

aa1

bb1 b2

aa1

a1

a

0.2a = 68

b1+ b2 = 2.2

�a1 = 0.03 0.09

b = 151

c = 151 c1+ c2 = 1.3 �

3.1�

1.9

NominalClearance


1989


Clearance Table

Working Piston and Piston Rings

Kn

k1

l

En

e1

l

H

40

C

B A

40

a

b

c

c

d

g

840 841 842 843 844

25

24

23

22

21

[mm]845

26

[mm]

846

lmin

lminN

Jm

j1

l

H

Cylinder liner bore ’a’

Piston ringwidth ’I’

The ring width at the positions A, B and C is the decisive criterion for re-fitting of used piston rings.Used piston rings may be re-fitted if they will keep within their min. ring width till the next overhaul(for judging and re-using the piston rings see also sheet 3425/1)

Clearance Clearance

Nominal dimension

normal, newmax. dueto wear

Nominaldimension

normal, newmax. dueto wear

a = 840 E = 16+ 0.40+ 0.35 e1 = 0.42-0.50 0.70

b = 832.7 7.30-7.73 J = 20+ 0.51+ 0.46 j1 = 0.46-0.54 0.75

c = 836.7 3.30-3.73 K = 16 + 0.28+ 0.23

k1 = 0.30-0.38 0.60

d = 838.9 1.10-1.53 dmin. = 836.8 l = 26.5 ±0.40 see diagram

g = 310- 0.056- 0.108 dmin. = 309 m = 20

0- 0.03

H = 27.5 n = 15.930

- 0.03

Wärtsilä NSD Switzerland Ltd8.98


Clearance Table

Working Piston with Piston Rings Cylinder Liner with Antipolishing Ring

Kn

k1

l

En

e1

l

H

40

C

B A

40

a

b

c

c1

d

g

840 841 842 843 844

25

24

23

22

21

[mm]845

26

[mm]

846

lmin

lminN

The ring width at the positions A, B and C is the decisivecriterion for re-fitting of used piston rings.Used piston rings may be re-fitted if they will keep within theirmin. ring width till the next overhaul(for judging and re-using the piston rings see also sheet 3425/1)

Pisto ringwidth ’I’

Cylinder iner bore ’a’

Clearance Clearance

Nominal


max. due

to wear

Nominal


max. due

to wear

a = 840 E = 20 + 0.49+ 0.44

e1 = 0.44-0.52 0.70

b = 832.4

c = 834.6 K = 20+ 0.37+ 0.32

k1 = 0.32-0.40 0.60

c1 = 836.7

d = 838.9 1.10-1.53 dmin. = 836.8 l = 26.5 ± 0.40 see diagram

g = 310- 0.056- 0.108 dmin. = 309

H = 27.5 n = 20 0- 0.03

Wärtsilä Switzerland Ltd Antip. Ring / UG / 2001



Clearance Table

Wheels for Camshaft Drive and Drive for P.T.O. Gear Box

A = 300

�b1+ 2 =0.6 1.1

a � 0.254

d1+ d2 = 0.6

C = 380

1= 0.162

b

c � 0.3581= 0.262

0.40

1.5

0.50

d = 290 �1.1 1.5

normal max.

1

2

3

= 0.36 �0.60

= 0.48 �0.72

= 0.48 �0.73

0.80

0.90

0.90

a = 300

b = 290

c = 380

NominalClearance


NominalClearance


Backlash of teeth

1989


Clearance Table

P.T.O. Drive

a = 380 a

c = 240

d = 260

1=

0.82

1.7

normal max.*

1

2

3= = 0.62

b = 300 b1= 0.441

0.358

c1= 0.435

d1= 0.379

0.50

0.81

0.69

1.5

= 1.11

f

0.91g =

e = 1.1 1.5

0.480.73

=0.360.57

0.360.520.90

0.68

0.60

0,50

normal max.*

0.262

0.377

0.377

0.315

0.6

NominalClearance


NominalClearance


Backlash of teeth

1989


Clearance Table

Camshaft and Reversing Servomotor

a1

�b1+b2 = 0.45 0.60

�330

= 0.17 � 0.256

0.14

0.35

c = 0.1 0.30 0.40

a 330=

A =

�d 0.16 0.30

0.30

1=0.1

�d 0.162=0.1

NominalClearance


NominalClearance


1989


Clearance Table

Gearing for Auxiliary Drives

Siehe auch Blatt 0330/15.1

SEE ALSO SHEET 0330/15.1



1

2

3

=

=

=

0.47

0.40

0.38

4 = 0.340.100.20

0.120.26

0.140.26

0.100.21

* = due to wear

normal max.* normal max.*Backlash of teeth

1989


Clearance Table

Gearing for Auxiliary Drives

d

m1 =

0.3

0.2

= 50

m = 60

d1 = 0.1750.110

0.1360.06

g = 1.0

h =

0.5

1.00.5

i = 0.2

k =

0.15

0.220.14

0.3

0.3

normal max.*

5 = 0.300.100.20

NominalClearance


NominalClearance


Backlash of teeth

1989


Clearance Table

Intermediate Shaft for Auxiliary Drives

b

aa1

95.7967

1Siehe auch Blatt 0330/11.1SEE ALSO SHEET 033/11.1

6

a1=a

b

0.2= 100 0.1060.036

= 0.80.3

normal max.*

1 = 0.47

normal max.*

6 = 0.500.120.26

0.120.26

NominalClearance

normal, newmax. due*

dimensionNominal

Clearance

normal, newmax. dueto weardimension to wear

1989


Clearance Table

Starting Air Distributor

90.7026

a1 a

b1 b

2

1

b = 55

a1 =0.11a = 50

b1

� 0.175 0.30

0.15

1.00

=0.06 � 0.09

1

2

= 1.0

= 0.45 �0.80

NominalClearance


NominalClearance


1989



Clearance Table

Roller Guides to Fuel Injection and Actuator Pumps

b = 300

a1 =0.03

�e1+ e2 = 0.9

�d1 0.080a = 70 -0.06-0.03

-0.34-0.28

B = 300 +0.0520

c = 120 -0.058-0.036

C = 120 +0.057

b1+b2 = 0.28�0.392

c1 =0.069

� 0.09

� 0.115

0.35

0.50

0.16

d = 102 -0.058

+0.022D = 102

e = 140 -0.30-0.60

= 140 +0.30+0.20E

= 0.036

0.5

0.12

1.3

+0.033

-0.036

0 �d2 0.069= 0.012 0.09

0.9

NominalClearance


NominalClearance


1989


Clearance Table

Gear Pump for Cylinder Lubricating Pump Drive



b

0.40a = 38 a1 = 0.050

=

0.009 0.15

max.

0.20

min.max. 0.130

0.055 0.20

1

2

=

=

min.max.

min.max.

0.140.26

0.060.13

NominalClearance


NominalClearance


1989



Clearance Table

Balancer Drive Units 2nd Order

b1

= �

e = 0.41 � 0.60

1f =

0.75a = 230

0.20 0.90

0.3 � 0.7

0.45c = 425

d = 139.7

a1 = 0.19 �0.32

+b2

= 0.6 � 1.4

c1 = 0.41 � 0.60

d1

0.45

2.0

0.75

1.5

e = 425

f = 139.7

g = 330

1

1g = � 0.300.23

1.5

NominalClearance


NominalClearance


1989


Clearance Table

Integrated Balancer 2nd order

b

a = 310 a1 =

=

1.50

0.30b = 220

-0.2-0.3 +a2 0.60� 1.10

1 0.121 � 0.20normal max.

1

2

= 0.48 �0.69

= 0.36 �0.57

0.90

0.75

NominalClearance


NominalClearance


Backlash of teeth

1989



Tightening Values of Important Screwed ConnectionsD

eta

ils

on

shee

t N

o.

Description

Th

rea

d

Wit

h h

ydr.

ja

cks

pre

ssu

re (

ba

r)

Tig

hte

nin

g t

orq

ue

(Nm

)

Elo

nga

tion

(m

m)

Tig

hte

nin

g a

ngle

�

Lu

bri

can

t

1

1112/1 Foundation bolts (metal and syntheticchocks)

M64x4 600 MOLYKOTE G

1132/1 Main bearing, jack bolts M125x6 600

1132/2 Main bearing, nut for waisted stud M56 35� MOLYKOTE G

1903/1 Tie rod M160x6 600

1st step 350 bar

MOLYKOTE G

Cylinder jacket bolting�up / bolts

Cylinder jacket bolting�up / fitted bolts

M64

M64

Elongation 0.55 ± 0.04 mm Oil

Elongation 0.45 ± 0.03 mm Oil

2

2124/2 Waisted bolts for filling piece in cylinder liner M10 1st step 5 Nm

1st step to 2nd step 15�no additional lu�bricant required

2708/2 Cylinder cover, nut for waisted stud M100x6 600 (330�) Oil

2722/1 Fuel injection valve, screwed connection withcylinder cover

(see instructions on sheet 2722/1)

M12 Tighten spring packet tosolid block length, thenloosen it by ¼ turn = 90�

MOLYKOTE G

Fuel injection valve, cap nut to 2P�nozzle

(loosen cap nut after initial assembly and then repeattightening procedure)


M64x2 1st step when� using a L'ORANGE test stand:

pre�tighten with 20 bar orhammer blow

� using a O.M.T. test bench:pre�tighten to 150 Nm

1st step to 2nd step 45�

MOLYKOTE G

2728/1 Starting valve spindle, nut

(spindle thread not to be lubricated in the region oflocking ring)

M30x2 (800) 55� MOLYKOTE G

Starting valve, nut for waisted stud M27 (750) 90� MOLYKOTE G

2751/1 Exhaust valve cage, nut for waisted stud M72x6 600 (150�) Oil

2751/2 Exhaust valve, screw for grooved valve conepiece

M16 180 MOLYKOTE G

Exhaust valve, screws for cylinder M16 170 MOLYKOTE G

Indicator valve, screws M20 80 MOLYKOTE G

Flywheel, nuts for coupling bolts M85x4 35� MOLYKOTE G

Crankshaft division, nuts for coupling bolts M85x4 50� MOLYKOTE G

� The values in parentheses (...) are for information only, to be used for comparison.

� The screwed connections must be tightened in accordance with the values not in parentheses.



Lu

bri

can

t

Elo

nga

tion

(m

m)

Tig

hte

nin

g a

ngle

�

Tig

hte

nin

g t

orq

ue

(Nm

)

Wit

h h

ydr.

ja

cks

pre

ssu

re (

ba

r)

Th

rea

dDescription

Det

ail

s on

shee

t N

o.

2751/2 Crankshaft�-�vibration damper, nuts for cou�pling bolts

M85x4 35� MOLYKOTE G

Crankshaft�-�counterweight, nuts for cou�pling bolts


Crankshaft�-�propeller shaft, nuts for cou�pling bolts


3

3146/1 Fixing bolt for axial detuner with bedplate M36 (2270) 50� MOLYKOTE G

3303/1 Connecting rod, stud for top end bearing M76x6 600 Oil

1st step 400 bar (gap = 0 mm)

2nd step 600 bar

Check: 1st step to 2nd step (23�)

Connecting rod, stud for bottom end bearing M90x6 600 Oil


2nd step 600 bar


Connecting rod (1�part), stud for bottom endbearing

M100x6 600 Oil


2nd step 600 bar


3403/1 Piston rod�-�crosshead, waisted screw M64 30� MOLYKOTE G

3403/3 Piston rod�-�piston crown, waisted screw M42 (1200) 50� MOLYKOTE G

�Piston rod�-�spraying plate, waisted screw M16 1st step 30 Nm

1st step to 2nd step 30�Oil

4

4103/2 Intermediate gear bearing for camshaftdrive, waisted screw

M48 45� MOLYKOTE G

Screwed connection, gear rim - hub of inter�mediate wheel

(nut secured with LOCTITE No. 262)

M42x3 75� no additional lu�bricant required

4103/3 Gear wheel on crankshaft, waisted screw M64x4 Elongation 1.05±0.05 mm MOLYKOTE G



4.01 / UG Wärtsilä NSD Switzerland Ltd


Lu

bri

can

t

Elo

nga

tion

(m

m)

Tig

hte

nin

g a

ngle

�

Tig

hte

nin

g t

orq

ue

(Nm

)

Wit

h h

ydr.

ja

cks

pre

ssu

re (

ba

r)

Th

rea

dDescription

Det

ail

s on

shee

t N

o.

4203/1 Reversing servomotor, fastening betweenshaft and wing

M42 40� no additional lu�bricant required

Reversing servomotor, longitudinal fastening M24 30� no additional lu�bricant required

Balance disc�camshaft, waisted screw forvibration damper (8-12 cylinder)

M24 (655) 45� no additional lu�bricant required

Waisted stud for fuel pump housing M64 60� MOLYKOTE G

Waisted screw for camshaft bearing in fuelpump housing


4203/6 Gear wheel in 2�part on camshaft, screwedconnection

(nut secured with LOCTITE No. 262)

M42x3 75� no additional lu�bricant required

5

5512/1 Fuel pump block, hexagon nut for waistedstud


Fuel pump block, pressure nipple for valves M39x2 300 MOLYKOTE G

(loosen pressure bush after initial assembly and thenrepeat tightening procedure)

Fuel pump block, screwed connection forvalve cover

M12 60 MOLYKOTE G

5512/4 Nipple for plunger bush M160x3 4 teeth MOLYKOTE G

(loosen nipple after initial assembly and then repeattightening procedure)

5513/1 Actuator pump, hexagon nut for waisted stud M33 (620) 90� MOLYKOTE G

8

8733/1 Cap nut for screwed connection of fuel pres�sure piping, fuel distributor - fuel injectionvalve


M35x1.5 250 Oil

When using other jacks, the required pressure in bar must be calculated in relation to the effective jack piston surface!

Conversion factor: 1 Nm = 0.102 mkp 1 bar = 1.02 kp/cm2

When using torque machine, please pay attention to the instructions of the respective manufacturers.



Wärtsilä NSD Switzerland Ltd UG / 4.01



Tightening Instructions for Normal Screws

This table is valid for all screws that are not considered on sheet 0352/1.

Attention: These tightening instructions are valid only if:

a) the screws are made of the 8.8 material.b) the threads have been lubricated with oil.

Remark: It is recommended to lubricate the threads for screws which come into contact with 'hot parts' like ex�haust pipings, expansion pieces, etc. with a heat�resisting lubricant, e.g. THREAD GARD.

Screw thread Tightening torque Nm

M8 20

M10 40

M12 70

M14 110

M16 170

M18 250

M20 350

M22 450

M24 600

M27 900

M30 1200

M33 1600

M36 2100

M39 2500

M42 2900

M45 3300

M48 3700

M52 4100

M56 4600

M60 5200

Wärtsilä Switzerland Ltd 1999


Waisted studs must be tightened according to the values in the following diagram:

� Before fitting a waisted stud clean and degrease the stud thread and the tap hole.

� Screw in the stud right to the bottom of the tap hole, and tighten.

Attention: Always utilize a stud driver or two nuts. Tools like a pipe wrench etc. which would damage the studshank must never be used.

For the protection of the stud in the cylinder jacket and cylinder cover, fill the annular space above the thread with anon�hardening sealing compound (see sheet 2751/1).

Anzugsmomente für Dehnbolzen

TIGHTENING TORQUE FOR WAISTED STUDS

97.8103

Anzugsmomente für Dehnbolzen

TIGHTENING TORQUE FORWAISTED STUDS

Gewindedurchmesser (mm)

THREAD DIAMETER (mm)

Gewindedurchmesser (mm)

THREAD DIAMETER (mm)

Anzugsm

om

ent in

Nm

TIG

HT

EN

ING

TO

RQ

UE

Nm

Anzugsm

om

ent in

Nm

TIG

HT

EN

ING

TO

RQ

UE

Nm

400

300

200

10

100

20 30 40 50 60

3500

3000

2500

2000

1500

1000

0

500

10 3020 40 50 60 70 80 100 11090 120

0

Wärtsilä Switzerland Ltd1999


Masses (Weights)

Individual Components per Piece in kg

Group Component kg

1132 Main bearing cover (narrow) for 4 to 7 cylinder 400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132 Main bearing cover (narrow) for 8 to 12 cylinder 471. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132 Main bearing cover (wide) 710. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132 Main bearing shell (narrow) per pair including shims 251. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132 Main bearing shell (wide) per pair including shims 463. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132 Thrust bolt to main bearing complete 188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1203 Thrust bearing pad 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1903 Tie rod short complete 1437. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1903 Tie rod long complete 1887. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1903 Tie rod nut 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1903 Intermediate ring to tie rod nut 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

End cylinder jacket (driving end) 18 400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End cylinder jacket (free end) 18 400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder jacket 15 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder jacket intermediate piece 8800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End cylinder jacket complete 28 380. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder jacket complete 25 280. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2124 Cylinder liner 6100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124 Support ring 2610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124 Antipolishing ring 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2303 Gland to piston rod 309. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2708 Cylinder cover: waisted stud with nut (8 pieces total = 960 kg) 120. . . . . . . . . . . . . . . . . . . . . . . 2708 Water guide ring 219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708 Cylinder cover without valves 5010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708 Cylinder cover complete with valves 7530. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2722 Fuel injection valve complete 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2728 Starting valve complete 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2740 Relief valve complete 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2751 Exhaust valve complete 2205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751 Exhaust valve spindle 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3103 Crankshaft semi�built 4 Cyl. including thrust bearing shaft 110 500. . . . . . . . . . . . . . . . . . . . . . . . 3103 Crankshaft semi�built 5 Cyl. including thrust bearing shaft 132 200. . . . . . . . . . . . . . . . . . . . . . . . 3103 Crankshaft semi�built 6 Cyl. including thrust bearing shaft 153 900. . . . . . . . . . . . . . . . . . . . . . . . 3103 Crankshaft semi�built 7 Cyl. including thrust bearing shaft 175 600. . . . . . . . . . . . . . . . . . . . . . . . 3103 Crankshaft semi�built 8 Cyl. including thrust bearing shaft 208 900. . . . . . . . . . . . . . . . . . . . . . . . 3103 Crankshaft semi�built 9 Cyl. including thrust bearing shaft 230 700. . . . . . . . . . . . . . . . . . . . . . . . 3103 Crankshaft semi�built 10 Cyl. including thrust bearing shaft 252 500. . . . . . . . . . . . . . . . . . . . . . . 3103 Crankshaft semi�built 11 Cyl. including thrust bearing shaft 274 300. . . . . . . . . . . . . . . . . . . . . . . 3103 Crankshaft semi�built 12 Cyl. including thrust bearing shaft 296 100. . . . . . . . . . . . . . . . . . . . . . .



Group Component kg

Flywheel (light) 4400 - 10 420. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel 19 800 - 22 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3303 Connecting rod complete 6200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Connecting rod shank 3580. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Lower bearing half to bottom end bearing 640. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Upper bearing half to bottom end bearing 940. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Bolt with nut to bottom end bearing 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Upper bearing half to top end bearing complete with waisted studs 591. . . . . . . . . . . . . . . . . . . . 3303 Bearing shell to top end bearing 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Linkage lever to piston cooling & crosshead lubrication complete 184. . . . . . . . . . . . . . . . . . . . .

1�part connecting rod:

3303 Connecting rod complete 6036. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Connecting rod shank 4200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Bearing cover with waisted studs to bottom end bearing 981. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Bearing shell to bottom end bearing 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303 Bearing cover with waisted studs to top end bearing 591. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3326 Crosshead pin without slippers 3118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326 Guide shoe to crosshead pin 565. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3403 Working piston complete with piston rod 3912. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403 Piston crown 1085. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403 Piston skirt 232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403 Piston rod 2374. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4103 Gear wheel on crankshaft complete 3278. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103 Intermediate gear wheel of camshaft drive complete with journal pin 2981. . . . . . . . . . . . . . . . . 4103 Gear wheel on camshaft 4-7 Cyl. complete with shaft and gear wheels 3934. . . . . . . . . . . . . . . 4103 Gear wheel on camshaft 8-12 Cyl. complete with shaft and gear wheels 3846. . . . . . . . . . . . . .

4203 Camshaft 4 Cyl. with cams, shaft coupling and gear wheel 12 970. . . . . . . . . . . . . . . . . . . . . . . . . . 4203 Camshaft 5 Cyl. with cams, shaft coupling and gear wheel 15 878. . . . . . . . . . . . . . . . . . . . . . . . . . 4203 Camshaft 6 Cyl. with cams, shaft coupling and gear wheel 17 278. . . . . . . . . . . . . . . . . . . . . . . . . . 4203 Camshaft 7 Cyl. with cams, shaft coupling and gear wheel 20 440. . . . . . . . . . . . . . . . . . . . . . . . . . 4203 Camshaft 8 Cyl. with cams, shaft coupling and gear wheel 21 907. . . . . . . . . . . . . . . . . . . . . . . . . . 4203 Camshaft 9 Cyl. with cams, shaft coupling and gear wheel 24 457. . . . . . . . . . . . . . . . . . . . . . . . . . 4203 Camshaft 10 Cyl. with cams, shaft coupling and gear wheel 26 112. . . . . . . . . . . . . . . . . . . . . . . . . 4203 Camshaft 11 Cyl. with cams, shaft coupling and gear wheel 29 374. . . . . . . . . . . . . . . . . . . . . . . . . 4203 Camshaft 12 Cyl. with cams, shaft coupling and gear wheel 30 317. . . . . . . . . . . . . . . . . . . . . . . . . 4203 Cam to fuel injection pump 192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203 Cam to exhaust valve actuator pump 273. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4220 Bearing housing to camshaft drive 2645. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5103 Woodward governor (PGA-200) 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5512 Fuel pump body complete without plunger and guide bushes 823. . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger VTR 564 complete 6300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger VTR 714 complete 12 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Group Component kg

6545 Auxiliary blower complete with electric motor 920 - 1189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545 Suction space 307 - 361. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6606 Charge air cooler GEA-K110 / Serck 3200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606 Charge air cooler GEA-K220 / Serck 4300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air duct before charge air cooler to VTR 564 1116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air duct before charge air cooler to VTR 714 1745. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7708 Balancer weight (balancer 4-5 Cyl.) complete with pinion and pin 2501. . . . . . . . . . . . . . . . . . . 7708 Balancer weight (balancer 6 Cyl.) complete with pinion and pin 2263. . . . . . . . . . . . . . . . . . . . . . 7708 Flexible coupling to balancer 4-5 Cyl. 3070. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7708 Flexible coupling to balancer 6 Cyl. 2425. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7708 Roller chain to balancer 4½" 642. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust manifold 4 Cyl. 7500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold 5 Cyl. 8350 - 8650. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold 6 Cyl. 9300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold 7 Cyl. 10 700. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold 8 Cyl. 14 900 - 15 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold 9 Cyl. 15 600 - 15 750. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold 10 Cyl. 16 600 - 17 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold 11 Cyl. 17 900. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold 12 Cyl. 18 700. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compensator DN 350 after the exhaust valve 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compensator DN 800 between the exhaust manifolds 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Dimensions and Material Specification of O�Rings and Rubber Rings G

rou

p i

n

Co

de�

Bo

ok

Component where the O�ringor the rubber ring is installed

Th

ick

nes

sØ

mm

I.D

.Ø

mm

Material

191 Tie rod 6.99 151.77 NBR 70 Sh

211 Relief valve to cylinder block type EVT224 8 210 Nitrile 70 Sh

214 Cylinder liner / guide portion in cylinder jacket of cylinder blockrespectivelyCylinder liner / water guide jacket

9

9

990

1130

Silicon (MVQ)

Silicon (MVQ)

214 Lubricating quill 3.53 36.09 FPM 70 Sh

231 Piston rod gland / housing 7 600 Rubber (Si) seaml.

270 Cylinder cover / water guide jacket 9 1130 Silicon (MVQ)

272 Fuel injection valve / shoulder nut 3.53 36.09 FPM 70 Sh

274 Starting valveStarting valveStarting valve

6.991.781.78

132.721410.82

NBR 70 ShNBR 70 ShFPM 70 Sh

275 Exhaust valve / valve drive housing, vent screwExhaust valve / valve drive housingExhaust valve / valve cageExhaust valve / valve cageExhaust valve / valve cageExhaust valve / guide bush in valve cageExhaust valve / piston to air cylinderExhaust valve / bush, oil transition

2.626.996.996.996.995.335.333.53

13.94367.67532.26380.37291.47110.4978.7432.92

FPM 70 ShMVQ 50 ShFPM 90 ShFPM 90 ShFPM 70 ShFPM 70 ShFPM 70 ShMVQ 50 Sh

277 Relief valve to cylinder cover 5.33 43.82 NBR 90 Sh

340 Working piston / oil pipeWorking piston / oil pipeWorking piston / spraying plateWorking piston / spraying plate

6.995.3399

135.89215.27550490

MVQ 50 ShMVQ 50 ShRubber (Si) seaml.Rubber (Si) seaml.

421 Camshaft / oil connections to slide ringCamshaft / oil connections to slide ringCamshaft / sleeve

5.335.336.99

37.4743.82

608.08

NBR 70 ShNBR 70 ShNBR 70 Sh

428 Gear box for auxiliary driveGear box for auxiliary drive

2.622.62

12.3715.54

NBR 70 ShNBR 70 Sh

434 Solenoid valveStarting air distributor / valve blockStarting air distributor / flangeStarting air distributor / guide flangeStarting air distributor / casing

1.783.535.335.337

1428.1740.6488.27

177.17

NBR 70 ShNBR 70 ShNBR 70 ShNBR 70 ShNBR 70 Sh

UG 1994


Material

I.D

.


Ø m

m

Th

ick

nes

s

Gro

up

in

Ø m

m

Co

de�

Bo

ok

436 Shut�off valve for starting air / casingShut�off valve for starting air / coverShut�off valve for starting air / valve for SLOW TURNINGControl valve / coverControl valve / cover

6.996.995.333.532.62

202.57177.1762.8744.0413.94

NBR 70 ShNBR 70 ShNBR 70 ShNBR 70 ShNBR 70 Sh

436-1 Valve for SLOW TURNING / bushValve for SLOW TURNING / coverValve for SLOW TURNING / casingValve for SLOW TURNING / coverValve for SLOW TURNING / bushValve for SLOW TURNING / control valveValve for SLOW TURNING / control valve

5.335.335.335.333.532.623.53

78.7459.6969.2243.8263.0913.9444.04

NBR 70 ShNBR 70 ShNBR 70 ShNBR 70 ShNBR 70 ShNBR 70 ShNBR 70 Sh

451 Reversing valve 5.33 110.49 NBR 70 Sh

460 Control air supply 1.78 9.25 NBR 90 Sh

461 Valve group for reversing blocking 3.53 20.22 NBR 70 Sh

461-1 Valve group for governor and air cylinder 2.62 4.42 Nitrile 70 Sh

466 Pick�up 5.33 50.17 NBR 70 Sh

469 Pneumatic logic unitPneumatic logic unit

22.62

104.42

Rubber 750Nitrile 70 Sh

532 Safety cut�out device / casingSafety cut�out device / valve plate

3.534.42

72.622.62

NBR 70 ShNitrile 70 Sh

554-1 Fuel pump / locking pin of roller guide 3.53 18.64 NBR 70 Sh

554-2 Fuel� and actuator pump / casing 5.33 196.22 NBR 70 Sh

558-1 Relief valve to fuel pump 3.53 66.27 FPM 90 Sh

581-3 Regulating linkage / air cylinder, cover and intermediate piece 3.53 72.62 MVQ 50 Sh

646 Receiver connection 12 720 Viton 70 Sh

725 Gear pump / casingGear pump / inlet and discharge valve

33

15050

Rubber 750Rubber 750

726 Cylinder lubricator control / flow regulating valve 3.53 26.57 NBR 70 Sh

770-3 Balancer / guide studCylinder cooling water air separator / throttle orifice

3.537

32.92266.07

NBR 70 ShNBR 70 Sh

UG1994


Material

I.D

.


Ø m

m

Th

ick

nes

s

Gro

up

in

Ø m

m

Co

de�

Bo

ok

843 Pre�lubricating valve 2 10 Rubber 750

844-1 Hydraulic piping of exhaust valveHydraulic piping / exhaust valveHydraulic piping / exhaust valveOil leakage return

5.335.335.336.99

100.97113.67123.19148.59

NBR 70 ShNBR 70 ShNBR 70 ShNBR 70 Sh

870 Priming valve on the fuel distributorPriming valve on the fuel distributor

1.783.53

9.2521.82

NBR 70 ShNBR 70 Sh

877 Fuel pressure retaining valve 2.62 18.72 NBR 70 Sh

877-1 Fuel suction / spill piping shut�off valve 3.53 17.04 Viton

Tool 94215 Hydraulic tensioning device for cylinder cover 2.62 12.37 FPM 90 Sh

Tool 94277 Setting device for relief valveSetting device for relief valve

1.783.53

9.2521.82

NBR 70 ShNBR 70 Sh

UG 1994



Dimensions and Material Specification of the Piston and Rod Seal Rings

Seal Ring SupportRing

Gro

up

in

Co

de

Bo

ok

Component where the Piston Seal Ring (PSR)or the Rod Seal Ring (RSR) is installed S

ort

Ø o

f ro

d o

ro

f cy

lin

der

wid

th o

fse

al r

ing

Ø

x Tu

rco

n/M

oly

bd

aen

PT

F/M

oS

2/G

lass

PT

F/B

ron

ze

Vit

on

FP

M70

±5

Sh

ore

A

Nit

rile

NB

R70

±5

Sh

ore

A

113 Thrust bolt / crankshaft bearing PSR 160x3.8 x x

275 Exhaust valve / piston to air cylinder

Exhaust valve / valve guide bush

PSR

RSR

280x7.8

80x6.1

x

x

x

x

434 Starting air distributor

Starting air distributor

PSR

RSR

100x3.8

75x3.8

x

x

x

x

436 Shut�off valve for starting air / valve PSR 190x5.8 x x

436-1 Valve for slow turning / piston

Valve for slow turning / piston

PSR

PSR

70x3.8

55x3.8

x

x

x

x

451 Reversing valve / valve

Reversing valve / cover

PSR

RSR

100x3.8

30x2.8

x

x

x

x

532 Safety cut�out device / piston

Safety cut�out device / casing

PSR

RSR

80x3.8

28x2.8

x

x

x

x

581-3 Air cylinder to regulating linkage / piston

Air cylinder to regulating linkage / cover

Air cylinder to regulating linkage / intermediate piece

PSR

RSR

RSR

80x3.8

40x2.8

28x2.8

x

x

x

x

x

x

843 Valve to cylinder oil pre�lubrication

Valve to cylinder oil lubrication

PSR

PSR

30x2.8

40x2.8

x

x

x

x

Cylinder

Piston

Bush

Rod

Support ring

Seal ring

Width

WidthSeal ring

Support ring

��

Piston Seal Ring (PSR) Rod Seal Ring (RSR)



Too

l N

o.

Component where the Piston Seal Ring (PSR)or the Rod Seal Ring (RSR) is installed S

ort

Ø o

f ro

d o

ro

f cy

lin

der

wid

th o

fse

al r

ing

Ø

x Tu

rco

n/M

oly

bd

aen

PT

F/M

oS

2/G

lass

PT

F/B

ron

ze

Vit

on

FP

M70

±5

Sh

ore

A

Nit

rile

NB

R70

±5

Sh

ore

A

94145 Foundation bolt jack / piston PSR 130x3.8 x x

Foundation bolt jack / cylinder RSR 85x3.8 x x

94180 Tie rod pre�tension jack / piston PSR 380x5.8 x x

Tie rod pre�tension jack / cylinder RSR 220x5.8 x x

94215 Cylinder cover pre�tension jack / piston PSR 280x5.8 x x

Cylinder cover pre�tension jack / cylinder RSR 140x3.8 x x

94252 Valve cage pre�tension jack / piston PSR 210x5.8 x x

Valve cage pre�tension jack / cylinder RSR 120x3.8 x x

94260 Valve seat withdrawing device / piston PSR 160x3.8 x x

Valve seat withdrawing device / cylinder RSR 90x3.8 x x

94314 Bottom end stud pre�tension jack / piston PSR 200x5.8 x x

Bottom end stud pre�tension jack / cylinder RSR 140x3.8 x x

94315 Top end stud pre�tension jack / piston PSR 200x5.8 x x

Top end stud pre�tension jack / cylinder RSR 120x3.8 x x

94424 Mounting tool for press�seat components on camshaft PSR 100x3.8 x x

94706 Pre�tensioning jack for balancer / piston PSR 140x3.8 x x

Pre�tensioning jack for balancer / cylinder RSR 80x3.8 x x

1�part connecting rod:

94314 Pre�tensioning jack to bottom end bearingSupporting ring (piston) � 260 x � 247.8 TurconO�ring (piston) � 240.64 x 6.99 NBR 90 Sh

Supporting ring (cylinder) � 130 x � 120.6 TurconO�ring (cylinder) � 120.02 x 5.33 NBR 90 Sh

98.7510

O-ring Supporting ring t

s

i∅o∅

i∅o∅

4.01 / UG Wärtsilä Switzerland Ltd


Maintenance Schedule

Inspection and Overhaul Intervals (Guidelines)

Sheet Component Work to be carried out Intervals

0

0900/1 Lubricating oil - Laboratory analysis 3000 Op. h (operatinghours)

Cooling water - Check concentration of inhibitor(as per supplier's instructions)

1

1112/1 Bedplate - Check pre�tension of foundation bolts,first time after 1500 Op. h

12 000 Op. h

Crankcase - Visual examination 1500-3000 Op. h

1132/2 Main bearing - Remove bearing upper half for inspection according toclassification society

- Remove bottom bearing shell for inspection acc. to class. society

1203/1 Thrust bearing - Check axial and radial clearances 6000-8000 Op. h

- Check bottom drain for free passage 6000-8000 Op. h

1224/1 - Remove thrust bearing pads for inspection acc. to class. society

1903/1 Tie rod - Check pre�tension, first time after one year(if necessary re�tension)

24 000-30 000 Op. h

2

2124/1 Cylinder liner - Establish wear in bore (in fitted condition) at every piston removal

2124/2 - Remove cylinder liner as required

- Replace O�rings at every removal

- Replace (soft iron) joint ring between cylinderliner and cylinder cover

at every piston removal

- Water guide jacket, replace O�rings at every piston removal

- Check condition of antipolishing ring (if fitted) at every piston removal

2124/3 - Grind off wear ridge in bore at every piston removal

- Clean scavenge ports and refinish their edges as required

- Refinish lubricating grooves as required

2136/1 Lubricating quill

and accumulator

- Check function and tightness

- Check function of non�return valves


at every liner removal

- Replace O�rings

- Check diaphragm of accumulator

at every liner removal


2303/1 Piston rod gland - Clean rings, establish wear at every piston removal

2708/1 Cylinder cover - Check combustion space for damage at every piston removal

UG / 2.05Wärtsilä Switzerland Ltd


Sheet IntervalsWork to be carried outComponent

2722/1 Injection valve - Check externally for tightness before starting engineafter a longer standstill

- Check spray pressure, tightness and condition ofnozzle tip (life time about 6000 Op. h)

3000 Op. h

2728/1 Starting valve - Check piping before valve during operation,if it is too hot: dismantle starting valve

from time to time

- Remove and dismantle one starting valve atrandom. From its condition determine time ofoverhaul for remaining valves

6000-8000 Op. h

2740/1 Relief valve to

cylinder cover

- Check, dismantle, assemble and set 18 000 Op. h

2751/1to

Exhaust valve - General inspection of valve housing, valvespindle and valve seat(without dismantling of exhaust valve)


2751/4 - Valve spindle, check condition and wear(if necessary regrind seat by machining)

24 000-36 000 Op. h

- Check piston seal ring / air spring & rod seal ring /guide bush

24 000-36 000 Op. h

- Valve seat, check condition and wear(if necessary regrind seat by machining)

24 000-36 000 Op. h

3

3103/1 Crankshaft - Measure crank deflection(always in case of grounding of the ship as well asbefore and after every docking)

6000-8000 Op. h

3130/1 Torsional vibration

damper

- Take a silicon oil sample from viscous vibrationdamper (based on results of 1st sample, intervalfor taking further samples will be decided)

first time after 15 000 -18 000 Op. h

3146/1 Axial damper - Dismantling and inspection 36 000-48 000 Op. h

Turning gear - Inspection interval acc. to instructions ofturn. gear manufacturer

0330/5 Connecting rod

bearings

- Check bearing clearances 6000-8000 Op. h

3303/2 - Inspect bottom end bearing(life time of shell to 1�part connecing rod60 000-72 000 Op. h)

30 000-36 000 Op. h oracc. to class. society

3303/3 - Inspect top end bearing 30 000-36 000 Op. h oracc. to class. society

3326/1 Guide shoe,

Crosshead pin

- Check clearances 6000-8000 Op. h

3326/2 - Remove crosshead as required




3403/1 Piston - Remove, clean and measure ring grooves(cylinder liner with antipolishing ring andchrome�ceramic uppermost piston ring)

18 000-20 000 Op. h

- Remove, clean and measure ring grooves(cylinder liner without antipolishing ring)

12 000-14 000 Op. h

- Check tightness on piston in situ with running oilpump, visual check through scavenge ports

after refitting

3403/3 - Dismantling and assembling (open and cleancooling space, min. one piston every three years)

as required

3403/4 - Check condition of piston top surface at every piston removal

- Visual check through scavenge ports to piston,piston rings and cylinder liner(rotate crankshaft with turning gear)

1500-3000 Op. h

Piston underside - Check condition of space, clean it as required 1500-3000 Op. h

- Check drains for free passage 1500-3000 Op. h

3425/1 Piston rings - Remove, clean and establish wear rate,if necessary fit new rings


- Replace uppermost piston ring 18 000-20 000 Op. h

4

4103/1 Camshaft driving

wheels

- Check condition of teeth 6000-8000 Op. h

- Check running clearance and backlash of teeth 6000-8000 Op. h

Camshaft bearing - Visual examination of camshaft housing 1500-3000 Op. h

Fuel cam - Check running surface 1500-3000 Op. h

Actuator cam - Check running surface 1500-3000 Op. h

Roller to injection

& actuator pumps

- Check running surface 1500-3000 Op. h

4303/1 Starting air

distributor

- Dismantle, clean and inspect pilot valves for easeof movement

24 000-36 000 Op. h

4325/1 Starting air

shut�off valve and

- Vent after each manoeuvringperiod

Valve for show

turning

- Dismantle, clean and check(particularly seat, springs and seal rings)

24 000-36 000 Op. h

4506/1 Rotation direction

safeguard

- Dismantle, clean and establish wear,functional check

24 000-36 000 Op. h

5

5307/1 Safety cut�out

device

- Dismantle, clean, inspect(if necessary replace sealing and O�rings)

24 000-36 000 Op. h

- Functional check 6000-8000 Op. h

5512/1 Injection pump - Clean, remove and inspect valves 12 000-18 000 Op. h

- Check controls, if necessary re�set 12 000-18 000 Op. h




5512/1 Injection pump - Apply MOLYKOTE paste G to sphericalconnections

weekly

- Check spring link for free movement oneccentric shaft

monthly

- Check wear of spherical bearings monthly

5512/2 - Lap sealing faces of valve covers as required

5512/3 - Check relief valves and set them 24 000-36 000 Op. h

- Check drain bore for relief valve in injectionpump block for leakage during operation as wellas for free passage and for indication of apossible discharge

1500 Op. h

5512/4 - Lap sealing face of guide bush and tighten it as required

- Check at random plungers and bushes 24 000-36 000 Op. h

- Check sealing face between injection pumpblock and plunger bush (check bore) for leakageduring operation

1500 Op. h

5513/1 Actuator pump - Dismantle and check one actuator pump 24 000-36 000 Op. h

6

6420/1 Scavenge air

receiver

- Check and clean air flaps 4000-6000 Op. h

- Clean receiver 4000-6000 Op. h

- Check water drain piping for free passage 1500-3000 Op. h

Exhaust gas

turbocharger

- Wash�cleaning of blower in service (see Operating Manual)

- Wash�cleaning of turbine in service (see Operating Manual)

- Dry cleaning of turbine in service (see Operating Manual)

- Air filter cleaning (�p max. 10 mbar) as required

6545/1 Auxiliary blower - Clean impeller and casing 24 000-36 000 Op. h

- Replace ball bearing 24 000-36 000 Op. h

Scavenge air cooler - Cleaning of scavenge air cooler (air side) inservice at the beginning weekly, later if �p(pressure drop through SAC) reaches 50 mbar(for further instructions see Operating Manual)

as required

6606/1 - Cleaning (water side) on engine at standstill as required

6606/2 - Remove cooler for general overhaul as required

- Check drains for free passage 1500-3000 Op. h




6708/1 Water separator - Check permanent drainage(outlet either air or a mixture of air/water)

daily

- Check water separator elements (if necessaryclean them), check drains for free passage

1500-3000 Op. h

7

7203/1 Cylinder

lubricating pump

- Drain and wash out casing,first time after 1000 Op. h

15 000-20 000 Op. haccording to instructionof pump manufacturer

7403/1 PTO gear box with

GEISSLINGER

coupling


0330/9 - Establish backlash and bearing clearance 6000-8000 Op. h

- External check for oil leakage and clear vents 1500 operating hours

7412/1 - Dismantle and inspect couplingClean and replace all seal rings

18 000-24 000 Op. h

- Overhaul, or replace spring stacks respectively 36 000-48 000 Op. h

7708/1 Balancer drive

elements

- Re�tension roller chain(after fitting new chain, first time after 500 Op. h)

3000 operating hours

- Measure roller chain stretching as required

- Inspection interval and dismantling ofGEISLINGER coupling

acc. to instruction ofcoupling manufacturer

7722/1 Integrated

balancer

(driving end)


0330/17 - Measure backlash of teeth and bearing clearanceof balancer

6000-8000 Op. h

8

8460/1 Hydraulic piping

to exhaust valve

- Recondition sealing faces as required

Starting air piping - Drain (de�water) before and after everymanoeuvring period

Pressure gauges

and pyrometers

- Compare and calibrate according to masterinstruments

6000-8000 Op. h

Fuel and

lubricating oil

filters

- Clean or replace filter elements(depending on make, follow special mainte�nance instructions by manufacturer)

as required

8733/1 Fuel pressure

piping

- Re�condition sealing faces as required



The indicated maintenance intervals must be taken as guidance and may vary depending on the installation. Theproper intervals are subject to the points mentioned below. Experience will show whether these intervals can beextended or must be shortened.

- Environmental and operating conditions

- Heavy fuel oil and lubricating oil qualities (see Operating Manual sheet 0710/1 and 0750/1)

- Engine load

- Fuel, lubricating oil and cooling water care (see Operating Manual sheet 0720/1 and 0760/1)

- Overhaul according to Maintenance Manual

- Genuine spare parts used

- Engine monitoring

- Engines according to specifications of Wärtsilä Switzerland Ltd.

On the engine sectional drawings, sheet 0803/1, those parts are marked with group numbers, as they are found in theMaintenance Manual.

Group numbers exist of the following engine components, although these parts are not marked on the sectionaldrawings:

Engine component Sheet numbers

Lubricating quills and accumulators 2136/1. . . . . . . . . . . . . . . . . . . . . . . . . .

Relief valve 2740/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibration damper 3130/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase 3301/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting air distributor 4303/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting air shut�off valve and valve for slow turning 4325/1. . . . . . . . . . . . .

Rotation direction safeguard 4506/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed governor PGA 200 5103/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety cut�out device 5307/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving shaft to flow control valve of cylinder lubrication 7212/1. . . . . . . . .

GEISLINGER couplings 7412/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated balancer 7722/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



6420/1

6606/1-/2

6708/1

6545/1

7403/1-/2

3103/1

1112/1

2303/1

5512/1-/4

4203/1

4203/2-/5

3326/1-/2

3303/1-/4

3206/1

8460/1

2751/1-/4

8733/1

2728/1

2708/1-/4

3425/1

3403/1-/4

89.7264

ÅÅÅÅÅÅ ÅÅÅÅÅÅÅÅÅÅÅÅÅÅÅ ÅÅÅÅÅÅÅÅÅÅÅÅÅÅÅÅ

ÅÅÅ ÅÅÅÅÅÅÅÅÅÅÅÅ

ÅÅÅ

5.92


7708/1

1132/1

3146/1

1132/2

3303/1

3326/1

2303/1

6545/1

2751/1

2124/1-/3

4103/3

4103/1-/2

1203/11224/1

1903/1

7203/1

2722/1-/3

6545/1

1903/1

4203/6

89.7271

4 - 7 Zylinder-Motoren

UG1994


Taking Oil Samples for Laboratory Analysis

At intervals of approx. 3000 operating hours, a sample should be taken of the engine oil and sent to a laboratory foran analysis.With the oil pump running and the engine oil at operating temperature drain a small quantity of oil from a cock inthe lubricating system to flush out any dirt accumulated in this cock.

Following this take an oil sample in a clean glass for the test.

The receptacle with the sample of oil must be marked with the following information for the laboratory:

- Ship's name or name of plant

- Engine type

- Engine serial number

- Date of sampling

- Operating hours of oil and of engine

- Oil brand and quality

Oil inspection

The condition of the lubricating oil charge or its alteration during operation can be assessed on the basis of someanalysis data. With regular checks a deterioration can be detected at an early stage and remedial measures taken.

The indications for limiting values are to be taken as guiding ones, which should not be exceeded in service, and inthe case of the flash point not fall below (see also sheet 0750/1 of the Operating Manual).

Parameter Unit Limit

Kin. Viscosity at 40 �C mm2/s [cSt] max. 160

Flash point (COC) �C min. 180

Total insolubles m/m [%] max. 2.0

Base Number (BN) mgKOH/g max. 30

Water m/m [%] max 0.5

Recommended test method is IP 316/88.

If one of the limits is reached appropriate remedial action should be considered to correct the situation. Such actionmay be intensified purification (reduction of throughput, adjustment of temperatures), treating in a renovatingtank or partial exchange of the oil charge.

These limits are set out as a guidance. The quality condition of the oil in circulation, however, cannot be fully judgedby a single parameter. Other oil parameters as well must be used in context to be able to find the cause of the prob�lem and the appropriate remedy for correction.

Experience shows that with correctly designed installations and carefully performed oil care measures, generally a

sufficient safety margin to the above values can be maintained.





Bedplate and Tie Rod Group 1

� Bedplate and Thrust Bearing

– Checking the Foundation Bolts 1112/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Main Bearing

– Loosening and Tensioning of Bearing Jack Bolts 1132/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Removing and Fitting of a Main Bearing 1132/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Thrust Bearing

– Checking the Axial Clearance 1203/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Thrust Bearing

– Removal and Fitting of Thrust Bearing Pads 1224/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Tie Rod

– Checking the Tie Rod Pre-tension and Tensioning the Tie Rods 1903/1. . . . . . . . . . . . . . . . . . . . . . . . .




Bedplate and Thrust Bearing

Checking the Foundation Bolts

Tools: Key to Illustration:

1 Feeler gauge 94122 1 Relief valve 11 Nut1 Pre�tensioning jack 94145 2 Vent screw 12 Angel1 HP oil pump 94931 3 Tensioning nut 13 Bush1 HP hose 94935 4 Piston

5 Spacer sleeve K Checking gap6 Nut M Pressure gauge7 Bedplate P HP oil pump8 Foundation bolt R Round bar9 Chock V Relief valve

10 Ship's foundation plate Y Measuring place

The foundation bolts shall be checked atlonger intervals e.g. during overhauls, fortheir tightening condition (see sheet0380/1).

The 'General Application Instructions' for the utilization ofhydraulic pre�tensioning jacks and screw fasteners are appli�cable (see sheet 9403/4).

Working sequence

Tension the foundation bolt with 600 bar and keep pressureconstant. Check with feeler gauge through the gap 'K' ifthere is any clearance between the nut 6 and its seating.

If there is no clearance, this means that the tightening condi�tion of the foundation bolt has remained unchanged sincethe last check. The pressure can be released to zero and thepre�tensioning jack removed.Should however a clearance be found, the nut 6 must betightened down onto its seating with round bar 'R' while thepressure is kept at 600 bar (then check again with the feelergauge for clearance). Lower the pressure to zero and re�move the pre�tensioning jack.

Remark:

Should clearance exist at 600 bar between nut 6 and seatingsurface and the nut can not be tightened down with theround bar, this means that the nut is jammed on the founda�tion bolt and the thread has first to be eased and the boltthread smeared with MOLYKOTE paste.Then the respective foundation bolt has to be tensioned with600 bar, the nut tightened onto its seating and checked forclearance.

95.7994

R

M

2 1

V P(94931)

65Y43

K

7

8

910

11

Gezeichnet für RT58DRAWN FOR RT58

Loosening of foundation bolts

Attention! For loosening, the pre�tensioning jack must be so fitted on the bolt, that a clearance of about 2 mmremains between spacer sleeve and tensioning nut i.e. at 'Y', before beginning to tension the founda�tion bolt (otherwise the hydr. pre�tensioning jack can later not be removed). Then the foundation bolthas to be tensioned with about 620 bar and the nut 6 turned loose by one turn. After releasing the pres�sure to zero, the pre�tensioning jack and later the nut 6 can be removed.

Wärtsilä NSD Switzerland Ltd 9.99


3

M

V

11

9

2 1

P(94931)4Y5

6 R

K

13

7

8

12

10

95.7995

DrucklagerhalterungTHRUST HOLDER

1989


Main Bearing

Loosening and Tensioning of Bearing Jack Bolts

Key to Illustrations:

1 Jack bolt2 Column center part3 Bearing cover4 Vent valve5 Locking wire6 Set screw7 Cylinder8 Nut9 Milled facing for

open end spanner

10 Piston seal ring11 Locking wire12 Shims

D Pressure spaceR Eye boltS Round barT RopeV Relief valve

Tools:

1 Special feeler gauge 941231 Depth gauge 941261 HP oil pump 949313 Pressure gauges (1000 bar) 949322 Connecters 94933

HP hoses 949351 Open end spanner to item 9 AF110

D

94933

A

a2

93.7151

2

10

11

5

94932

6

7

S

94935

8

9

1

94932

3V94931

94933

R

24

T

a1

12 12

10.94


Attention!

Loosening and tensioning the jack bolts may only be undertaken when the engine tie rods are fully tightened tospecification (see sheet 1903/1).The jack bolts are so designed that they must be loosened or tensioned hydraulically, and for which the tools sup�plied with the engine are to be used.

Before detensioning the bearing jack bolts secure these with rope 'T' and eye bolt 'R against falling outward.

L o o s e n i n g the jack bolts

Working sequence: (see Fig. 'A')

- Remove locking wire 11. Unscrew threaded plugs for oil input to cylinders 7, and in their place screw in connect�ers 94933 firmly. Connect these to HP oil pump 94931.

- Tension jack bolts with abt. 620 bar and keep this pressure constant until both nuts 8 have been screwed back byabt. 1 to 2 turns. Release pressure to zero, by opening relief valve 'V' on the pump and unscrew the connecters94933.

- Thread back both nuts 8 until the jack bolts can be removed.

- Close oil input holes again with the threaded plugs to prevent the entry of foreign matter (dirt).

T e n s i o n i n g the jack bolts

Working sequence:

- Compare the three pressure gauges 94932 with a calibrated pressure gauge for correct indications.

- Clean seat faces for spherical thrust bolt ends on bearing cover and in column center part.

- Fit the jack bolts turning their cylinders 7 to such a position that the connecters with pressure gauge can be fitted,tighten nuts 8 with the round bar 'S' (without any extension).

- Screw in both connecters 94933 firmly and connect them to the HP oil pump 94931 by HP hoses 94935.

- Establish distances 'a1' and 'a2' with depth gauge 94126. The difference between the two distances may not ex�

ceed 0.30 mm. If necessary bring the bearing cover 3 to the right position by slightly loosening the nut 8 of thethrust bolt on which side distance 'a' is less, and tighten the nut of the other thrust bolt with round bar 'S' whileholding thrust bolt firm with an open end spanner.

- When the difference between distances 'a1' and 'a2' is within 0.30 mm tighten both nuts with the round bar untilfully seated.

- Remove locking wire 5 and slightly loosen vent valve 4 while actuating the HP oil pump until the air has escapedfrom the pressure space 'D'. Then tighten vent valve 4 again and lock it with locking wire 5.

- Actuate pump and build up a pressure of 600 bar (check whether all three pressure gauges show the same pres�sure). Hold this pressure constant until both nuts 8 have been tightened with the round bar 'S' till fully seated onthe cylinders 7 (check seating with feeler gauge).

- Release the pressure on the pump and measure the distances 'a1' and 'a2'. Should the difference exceed 0.30mm, loosen the jack bolts, adjust the bearing cover correspondingly and repeat the tensioning procedure.

- Finally lock the nuts with locking wire 11, remove the two connecters and close the oil input holes with thethreaded plugs. For safeties sake check with the special feeler gauge 94123 whether sufficient bearing clearance

is available (see Clearance Table sheet 0330/1).

Remark: In case of new jack bolts or such ones which had been dismantled consideration must be given to thefact that for filling the pressure space the oil level in the pump will drop considerably. In case of utiliz�ing a motor driven oil pump the oil level must therefore be carefully watched to avoid a dry�running.

10.94


Main Bearing

Removal and Fitting of a Main Bearing

Tools Key to illustrations

1 Suspension device 94111 1 Main bearing cover1 Roller support 94117 2 Upper bearing shell1 Removal device for bearing shell 94118 3 Crankshaft2 Steel ropes 94119 4 Holding strap1 Girder 94141 5 Lower bearing shell1 HP oil pump 94931 6 Bearing girder1 Distributor piece 94934a 7 Thrust bearing flange3 HP hoses 949352 Hydr. jacks 94936 R Eye bolt1 Dial gauge with magnetic base

Lifting tackle1 Impact ring spanner AF 85

Removal of a main bearing cover 1 and of the upper bearing shell 2

Remark: On eight to twelve cylinder engines, first the thrust bearing casing on the driving end must be removed,prior to the dismantling of No. 1 main bearing cover and shell.Depending on number of cylinders and engine design execution the main bearing cover of the outer�most main bearing one is fastened by two screws instead of with the jack bolts.

- Turn crankshaft 3 (Fig. 'B') to bring the crank web of the respective bearing to approximately horizontal position.Loosen bearing pressure bolts as described in sheet 1132/1 and remove them, as well as possibly fitted retainingscrews to the main bearing cover one.

- Mount roller support 94117, as well as suspension device 94111 as shown in Fig. 'A'.

- Using one rope and lifting tackle lift main bearing cover 1 by only a few millimeters.

Should the upper bearing shell 2 be lifted with the cover, knock the same with a piece of wood or a lead hammeron the bearing collar to separate the shell from the cover.

- Lift now bearing cover (without bearing shell) high enough to permit pulling it with a second rope in the engineaxis (Fig. 'B').

- Using a second lifting tackle and another rope lift the bearing cover out of the engine.

For engines with camshaft drive at the driving end of the engine the instruction for removal of main bearing coverone and two are the same as described above, however in addition the following points have to be observed:

� To remove the main bearing cover 1 (Fig. 'D') in the thrust bearing region, holding straps 4 for the thrust padsmust not be removed.

� Remove piping to thrust bearing lubrication.

� The broader main bearing cover can be removed through the opening of cylinder one.

� The narrow main bearing cover one has to be removed on exhaust side as shown in Fig. 'D'. For this, the end coverof the gear train has to be removed.

The removal of the two types of upper bearing shell 2 are effected the same way as the bearing covers. In order to liftthe shell a eye bolt 'R' have to be driven into the threaded hole on the shell crown (Fig. 'C'). Using a rope, a liftingtackle and roller support 94117 lift upper bearing shell 2 and remove it from the engine crankcase.

Removal of a lower bearing shell 5

Remarks: Girder 94141 is used specially for the removal of the broader lower bearing shell 5. It has however alsoto be used for removing the narrow lower bearing shell in the thrust bearing region. For this an addi�tional jack can be used outside the engine under the crankshaft flange.When removing lower bearing shell never remove at the same time two neighbouring lower bearing

shells.

- For the removal of a lower bearing shell 5 turn the crankshaft to such a position that the lower side of the respec�tive crank is parallel to the bedplate, which corresponds to about 106� before or after T. D.C. (Fig. 'E').

- Place a dial gauge above a crank web near the bearing shell to be removed (if possible dial gauge with magneticbase) and set it to zero.



- Mount removal device 94118 on one separating face of the lower bearing shell and screw fasten it with the specialAllen wrench in the tool set.

- Attach a steel rope to the short hook on removal device 94118 and lead the same outside along the shell collar tothe other side and on to roller support 94117. (If necessary two steel ropes on either side of the bearing shell canbe applied).

- Place girder 94141 on bearing girders 6 of the respective cylinder as shown in Fig. 'E'.

- Place hydraulic jacks 94936 on girder 94141 as per Fig. 'E'. Connect jacks to HP oil pump 94931 and build uppressure to lift the crankshaft by the bearing to be removed. Lift the crankshaft max. to the point where the

neighbouring main bearings show no vertical clearance any more between main bearing cover and crankshaft.

This process is to be checked by means of the dial gauge fitted over the crank web.Keep the pressure at the jacks constant!

- By pulling on the steel rope turn bearing shell 5 out.

- When the bearing shell lies on the crankshaft journal, remove the steel rope and screw eye bolt 'R' into thethreaded holes on the crown of the shell rear surface. Then lift bearing shell 5 and remove it out of the engine bylifting tackle.

Fitting a lower bearing shell 5

Before fitting a lower bearing shell 5 smear its rear surface lightly with MOLYKOTE G paste. Smear crankshaftjournal and running surface of bearing shell lavishly with clean bearing oil. Check to verify that bearing girder 6 isclean in the bore and undamaged.

- Place lower bearing shell with help of eye bolt 'R' and roller support 94117 carefully on the crankshaft journal, i.e.analogous to the removal but in reverse sequence. Make sure that the bearing numbering corresponds with thenumber on the bearing girder.

- Remove eye bolt and lift the crankshaft again as described for the removal, in case it has meanwhile been low�ered.

- Turn in the bearing shell till the separating faces are equidistant from the upper edge of bedplate (measure thiswith a depth gauge).

- Release pressure on oil pump 94931 and remove all tools out of the engine.

Attention! Should a crank web deflection check be made before upper bearing shell and bearing cover 1 are fitted,then care must be taken to prevent the lower shell 5 from turning. Locate the shell temporarily by awooden piece.

Fitting of upper bearing shell 2 and of bearing cover 1

Fitting of upper bearing shell 2 and of bearing cover 1 is effected in reverse sequence to their removal. Great caremust be taken that no dirt is on crankshaft journal and running surface as well as on the rear surface of the bearingshell and bore of bearing cover.Before placing the bearing shell in position smear the crankshaft journal lavishly with bearing oil. The rear surfaceof the bearing shell and the bore of the bearing cover must be clean and dry and free from oil.For lining up the main bearing cover and for tensioning the bearing bolt, the instructions on sheet 1132/1 must befollowed.

On engines, the main bearing covers of which are held by two screws at the DRIVING END, these have to be tight�ened to an tightening angle of 35 � and to be locked with a locking plate.

Check: After fitting of a main bearing shell the following points must be checked:

� Crank deflection (see sheet 3103/1).

� Vertical bearing clearance (see Clearance Table 0330/1).

� Lubricating oil supplied to the main bearing with the oil pump in operation!



A B

C

94117

94117

1

94117

R

94111

2

94111

2

53

1

94111

1

2

96.7000

1989


1

94

111

41

27

12

96.7

001

AntriebsseiteDRIVING END

D

1989

1132/2

.5M

ain

tena

nce

RT

A84C

94931

94117

94118

94936

94117

R

94141

96.7002

94935

5

3

94935

94934a

6

9414194936

94119

5

6

94118

94119

E

�

1989



Thrust Bearing

Checking the Axial Clearance


1 Inside micrometer 94101 1 Coupling flange for 5 Thrust flange1 Feeler gauge 94238 flywheel 6 Crankshaft1 Dial gauge with magnetic base 2 Oil catcher 7 Thrust bearing pads for

3 End cladding (driving end) ASTERN4,4a Holding stirrups 7a Thrust bearing pads for

AHEADf1 Axial clearanceX Checking measure

Should the classification society demand measuring of axial clearance of the thrust bearing flange in the thrust bear�ing, or should other reasons call for it, this can be done in various ways:

Method 1

The total displacement which results from pushing the crankshaft axially both ways until it contacts the thrust bear�ing pads AHEAD and ASTERN, is measured with a clock gauge. This is then checked against the figure marked onthe sheet 'Checking Dimensions' in the engine documents supplied.A possible increase against the nominal figure signifies wear of the thrust bearing pads.

Axial clearances f1 = 0.8 - 1.3 (see clearance table 0330/1)

Method 2

The crankshaft is displaced axially until it rests on the engine side thrust bearing pads (AHEAD) and is then fixed inthis position. The distance between the flywheel coupling flange and the upper part of the oil catcher is measuredwith an inside micrometer at the position indicated (see Fig. 'B').The amount by which the distance 'X' is smaller than that given on the sheet 'Checking Dimensions' corresponds tothe wear of the engine side thrust bearing pads (AHEAD). By displacing the crankshaft axially until it rests on thethrust bearing pads for 'Astern', the inside micrometer can be used to determine the total axial clearance as well.

1989


89.7126

5

4a

6

7a

3

2

4

7

f1

SchubTHRUST

A

1

EVERY 6000 - 8000 OPERATING HOURS THEHOLE IS TO BE CHECKED FOR FREE PASSAGE

Alle 6000 - 8000 Betriebsstunden ist die Bohrungauf freien Durchgang zu kontrollieren

1989


1 2 5 63

94101

96.7003

B

1989



Thrust Bearing

Removal and Fitting of Thrust Bearing Pads


1 Carrier bolt 94155 for 4-7 cylinders 1 Thrust bearing flange 6 Casingswith nut 2,2a Thrust bearing pads 7 Retaining clamp

1 Turning�out device 94155a for 8-12 cylinders 3 Split gear wheel on 8 Oil pipe1 Eye bolt M16 thrust bearing flange 9 Screws

4 Screws5 Screws with spacer S Nut for 94155

sleeves

Removal

Should it become necessary to remove thrust bearing pads, the retaining clamps 7 of the respective row of thrustbearing pads must be removed. To reach these, remove the oil pipes 8 and additionally the two casings 6 for the 4-7cylinder engines, then the retaining clamps 7 can be removed on the required side (see Fig. 'A' and 'B').

The access to the thrust bearing pads being now freed by the removal of the above mentioned parts, insert the car�rier bolt 94155 into the respective drilling of the split gear wheel 3 on the thrust bearing flange and fasten it with thenut 'S' (by only light tightening) in its position (Fig. 'C').

Refer also to the removal alternative according to Fig. 'D' for engines with 8-12 cylinders, in which gear wheel 3 isnot fitted to the thrust bearing flange but instead on the crankshaft coupling (mid�engine). For this removal alterna�tive of the thrust pads turning�out device 94155a has to be used. It has to be fastened on the circumference of thethrust bearing flange with two screws 9. Therefore, threaded holes are provided.

The crankshaft is then to be turned with the turning gear until an eye bolt M16 can be screwed into a pad which canthen be lifted up and taken away.

Remark: When only a few thrust bearing pads are removed the crankshaft is located in its axial position by the re�maining pads. Should however the necessity arise that all thrust bearing pads must be removed then thecrankshaft must be prevented from sliding axially from its specific position. This might happen for exam�ple if the ship is heavily stern trimmed. (To avoid such shifting, insert a piece of hardwood of the samethickness as the pads in the place of the thrust bearing pads).

Fitting

Make absolutely sure that all the thrust bearing pads are meticulously clean and smeared with fresh engine oil; thethrust bearing pads must all be replaced in their original position. Note the numbering of the individual pads. Pleasealso refer to the following sheets for the arrangement of thrust bearing pads on engines with fixed pitch propellers(F.P.P.) and controllable pitch propellers (C.P.P.) respectively.

Fitting the thrust bearing pads for AHEAD operation should pose no problems, as the crankshaft in a sterntrimmed ship rests against the ASTERN thrust bearing pads.For fitting the thrust bearing pads tools 94155 or 94155a respectively can also be utilized. Please note in this respectthat the first pad, when pushed in, rests against the tool. The following thrust bearing pads can then be fitted oneafter the other while simultaneously turning the crankshaft. The thrust bearing pads should slide in without effort totheir end position.With all the thrust bearing pads in position the end ones on the fuel pump side and on the exhaust side must standback by the same distance over the upper edge of the bedplate; the retaining clamps 7 can now be refitted.

When fitting the thrust bearing pads for ASTERN operation it may possibly be necessary to shift the crankshaftslightly in an axial direction towards the free end.

After fitting the thrust bearing pads immediately remove tool 94155 or 94155a respectively.

Attention!

When fitting new or remetalled thrust bearing pads, care must be taken that their thickness (final dimension) corre�sponds exactly with the neighbouring pads.

When replacing a complete row of new or remetalled thrust bearing pads the clearance must be adjusted to theoriginal values (as shown in the Clearance Tables 0330/1) by using the inside micrometer tool 94101 as shown onsheet 1203/1.

1989


A

B

ÅÅÅ ÅÅÅÅÅÅ

6

7

7

2/2a

2/2a

3mm

8

6

4

7

7

4

5

3mm

3mm

3mm

ÅÅÅ 8

ÅÅÅÅ

89.7066

Ab

gass

eite

EX

HA

US

T S

IDE

Gezeichnet für 8–12 Zyl.DRAWN FOR 8–12 Cyl.

Gezeichnet für 4–7 Zyl.DRAWN FOR 4–7 CYL.

1989


I

I

I

I

II - II

II - II I - I

I - I

II

II

II

II

C

DGezeichnet für 8–12 Zyl.DRAWN FOR 8–12 Cyl.


94155a

1

2

94155

2

9

1

2a

3

2a

94155a

2

9

94155

S

2

96.7004

1989


96.7005

SUPPORT SURFACESUPPORT SURFACE


Antriebseite

DRIVING END

Motorseite

ENGINE END

Klötze für ”Zurück”

PADS FOR ”ASTERN”

Klötze für ”Voraus”

PADS FOR ”AHEAD”

”S” voraus

”S” AHEAD

”S” zurück

”S” ASTERN

Propellerschub ”S”

PROPELLER THRUST ”S”

Auflagefläche Auflagefläche

AuflageflächeAuflagefläche

zurück

ASTERN

voraus

AHEAD

zurück

ASTERN

voraus

AHEAD

96.7005

Rechtsdrehender Motor

CLOCKWISE ROTATING ENGINE

Linksdrehender Motor

COUNTER-CLOCKWISEROTATING ENGINE

von Antriebsseite gesehenKlötze auf Motorseite

VIEW FROM DRIVING ENDPADS ON ENGINE SIDE

von Antriebsseite gesehenKlötze auf Antriebsseite

VIEW FROM DRIVING ENDPADS AT DRIVING END

Anordnung der Drucklagerklötze für Motoren mit Festpropeller

ARRANGEMENT OF THRUST BEARING PADS FOR ENGINESWITH FIXED PITCH PROPELLER

1989


96.7006



Antriebseite

DRIVING END

Motorseite

ENGINE END





”S” voraus

”S” AHEAD

”S” zurück

”S” ASTERN





zurück

ASTERN

voraus

AHEAD

zurück

ASTERN

voraus

AHEAD

96.7006

Anordnung der Drucklagerklötze für Motoren mit Verstellpropeller

ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITHCONTROLLABLE PITCH PROPELLER









1989


96.7007



Antriebseite

DRIVING END

Motorseite

ENGINE END





”S” voraus

”S” AHEAD

”S” zurück

”S” ASTERN





zurück

ASTERN

voraus

AHEAD

zurück

ASTERN

voraus

AHEAD

96.7007









Anordnung der Drucklagerklötze für Motoren mit Festpropeller

ARRANGEMENT OF THRUST BEARING PADS FOR ENGINESWITH FIXED PITCH PROPELLER


1989




Antriebseite

DRIVING END

Motorseite

ENGINE END





”S” voraus

”S” AHEAD

”S” zurück

”S” ASTERN





zurück

ASTERN

voraus

AHEAD

zurück

ASTERN

voraus

AHEAD

96.7008

Anordnung der Drucklagerklötze für Motoren mit Verstellpropeller

ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITHCONTROLLABLE PITCH PROPELLER










1989



Tie Rods

Checking the Tie Rod Pre�tension and Tensioning the Tie Rods


2 Pre�tensioning jacks 94180 1 Cylinder jacket 16 Opening for solvent1 HP oil pump 94931 2 Intermediate ring 17 Clamp screw3 Pressure gauges 94932 3 Upper tie rod nut 18 Column2 Connecting piece 94933 4 Allen screw 19 Bed plate1 Oil branch piece 94934 5 Jack cylinder base 20 O�ring1 Distributing piece 94934a 6 Jack cylinder 21 Lower backing ring2 HP hoses 94935 7 Jack piston 22 Lower tie rod nut1 HP hose 94935a 8 Flange ring 23 Bush

9 Belleville spring stack AN Drain slot10 Screw L Thread protrusion11 Vent screw K Checking slot12 Round bar S Measuring place

13,13a Tie rod V Relief valve14 Screw Y Measuring place15 Protection cap Z Checking place

We recommend that about one year after commissioning the engine all the tie rod are checked for their correctpre�tensioning and if necessary to tension them to the specified value. Later it is sufficient to make random checksduring major overhauls.For such checks it is n o t required to loosen the thrust bolts of the crankshaft main bearings nor the clamp screwsof the tie rods.

A

94931

9

10

8Z

7

6

3

Y

2

1

96.7033

V 94934

13

12

K

S

94935a

94932

94180

94933

94932 94935 94932

94934a

54

94933 11


1989


Checking the pre�tension of tie rods

Procedure:

Remove the thread�protecting hoods 15 from all tie rods and clean the contact face of the intermediate ring 2.

Screw both pre�tensioning jacks onto two tie rods lying opposite each other until the lower part of the cylinder 5rests on the intermediate ring 2. If necessary, turn the whole pre�tensioning jack back a little so that the holes in thetie rod nuts are easily accessible. Slightly slacken vent screws 11.

Connect both pre�tensioning jacks with hoses to the high�pressure oil pump and operate pump until any air presentin the pre�tensioning jacks has escaped; then re�tighten vent screws.

Operate pump up to 600 bar and maintain this pressure.

Using a feeler gauge inserted through the checking slot 'K', check at 'S' if there is any clearance between the tie rodnut 3 and the intermediate ring 2.

If any clearance does exist, tighten the tie rod nut with tommy bar 12 until it rests firmly on the intermediate ring(check with feeler gauge) and then release the pressure. If no clearance exists, the pressure can immediately bereleased and the pre�tensioning jacks removed. All the tie rods have to be checked in this manner and, wherevernecessary, the tie rod nut has to be tightened.

After checking has been completed, the tie rod threads have to be protected against corrosion by coating them withnon�acidic grease. Afterwards, the protecting hoods must be screwed on tightly.

Remark: If it is impossible to tighten the tie rod nut with the round bar although there is clearance at 'S', thismeans that the thread is blocked/seized. In this case remove screw plug in bore 16 and press in somereleasing agent or lubricant. Insert a strong brass or copper bar into a hole in the tie rod nut through theslotted orifice in the lower part of the cylinder and first loosen, then tighten the nut with several heavyhammer blows. Make sure, however, that the edge of the hole is not seriously deformed or it will beimpossible to remove the pre�tensioning jack. Seal off the bore 16 again with the screw plug.

After completion of the checks, the pre�tensioning tools have to be preserved and the connections blanked off.Thereafter they are to be stored in a safe place.

Loosening and tightening the tie rods

Should, for some reason or other, tie rods have to be removed, the following points have to be carefully observed:

Tie rods may only be loosened or tensioned when the thrust bolts of the main bearing have been previously loosened(see sheet 1132/1).

The clamping screws 17 must also be removed.

Loosening and tensioning has to be carried out in two steps. The order in which the tie rods are to be loosened ortensioned is shown in schematic illustration (Fig. 'D'), i.e. in pairs, first tie rods a/a, then b/b, etc.

Loosening

The procedure for loosening the tie rods is the same as the one described above for checking pretension, except thatafter being screwed down onto the intermediate ring (2) the pre�tensioning jacks must be released again by 3/4 turnsso that a measurable clearance of 4.5 mm is achieved at 'Y'. At this starting point connect the jacks to the high�pres�sure pump with the hoses and operate the pump until a pressure of 600-620 bar is reached. The tie rod nuts are nowloose and can be unscrewed with the round bar 12 until they touch the pre�tensioning jack cylinders.

Before releasing the hydraulic pressure to zero, it is of great advantage to place a hardwood wedge under the lowertie rod nut in the bed plate, whereby the wedge will take the full weight of the tie rod.The pre�tensioning jacks can now be removed.

1989


Tensioning

Preliminary work:

Clamping screws 17 must not be tightened up.

The lower nut 22 of the tie rod is screwed on.

Clean the seating surface for backing ring 2 and the upper nut 3 and smear with MOLYKOTE paste G.

Smear the tie rod thread for the upper nut 3 lavishly with MOLYKOTE paste G and screw the nut on (check for easythreading).

Screw ring screw into the tie rod and lift carefully till the lower tie rod nut rests snugly against the bearing girder.(The safest way is to use a lifting tackle hooked onto the crane, with which the tie rod can be lifted till the lower nut issnug on its seating, as with the crane the landing of the nut cannot easily be felt and the rope might break.).

In this position tighten the upper tie rod nut with the round bar 12 till firmly seated on the backing ring, separatelifting tackle from tie rod and remove ring screw. (Between bearing girder and lower tie rod nut there must now beno clearance and the lower tie rod nut must e flush with the tie rod end).

Working sequence for tensioning

All points of the preliminaries completed, measure on all tie rods the distance 'L' and record them (see Fig. 'C').

Set pre�tensioning jacks on the two tie rods a/a, so that the jack�cylinder base 5 comes to rest on the backing ring 2(arrange base 5 for easy access to tightening window for nut!)

Join pre�tensioning jacks by hp�hoses to hp�oil pump.

Loosen vent screw 11 on pre�tensioning jacks a little and actuate oil pump till oil flows out bubble�free, then tightenvent screw.

Verify that no play or only very little play remains at 'Z' (Fig. 'A'). If necessary open relief valve 'V' on the pump todrain the oil back into the pump, then screw the jack piston 7 sufficiently down onto the tie rod until the clearance at'Z' is eliminated. This is very important, as otherwise the required pre�tensioning pressure will not be attained.

Actuate the hp�pump and raise a pressure of 350 bar (lst stage), keep pressure constant till the two upper tie rodnuts 3 have been tightened down with the round bar 12 firmly. Then open relief valve 'V' on the pump to lower thepressure to zero and no clearance remains at 'Z'.

In this manner tension all the tie rods in the sequence described before and measure on all the distance 'L' and re�cord them as 'L1'

(reference value 'L1' - 'L' = about 6.0 mm for the short tie rods= about 7.5 mm for the long tie rods)

Repeat the same procedure, but raise the pressure to 600 bar (2nd stage).

Finally measure again the distance 'L' and record them as 'L2'. The tie rods are correctly tensioned when on a pres�sure of 600 bar a total elongation of

� L = 10.0 mm on the short tie rods � L = 12.5 mm on the long tie rods

is attained ('L2' - 'L').

After completing the tensioning, smear the protruding thread portion of all the tie rods lavishly with acid free greaseand fit the protection caps 15. All the clamp screws 17 must be firmly tightened!

Follow the Remark at the end of 'Checking the pre�tension of tie rods'!

1989


96.703496.7034

B

III - III

IV

II

I

IV

III

II

III

1

18

19

14

19

13

18

13a

17

23

16

2

3

15

13

1

1723 113AN

21

22

20

Hier bündigFLUSH

I I

1989


ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ13

13a

ÅÅÅÅÅÅDC ÅÅÅ

f e c a b d

df e c a b

An

trie

bss

eite

DR

IVIN

G E

ND

1989




Cylinder Liner and Cylinder Cover Group 2

� Cylinder Liner

– Measuring Bore Wear 2124/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Removal and Fitting 2124/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Removing Wear Ridge, Re-dressing Lubricating Grooves, and Edges 2124/3. . . . . . . . . . . . . . . . . . . of the Scavenge Ports

� Lubricating Quills and Accumulators (Multi-level Lubrication)

– Function Check 2136/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Piston Rod Gland

– Dismantling and Assembling as well as Measuring the Wear 2303/1. . . . . . . . . . . . . . . . . . . . . . . . . . .

� Cylinder Cover

– Removing and Fitting 2708/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Hydraulic Loosening and Tensioning of Cylinder Cover Studs 2708/2. . . . . . . . . . . . . . . . . . . . . . . . . . .

– Mechanical Loosening and Tightening of Cylinder Cover Studs 2708/3. . . . . . . . . . . . . . . . . . . . . . . . .

– Manual Overhaul of Sealing Face for the Injection Valve in the Cylinder Cover 2708/4. . . . . . . . . . . .

� Fuel Injection Valve

– Checking, Dismantling, Assembling and Setting (with L’ORANGE Test Stand) 2722/1. . . . . . . . . . . .

– Checking, Dismantling, Assembling and Setting (with O.M.T. Test Bench) 2722/1. . . . . . . . . . . . . . . .

– Cleaning and Overhauling of Injection Nozzle 2722/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Lapping of Nozzle Holder Contact Surface 2722/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Starting Valve

– Removing, Fitting and Dismantling, Grinding-in and Assembling 2728/1. . . . . . . . . . . . . . . . . . . . . . . .

� Relief Valve for Cylinder Cover

– Dismantling, Assembling and Testing (with L’ORANGE Test Stand) 2740/1. . . . . . . . . . . . . . . . . . . . . .

– Dismantling, Assembling and Testing (with O.M.T. Test Bench) 2740/1. . . . . . . . . . . . . . . . . . . . . . . . . .

� Exhaust Valve

– Removal and Fitting of the Exhaust Valve 2751/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Dismantling and Assembling 2751/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Replacing and Grinding the Valve Seat 2751/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Grinding the Seating Surface on the Valve Head 2751/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Cylinder Liner

Measuring Bore Wear


1 Cylinder linerS Setting screws 'S'

Tools:

1 Inside micrometer 941011 Ladder 942241 Measuring gauge 94225

Whenever a working piston isremoved for overhaul, the cylin�der liner bore has also to bemeasured. The figures foundare to be recorded so that theycan serve as comparison withearlier or later measurements.In this way, normal wear can bedetermined and followed.

Comparisons with other mea�surements can, however, only bemade if the measurements arealways taken at the same place.For this reason, use the measur�ing gauge 94225 which is part ofthe tool kit.

The measurements have to betaken in both longitudinal andtransversal directions to the en�gine axis by putting the insidemicrometer 94101 into the holesespecially provided for this pur�pose in the measuring gauge.

The ridge formed during thecourse of operation at the top ofthe cylinder bore has to be re�moved carefully without dam�aging the running surface forthe piston rings.

Should the thickness of the com�pression shims be altered afterputting the engine into opera�tion, then on measuring gauge94225 the length of the settingscrew 'S' has to be adjustedaccordingly. By this the measur�ing bores of the gauge 94225 areagain brought to the originalsetting relative to the position ofthe piston.

10.94

94.7275

94225

1

94101

S



Cylinder Liner

Removal and Fitting

Key to Illustration:

1 Clamp2 Holder3 Centring pin4 Centring pin5 Cylinder cover waisted stud

5a Nut6 Allen screw7 Cylinder cover8 Water guide jacket9 Cylinder jacket

10 Cylinder liner

11 Supporting ring12 Round rubber ring13 Round rubber ring14 Antipolishing ring15 Screw16 Filling piece17 Waisted bolt

AF Seating surfaceH Wooden underlay

Tools:

1 Suspension bridge beam 942021 Supporting beam 942032 Suspension straps 942062 Screws to 94206 942074 Suspension straps 942081 HP oil pump 949311 Pressure gauge 949321 Connection piece 94934a1 HP hose 949352 HP hoses 94935a2 Hydr. jacks 94936

Preparations for the removal of a cylinder liner

- Drain cylinder cooling water from the respective cylinder, and remove cylinder cover (see sheet 2708/1).

- Remove piston together with piston rod gland (see sheets 3403/1 and 2303/1).

- Remove the two screws 15 which locates cylinder liner 10 on support ring 11 (see Fig. 'C').

If a SIPWA transmitter is provided remove it from the cylinder liner.

- Separate all cylinder lubricating oil connections from the lubricating quills. Remove all passages for lubricat�

ing quills as well as their protecting bushes (see sheet 2136/1) before pulling out any cylinder liner.

If cylinder liner 10 has to be pulled out together with support ring 11 then Allen screws 6 must be loosened andremoved instead of screws 15. The passages for lubricating quills and their protection sleeves do not have to be re�moved for this work provided the support ring does not have to be separated from the cylinder liner.

Removal (Fig. 'B')

Working procedure:

- Lower supporting beam 94203 of the dismantling device, suspended on the crane, through the bore of the cyl�inder liner and place it on the piston rod gland seating of the cylinder jacket in longitudinal direction of theengine.

- Put both hydr. jacks 94936 onto the supporting beam 94203 and position these below the cylinder liner.

- Connect hydr. jacks by HP hoses 94935 and 94935a as well as connection piece 94934a to the HP oil pump94931.

- Jack cylinder liner 10 out of its guide portion.

- Mount suspension bridge beam 94202 and screw fasten it together with the suspension straps 94206 and screws94207.

- Pull cylinder liner fully out by the crane.

- Remove hydr. jacks and supporting beam 94203.

Preparations for the fitting

- Clean all guide areas and sealing surfaces on cylinder liner 10, cylinder jacket 9 and supporting ring 11.

- Place round rubber rings 12 of the specified quality and dimension, into the grooves on the cylinder liner.

- Smear round rubber rings and guide areas of cylinder liner and of cylinder jacket with lubricating oil.

- Clean seating surfaces 'AF' of supporting ring 11 and of cylinder liner 10 carefully.



Fitting

- Fit suspension bridge beam 94202 to the cylinder liner, as used for the removal (see Fig. 'B').

- Move the cylinder liner hanging on the crane over the supporting ring 11.

- Apply a non�hardening sealing compound (e.g. silicone) to the seating surface 'AF' on supporting ring 11 andto the collar of the cylinder liner 10.

- Lower cylinder liner while guiding centring pin 3 (Fig. 'C') into the centring hole in supporting ring 11.

- Place a cylinder cover 7 on cylinder liner 10, and fit four nuts 5a of cylinder cover waisted studs 5 equally spaced.

- Tighten nuts alternately to press the cylinder liner firmly onto the supporting ring (Fig. 'D').

- After removing the cylinder cover refit and firmly tighten screws 15 for locking the cylinder liner on the supportring (Fig. 'C').

Remark: The waisted bolts 17 for the filling piece 16 (Fig. 'C') must be pre�tightened to 5 Nm, and subsequentlytightened with an angle of 15�.

Removal and fitting of the antipolishing ring

Depending on design of the cylinder liner an antipolishing ring 18 (Fig. 'E') may be provided at the top of the collar.

Four suspension straps 94208 are fitted for removing and fitting the antipolishing ring as shown in Fig. 'A'.The latter can be lifted with the aid of wire ropes which are attached to the suspension straps and connected to thecrane.

Before fitting, clean the seating surfaces on the antipolishing ring as well as the cylinder liner, and smear the antipol�ishing ring lightly with oil. Further pay attention that one of the holes for fastening the suspension straps lies on fuelside.

A

00.7364

1094208 14



00.7684

B

I

I - I

94931

94935

94934a

94935a

94935a

949369493694936

94936

94203

9493594936

94203

I

10

94207

94206

94202

94932



90.7039

8

3

2

10

11

8

15

1

10

11

7

8

13

3

2

11

10

7

8

15

1

11

10

3 15

15 6

11

4

9

10

AF

11

9

12

III

IV

I

I

II

II

6

Befestigung des AufsatzringesFASTENING OF SUPPORTING RING

Abgasseite

I - I

II - IIIV

III

EXHAUST SIDE

17 16

C



Putting upright or laying down a cylinder liner (Fig. 'E')

The suspension bridge beam 94202 is fitted to the cylinder liner and suspended to the crane hook according to Fig.'E'. The cylinder liner can now be put upright or laid down with the aid of the crane.

Attention! Putting upright or laying down must only be carried out in longitudinal direction of the suspension

bridge beam as shown in Fig. 'E'!

Remark: The supporting ring 11 (Fig. 'E') is fastened with three Allen screws 6 to the cylinder jacket 9 and lo�cated on the fuel side by centring pin 4. For the removal of the supporting ring the three Allen screws 6can be used as jacking screws. Prior to re�fitting the supporting ring, the sealing surfaces on the sup�porting ring and on the cylinder jacket must be carefully cleaned. For re�fitting the sealing surfaces areto be smeared with a non�hardening sealing compound (e.g. silicone).

87.7040

5a

7

10

5

9

5a

7

9

90.7043

94202

94206

94207

AF

H

H

D E




Cylinder Liner

Removing the Wear Ridge, Re�dressing the Lubricating Grooves, as well as the Edges of the

Scavenge Ports


1 Roller support2 Holder3 Holder4 Spacer roller5 Pipe (column)6 Grinder7 Air hose8 Hose oiler

9 Thread nozzle10 Carbide milling cutter11 Cylinder liner12 Top piston ring

G Lubricating groovesK Check boreP Scavenge port

Tools:

1 Wear ridge grinding device 94299Emery clothAssorted filesFine grain carborundum

Due to wear by the piston movement in the cylinder liner running surface ridges are formed on top and bottom towhere the piston does not reach. Due to the wear the lubricating grooves in the cylinder liner lose their depth, fur�thermore the corner radii of the scavenge port edges become smaller and thereby sharper. It also happens that theedges get damaged.

When a piston is removed the opportunity should be taken to measure the bore of the cylinder liner (see sheet2124/1) and to remedy any irregularities which occurred. The following points are of particular importance:

Protect the space below the cylinder liner from falling particles with suitable material.

After completing the reconditioning clean the bore of the cylinder liner thoroughly and remove anytrace of metal dust (particularly from the lubricating grooves).

Carefully remove waste particles which may have passed into the scavenge space through the ports.

Actuate the cylinder lubrication until oil flows from all the lubricating points, thereby flushing anymetal dust which accumulated there.

Removing the wear ridge

When grinding away the wear ridge take greatest care not to damage the running surface within the area covered bythe piston and piston ring stroke from T.D.C. to B.D.C. The machining of the wear ridge has to be carried out asshown in Fig. 'B'.

We therefore recommend using a wear ridge grinding device (Fig. 'B') for carrying out this work. It is listed in thetools list under 'Recommended Special Tools'.

Redressing the lubricating grooves

If the depth of the lubricating grooves has worn to less than 1.5 mm (new depth 2.5 mm) re�dress them to their origi�nal depth and slightly chamfer their edges with an oil stone or similar. The execution type of the cylinder liner iseither equipped with one or two rows of lubricating grooves.

Re�dressing the edges on the scavenge ports

The shape of the scavenge ports shown in Fig. 'A' corresponds to new cylinder liners. If the condition of the edgesrequires reconditioning (depending on the degree of wear or damage) aim at matching these shapes. Take greatcare not to damage the running surface in the cylinder liner bore. Polish the passages into the running surface withemery cloth.

10.94


I

94.7068

G I

II

II

K

P

Bre

nnsto

ffpum

penseite

FU

EL P

UM

P S

IDE

Kanten gebrochen

SHARP EDGES REMOVED

A

I - I

10.94


2

B

3

6

4

7 8 9

10

94299

11

5 1

2-3mm

1mm

TDC

12 11

93.7460

10.94



Lubricating Quills and Accumulators (Multi�level Lubrication)

Function Check


1 Accumulator cylinder 12 Passage for lubricating quill2 Spring 13 Filling pin3 Accumulator piston 14 Steel ball4 Cap nut 15 Non�return valve housing5 Diaphragm 16 Flange ring6 Accumulator casing 17 Screw7 Cap nut 18 Support ring8 Backing screw 19 Flange9 Copper sealing rings 20 Joint

10 Cylinder liner 21 Protecting bush11 Lubricating quill 22 O�ring

'DF' Sealing face

When pulling a working piston, the cylinder lubrication system should also be checked for correct functioning. Thefunction check must also be carried out in case of malfunctioning of the cylinder lubrication.

Turn the crank of the respective cylinder lubricating pump until oil emerges from all the lubricating points in thebore of the cylinder liner. Note that on cylinder liners with two rows of lubricating grooves (multi�level lubrication)the oil delivery for upper and lower row of lubricating grooves may be differently set on the lubricator (Correctsetting is recorded on the acceptance records). Whatever the settings, make sure that on all the lubricating points ofthe same row of lubricating grooves the oil quantity outflow is equal

Should deliveries differ, check on the cylinder lubricating pump the setting screw pertaining to the respective lubri�cating point, in relation to the others setting screws of the respective row.

Use the occasion to check at random several accumulators. Open them to inspect the diaphragm 5. If oil is found inthe inner space of the accumulator piston 3 or in cylinder 1, the diaphragm is leaking or brittle and must be replacedby a new one.

New diaphragms are supplied in special plastic boxes, ready for fitting. Fit the diaphragm with greatest care so asnot to damage it.

If a non�return valve has to be replaced, remove first the backing screw 8 after which the valve can be pulled outtogether with the filling pin 12 which is joined to it.

Non�return valves are only supplied complete with filling pin as replacement parts.

After fitting the new valve tighten the backing screw 8 moderately and lock it with a centre punch.

Before removing a cylinder liner 10, the passages for lubricating quills 12 and the protecting bushes 21 must be firstdisconnected.

If only the passage for lubricating quill 12 has to be removed, with cylinder liner 10 fitted, then the protecting bush21 can remain in place.

When refitting the passage for lubricating quill make sure that the sealing surface 'DF' between cylinder liner 10and passage for lubricating quill 12 is absolutely clean. Sealing surface 'DF' must seal metallically and the use ofgaskets is prohibited.

Remark: The design of the lubricating quills for the upper and the lower row of lubricating grooves is the same.

1990


90.7016

10 18

DF 22 21 13 12 17 11 99 8 7

ÅÅÅÅÅÅ ÅÅÅ ÅÅÅÅÅÅ ÅÅÅ1415

ÅÅÅ ÅÅÅ20

19

16

5

6ÅÅÅÅÅÅÅÅÅ ÅÅÅ 1

2

3ÅÅÅÅÅÅÅ4

1990


Piston Rod Gland

Dismantling and Assembling as well as Measuring the Wear


1 Housing, 2�part2 Upper housing3 Scraper ring4 Sealing ring

4a Sealing ring5 Sealing ring6 Oil scraper ring7 Scraper ring8 Screws9 Sealing segment

10 Piston rod11 Screw

12 Tension spring13 Tension spring14 Screw15 Cover16 Cylinder jacket (block)17 O�ring18 Locating pin19 Locating pin20 Sealing ring21 Fixing plate22 Locating pin

Tools:

1 Distance pipe (2�part) 943451 Taper ring (2�part) 94345a1 Clamp ring (2�part) 94345b2 Templates 94345c2 Fitting tools 94345e4 Distance pieces 94345f1 Piston supporting device 94350

To remove the gland box, screw the distance pipe (2�part) 94345 onto the foot of piston rod 10 (Fig. 'A'). Loosen thefour screws 11 (Fig. 'B') after which the gland box can be removed, including the piston (refer also to sheet 3403/1,Removal of a Working Piston).

At every piston overhaul, the piston rod gland must also be dismantled and inspected. Excessively worn or damagedparts are to be replaced.

It is important that a piston rod gland is in perfect condition when it is assembled, as an earlier than planned inspec�tion also necessitates the removal of cylinder head and working piston. The gland is dismantled after the workingpiston has been pulled out and placed into its supporting device 94350 arranged on the upper platform.

98.7262

A

94345

2

10

1

Dismantling a gland

- Fix working piston in the piston supporting device 94350. For this the split housing 1 of the gland must rest onthe two covers 15 of the device.

- Loosen screws 8 (two fitted screws and two standard screws each), and remove the upper housing 2 (Fig. 'B'and 'C').

- Remove tension spring 12 to the scraper rings 3 and the sealing rings 4, 4a by means of fitting tool 94345e (seeTool List 9405/1).

- Remove the four screws 14 (two fitted screws and two standard screws each) with their locking plates to the2�part housing 1.

- Push the two gland housing halves 1 away from the piston rod.



- Remove tension springs 13 as well as the sealing rings 5 with the sealing segments 9, and the scraper rings 6, 7.

- Determine the wear on the following parts:

Upper gland group Scraper rings 3 (4�part). . . . . . . . . . . . . . . . . . . . . . Sealing ring 4, 4a (4�part)

Lower gland group Sealing rings 5 (3�part). . . . . . . . . . . . . . . . . . . . . . Oil scraper rings 6 (3�part)Scraper ring 7 (3�part)

- The admissible wear on the wear parts is indicated in clearance table sheet 0330/4.

- Such parts which are beyond the admissible tolerance must be replaced. Wear parts approaching the tolerancelimit should be replaced in doubtful cases, as they cannot be checked again before the next piston overhaul.

- The tension spring 12 and 13 as well as the O�rings 17 must be replaced as well when they are no longer inperfect condition.

Assembling a gland (see Fig. 'D' and 'E')

- Fix working piston in the piston supporting device 94350.

- 2�piece clamp ring 94345b and taper ring 94345a can be used for better fitting of tension springs 13 to the lowergland group.

- Place oil scraper ring 6 between clamp ring and taper ring.

- Fit tension spring 13 onto taper ring 94345a. The tension spring can now easily be pushed over the taper part ofthe device into the groove in the oil scraper ring.

- In the same way fit all oil scraper rings 6. Pay attention that their designations TOP point upwards, and thelocating pin 18 of a segment fits into the corresponding upper segment.

- For fitting of the two sealing rings 5 proceed as mentioned above, whereby sealing segments 9 must be addi�tionally fitted.

- Remove clamp ring 94345b and taper ring 94345a from the piston rod.

- Fit scraper ring 7 with spring 13.

- Place the two templates 94345c on the covers 15 of the piston supporting device and use them to adjust thescraper ring as well as the oil scraper rings and the sealing ring pair, so that each group is in place at the height ofits allotted ring groove in the 2�part housing 1.

- Smear piston rod as well as all rings with bearing oil. Then push both housing halves on the covers 15 over thering packs against the piston rod, then screw them together with screws 14 (two fitted screws and two standardscrews each) and lock these.

After assembling of the lower gland group, the upper gland housing has to be assembled as follows:

- Place two distance pieces 94345f (8 mm thick) on the 2�part housing 1 as shown in Fig. 'C'.Place the sealing rings 4 and 4a with their designations TOP pointing upwards on the distance pieces. Payattention to the radial locating pins 19!

- Fit scraper rings 3. Pay attention to the locating pins 18 and designation TOP.

- Fit tension spring 12 by means of fitting tool 94345e (see Tool List 9403/5).

- Fit two distance pieces 94345f (9 mm thick) as shown in Fig. 'C' and install the two uppermost scraper ring pairs3 in the same way as mentioned above.

- After fitting of the tension spring remove all distance pieces 94345f required for positioning.

- Smear piston rod and rings lavishly with bearing oil.

- Screw up the upper housing 2 using the four screws 2 (two fitted screws and two standard screws each).

Check the upper housing 2 for free moveability.

Just before the gland is fitted with the working piston, smear the respective centering portions in the cylinder jacketas well as on the gland casing in the O�ring 17 region with lubricating oil.

When fitting the gland into the cylinder jacket the spacer tube 94345 must be mounted on the foot of the piston rodas shown on Fig. 'A'. The locating pin 22 (Fig. 'B') must mate with the corresponding bore in the two�part casing 1.Fit upper scraper ring 2 with tension spring 7. Tighten and lock screws 11.



98.7453

Bre

nnsto

ffpum

penseite

FU

EL P

UM

P S

IDE

20

II - II

I - I

6

3

2

21

4

I

I

II

II

16

12

4a

7

17

5

B

1

11

14

8

9

unte

re H

älfte

LO

WE

R H

ALF

obere

Hälfte

UP

PE

R H

ALF

11

22

10 13



98.7449

6

C

94345f

3 2

12

1

20

13

7

5

9

4a

4

18

3

19

18

3

18

6

18

6

18

6

7

21

11

18

9 m

m

8 m

m

94345f



93.7012

D

E

94350

10

94345a

13

15

10

94345c

15

94345b

94345




Cylinder Cover

Removing and Fitting


1 Hydr. pre�tensioning jack 94215 1 Cylinder cover 7 Fuel injection valve1 Suspension device 94265 2 Nut 8 Starting valve2 Spec. eye screws 94265a 2a Cylinder cover stud 9 Connection for hydr. oil3 Protection caps 94265b 3 Cyl. cooling water outlet 10 Indicator valve

4 Leak oil outlet 11 Relief valve5 Exhaust valve cage 12 Air inlet for valve spring

5a Stud of exhaust valve cage 13 Water guide jacket6 Connection for valve

shank lubrication R Eye boltS Lifting screw

10

S

5

A

94.7293

12

1

7

4

3

R119

6

2 2a

8

Abgasseite

EX

HA

US

T S

IDE

Bre

nnsto

ffpum

penseite

FU

EL P

UM

P S

IDE

Removal

Drain the cylinder cooling water from the affected cylinder, i.e. first shut the two valves for cylinder cooling waterinlet and outlet and then open the drain valve which is located directly behind the cooling water inlet valve at thebottom of the cylinder jacket on the fuel pump side. The cooling water outlet valve is on the top above the exhaustvalve cage. Then open the vent valve in the cylinder cooling water outlet pipe of the respective cylinder!

- Disconnect all the pipes to the cylinder cover and to the exhaust valve.

- Clean all the thread protrusions on the cylinder cover studs.

- Loosen and remove the nuts of the cylinder cover studs in accordance with the instructions on sheet 2708/2.

- Screw the spec. eye screws 94265a to suspension device 94265 onto the studs 5a of the exhaust valve cage. Insertthe two hooks of the suspension device into the spec. eye screws.

- Lift the cylinder cover 1 and water guide jacket 13 together with the crane (see Fig 'C').

Attention! For dismantling and fitting, as well as for transportation of the cylinder cover, with installed valve cage,the eye bolts 'R' may not be used. For this purpose, tools, as shown in Fig 'C' must be utilized.

Alternative: (see Fig 'B')

Removing and transporting the cylinder cover is the same after the exhaust valve cage 5 has already been removed.For the transport of a cylinder cover the three suspension screw 'S' on Fig 'A' should be used.They are fitted with LOCTITE in the cylinder cover and therefore locked.

1994UG


Fitting

Before placing the cylinder cover in position the following points must be taken care of:

The compression space must be absolutely free of foreign particles or dirt.

The seating surfaces on cylinder cover and cylinder liner must be clean and undamaged.

A new soft iron joint ring 2 mm thick must be placed on the cylinder liner in such a way that it lies flat all over.

The inner surface of the water guide jacket 13, screwed onto the cylinder cover, as well as the corresponding guideportion on the collar of the cylinder liner must be clean and smeared with clean bearing oil.

The grooves in the cylinder liner must be equipped with new rubber rings of specified size and quality, they have alsoto be oil smeared.

The threads of the cylinder cover studs must be clean and smeared with MOLYKOTE paste.

Place three protection caps 94265b on cylinder cover waisted studs 2a (see Fig 'C').

When these conditions are all met, lower the cylinder cover, attached to the suspension device 94265, slowly overthe cylinder cover studs, the correct position being provided by the guide pin (see sheet 2124/2).

After the removal of the suspension device screw all the nuts by hand onto the cylinder cover studs, pay attention toeasy turning. If necessary the stud thread may have to be reconditioned, so that the nuts can be screwed on by handwithout spanner.

Pre�tension the studs with the hydraulic pre�tensioning device 94215 in accordance with sheet 2708/2 then fit allpipes to cylinder cover and exhaust valve.

Finally shut drain and vent cock, and open the cocks for cooling water inlet and outlet.

B C

96.7037

94265

94265a94265a

5a

1

13

5a

5

94265b

2a

1989


Cylinder Cover

Hydraulic Loosening and Tensioning of Cylinder Cover Studs


1 Cylinder cover stud2 Stud nut3 Vent screw4 Piston5 Round nut6 Flow control valve7 Pressure limiting valve8 Pressure gauge9 Cylinder

10 Distributor11a, b Support and O�ring12a, b Support and O�ring

13 Connecting piece to HP hose14 Connecting piece15 Ball

16 Sleeve17 Coupling18 Screw19 Lower spring pack20 Screw21 Cover22 Connecting halve

R Round barW Emplacement for round

nuts 5 when not in useS Emplacement for round

bars 'R' when not in useX Distance about 7 mm

Tools:

1 Hydr. tensioning device 94215consisting of:2 Device halves each withfour pre�tensioning jacks 94215aHP hoses 94215cCompr. air hose 94215dSuspension device 94215e

1 Air hydraulic oil pump 94941

Remark: The instructions on sheet 9403/4 concerning the application of the hydraulic pre�tensioning jacks forscrewed fastenings must be followed.Should a cylinder cover stud have to be replaced, please observe the indication on sheet 2751/1.

1) Preparations for loosening or tensioning

� Clean the threads of all cylinder cover studs 1 (Fig. 'C') as well as the area around stud nuts 2.

� Mount two device halves of the hydraulic pre�tensioning device 94215 over the cylinder cover studs and restthem on the cylinder cover (arrangement according to Fig. 'A').

� Open the air vent screw 3 of each tensioning jack so that their pistons 4 can automatically take up their startingpositions and that the air can escape when starting to pump.

� Screw the round nuts 5, one nut to each pre�tensioning jack (which hang on hooks 'W' when not in use) onto thecylinder cover studs till seated on the piston 4. The round nuts 5 must only be slackened afterwards by about 1turn for loosening.

� Check that the dimension 'X' at each tensioning jack is about 7 mm, i.e. they are in the correct initial position.

� Connect the two device halves by HP hoses to the air�hydraulic pump (called pump for short) as shown in Fig.'A'.

� Verify the oil level in the pump. The pump may not be started�up when insufficient or no oil is present in thecontainer.

� Connect pump by compressed air hose 94215d to compressed air system (7bar). For operating the air motor onlyclean slightly oily air must be used.

2) Hydraulic loosening

After completing all preparations as per section 1) proceed as follows:

- Move hand lever of flow control valve 6 to position open for oil supply to the jacks.

- Turn knob of pressure limiting valve 7 till the stop in direction of arrow '-' (minus).

- Open air supply, which starts the pump.

- Close vent screws 3 on the jacks as soon as oil flows bubble�free.

- Slowly turn pressure limiting valve 7 in direction of arrow '+' (plus) until a pressure of 620 bar is indicated on thepressure gauge 8.

- Turn all the cylinder cover nuts upwards till they contact the cylinder 9, using round bar 'R'. Store round bar 'R' at'S' while not in use (see Fig. 'A').

- Release pressure to zero by moving hand lever of flow control valve 6. Assist lowering of pistons 4 by lightlymoving round nuts 5 with the round bar.



- Stop air supply; Pump stops.

- Disconnect all HP hoses between pre�tensioning jacks and pump.

- Unscrew round nuts 5 from cylinder cover studs and deposit them on hook 'W' (see Fig. 'A').

3) Hydraulic tensioning

Preparations:

In addition to the steps described in section 1) arrange for the following:

� Smear threads and seating surface of stud nuts 2 with MOLYKOTE paste G.

� Prior to mounting the tensioning device, tighten all stud nuts down with the round bar till fully seated (check withfeeler gauge).

� Mark position of all stud nuts, with a line on nuts and cylinder cover with a felt�tip pen (this will serve for a latercheck).

Tensioning

- Move hand lever of flow control valve 6 to position open for oil supply to the jacks. Turn knob of pressure limit�ing valve 7 till the stop in direction of arrow '-' (minus).

- Open air supply, which starts the pump.

- Shut vent screws 3 on the jacks as soon as oil flows bubble free.

- Slowly turn pressure limiting valve 7 in direction of arrow '+' (plus), until a pressure of 600 bar is indicated onpressure gauge 8.

- While keeping this pressure constant tighten all stud nuts with round bar 'R' till fully seated on the cylinder cover(check seating with feeler gauge), verify while tightening that all stud nuts can be turned by about the same angle

i.e. about 330�.

- Where it is found that a stud nut can only be turned considerably less than the others, it must be assumed that therespective cylinder cover stud has become insufficiently tensioned. This can occur if support and O�rings 11a, band 12a, b (Fig. 'B') of a hydr. jack are defective or if a piston 4 has been jammed. A further possibility is anincorrect connection between connecting piece 13 of HP hose and connecting piece 14 (Fig. 'C'). In this case thenon return valves 15 (balls) do not open or open only partly, in which case the oil supply to the respective jack isrestricted. For this reason the sleeves 16 of the connecting piece 14 must always be fully tightened. If necessarythe whole tensioning procedure must be repeated after the cylinder cover studs have again been loosened.

- When all stud nuts have been tightened by practically the same angle, release the oil pressure to zero by turningthe hand lever of the flow control valve 6. Assist lowering of pistons 4 by lightly moving round nuts 5 with theround bar.

- Stop air supply; Pump stops.

- Unscrew round nuts 5 from the cylinder cover studs and deposit them on hook 'W' (see Fig. 'A').

- Verify by the previously applied marks that all stud nuts have been turned equally by an angle of about 330�.

- When this is confirmed loosen hose connections between pump and tensioning device and remove them. Closeopen hose couplings with dust caps. Lift device by crane and store away.

4) Overhauling the hydraulic pre�tensioning jacks

In the event of the support and O�rings 11a, b or 12a, b having to be replaced, proceed as follows:

- Slacken off bolts 18 and remove them together with the lower spring packs 19.

- Slacken off and remove screws 20. Slacken off vent screw 3.

- Lift the cover 21 off the piston 4.

- Pull the piston 4 out of the cylinder using two eye bolts.

Assembly of a pre�tensioning jack is carried out in reverse order from dismantling it. All the parts have to be coatedwith clean oil before assembly.When fitting the support and O�rings 11a, b and 12a, b resp., care has to be taken to ensure that their support ringsare not over stressed (deformed). It is recommended to soak the support ring in boiling water before fitting so thatit is considerably more pliable.



A

22

94215e

94215d

94215c

94941 94215c

94215a W S

R

20

99.7486

10

867

Bre

nnsto

ffseite

FU

EL S

IDE



93.7171

B

1I - I

II

2

R 2

21 3 4 5

12a,b

11a,b

9

X

13

15

16

15

14

17

C18 19

93.7170



Cylinder Cover

Mechanical Loosening and Tightening of Cylinder Cover Studs

(Exceptional Case)

Tools:

1 Pneumatic impact wrench 94264with socket spanner insert

1 Closed impact wrench

Attention!

Never loosen all adjacent nuts simply one after another, or tighten either in this way, but always only diagonallyacross and in small steps as described hereafter. Non�observance of this strict requirement can lead to the cylindercover being damaged.

Whenever possible loosen or tighten cylinder cover stud nuts always by pre�tensioning the studs with the hydraulicpre�tensioning device, so that any possible inequality in the stress of each stud is prevented, as such can bring aboutwarping of the cylinder cover.Only in cases where the hydr. pre�tensioning device cannot be used may the cylinder cover stud nuts be loosened/tightened by mechanical means, strictly then, in accordance with the following procedure.

Loosening

Loosen all nuts with the pneumatic impact wrench by a preliminary 150� (1st step) in the exact sequence shown onFig. 'A'.

Follow again the same sequence to loosen evenly in several steps all nuts fully.

Tightening

Smear the thread of studs and nuts as well as the landing surfaces of nuts and areas on the cylinder cover with MO�LYKOTE paste G and screw all nuts on by hand till fully seated.

Tighten with a spanner by a smart jerk (by hand) all nuts equally (check with feeler gauge for full seating).

Mark with felt�tip pen the '0' position on a corner of each nut and on the cylinder cover.Further mark on the cylinder cover the tightening positions at the end of tightening step 1, 2 and 3 as shown on Fig.'B', with the felt�tip pen.

Set the socket spanner with its '0' mark (on its circumference) at the same corner as the mark on nut and cylindercover.

Tighten all nuts in the sequence shown on Fig. 'A' by 60� (1st step).

Then tighten all nuts in the same sequence by further 120� (2nd step) and finally by the last 150� (3rd step).

The total tightening angle of 330� must be once more checked on all nuts at the end of the tightening process.

1st step

2nd step

3rd stepA B

60�

2

1

8

7

4

6

5

3Total 330�

120�

150�

'0' Marks

10.94



Cylinder Cover

Manual Overhaul of Sealing Face for the Fuel Injection Valve in the Cylinder Cover


1 Cylinder cover2 Milling cutter holder3 Guide flange4 Setscrews5 Profiling cutter6 Centring mandril

S Screw* Threaded holes to take

the screws 'S' when thetool is not in use

Tools:

1 Overhauling device 942701 Ring spanner AF 36

When fitting the fuel injection valve, the seat sealingface in the cylinder cover must be clean and undam�aged as the sealing is metallic.

Should any blow�by of combustion gases have beennoticed during engine operation, the spring packetswith their screws of the fuel injection valve are not,under any circumstances, to be tightened further as acounter measure as this might lead to deformationof the fuel injection valve.

Dirty or slightly damaged sealing faces can be re�conditioned on the spot by using the overhauling de�vice 94270 which forms part of the tool kit. This isdone by carefully inserting the profiling cutter,bolted to the milling cutter holder, into the hole inthe cylinder cover with the guide flange. This flangeis clamped down with two screws 'S' which are keptscrewed into the threaded holes marked * when notin use.

When the tool is being used, the centring mandril onthe profiling cutter on the one hand and the guideflange on the other, give the tool the necessary sta�bility and direction. Cutting is done by pressingdown lightly with the hand on the milling cutterholder at the same time as turning the hex. headevenly with the other hand using the AF 36 ringspanner.Try to remove as little material as possible but suffi�cient, however, to obtain the desired standard forthe seating area.

Putting some sticky grease on the profiling cutterwill prevent any foreign matter entering the combus�tion chamber during overhaul.

SW36

*

4

2

S3

1

6

5

96.7041

RT

52 –

84C

1989



Fuel Injection Valve

Checking, Dismantling, Assembling and Setting with L' ORANGE Test Stand


1 Allen screw2 Spring plate3 Cup spring (packet)4 Nozzle holder5 Spring tensioner6 Collar nut7 O�ring

13 Compression spring14 Spring plate16 Guide bush17 Spindle18 Stop�/guide bush19 Cap nut20 Nozzle body with

needle seat21 Nozzle needle22 Locating pin23 Locating pin24 Nipple25 Pressure sleeve26 Nozzle tip27 Locating pin28 Locating pin

EV Relief valveFL FilterH Pump lever

MA Pressure gaugeSN Lubricating nipple

Tools:

1 Hydr. tightening device 942691 Protective cap 942711 L' ORANGE valve test stand 942721 Holding angle 942731 Connection piece 942741 Hose pipe (1500 bar) 94275

94.7069

18

19

20

21

25

26

13

14

16

17

27

28

22

1

2

3

2

3

1 4 4 7

6

5

23

5.5

mm

24

A

Arrangement of the cupsprings (spring packet)

1994UG/L' ORANGE


94269a

C D

EV 94269b 20

94269c

19

3380–6 80–9

1994 UG/L' ORANGE


For testing, dismantling, assembling and setting the fuel injection valve utilize the L' ORANGE valve test stand94272 belonging to the engine tool set. Pay attention to the following points:

Keep the valve test stand clean and always fill only clean diesel fuel (gas oil) into its tank. Do notpour the once used fuel oil back into the test stand. (For filling remove the cover, which is securedby two spring latches).

From time to time the pressure gauges have to be calibrated or compared with a test�pressuregauge and reset if necessary.

When working with the fuel injection valve the connection at top left is to be used, to which the lefthand pumping lever and the upper pressure gauge (0-600 bar) belong. The connection at topright the lower pressure gauge (0-1600 bar) and the pumping lever at the right are used for testingthe relief valves of the fuel injection pumps.

Judgeing a fuel injection valve (called f.i. valve for short)

A f.i. valve atomizes correctly when at specified opening pressure fuel oil is sprayed from all the nozzle holes inequally atomized condition. This should be accompanied by a loud 'chatter', and after the end of the pumpingstroke no fuel should 'dribble' from the injection nozzle.

To check whether the atomizing is equal, hold a clean sheet of paper in front of the spray holes of the injectionnozzle, and bring the f.i. valve to spray by single short pump jerk. On the 'spray pattern' thus obtained it is easy toestablish whether individual spray holes are partly or fully blocked.

Attention! Never actuate pump when a finger or a hand is held directly against the injection nozzle!(danger of accident)

Injection nozzles which do not spray properly must be taken apart and reconditioned or replaced (see sheet 2722/2and /3).

Testing a f.i. valve (see Figs. 'A' and 'B')

Working sequence:

Place f.i. valve (injection nozzle downwards) into the holding angle of the valve test stand and fasten with the twonuts.

Clean injection nozzle outwardly with a brass wire brush (removing combustion residue).

Fit screw�in connection piece (tool No. 94274) onto nipple 24 and join it to hose pipe 94275.

Check first with a few short pump lever jerks the atomization of the fuel, then with slow equal pump strokes observeat what pressure the f.i. valve opens (see pressure gauge 'MA'). The specified opening pressure is given in the testand timing records of the engine.

Finally remove hose pipe 94275 and screw�in connection piece 94274. For inspection tighten nipple 8.

Dismantling a f.i. valve (see Figs. 'A', 'C' and 'D')

The following basic rules must always be observed:

1. The cap nut 19 to the f.i. valve may never be loosened, before the spring tensioner 5 is notunscrewed sufficiently to detension the spring 13 completely (Fig. 'A').

2. Never interchange nozzle needle 21 and nozzle body 20! Each nozzle needle belongs to itmated nozzle body into which it has been individually fitted with greatest precision.

1994UG/L' ORANGE


Working sequence:

Bring holding angle 94273 with f.i. valve into horizontal position (Fig. 'C').

Place spanner 94269a on cap nut 19 and loosen the cap nut with the aid of hydraulic jack 94269b and pump 94269c(Fig. 'C') then remove the injection nozzle.

Attention! The spanner 94269a must always be set back before the piston of the jack is fully pushed out. At thestart of pumping the spanner must stand as close as possible to the jack while its piston is fully pushedin. The relief valve 'EV' at the pump to be slightly opened.

Remove spring tensioner 5, spindle 17, spring plate 14 and spring 13 and inspect their condition.

If necessary lap the sealing face of the nozzle holder 4 (please refer to 2722/3).

Assembling a f.i. valve

Always observe the following basic rules:

1. Fit only completely clean nozzles, which were washed in kerosene and blown out with compressed air.

2. Assemble nozzle tip 26, pressure sleeve 25 and nozzle body 20, taking care that locating pins 27 and 28 fit into therespective holes. During the assembly of these above parts ensure meticulous cleanliness and absolutely perfectsealing surfaces.

3. If the spindle 17, the spring plate 14, the spring 13 and the spring tensioner 5 are already fitted, the spring ten�sioner may only be screwed in by about one turn, so that the spring 13 is absolutely not under tension. Should thisrule be neglected then the nozzle body 20 does not lie flat on the nozzle holder 4, for the assembling.

Working sequence:

Adjust the holding angle 94273 with nozzle holder 4 so that the sealing face is on top (Fig. 'D').

Wipe sealing face on nozzle body 20 and nozzle holder 4 with the clean hand and place the nozzle body with needleon top. Take care that the needle does not fall out and that the cylindrical locating pins 22 of the nozzle holder fit intothe corresponding holes in the nozzle body (Fig. 'D').

Tighten cap nut 19 by hand till seated firmly.

Swing mounting angle 94273 with fuel valve to the horizontal position. Apply spanner 94269a and hydr. jack 94269band raise with pump 94269c a pressure of 20 bar (or with a hammer blow on the spanner) to pre�tighten cap nut 19.Thus pre�tightened mark the position of cap nut 19 against nozzle holder 4 with a felt scribe ('0'� mark). From this'0'�mark the cap nut has to be tightened by further � 45�.

If a new nozzle tip 26 has been fitted, release the cap nut 19 again after tightening as above mentioned and repeatthe tightening procedure as before to ascertain that any clearance or deformations have been cancelled out.

Attention! Always set spanner 94269a back before the jack piston is fully extended. Before starting to pump, setthe spanner as closely as possible to the jack, the piston being pushed right in, after slightly openingvent valve 'EV' at the pump.

Remove hydraulic tool and spanner and swing the holding angle 94273 with f.i. valve to a vertical position (injectionnozzle pointing downwards).

Fit the lightly oil smeared parts 17, 14 and 13 and screw in the spring tensioner 5. Do not tighten the collar nut 6before the opening pressure is set and checked.

L'ORANGE10.94


Setting the opening pressure

Adjust the f.i. valve in the test stand as described under "testing a f.i. valve" (Fig. 'B').

Move pump lever 'H' slowly up and down, while simultaneously tightening the spring tensioner 5 until the specifiedpressure (refer to the test and timing records of the engine) is attained. Check then with a few short fast pump jerkswhether the injection nozzle atomizes equally and thereby 'chatters'.

When this condition is reached, tighten the collar nut, thereby locking the spring tensioner.

Maintenance of the L' ORANGE valve test stand

Depending on how frequently the test stand is used, grease must be pumped into the lubricating nipples 'SN' fromtime to time.

Likewise, the two filters 'FL' must be removed and cleaned periodically or replaced by new ones.

When cleaning the fuel oil container, do not use any fibrous cloth materials or cotton waste. Use only brushes andcompressed air instead. Do not re�use fuel collected in the transparent plastic drip tray.

It is necessary to subject the test stand occasionally to a high�pressure test. For this, close the connecting nipple withthe steel ball and cap nut supplied. When pumping strongly � up to approx. 600 bar (left�hand pump) and 1200 bar(right�hand pump) �, the pointer of the pressure gauge in question should remain in the same position. Rapid pres�sure drop shown on the pressure gauge indicates leakage.

Fitting a fuel injection valve into the cylinder cover

Before fitting a fuel injection valve into the cylinder cover, make sure that the seat in the cover is clean. If necessary,re�condition this seat with the tool supplied with the tool kit (see sheet 2708/4). The sealing must be metallic, i.e. nojoint whatsoever may be fitted. For storing and transporting the nozzles together with the nozzle holder, protect thenozzle tip with a protective cap tool 94271 on tools list, to prevent its being damaged.

Carefully fit the fuel injection valve into the cylinder cover.

Press down the fuel injection valve evenly onto its seat with the two Allen screws. The correct pre�tension is reached,when the cup springs 3 (Fig. 'A') are first fully compressed by the two Allen screws 1, to their block length, after

which the Allen screws are again loosened by an angle of 90�. The so�called block length is then reached, when anoticeable increase of tightening torque is felt while tightening the Allen screws.

FL

SN

3380–16

L'ORANGE 10.94




Checking, Dismantling, Assembling and Setting with O.M.T. Test Bench


1 Allen screw2 Spring plate3 Cop spring (packet)4 Nozzle holder5 Spring tensioner6 Collar nut7 O�ring8 Compression spring9 Spring plate

10 Guide bush11 Spindle12 Stop�/guide bush13 Cap nut14 Nozzle body with

needle seat15 Nozzle needle16 Locating pin17 Locating pin18 Nipple19 Pressure sleeve20 Nozzle tip21 Locating pin22 Locating pin23 Holding angle24 HP hose25 Torque beam

Tools:

1 Protective cap 942711 O.M.T. test bench 94272

94.7069

12

13

14

15

19

20

8

9

10

11

21

22

16

1

2

3

2

3

1 4 4 7

6

5

17

5.5

mm

18

A

Arrangement of the cupsprings (spring packet)

1995UG/O.M.T.


C

24

94272

24

1

17

23

25

94272

23

B

95.7534

1995 UG/O.M.T.


Use test bench 94272 (Fig. 'B' and 'C') part of standard�tools for testing, dismantling, assembling and setting of thefuel injection valve.Pay attention to the manufacturer's detailed instructions and working specifications of the test bench, in particularprior to commissioning as well as for the various operations of the test bench.Keep test bench always clean and fill only clean Diesel oil (Gas oil) into the fuel tank.Check and compare the pressure gauges of the test bench from time to time with a control pressure gauge; If neces�sary reset them.

Testing of a fuel injection valve (called injection valve in the following text)

- Clean injection nozzle externally with a brass wire brush to remove combustion residues.

- Fit injection valve, nozzle pointing downwards, into holding angle 23 of test bench 94272 and fasten it by bothscrews 1 (Fig. 'C'), thereby pay attention to the correct position given through locating pin 17.

- Connect high pressure hose 24 of the test bench with fuel inlet of injection valve.

- Start test bench, following the instructions of the test bench maker's.

- Check atomization of fuel spray by a few smart pump strokes, then with slow pump strokes observe opening ofinjection valve on the pressure gauge.

Attention! Never hold finger or hands directly before the spray holes of the injection nozzle. Risk of bad accident.

For correct functioning and for a re�use of an injection valve observe the following points:

� The injection valve sprays correctly, when the fuel at the prescribed opening pressure (see setting table), spraysfrom all spray holes of the injection nozzle, equally well atomized. The spraying should be accompanied by a'Chatter' and after the end of pumping the injection nozzle must not drip.

� In order to test tightness between nozzle needle 15 (see Fig. 'A') and needle seat, keep the pressure constant inthe test bench over a period of 10 seconds at 20 bar below the opening pressure. During this period of time nodripping should occur at the nozzle tip.

� The internal tightness within the injection valve, i.e. tightness of sealing surfaces as well as leakage betweennozzle needle 15 and nozzle body 14 (see Fig. 'A') must be checked in such a way, that a pressure set at the testbench at 100 bar may not drop below 70 bar within minimum 10 seconds.

� The spray holes of nozzle tip 20 may not be unduly flushed out (see sheet 2722/2).

- Injection valves which do not spray efficiently must be dismantled as described under 'Dismantling an injectionvalve'. Often, a through cleaning suffices to make them fully functional.

- Nozzle tip 20 with flushed out spray holes must be replaced by new ones.

- Injection nozzle which leaks or drips must be dismantled and reconditioned or replaced (see sheet 2722/2 and-/3). Therefore we recommend reconditioning of such injection nozzles by the nozzle manufacturer or by aspecialized firm.

Dismantling an injection valve

For dismantling, the injection valve has to be held in holding angle 23 of test bench 94272, as already mentioned.Prior to dismantling an injection valve unscrew collar nut 6, then loosen spring tensioner 5 till compression spring 8is fully relaxed.To remove the following items, turn holding angle 23 with injection valve fitted, so that the injection nozzle pointsupwards (Fig. 'B').

- Lower torque beam 25 with the socket spanner of test bench 94272 over the injection valve. Note test benchmanufacturer's application instruction.

- Actuate hydraulic loosening (or tightening) device of the test bench to loosen retaining nut 13, then removethem.

- Dismantle pressure sleeve 19, nozzle tip 20 as well as nozzle body 14 with nozzle needle 15.

- For removing spring tensioner 5, spindle 11, spring plate 9 and compression spring 8, the holding angle 23 of thetest bench 94272 must be turned so that nozzle holder 4 comes to horizontal position.

Attention! Never interchange nozzle needle 15 and nozzle body 14! Each nozzle needle is adjusted individuallywith its nozzle body; they form a unit together.

1995UG/O.M.T.


Assembling an injection valve

To assemble an injection valve, follow generally the reverse sequence to the dismantling process, but note also thefollowing points:

� To clean injection valve parts, use only clean Diesel oil (gas oil) or fresh kerosene, and dry compressed air.

� Turn holding angle 23 with nozzle holder 4 to vertical position so that its sealing surface points upwards (Fig.'B').

� Assemble nozzle tip 20, pressure sleeve 19 and nozzle body 14, taking care that locating pins 21 and 22 fit into therespective holes. During the assembly of these above parts ensure meticulous cleanliness and absolutely perfectand dry sealing surfaces.

� Wipe sealing face on nozzle body 14 and nozzle holder 4 with the clean hand and place the nozzle body withneedle on top. Take care that the needle does not fall out.

� If the spindle 11, the spring plate 9, the compression spring 8 and the spring tensioner 5 are already fitted, thespring tensioner may only be screwed in by about one turn, so that the compression spring is absolutely not undertension. Should this rule be neglected by the assembly, then the nozzle body 14 does not lie flat on the nozzleholder 4.

� Firmly tighten by hand cap nut 13 till solid metallic seating is obtained.With the aid of hydraulic tightening (or loosening) device of the test bench 94272 (Fig. 'B'), pre�tighten cap nutto 150 Nm. Starting from this position, tighten it by a further angle of � 45�.

� If a new nozzle tip 20 has been fitted, release the cap nut 13 again after tightening as above mentioned and repeatthe tightening procedure as before to ascertain that any clearance or deformations have been eliminated.

� If parts 8, 9 and 11 still have to be fitted, lightly smear them with oil and fit spring tensioner 5. Do not tighten thecollar nut 6 before the opening pressure is set and checked.

Setting the opening pressure

Adjust the f.i. valve in the test bench as described under 'Testing of a fuel injection valve' (Fig. 'C').

Check atomization of fuel spray by a few smart pump strokes and simultaneously tighten the spring tensioner 5 untilthe specified pressure (refer to the setting table of the engine) is attained. Check then with a few short fast pumpjerks whether the injection nozzle atomizes equally and thereby 'chatters'.

When this condition is reached, tighten the collar nut, thereby locking the spring tensioner.

Fitting a fuel injection valve into the cylinder cover

Before fitting a fuel injection valve into the cylinder cover, make sure that the seat in the cover is clean. If necessary,re�condition this seat with the tool supplied with the tool kit (see sheet 2708/4). The sealing must be metallic, i.e. nojoint whatsoever may be fitted. For storing and transporting the nozzles together with the nozzle holder, protect thenozzle tip with a protective cap tool 94271 on tools list, to prevent its being damaged.

Carefully fit the fuel injection valve into the cylinder cover.

Attention! When fitting the injection valve take care in any case, that the nozzle tip 20 is not striking anywhere andthereby damaged.

Press down the fuel injection valve evenly onto its seat with the two Allen screws. The correct pre�tension is reached,when the cup springs 3 (Fig. 'A') are first fully compressed by the two Allen screws 1, to their block length, after

which the Allen screws are again loosened by an angle of 90�. The so�called block length is then reached, when anoticeable increase of tightening torque is felt while tightening the Allen screws.

1995 UG/O.M.T.



Cleaning and Overhaul of Injection Nozzle


1 Case consisting of 94280 1 Nozzle body a = positioning holesspecial tools 94281-94287 2 Nozzle needle b = bores for fuel

1 Face plate 94288 3 Nozzle tip c = channel for circulating fuel4 Pressure sleeve f = sealing face5 Cap nut

Injection nozzles which no longer atomize perfectly maynot be used again. It is often sufficient to clean them thor�oughly to fully restore them. If this proves insufficient,the nozzle has to be repaired.

Unskilled handling renders a nozzle useless. We recom�mend, therefore, that such nozzles be sent to a specialistfirm or to the manufactures.

Cleaning injection nozzles

Remove carbon deposits from the outside of the nozzlewith the wire brush 94284.

Carefully clean carboned�up spray holes by hand, using adrill 94285 which should be 0.025 mm smaller than thenominal diameter of the spray holes.Once all spray holes have been cleaned in this way, tap thenozzle - with its sealing face pointing downwards -against a piece of wood or lead so that the deposits fallout.Thoroughly wash the nozzle with paraffin, gas oil, perch�lor or similar and blow out with compressed air. If furthercleaning is necessary in the interior of the nozzle, a metalobject may never be used. A wooden dowel rod coveredwith a piece of cloth is the most suitable thing to use forthis purpose.With a clean nozzle, the nozzle needle (after having beendipped in clean paraffin or gas oil) should slide onto itsseat under its own weight.

Checking spray holes

Check with the pin gauge 94286 supplied that the sprayholes have not been scoured out excessively.If the pin gauge can be inserted into one of the sprayholes, the nozzle is to be replaced.

Re�conditioning of injection nozzles

Should careful cleaning of the nozzle not suffice to re�store its serviceability, although nozzle needle, needleseat as well as spray hole diameters are in order, or shouldthe needle lift 'N' (the measure engraved on the nozzlebody) have increased by more than 0.1 mm, the nozzlemust be reconditioned by a specialist firm.

Should any damage show on the sealing face 'f' this mustbe lapped at right angles to the bore of the needle guide,on the face plate 94288.

1

5

I

Spritzlöcher

4

a

2

3

SPRAY HOLES

b

a

c

NadelhubNEEDLE STROKE ’N’

DichtflächeJOINT FACE ’f’

I

96.7867

1989




Lapping of Nozzle Holder Contact Surface


1 Lapping disc 94281 23 Nozzle holder1 Copper mandrel 94282 30 Hardened bush1 Face plate 94283

Lapping powder 942871 Lapping plate 94288

Tools only delivered under separate order.

Rough or slightly deformed nozzle holder sealing surfaces have to be reconditioned. If the surface is only slightlyworn, reconditioning by lapping in is sufficient. In more severe cases, however, it is necessary to grind the contactsurface by machine and then lap it, making sure that the seat is at right angles to the axis of the nozzle holder. Afterthe contact surface has been machined, the hardened bush in the center of the nozzle holder must be approx. 0.02mm below the face edge. This is obtained by grinding the bush - with only very little of a fine grinding paste - usinga drilling machine and the copper mandrel 94282. A disc punched out of fine emery cloth may be used in place of thegrinding paste (see Fig. 'A' overleaf).

Before starting to lap the contact surfaces, check the faces of the lapping disc 94281 for flatness. Where necessary,lap them in on the cast iron lapping plate 94288 with lapping powder/paraffin (kerosene) mixture until flat.

After having been a long time in service the contact surface of a nozzle holder will be slightly convex (arched out�wards). The center area must, therefore, be lapped in first with the small lapping disc (Fig. 'B').

For checking the contact surface to be lapped in, use the dry, special bronze check disc 94283. From time to time thisdisc has to be checked for flatness on a dressing plate.Since the check disc is made of bronze, the contact spots appear slightly yellow (Fig. 'C').

The lapping disc works more effectively where it is pressed by the thumb. Rotating should therefore be done overthe whole surface during lapping.

As soon as yellow spots are visible on the whole contact surface when checking with the check disc, the reverse sideof the lapping disc, which has a greater diameter, should be used to finish lapping the face (Fig. 'D'). Care should betaken not to rotate too far over the edge of the face in order to prevent it from becoming convex. The final face mustbe clean, smooth and flat or slightly concave (arched inwards), but never convex!During the last check, contact spots should be visible everywhere on the contact face with the exception of the hard�ened bush.

After lapping, the nozzle holder must be washed with paraffin or similar and blown out.

a b c d e

15 8 46 40 54

Diameter of lapping tools in mm

1989


98.7837

A

B

C D

E

4 mm

a

0.0

3 m

m

~300 mm

d

c

c

d

b

e

94288

9428194283

94281

23

30

min

. 0.0

2 m

m

Falls die Abrichtplatte uneben geworden ist, muss sie wieder plangehobelt werden, wobei die Oberfläche ein Profilerhalten soll, das der Abb. 'E' entspricht.

SHOULD THE DRESSING PLATE HAVE BECOME UNEVEN, IT MUST BE PLANED FLAT AGAIN ANDGIVEN A SURFACE PROFILE AS SHOWN IN FIG. 'E'.

1989


Starting Valve

Removing, Fitting and Dismantling, Grinding�in and Assembling

Tools: Key to Illustrations:

l Depth gauge 94124 1 Nut 12 Joint ring2 Jacking screws 2 Cover 13 Control valve

3 Intermediate ring 14 Transfer sleeve4 Casing 15 O�ring5 O�ring to casing 16 Piston ring6 Cylinder cover H Control air pipe 7 Self�locking nut (from starting air distributor)8 Piston J Control air pipe 9 Valve spindle (from starting air pipe)

10 Allen screws R Eye bolt11 Compression spring S Air cap

Should functional difficulties occur with the starting valves when starting or during manoeuvring, or should a start�ing air pipe near to where it joins the cylinder cover become noticeably hotter in operation than on the neighbouringcylinders, then the starting valve must be dismantled and reconditioned at the very next opportunity.

If no such difficulties occur it is recommended to dismantle yearly at random one starting valve for a thorough checkand to overhaul the other starting valves in frequencies determined by such checking.

Removal from the cylinder cover

Loosen control air connections and push control air pipes 'H' and 'J' aside.

Loosen and remove all four nuts 1.

Loosen and remove allen screws 10. Screw jacking screws into the threaded holes in the casing 4 and by tighteningthem jack the complete starting valve from the bore in the cylinder cover 6. To remove the complete valve insertboth screws 10 again. The valve can then, suspended by the two eye bolts 'R', be lifted by crane from the cylindercover.

When the removal is carried out with the cylinder cover fitted on the engine, the vacated opening must be immedi�ately covered by suitable means to prevent the possibility of foreign particles entering the combustion space.

Dismantling a starting valve

Lift cover 2 with mounted control valve 13 of casing 4. Take care that during lifting, the cover does not get jammed,whereby transfer pipe 14 risks being damaged.

Remove intermediate ring 3 from casing 4.

For further dismantling clamp the valve on the milled faces below the spindle head (spanner purchase) in a vice.

Loosen self�locking nut 7 with a socket spanner, and remove it.

Pull piston 8 and compression spring 11 from the casing.

Lift casing 4 up over valve spindle 9.

Grinding�in

Should the valve seat require regrinding, apply some grinding paste to the spindle seat and grind it in on the valveseating.

Badly worn seat faces must first be machined (angle 60�) and only then ground in (lapped) manually.

1989


Assembling

Clean all parts and smear them lightly with oil.

Assemble the valve (excluding the cover 2) in reverse sequence to the dismantling.

Apply MOLYKOTE paste G to the thread of spindle 9 and tighten the self�locking nut 7 with 800 Nm or by a tight�ening angle of 55�. The spindle thread in the region of the synthetic material, locking ring of the self�locking nut 7must not be lubricated.

Place new O�rings 5 and 15 in the groove in the valve casing, and transfer sleeve respectively and oil lightly.

After completing the assembly (without cover 2) check the easy movement of the spindle by moderately tapping thespindle top several times with a lead block in an axial direction; the spindle must jump every time back on the seat.

Should the valve seat have been ground / machined several time, check the air gap 'S', as it diminishes with everyreconditioning of spindle or seat, in the extreme case the valve will no longer shut.

The air gap 'S' (see Fig.) must be minimum 1 mm:

The gap can be measured with depth gauge (tool 94124) from the upper edge of intermediate ring 3 onto the piston8.

Fit cover 2 and tighten it with allen screws 10. Take care that when assembling the cover 2, the transfer sleeve 14 doesnot interfere.

Fitting in the cylinder cover

Place a new joint ring 12 on the shoulder of the bore in the cylinder cover.

Smear bore in cylinder cover lightly with oil and fit the assembled starting valve.

Screw in the nuts 1 and tighten them crosswise through an angle of 90�.

1989


R

10

1

13

H

J

R

10

2

4

2

15

14

15

47

16

16

8

9

11

12

13

1

2

3

4

5

6

S

H

J

IV - IVIII - III

II

I - I

II

89.7127

III

I I

IV

IV

III

1989



Relief Valve for Cylinder Cover

Dismantling, Assembling and Testing with L'ORANGE Test Stand


1 Spring tensioner2 Distance ring3 Nut4 Studs5 Round rubber ring6 Housing7 Compression spring8 Spring plate9 Valve body

10 Valve seat11 Cylinder cover

11a Copper joint12 Nut13 Tie rod14 Testing head15 Connecting union16 Closing union with

protective cap16a TREDO seal17 Pump lever18 High pressure hose19 Stop lever

Tools:

1 Valve test stand L' ORANGE 942721 Mounting angle bracket 942731 Flexible hose (1500 bar) 942751 Testing head 942761 Copper joint (for 94276)2 Jacking screws M12

All relief valves are to be removedfrom the cylinder covers at intervals ofapprox. 6000-8000 running hours -earlier, if necessary - with the twojacking screws M12 and checked forabsolute tightness and correct openingpressure, with the aid of the valve teststand.Even if the opening pressures are stillcorrect, it is advisable to check a fewrelief valves at random. Depending onthe condition found, possibly checkthe remaining ones too.The correct opening pressure ismarked on the rectangular flange ofthe valve housing and given in the set�ting records of the engine.

A

98.7838

1 m

m

1

32

4

5

7

6

8

9

10

11

11a

1989L’ORANGE


98.7839


94273

15 16a

1

212

13

9

11a10

14 (94276) 16 18 (94275)

6

B

1989 L’ORANGE


Dismantling and assembling

DC

(94276)

(94275)

1

2

14

16

15

18

12

94273

19

17

Procedure for dismantling

The relief valve, clamped in the test stand according to Fig. 'B' and 'C', is moved into horizontal position.

Unscrew spring tensioner 1 and remove spring 7 and spring plate 8.

Clamp valve housing at the rectangular upper part in the vice and unscrew valve seat 10. After that, the valve body 9can also be removed.

All components should be thoroughly cleaned and checked.

10

9

a

43°

98.7660

E

SchutzPROTECTION

45° + 10’0

b

Wärtsilä Switzerland Ltd L’ORANGE / 3.03


Procedure for grinding�in

Valve seats of which the contact surfaces are in bad condition are best re�ground by machine, aiming at the followingangles:

- Seat of valve body 9 = 43�

- Seat of valve seat 10 = 45�+ 10'

0

Valve seats which are only slightly damaged, however, can be re�conditioned by grinding�in by hand, following theprocedure below (Fig. 'E'):

Clamp valve body 9 into a bench vice. Using a small pointed stick, place a few dots of grinding paste onto the seat ofthe valve body, towards the greater diameter (Fig. 'E'/a).

Put valve seat 10 onto valve body 9 and turn valve seat backwards and forwards. Clean the faces several times andrepeat the grinding process until a relatively narrow, shiny band� towards the smaller diameter � indicates the con�tact area (Fig. 'E'/b).

Finally thoroughly clean valve seat and body.

Procedure for assembling

Thoroughly clean all components and lightly oil them.

Coat valve body 9, the landing faces of spring 7 and the threads of spring tensioner 1 with MOLYKOTE paste G.

Use a high temperature resistant lubricant, such as THREAD GARD or LOCTITE ANTI SEIZE COMPOUND,for coating the threads of valve seat 10. (These lubricants can of course also be used for the parts mentioned above).

Clamp the relief valve at the rectangular upper part in the vice and screw the valve seat 10 � with valve body 9 fitted �into the housing 6 and tighten firmly.

Place relief valve vertically into the test head 14 already screwed into the mounting angle bracket of the test standand firmly tighten with nuts 12.

Attention! First insert copper joint 11a into test head.

Fit spring plate 8 and spring 7 and screw in the spring tensioner 1 (at first without distance ring 2) until the distanceto the valve housing corresponds approximately to the thickness of the distance ring.

Procedure for testing

Connect high pressure hose 18 to connecting union 15 of the test head (see Fig. 'C') and operate pump lever 17 untilthe relief valve opens (check the opening pressure on pressure gauge).

Depending on the opening pressure found, further tighten or loosen spring tensioner 1 until the correct openingpressure has been established.

Now measure the distance between the spring tensioner 1 and the valve housing and prepare a distance ring 2 ofcorresponding thickness.

Unscrew the spring tensioner and insert distance ring. Test relief valve once again.

Fitting the relief valve into the cylinder cover (see Fig. 'A')

Before fitting the relief valve, thoroughly clean the bore and contact surface in the cylinder cover. Make sure that noforeign matter enters the combustion chamber when carrying out the work with the cylinder cover fitted.

Fit the relief valve with a rubber ring in perfect condition and place a new copper joint onto the contact surface in thecylinder cover. Coat the outside of the valve housing with a little grease or oil to protect it against rust.

Coat the threads of the studs 4 with MOLYKOTE paste G and, after fitting the valve very firmly tighten the nutscrosswise and in even stages.

Wärtsilä Switzerland Ltd3.03 / L’ORANGE


Relief Valve in the Cylinder Cover

Dismantling, Assembling and Testing with O.M.T. Test Bench


1 Spring tensioner2 Distance ring3 Nut4 Studs5 O�ring6 Housing7 Compression spring8 Spring plate

9 Valve body10 Valve seat11 Cylinder cover

11a Copper joint12 Nut13 Tie rod14 Adapter (testing head)

Tools:

1 O.M.T. test bench 942722 Jacking screws M12

93.7179

1

3

4

5

6

7

8

9

10

11

11a

2

All relief valves are to be removed fromthe cylinder covers at intervals of approx.6000-8000 running hours - earlier, ifnecessary - with the two jacking screwsM12 and checked for absolute tightnessand correct opening pressure, with the aidof the test bench 94272 (Fig. 'B').

Even if the opening pressures are still cor�rect, it is advisable to check a few reliefvalves at random. Depending on thecondition found, possibly check the re�maining relief valves too.

The correct opening pressure is markedon the rectangular flange of the valvehousing and given in the setting records ofthe engine.

Dismantling (Fig. 'A')

For dismantling clamp the relief valve atthe rectangular upper part in the vise.

Unscrew spring tensioner 1 and removecompression spring 7 with spring plate 8.Then loosen valve seat 10 and after thatvalve body 9 can also be removed.

All components should be thoroughlycleaned and checked.

A

O.M.T. 1995


Procedure for grinding�in

Valve seats of which the contact surfaces are in bad condition are best re�ground by machine, aiming at the followingangels:

- Seat of valve body 9 = 43�

- Seat of valve seat 10 = 45�+ 10'

0

Valve seats which are only slightly damaged, however, can be re�conditioned by grinding�in by hand. In this casefollow the procedure below (Fig. 'C'):

Clamp valve body 9 into a bench vice. Using a small pointed stick, place a few dots of grinding paste onto the seat ofthe valve body, towards the greater diameter (Fig. 'C'/a).

Put valve seat 10 onto valve body 9 and turn valve seat backwards and forwards. Clean the faces several times andrepeat the grinding process until a relatively narrow, shiny band� towards the smaller diameter � indicates the con�tact area (Fig. 'C'/b).

Finally thoroughly clean valve seat and body.

Assembly

- Thoroughly clean all components and lightly oil them.

- Apply MOLYKOTE paste G to valve body 9, the landing faces of compression spring 7 and the threads of springtensioner 1.

- Use a high temperature resistant lubricant, such as THREAD GARD or LOCTITE ANTI SEIZE COM�POUND, for coating the threads of valve seat 10. (These lubricants can o course also be used for the parts men�tioned above).

- Clamp the relief valve at the rectangular upper part in the vice and screw valve seat 10 (with valve body 9 fitted)into housing 6 and tighten firmly.

- Place relief valve vertically into adapter 14 already screwed into test bench 94272 (Fig. 'B') and tighten with nuts12 (first insert copper joint 11a into the adapter).

- Fit spring plate 8 and compression spring 7 and screw in spring tensioner 1 (at first without distance ring 2) untilthe distance to the valve housing corresponds approximately to the height of the distance ring.

Testing the relief valve

Pay attention to the manufacturer's detailed instructions and working specifications of the test bench, in particularprior to commissioning as well as for the various operations of the test bench.

- Depending on the opening pressure found, further tighten or loosen spring tensioner 1 until the correct openingpressure has been established.

- Now measure the distance between spring tensioner 1 and valve housing and prepare a distance ring 2 of thecorresponding height.

- Unscrew spring tensioner and insert distance ring.

- Tighten spring tensioner 1 once again and re�check the relief valve.

Fitting the relief valve into the cylinder cover (see Fig. 'A')

Before fitting the relief valve, thoroughly clean the bore and contact surface in the cylinder cover. Make sure that noforeign matter enters the combustion chamber when carrying out the work with the cylinder cover fitted.

Fit the relief valve with a rubber ring in perfect condition and place a new copper joint onto the contact surface in thecylinder cover. Coat the outside of the valve housing with a little grease or oil to protect it against rust.

Apply MOLYKOTE paste G to the threads of studs 4 and after fitting the valve, firmly tighten the nuts crosswise andin even stages.

3.03 / G.M.T. Wärtsilä Switzerland Ltd


94.7252

12

I

I

13

14

94272

12

1

13

14

11a

B

C

10

9

a

43°

98.7660

SchutzPROTECTION

45° + 10’0

b

Wärtsilä Switzerland Ltd G.M.T. / 3.03



Exhaust Valve

Removal and Fitting of the Exhaust Valve


1 Hydr. tensioning device 94252 1 Waisted stud1 Valve protector 94262 2 Stud nut1 Impact tightener with socket spanner 94264 3 Valve seat1 Suspension device 94265 4 Steel ball2 Jack screw 94267 5 Connecting piece1 HP oil pump 94931 6 Connecting piece to HP hose1 Distribution piece 94934a 7 Sleeve to connecting piece1 HP hoses 94935 8 Cylinder cover2 HP hoses 94935a 9 Soft iron gasket1 Air hydr. pump 94941 10 Valve spindle1 Impact wrench AF 105 11 Valve cage

AF Seating surfaceR Round bar

After loosening the four nuts which fasten the exhaust valve to the cylinder cover and after disconnecting the piping,the complete exhaust valve can be pulled by the crane with suspension device 94265 (Fig. `E`) out of the cylindercover.

Should the valve cage be jamming in the cylinder cover (due carbon formation), two jack screws 94267 have beenprovided. Insert these in the threaded holes EX on the valve cage (see sheet 2751/2, Fig. 'A') and jack the valve cageout of the cylinder cover.

Remark: It is essential that the instructions on sheet 9403/4 referring to the application of hydraulic pre�tension�ing jacks to screwed fastenings be strictly followed. The loosening or tightening of the waisted studs,holding the valve cage to the cylinder cover, with the impact tightener is only permitted in exceptional

cases.

Regarding draining cylinder cooling water please refer to sheet 2708/1.

Working sequence for removal

Clean the threads of waisted studs 1 of the valve cage as well as the area around the stud nuts 2 (Fig. `B`).

Mount tensioning device 94252 consisting of four pre�tensioning jacks with straps on the four waisted studs 1 (Fig.'B'), afterwards turn them back by ½ turn.

Connect jacks up to the HP oil pump with HP hoses 94935, 94935a and oil distributor 94934a (see Fig. 'C').

Start up HP pump, at the same time open the vent screws of the pump till oil flows out bubble�free.

Raise a pressure of 600 - 620 bar with the pump and keep this constant till the four stud nuts 2 have been loosened.

Loosen all stud nuts with a round bar by one turn.

Open valve on HP pump to release pressure to zero, remove hydr. pre�tensioning device 94252.

Hang the hooks of suspension device 94265 (Fig. `E`) into the eye screws of the valve cage 11, then lift completeexhaust valve, with the crane.

If the exhaust valve is not to be dismantled at site immediately, mount the valve protector 94262 (Fig. `D`).

1989


Working sequence for fitting

Before fitting the exhaust valve into the cylinder cover, the sealing surfaces must be checked for cleanliness andpossible damage.

Make sure that the soft iron gasket 9 of 2 mm thickness lies flat in its recess in the cylinder cover.

Replace all O�rings by new ones of specified dimensions and quality, oil O�rings slightly before fitting.

Fit the complete exhaust valve with the help of the suspension device 94265, taking greatest care not to damage thethread of the waisted studs.The correct position of the exhaust valve cage is determined by the cylindrical dowel pin set in the cylinder cover.

Smear thread of waisted stud lightly with MOLYKOTE paste G.

Fit stud nuts 2 and tighten them firmly with a spanner till fully seated before mounting the hydr. tensioning device94252 (check seating with feeler gauge).

Mark position of stud nuts on a corner and their position on the valve cage 11 with a felt�tipped pen (for laterchecks).

Mount the four jacks of the hydr. tensioning device 94252 as described under paragraph 'Working sequence for theremoval' and vent the same, whereby the jacks are to be screwed on completely.

Slowly raise a pressure of 600 bar at the HP oil pump. Keep this pressure constant and tighten the four stud nuts 2with a round bar till firmly seated on exhaust valve cage 11 (check seating with feeler gauge). After tightening thestud nuts ascertain that the nuts have been turned by about the same angle i.e. about 150�.

Remark: When coupling�up and connecting HP hoses, always tighten sleeve 7 of connecting piece 5 (Fig. 'A')fully. This assures that non return valves 4 (balls) are open and the oil supply to the respective jack isnot restricted.

1989


AB

C98.7738

6

94935a

4

47

5

98.7738

I - I

I I

R

1

AF2

R94252

94941 (94931)

AF

94935a

94934a

94935a94935

98.7841

1989


D E

98.7842

I - I

I I

94265

94262

11

3

10

109

11

8

1989


Mechanical loosening and fastening of the valve cage on the cylinder cover

Whenever possible the waisted studs of the valve cage must always be loosened or tightened with the hydraulicpre�tensioning device, which prevents any unequal stresses in the studs which could lead to deformations of thevalve cage.Only in emergencies e.g. when the hydr. pre�tensioning device cannot be utilized, may the nuts of the valve cagewaisted studs be loosened or tightened with the pneumatic impact tightener 94264, when the procedure describedbelow must be followed.

Loosening

Use pneumatic impact wrench to loosen by 60� two diagonally opposed nuts 2 (Fig. 'F').Loosen the other two nuts 2 completely and remove them.Loosen, in several equal steps, the first two nuts, which had been loosened by 60�, till fully loose and remove them.

Tightening

Smear threads of studs as well as nut seating surface on the valve cage well with MOLYKOTE paste and thread�onthe nuts by hand till fully seated.

Tighten with spanner by hand with a smart jerk all nuts equally (check seating with feeler gauge).

Mark, with felt tipped pen a corner on each nut and corresponding point on the valve cage, the position '0'.

Further also mark on the valve cage by each nut in accordance with Fig. 'G' the positions for the 1st�, 2nd� and 3rdstep with a short line.

Apply the socket spanner in such a way that its '0' mark (on its circumference) corresponds with the '0'�mark on nutand valve cage.

Tighten the four nut Fig. 'F' cross�wise by an angle of 30� (1st step).

Then tighten four nuts by further 60� (2nd step), then by 60� (3rd step).

Finally check the complete tightening angle, it should be 150� (Fig. 'G') on four nuts equal.

F

G

98.7843

11 8 2

60 �

2. Stufe / STEP

Total 150 �

”0” – Marke

MARK

1989


Replacement of waisted studs

Should waisted studs 1 (in the following text called stud for short) of the valve drive, cylinder cover, relief valve orstarting valve have to be replaced, then their annular spaces must be filled with a sealing compound! Moreover thefollowing points must be observed:

� Before fitting a stud clean its thread and corresponding tap hole. The sealing faces must be degreased (usewhite spirit) and subsequently primed.

� Screw in the stud without lubricant on the thread, right to the bottom, and tighten it according to the instruc�tions on sheet 0352/1.Always utilize a stud driver or two nuts. Tools like a pipe wrench etc. which would damage the stud shank mustnever be used.

� For the protection of the stud in the cylinder cover, fill the ring space above the thread with a well adhering,water and oil proof sealing compound. The sealing compound must remain plastic at normal operating tem�peratures.

Recommended jointing compound and adhesive primers

Jointingcompound

No. ofcompounds

Hardener Adhesive primer Manufacturer

RTV�ME 622A 2 ME 622B G 790 Wacker Chemie (Switzerland) Ltd.Lautengartenstr. 23PO Box 4002 BaselCH�4052 Basel BS

Silcosed 6/105 2 A or D without typedesignation or OP

Wachendorf Ltd.Auf dem Wolf 17PO Box 4002 BaselCH�4052 Basel BS

Equivalent products of other manufacturers may also be used.

Dichtmittel

SEALING COMPOUND

93.7194

1

Dichtfläche

SEALING FACE

Ringraum

ANNULAR SPACE



Exhaust Valve

Dismantling and Assembling


1 Feeler gauge 94122 1 Valve cage 10 Guide bush1 Depth gauge 94124 2 Valve drive housing 11 Rod seal ring2 Jack screws 94263 3 Damper 12 Valve spindle1 Rotation device for 94290 4 Piston (hydraulic) 13 Rotation wing

valve cage 5 Bush 14 Valve seat5a Retaining ring 15 Cylinder cover6 Pressure flange 16 O�ring

6a Screw 17 Vent screw7 Ridged valve cone piece 18 Spacer ring8 Piston 19 Locating dowel

8a Piston seal ring B Shim9 Air cylinder housing R Eye bolt

EX Threaded holefor jack screw

Remarks:

For inspection or dismantling, tool 94290 has to be used, onto which the complete exhaust valve is mounted to per�mit locating it in any desired position (Fig. 'D').

Dismantling an exhaust valve

Valve cage is located vertically in rotation device 94290.

Loosen all four screws fastening the valve drive housing 2 to the valve cage.

Attach eye bolt 'R' to the lifting tackle and lift damper 3, together with valve drive housing 2, hydr. piston 4 and bush5 off the valve cage 1. The hydr. piston 4 remaining in bush 5 is thereby pulled up and held by retaining ring 5a.

Bring valve cage to the horizontal position with the help of the rotation device 94290.

Loosen and remove screw 6a in pressure flange 6 from the connection piston 8 / valve spindle 12. The piston 8 cannow be pushed down in the air cylinder 9 and the two ridged valve cones 7 can be pushed from the groove in theshank of the valve spindle 12.

Actuate inverting drive on the inverting support and bring the valve cage with the still fitted valve spindle (forspindle removal upwards) into the vertical position. Should the height for spindle removal be restricted, the re�moval is also possible in a horizontal position (see Fig. 'B').

Remove valve spindle.

If the guide bush 10 has to be removed, press it out with the two jack screws 94263 (Fig. 'B1').

1989


98.7846

A

Lecköl

LEAK OIL

R

17

1

6a

162

17

2

2

3

4

5

5a6

8a

7

18

1

19

8

9

11

10

EX

13

12

15

14

1989


98.7847

B

B1Einbau

ASSEMBLINGAusbau

DISMANTLING

94263

10

1

10

Gezeichnet für RTA76

DRAWN FOR RTA76

1989


Assembling the exhaust valve

The assembly is carried out along the same lines as the dismantling but in reverse sequence. Note that rod seal ring11 and spacer ring 18 must always be fitted after fitting the valve spindle, otherwise the rod seal ring might be dam�aged when the valve spindle is inserted.

For attention

� The condition of the piston seal ring 8a has to be checked at every opportunity, at the latest however during anexhaust valve overhaul according to the maintenance schedule. A defective piston seal ring as well as rod sealring 11 must be replaced without fail. For the admissibles dimensions of the exhaust valves please consultClearance Table sheet 0330/4.

� When an exhaust valve is equipped with a new valve seat or valve spindle, in every case without exception thevalve seat must be reconditioned in the fitted condition with the valve seat grinding machine (see instructionson sheet 2751/3).

� Smear threads of screws 6a to pressure flange 6 lightly with MOLYKOTE G paste, then screw them in.Tighten the screws equally to a final tightening torque of 180 Nm. After tightening all screws 6a, check themrepeatedly for correct tightening, as the valve cone pieces 7 embed themselves during the tightening proce�dure. The screws which have already been fully tightened can thereby lose their pre�tension, and must there�fore be checked again for correct pre�tension.

� Apply a bit of MOLYKOTE paste to the screws for the bush 5 and the retaining ring 5a. Subsequently thescrews must be tightened to 170 Nm and secured with a locking wire.

� In the course of every overhaul of the exhaust valve seat/spindle the damper 3 must be removed. Establish withdepth gauge 94124 the measure 'H' from the upper edge of housing head 2 to the bottom of the damper bore inpiston 4 (see Fig. 'C'); for this the exhaust valve must be closed (check with feeler gauge whether the valve platelies against the valve seat without clearance).Establish the thickness 'h' for the new shims 'B' to be fitted with the help of formula below:

h = 207 - H ± 0.50 mm

Fit damper with newly adjusted shim stack. Single shim rings to 1 mm thickness are available.

� After each overhaul the vent screw 17 (Fig. 'A') must be checked and cleaned.

88.7023

C

H

h

4

2

94124

20

3



D

98.7848


DRAWN FOR RTA76

1

94290

1989



Exhaust Valve

Replacing and Grinding the Valve Seat


1 Valve cage2 Valve seat3 O�ring

AF Seating faceH HammerR Eye boltT Tensioning screwsZ Centring

Tools:

1 Feeler gauge 941221 Valve seat fitting and dismantling device 942611 Valve seat grinding machine 942781 Pilot 94278a1 Holding strap 94278b1 Milling cutter 94278c1 Gauge 942791 Rotation device for valve cage 94290

On valve seats where the seat surfaces are badly damaged, or on which the wear limit has been reached throughfrequent grinding, must be replaced.The most advantageous position for replacing the valve seat is to bring the valve cage to the vertical (see Fig. 'C').This is also the position required for grinding with the valve seat grinding machine.The guide bush (spindle guide) does not have to be removed.

Grinding as well as any repair work on the valve seat must be recorded on the sheet 'Exhaust Valve Record', Form4-107.044.059-1/-2.

Removing the valve seat (Fig. 'A')

Fit both pairs of ring halves of the valve seat fitting and dismantling device 94261 into the groove on the circumfer�ence of the valve cage 1 and valve seat 2 respectively.With the aid of the three jack screws of the valve seat fitting and dismantling device, the valve seat can be pressed outof its seating in the valve cage.Should a used valve seat be re�used, then it must be marked together with the valve cage before removing. Whenre�fitting the valve seat the previously applied markings must again be brought in line.

A

94261

2

3

1 99.7487



Fitting the valve seat (Fig. 'B')

- Place valve cage - as for the seat removal - vertically (Fig. 'C').

- Clean bore as well as seating shoulder at 'AF' meticulously and with greatest care. Unevenness or damage toseating face 'AF' would lead to leaks.

- Smear the bore into which the valve seat has to fit with oil, or lubricants such as e.g. THREAD GARD, LOC�TITE, ANTI�SEIZE COMPOUND etc.

- Smear with the same lubricant and place new O�ring 3 of original specification into the groove in the valvecage.

- Push valve seat as far as possible into the bore, then mount valve seat fitting and dismantling device 94261 (Fig.'B') and by even tightening of the jack screws press the valve seat down till fully seated. Through the controlopenings in the valve seat fitting and dismantling device check with the feeler gauge 94122 all around the cir�cumference that no clearance remains at 'AF'. For this check the fitting device has still to be fitted fast as re�quired for the subsequent grinding of the valve seat.

B

94261

2

1

99.7488

3

AF

94261

94122



Grinding the valve seats

Valve seats must be ground only with the valve seat grinding machine. Grinding in valve seats using valve spindlewith grinding paste must be avoided as a matter of principle!

When should valve seats be ground in the valve cage?

Always when new valve seats are fitted to the valve cage.

When new or reconditioned valve spindles are fitted. An exception can be made if the seating surface is neitherworn nor damaged by corrosion.

When the seat surface on the valve seat is badly damaged through operation with heavy fuel oil (Impacts, corrosionscars).

Chamfer h h1 i i1

Angle 15� 15�

Width 10 mm 30 mm

C

302’+0

�

98.7856

ii1

h

h1

94278b

94278a

94261

Z

T


DRAWN FOR RTA58

1989


The machines from the makers HUNGER and CHRIS MARINE are well proven for valve grinding.

When grinding the valve seat, take care that as little grinding dust as possible falls into the valve cage or even staysthere. A thorough cleaning after completion is absolutely essential.

Regarding the operation of the grinding machine please refer to the operating instructions supplied with it.

The grinding must produce an even and smooth surface.

It is particularly important that the grinding machine is mounted in such a way that it is correctly centred in the valveguide bush. The chamfers in the valve guide bush provide fixed setting surfaces for the cones on the 'Pilot' (see de�tails in Fig. 'C'). Before inserting the grinding machine remove carbon deposits from the chamfers with tool 94278c.With the help of centring aid 'Z' fitted to the 'Pilot' fasten the grinding machine optimally. Furthermore remove rodseal ring 11 (see Fig. 'A' on sheet 2751/2) to save it from being damaged. For grinding fit spacer ring 18 (without rodseal ring), as its chamfer serves as a guide.

Experience has shown that when grinding valve seat surfaces 'chatter' marks are generated if vibrations are set up bymotors or other machines in the vicinity. To prevent with certainty such 'chatter' marks always mount the valve cagefor grinding the valve seat, in the mounting trestle tool 94290, which is seated for this reason in spring elements.

To prevent counter�rotation of the grinding machine during the grinding fix the holding strap 94278b as shown inFig. 'C' to the ring of valve seat fitting device 94261. The forked end of the holding strap grasps the hand grip andthus keeps the machine head in position.

In principle grinding can be carried out in both directions . We recommend however always to grind from insideto outside. Finishing however must be done from inside out, as only this method achieves the required angle preci�sion.

Valve seat angle = 30� + 2’0

The grinding allowance on the valve seat is maximum 3 mm. The wear condition can be checked efficiently withgauge 94279 in combination with feeler gauge 94122 (see Fig. 'D'). Possible burn scars at the inside of the valve seatmust not exceed 13 mm. The depth of the burn scars can also be verified with the gauge 94279 as shown in Fig. `D'.Valve seats which exceed the above mentioned values must be replaced.ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ 97.7079

max. 13mm

94279

HR

D

E



After grinding it is necessary to check whether the new or re�ground valve makes correct contact with the valve seat.For this the spindle head seat face is stained with a thin coating of blueing paste, then inserted vertically into thevalve guide bush.

The angle difference is chosen such that in the hot operating condition the valve makes contact by 50% - 100%from the outer edge. The blueing check should show that the cold valve makes contact only from inside around thewhole circumference. The angle difference can be checked at the gap 'S' on the outer edge with a feeler gauge (Fig.'G').

For careful attention: The "Remarks" in sheet 2751/2 concerning the fitting of re�ground valves or valveseats must be considered.

The blueing on the valve seat must be checked by tapping the valve head three or four times with a hammer on awooden block! (Fig. 'E').Do not rotate the valve spindle on the valve seat face, as this risks seizure of the seating.

S = 0.13–0.16 mm

93.7199

302’+0�

F

G

50–100%

1989


1989


1989



Exhaust Valve

Grinding the Seating Surface on the Valve Head

Tools:

1 Feeler gauge 941221 Valve grinding machine 942911 Gauge 94292

Information concerning the grinding of valve seats in valve cages isgiven in sheet 2751/3.All grinding and repair work carried out on the valve spindle mustbe recorded on the Sheet "Exhaust Valve Record", Form umber4-107.044.059 -1/-2. Form samples are attached as sheets 6/7 atthe end of group 2751/3.

Grinding in a valve together with its valve seat with grinding paste is not permitted.

Valves which have had the seating surfaces badly damaged by pitting or corrosion have to be reground by machine.It is strongly recommended that a suitable grinding machine such as tool 94291 be made available.The machines from the makers HUNGER and CHRIS�MARINE are well proven for valve grinding and can alsobe ordered direct from Wärtsilä Ltd, Winterthur.

Seating face angle on valve

� = 30� +18'+20'

94291

A

98.7857

�

Only as little material as necessary should be ground off the valve seating face to provide a clean and smooth fin�ished surface.

Only grind with cooling (wet).

In order to avoid the appearance of chatter marks on the seating surface, the grinding machine should be placed inan area which is free of vibration from running machinery or engines, etc. If necessary the grinding machine shouldbe stood on a rubber mat.

For the operation of the grinding machine, please refer to the operating instructions of the respective makers.

Good results have been obtained by using the following recommended grinding wheels:

Cut

Supplier Stone quality Coarse Fine

HUNGER 64A46H15 VPapprox. 0.025 mm approx. 0.010 mm

CHRIS�MARINE 01/1373approx. 0.025 mm approx. 0.010 mm

Feed rate

with automatic oscillation system

10.94


A maximum of 3 mm may be ground off the valve seatingface.

The wear condition can be checked at any time with thegauge (tool 94292) and feeler gauge (Fig. 'B').

Where the precise angle required has been obtained duringgrinding, a check with marking blue with the valve on the re�ground valve seat in the valve cage will show only a line con�tact or a very narrow band (extent of contact) starting fromthe smaller diameter (Fig. 'C').

See also remarks on sheet 2751/3 regarding the valve beha�viour at running temperature.

On engines with heavy operation duty, corrosion may format the bottom of the valve plate, after a longer operatingtime. Valve plates, on which the corrosion layer is deeperthan 12 mm or where the seat surface has been ground backby more than 3 mm (Fig. 'B'), can be reconditioned bybuild�up welding.

Such a repair process may, however, only be carried out by aWärtsilä Switzerland Ltd authorized repair workshop.

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ94292

max. 12 m

m

max. 3mm

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ95.7977a

B

C

Please note: A valve spindle with missing rotation wing may not be reground. The wing hub must be shrink�fitted on the valve shaft by heating it to 480° C. Grinding may first begin after the whole unit hascooled down.




Crankshaft, Connecting Rod and Working Piston Group 3

� Crankshaft

– Measuring Crank Deflection 3103/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Vibration Damper

– Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper) 3130/1. . . . . . . . . . . . . .

� Axial Detuner


� Turning Gear

– Oil Change and Checking the Worm Wheels 3206/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Crankcase

– Utilization of the Working Platform 3301/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Connecting Rod

– Loosening and Tensioning the Connecting Rod Studs and Bolts 3303/1. . . . . . . . . . . . . . . . . . . . . . . . .

– Inspection, Removing and Fitting of Bottom End Bearing 3303/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Inspection, Removing and Fitting of Top End Bearing 3303/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


� Connecting Rod (1-part)

– Loosening and Tensioning the Connecting Rod Studs 3303/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Inspection, Removing and Fitting of Bottom End Bearing 3303/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


� Crosshead

– Checking Clearances 3326/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Removal and Fitting of a Crosshead Pin 3326/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Working Piston

– Removal and Fitting 3403/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Changing the Compression Shims 3403/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


– Checking Piston Top Surface 3403/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

� Piston Rings

– Checking Piston Ring Wear 3425/1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Checking Piston Ring Wear (Cylinder Liner with Antipolishing Ring) 3425/1. . . . . . . . . . . . . . . . . . . . .




Crankshaft

Measuring Crank Deflections


1 Flywheel2 Pinion

Tools:

1 Dial gauge 94305

In order to ascertain whether the axes of the crank journals deviate from the theoretical shaft axis, the crank deflec�tions must be measured. When doing so the ship must be floating freely.Under normal circumstances, it is sufficient to measure the crank deflections once a year. They must, however, bemeasured as soon as possible in case the ship has grounded or after replacing the main bearing shells. The deflec�tions have to be measured again approx. 100 service hours after replacing the bearing shells.

Should signs of damage of the main bearings be found during inspection of the crankcase, the crank deflectionsshould also be measured.

Measuring is carried out using a crankshaft dial gauge (tool 94305) which, for this purpose, is inserted between thecrank webs of the crank to be measured. When turning the crankshaft, the change in distance between the crankwebs can be read from the dial gauge as this indicates any opening or closing up. The smaller the variations thebetter the position of the shaft.

Rotation direction of crankshaft:

To measure the crank deflection the crankshaft must always be turned in such a manner - despite the ordinaryrotation direction of the engine - that flywheel 1 and pinion 2 of the turning gear are rotating as indicated by thearrow (see Fig. 'A').

99.7009

1

2

A



Measuring procedure (indicator valves must be open)

With the running gear in place, the crank to be measured has to be turned towards (before or after) B.D.C. until thedial gauge can be fitted next to the connecting rod at the position indicated. Pretension the dial gauge slightly andset it to "0" (see Fig. 'B').

Turn the crankshaft with the turning gear, reading the dial gauge in the crank positions which are indicated in Fig.'B' and noting down the values. The last value is for checking; if everything has been carried out correctly it shouldbe nearly "0".

Measuring pointsKurbel im O.T.P.

CRANK AT T.D.C.

93.7167

Dial gauge

94305

B

Noting down the values:

The values which have been read are to be noted down in a table containing the following data:

- At what positions of the crankpin the values have been read, in terms ofB.D.C. � fuel side - exhaust side � T.D.C.

- Rotation direction of the crankshaft when measuring the crank deflection.



The difference (�a) between the indicated values at B.D.C. and T.D.C. shows the amount of crank deflection dur�ing one revolution (see Fig. 'C').All influences which cause a temporary deformation of the hull and/or the engine affect the crank deflection.

These are for example: - loaded condition of the ship- engine cold or at service temperature- differing air/water temperatures- strong sunshine

The values of �a given below are valid for all conditions independent of outside influences.

Where values are measured which lie over the maximum permissible limits, the cause has to be found and the neces�sary remedial measures taken (defective main bearing, engine support altered due to hull deformation, loose hold�ing�down bolts, defective shaftline bearings, etc.).

When measuring the crank deflection, ensure that the crank journals are fully seated in their bearings.

a = a T.D.C. – a B.D.C.Difference

Good values

Values still admissible

�

a = 0 – 0.30 mm

a = 0.30 – 0.60 mm

�

�

Str

oke s

a T.D.C.D

a B.D.C.

Dial gauge94305

C




Vibration Damper

Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper)


1 Large screw driver 1 Cladding 8/8a Spacer ring1 Flat caulker 1a Hood 9 Balance mass1 Medium hammer 2/2a Casing bottom 9a Counter weight1 Center punch 3/3a Casing cover 10 Rubber ring

assorted spanners 4 Rubber ring 11 Sealing ring5 Intermediate shaft 12 Screw plug6 Crankshaft end C Sample container

6a/b Coupling bolts D Cover7 Camshaft K Lock by center punching

7a Coupling *Alternative execution

The service life of a vibration damper is largely dependent on the speed range in which the engine is run. Wear of theinner parts as well as changes in the silicone oil properties can contribute to a reduction in the damper's effective�ness. By periodic examination of the silicone oil the makers of the vibration damper can draw conclusions on itscondition.It is therefore recommended to have the silicon�oil examined periodically the first time after about 15-18'000 op�erating hours. Future intervals for examinations depend on the result of these first findings.

Special sample containers can be obtained from the damper makers (see Fig. 'C').

Remark on the drawing of a silicone oil sample:

In the casing bottom 2/2a or in the casing cover 3/3a, two oil drawing holes are carefully closed and sealed with screwplugs 12. Vibration dampers of very recent manufacture will be equipped with two each withdrawing points on ei�ther side, so that the samples can be taken on the side of best accessibility.

Vibration damper on the free end (crankshaft)

5.92


Vibration dampers on the free end (camshaft)

Preparations

Remove the hood 1a or cover 'D' respectively.

Rotate the crankshaft or the camshaft until one of the screw plugs 12 on the sample drawing side chosen, is in thebest accessible position (Fig. 'B').

Pay attention to the vibration damper make concerned!

Using a flat caulker, hammer back the squeezed material in the slot, which serves as locking means.

Loosen the screw plug, but do not unscrew it yet, it must still seal the oil in.

Rotate the crankshaft or camshaft respectively until the chosen and prepared oil drawing opening reaches the bot�tom most point.

Leave the damper in this position for at least two hours. (If the oil sample is to be withdrawn from a removed vibra�tion damper the same conditions apply as regards the positions and the waiting time). In both cases the vibrationdamper must have cooled down to about room temperature.

Prepare the sample container, i.e. remove the cap nut and examine the bore which must be meticulously clean.

Attention! The threads on the two ends are different on the Holset damper (see Fig. 'C').

1989


Drawing a sample

- Unscrew the screw plug 12 and in its place screw in the prepared sample container.

- Wait till the silicone oil flows out of the open sample container end. Depending on the viscosity of the siliconeoil this may take some time.

- As soon as the silicone oil begins to flow out, close the sample container with the first cap nut.

- Unscrew the sample container from the damper casing (hold vertically) and fit immediately the screw plug 12with a new sealing ring11. (Avoid unnecessary leakage of silicone oil)!

- Fit the second cap nut on the sample container and finally tighten both moderately.

- Tighten the screw plug 12 with about 25 Nm and lock it by caulking metal into the slot.

If a sample is not obtained by the method described, proceed as follows:

1. Leave sample container in position.

2. Remove the opposite screw plug, connect a compressed air supply and apply about 3.5 bar pressure.

3. Only dried and filtered air may be used (connections and air hose must be clean, free from any fouling).

4. As soon as fluid reaches open end of sample container shut off compressed air supply and then fit one of thetwo cap nuts to the sampling container.

5. Disconnect compressed air supply. Remove sample container and fit the other cap nut.

6. Re�fit the corresponding screw plugs to all withdrawal openings.

7. Tighten and lock the screw plugs as already mentioned under 'Drawing a sample'.

Attention: The special sample container permits drawing a specific quantity of silicone fluid from the damper.The total numbers of samples should be limited to ten times.

The filled sample container has to be labelled and sent to the following address for examination:

Hasse & Wrede Holset

Carl Hasse & Wrede GmbH Simpson International Ltd (UK)Mohriner Allee 30-42 or 131 Parkinson LaneD-12347 Berlin GB�Halifax HX1 3RDGermany United Kingdom

Telefon: 0049 30 70 181�0 Telefon: 0044 1422 357 234Telefax: 0049 30 700 90 8�11 Telefax: 0044 1422 354 432

The label must contain the following information:

� Engine type,

� Engine No.,

� Number of operating hours of the vibration damper,

� also its manufacturing serial number (this number is stamped into the cover in the vicinity of the warning plate).



1989


Axial Detuner

Dismantling and Assembling


1 Upper part of cylinder2 Lower part of cylinder3 Screw4 Screw5 Screw6 Large seal ring7 Small seal ring8 Self�locking nut9 Allen screw

10 Throttling valve11 Spindle12 Locking screw13 Diaphragms14 Oil inlet pipe15 Main bearing cover16 Crankshaft17 Main bearing shellR Eye bolt

Tools:

1 Wire rope with two shackles 941191 Roller support 943102 Eye bolts M30

Prior to any overhaul work being started on an axial detuner, switch off the bearing oil pump. Then remove theupper half of the two�piece crankshaft cladding at the free end.

Dismantling

- Remove oil inlet pipe 14.

- Pull both taper pins locating the upper and lower part of cylinder 2 and 1 respectively. For this purpose thetaper pins have been provided with respective threads.

- Loosen and remove all screws 5 and 3 (Fig.'A').

- Loosen screws 4 to the upper part of cylinder 1 and pull them out as far as possible.

- Screw in the two eye bolts 'R' (Fig.'B') into the upper part of cylinder and join the two eye bolts by wire rope94119 and the two shackles.

- Fasten roller support 94310 to the face of the free end of the engine as shown in Fig. 'B'.

- Using lifting tackle carefully raise upper part of cylinder . Make absolutely sure that the upper part of cylinderslides out of the seal rings 6 and 7 without jamming, as otherwise the seal rings risk being damaged.

- Should seal rings 6 and 7 (in two parts) have to be replaced, loosen first self�locking nut 8 and remove Allenscrew 9. The sealing rings can then be turned out of their grooves in the lower part of cylinder 2 without prob�lems.

Checking the throttling valve

When overhauling the axial detuner check also the condition of throttling valve 10. The spindle position has beenlocked by locking screw 12 and a locking plate. This has been done because changing this position is forbidden.

The throttling valve is turned back by about four turns starting from the closed position. No further adjustment isnormally necessary after setting the proper position.

Should it become necessary to replace a spindle for any reason, at a time where no instrument is available for mea�suring the axial vibrations of the crankshaft, then the spindle must be adjusted in the following manner:

Turn the spindle clockwise till the stop, then turn it back by the distance marked on the nameplate.

Should this mark not have been made on the nameplate, then measure the distance from the spindle face to thecasing of throttling valve. A new spindle has to be adjusted to the same distance.

When the above check brings to light any defect of throttling valve 10 (Fig. 'A') then diaphragms 13 screwed into thethrottling valve must also be checked for possible damage and replaced if necessary.

Attention The spindle must not be turned back by more than 16 turns, that corresponds to a stroke of 48 mm.The engine must not be operated with the spindle removed or with the oil supply to the axial detunerinterrupted.



Assembling

Badly worn or damaged seal rings 6 and 7 must be replaced. The seal rings are fastened by two Allen screws 9 andself�locking nuts 8. Immediately before fitting them smear the seal rings with clean engine oil.

Newly fitted seal rings must allow radial movement when fitted

The assembling of the axial detuner is done analogous to dismantling but in reverse sequence. Pay the utmost atten�tion when lowering upper part of cylinder 1 into place that seal rings 6 and 7 are not being damaged.

Before tightening screws 3 as well as 4 and 5 fit the taper pins for the upper part and lower part of the cylinder.

Tighten screw 4 between axial damper and bedplate with a tightening angle of 50 ��.

9.99 Wärtsilä NSD Switzerland Ltd


13

15

1

5

4

3

2

16

17

15

10

12

7

11

6

99.7489

7

9

8

I

89.7070

I

7

A



94310

R

1

16

94310

94119

R

16

15

94119

B

I

I

89.7067

1989


Turning Gear

Oil Change and Checking the Worm Wheels


1 Housing 22 Electric motor2 Spacer ring 23 Handwheel3 Bearing flange 24 Large worm wheel4 Bolt with locking plate 25 Oil filling screw5 Oil drain screw 26 Engaging / disengaging lever 6 Worm wheel 27 Pinion shaft7 Cover 27a Protective tube over pinion shaft8 Backing plate 28/28a Turning pinion/Turning wheel9 Bolt with locking plate 29 Flexible coupling

10 Oil level indicator 30 Bolt with locking plate11 Spacer sleeve 31 Bearing flange12 Tapered roller bearing 32 Connecting piece13 Horizontal worm shaft 33 Tapered roller bearing14 Bearing flange 34 Vertical worm shaft15 Bolt with locking plate 35 Intermediate flange16 Intermediate flange 36 Spacer ring17 Spring pack 37 Spring pack18 Closing cover 38 Bolt with locking plate19 Bolt with locking plate 39 Bearing flange20 Bolt with locking plate

1989


Before putting the turning gear into operation, always first check the oil level in the housing by removing the dip-stick from the oil level indicator 10. The oil level must lie between the two marks on the dipstick.Top up the oil if necessary, using a

Hypoid gear oil of viscosity 220-270 cSt at 40�C(16.5-19.7� E at 50�C)

The pinion shaft 27 must always be coated liberally with MOLYKOTE grease whereas it is sufficient for the teeth ofthe turning pinion 28 to be greased lightly.Once a year, drain off some oil from the turning gear and visually examine it for wear particles (firmly retighten oildrain screw 5 afterwards). If this examination clearly shows contamination, the oil has to be drained off completelyand the condition of the worm wheels has to be checked. This can be done after removing the cover 7 and the oilfilling screw 25. This check must in any case be carried out at least every four years.The oil capacity is approx. 60 liters for 4 - 7 Cyl. engines, approx. 148 liters for 8 - 12 Cyl. engines.The housing has to be thoroughly flushed out with flushing oil before filling up with oil.

Replacing the tapered roller bearings

Should it become necessary to replace the tapered roller bearings of either the horizontal or vertical worm shafts,the procedure is as follows:

a) Horizontal worm shaft (see Fig. 'A'):

Drain off all the oil and remove cover 7.

Slacken off and remove the four bolts 9 which secure the backing ring 8 of the worm wheel 6 on the worm shaft.Using two of the removed bolts, now bolt the backing ring onto the side face of the worm wheel 6; two threadedholes are available.

With the aid of a jacking screw M 24 screwed into the threaded hole in the center of the backing ring 8, jack off theworm wheel from the shaft.

Remove the mounting bolts of both the bearing flanges 3 and 14 and pull off the latter using jacking screws. Theworm shaft can then be removed.

When fitting new tapered roller bearings, the same procedure as for removal is followed in the reverse order. Whendoing so, ensure that the spacer sleeve 11 is replaced between the tapered roller bearing 12 and worm wheel 6 aswell as the spacer ring 2 under bearing ring 3.

b) Vertical worm shaft (see Fig. 'B'):

Drain off all the oil and remove cover 7.

After removing the mounting bolts, lift off the electric motor with the crane.

Remove the mounting bolts of both the bearing flanges 31 and 39 and pull off the latter using jacking screws. Theworm shaft can then be removed.

When fitting new tapered roller bearings, the same procedure as for removal is followed in the reverse order. Whendoing so, ensure that the spacer sleeve 36 is placed under bearing flange 31.

1989


1989


1989


Crankcase

Utilization of the Working Platform


1 Engine longitudinal beam2 Crank web3 Step4 Strap

Tools:

2 Working platforms, 94142consisting of 3 grids each

3 Working supports 94143

To avoid accidents, the grids of working platform 94142 and working supports 94143 should be used for inspectionsor work in the crankcase. The grids must always be fitted in such a way that their U�profiles come to lie betweenengine longitudinal beam 1 and that the opposite end rests on crank web 2.

Working support 94143 can be fitted between the columns at the desired height, on steps 3. These are safeguardedagainst falling down by shoving straps 4 against the steps.

Attention! Never rotate the crankshaft while the grids or working supports are in position.

I - I I

I

94143

94142

1

Bre

nnsto

ffseite

FU

EL S

IDE

94143

3

94142

1

2

A

010.858/03

010.859/03

94143 4

3




Connecting Rod

Loosening and Tensioning the Connecting Rod Studs and Bolts


1 Connecting rod stud / bolt2 Nut3 Cylinder4 Rod seal ring5 Piston seal ring6 Piston7 Vent screw8 Screws

8a Cover with grip9 Cup springs

K Checking slotR Round barV Relief valveX Check point

Tools:

2 Pre�tensioning jacks 94314/3151 HP oil pump 949312 Pressure gauge 949322 Connecting branchs 949331 Distributing piece 94934a3 HP hoses 94935/a2 Impact ring spanner AF 85/1151 Feeler gauge 941221 Depth gauge 941241 Sledge hammer *

* To be used only in emergency when the hy�draulic pre�tensioning device is out of order.

94932

6

93.7200

A

94933

5

4

3

7 8

X 1

9

R

K

8a

9431494315

2

Attention!

Never rotate the engine (with the turning gear)when the hydraulic pre�tensioning jacks aremounted on the connecting rod (waisted) studs orbolts!

Important Remarks!

To loosen or tension the connecting rod studs /bolts always use the hydraulic pre�tensioning de�vice. Only in emergency in case the hydr. pre�ten�sioning device is not serviceable, may spanner andsledge hammer be used for tightening.

For loosening and for tensioning the connectingrod studs / bolts always follow the sequence shownin Fig. 'B' i.e. a + a and b + b.

Before screwing the nuts onto the studs cleantheir threads and the seating surface for the nutcarefully: corrosion protecting oil may remain inthe thread. Furthermore check that the nuts turnfreely on the stud thread.

1990


1989


For loosening and for tightening the studs of connecting rod top end bearing as well as the bolts of connecting rodbottom end bearing the crank of the respective cylinder should be turned to B.D.C. or T.D.C. position.

The pre�tensioning jacks are auto�resetting, i.e. when the oil pressure is released, by opening the release valve onthe oil pump, their pistons are again returned to their neutral position by the force of the cup springs (springpacket). This entails that the release valve at the pump remains open ½ � l minute, allowing the oil to flow back to thepump.

For information on the removal and fitting as well as inspection of bottom end and top end bearings refer to sheets3303/2 and 3303/3.

Under no circumstance the separating faces of the upper connecting rod bearing shells must be reduced by filingetc. as otherwise the essential pre�stress for the bearing assembly would be lost.

Loosening the connecting rod studs and bolts of top and bottom end bearing shells

1) Hydraulically:

For this, follow the general instructions for the application of hydraulic pre�tensioning jacks in sheet 9403/4.

2) Mechanically (only in case of emergency):

Should it be impossible to use the hydraulic device, then the nuts must be loosened in pairs across and in equal smallsteps using impact ring spanner and sledge hammer.

Tensioning the connecting rod studs and bolts

1) Hydraulically:

The previously mentioned 'Important Remarks' must be considered.

Tighten the nuts first with the spanner by hand with a smart jerk.

Distribute the clearance equally between the bearing cover and connecting rod shank (bearing projection) of thetop end bearing by using feeler gauge 94122.

Check whether the nuts rest flush.

Screw both pre�tensioning jacks 94314 or 94315 respectively onto the connecting rod studs or bolts of the corre�sponding bearing (see Fig. 'B', a + a and b + b) until they rest against the connecting rod shank. If necessary turnjacks back a little to allow access of nuts 2 with the round bar, so that it can later be turned.

Connect the jacks to the pump and set pressure to 400 bar for the connecting rod top end bearing, and 350 bar forthe bottom end bearing (1st step) and hold these constant.

Tighten the nuts with the round bar and check with the feeler gauge that no clearance 'X' remains between nut andconnecting rod shank.

Proceed in the same manner for the second pair of connecting rod studs or bolts.

Check with the feeler gauge that no clearance remains between bearing cover and connecting rod shank (for topend bearing). Should clearance remain, loosen the fastening and compare the bearing projection with the nominalvalue as indicated in sheet 3303/3.

Mark the position of the nuts against shank as shown in Fig. 'a', with felt marker or similar.

Raise the pressure to 600 bar and hold it constant (2nd step).

Tighten nuts down and check correct seating with feeler gauge.

Check from the markings applied by how much the nuts were turned after pre�tightening (1st step).Tightening angle (1st to 2nd step) to be = about 23� on the studs of top end bearing (Fig. 'b')Tightening angle (1st to 2nd step) to be = about 40� on the bolts of bottom end bearing (Fig. 'b')

For an additional check, the elongation can be measured with depth gauge 94124 by unscrewing the jacks after pre�tensioning (1st step), and measuring the lengths 'L' on all the connecting rod studs or bolts and recording them indi�vidually (Fig. 'c').

Mount the pre�tensioning jacks again as described before, then raise the pressure to 600 bar and hold it constant(2nd step).

Tighten nuts down, check correct seating with feeler gauge.



When all connecting rod studs / bolts are fully pre�tensioned, remove jacks and measure the lengths 'L' a secondtime with the depth gauge 94124 and record these readings as 'L1' (Fig. 'c'):

�L = 0.39 mm for studs of top end bearing (1st to 2nd step)L1 - L =

�L = 0.70 mm for bolts of bottom end bearing (1st to 2nd step)

Should considerable differences to these nominal values be encountered then repeat the tensioning process.

Finally check the vertical bearing clearance (compare with Clearance Table 0330/5) and lock the nuts 2.

2) Mechanically (only in case of emergency):

The previously mentioned 'Important Remarks' must be considered.

Tighten the nuts with the spanner by hand with a smart jerk.

Distribute the clearance equally between the bearing cover and connecting rod (bearing projection) on the top endbearing by using feeler gauge 94122.

Check to ascertain that the nuts are fully seated on the connecting rod and that the two bearing halves of the con�necting rod bottom end bearing are seated without clearance in the dividing faces.

Tighten all nuts of the top end bearing in small steps with impact ring spanner and sledge hammer until the clear�ance on either side of the bearing between cover and connecting rod shank measures 0.04 mm.

Mark the position of nuts against the shank Fig. 'a' with felt marker .

Measure the lengths 'L' on all the connecting rod studs or bolts with the depth gauge 94124 and record the readings(Fig. 'c').

Tighten all nuts of respective bearing alternately and in small steps with impact ring spanner and sledge hammer tothe following tightening angles (Fig. 'b')

45� for studs of top end bearing

90� for bolts of bottom end bearing

Measure the lengths 'L' a second time with the depth gauge and record the readings as 'L1':

�L = 0.75 mm for studs of top end bearingL1 - L =

�L = 1.50 mm for bolts of bottom end bearing

In case of considerable deviations from these nominal values, repeat the tightening process.

Finally check the vertical bearing clearance (compare with Clearance Table 0330/5) and lock the nuts 2.

Nut

Tightening angle

fully tensioned

Stud thread

pre-tensioned

Connecting rod

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉyx

y

x

� L

L

L1

Fig.'a' Fig. 'b' Fig. 'c'

x = Mark with felt marker on connecting rod shank

y = Mark with felt marker on the nut



Connecting Rod

Inspection and Removal of Bottom End Bearing


4 Holding pins 94323 1 Connecting rod bolts 9 Threaded holes Hydr. tools as per 2 Nut for eye boltssheet 3303/1 3 Locking element 10 Connecting rodLifting tackle 4 Locking plate 11 Allen screw

2 Eye bolts 5 Locking screw 12 Cylindrical dowelAssorted steel ropes 6 Lower bearing cover 13 Cylindrical dowel

7 Top end bearing cover 14 Crankshaft8 Guide rail 15 Strap

16 Holder

Inspection and removing

For removing the lower cover to the bottom end connecting rod bearing loosen nuts 2 of connecting rod bolts 1hydraulically as described in sheet 3303/1, which operation must be carried out with the crank in T.D.C. Prior to thatremove locking plates 4, locking screws 5 and locking elements 3. Fit a eye bolt on either side of lower bearing cover6 in the threaded hole 9 provided on its crown. Further secure lower bearing cover 6 by two steel ropes attached tostraps 15 (Fig. 'A') and two suitable lifting tackle.

Remove all four nuts 2. The connecting rod bolts are secured by holders 16 from falling out.

Gradually and carefully lower lower bearing cover with the four connecting rod bolts 1 using two lifting tackles.Take great care that the two cylindrical dowels 13 slide out of their bores without jamming and that the threads of theconnecting rod bolts are not damaged.

Remove the lower bearing cover together with the four connecting rod bolts from the crankcase.

Should the case occur that after the removal of the lower bearing cover the top end bearing cover 7 has to be in�spected or removed then proceed as follows:

Insert all four holding pins 94323 into the guide rails (Fig. 'A').

Secure connecting rod with a rope and lifting tackle on the fuel pump side.

Turn crankshaft carefully towards fuel pump side till the slippers come to rest on the holding pins 94323. If neces�sary turn the holding pins somewhat till the slippers rest snugly against the excenters of the holding pins.

Attention: Do not yet unscrew ALLEN screws 11 (Fig. 'B').

Turn crankshaft further downwards while at the same time correcting with the lifting tackle on the fuel pump side sothat during this operation the upper bearing cover 7 stays always free off the crank pin. In the position shown in Fig.'A' the upper bearing cover can be inspected.

Should an upper bearing cover have to be removed then the lifting tackle has to be slackened until connecting rod 10hangs vertically down.

Screw two eye bolts into the threaded holes 9 in the upper bearing cover. Secure the upper bearing cover with tworopes attached to straps 15 and hold the upper bearing cover with two lifting tackles in its position.

Remove both 'Allen' screws 11.

With the aid of the two lifting tackles slowly lower the upper bearing cover taking care that the two cylindrical dow�els 12 can slide out of their bores without jamming.

Remove the upper bearing cover.

Fitting

The fitting of the upper as well as the lower bearing cover to the connecting rod has to be carried out in reversesequence to the removal.

Smear bearing running surfaces lavishly with clean engine oil. The tensioning of the connecting rod bolts in de�scribed on sheet 3303/1.

Attention! Never turn the crankshaft as long as the hydraulic jacks are screwed onto the connecting rod bolts.After completing the work, never forget to remove holding pins 94323 from the slide rails.

1989


1989


Connecting Rod

Inspection, Removing and Fitting of Top End Bearing


4 Retaining pins 94323 1 Crankshaft 9 Threaded holes for ring screws 1 Connecting flange 94336 2 Toggle lever 10 Cylindrical pins

Hydr. tools according to 3 Connecting rod 11 Bearing shellsheet 3303/1 4 Locking plate 12 Hexagon socket head screw

2 Eye bolts 5 Locking screw 13 Bearing coverGrip screws 6 Locking device 14 Guide segments

7 Nuts8 Studs L Oil pressure pipe

P Lubricating pumpR Eye bolt

Inspection and removal

When a top end bearing has to inspected or removed, proceed as follows:

Turn crank of the corresponding cylinder to B.D.C.

Loosen the five screws fastening the toggle lever 2 of the crosshead lubrication and piston cooling, and separate thetoggle lever from the connecting rod 3.

Remove the locking screws 5, locking plates 4 and locking device 6.

Loosen all four nuts 7 of studs 8 of top end bearing with the hydraulic device as instructed on sheet 3303/1 and re�move the nuts.

Turn crank upwards till the holding pins 94323 can be inserted into the slide rails. Finally turn the holding pins sothat the excenters prop up the slippers.

Fit two eye bolt 'R' on both sides of the top connecting rod head into the threaded holes 9.

Secure the connecting rod with the two eye bolt 'R', the lifting tackle and a holding rope.

Turn the crank down carefully and guide the connecting rod down with the holding ropes (Fig. 'B').

Take care that the cylindrical pins 10 and the four studs 8 slide out through the bores without jamming (Fig. 'C').

Before removing the bearing shell 11 loosen the two hexagon socket head screws 12 and remove them. Use the gripscrews (M 8) to lift the bearing shell out.

Attention: Should the case occur that after the removal of the piston an inspection or a removal of the top endbearing is carried out then the suspension device 94324 for the crosshead (see sheet 3326/2) must with�out fail be fitted. This is to prevent the bearing cover 13 from turning and falling down when the connect�ing rod is being lowered.

Fitting

The fitting of bearing shell 11 and of bearing cover 13 is carried out analogously but in the reverse sequence to theremoval. When fitting the bearing shell 11 take care that, the two recesses (for hexagon socket head screw 12)which are milled into the front face of the bearing shell, coincide with the corresponding recesses in the connectingrod.

Before fitting smear the running surfaces lavishly with clean bearing oil. The tensioning of the bearing studs must becarried out as instructed in sheet 3303/1.

Remarks: When fitting the bearing shell as well as the crosshead pin, pay careful attention not to damage the two guide segments 14. The two white metal lined guide segments are fitted to the front sides of thebearing saddle (Fig. 'C').

Always fit toggle lever 2 in such a way that its curvature (knee) stands upwards.

After completing the work the retaining pins 94323 must be removed without fail.

5.92


Remarks to the fitting of a bearing shell:

Should it become necessary to replace a bearing shell to the top end bearing then care must be taken, that the run�ning surface of the journals are in perfect condition.While fitting a bearing shell the utmost attention must be given to prevent dirt or foreign particles entering betweenthe shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be freefrom any damage. Immediately before inserting the bearing shells they have to be wiped with a slightly oily hand, sothat a trace of oil is on them.The bearing shell should be placed in the connecting rod head such that it protrudes at both ends of the separatingface by the same distance. This protrusion is a must and under no circumstances may the separating face of thebearing shell be filed to reduce it! (Fig. 'A').

On a new bearing shell of the top end bearing the protrusion should be:x1 + x2 = 0.58 - 0.66 mm.

Above measuring checks must be carried out without fail when fitting new bearing shells. For this the bearing shellsare placed in position the bearing covers fitted and tightened down by hand with a spanner and a slight jerk.

Prior to final assembly smear the running surfaces lavishly with clean bearing oil. Should, however, the engine haveto be frequently turned after the fitting of the bearing, or should a re�start of the engine not be immediately planed,then instead of bearing oil a mixture of 2/3 steam�engine cylinder oil and 1/3 normal bearing oil should be used.Special oils suited to this purpose are also available from reliable suppliers.

In order to further reduce the risk of dry running on newly fitted bearing shells, a connecting flange 94336 can befitted (see Fig. A1), after removing oil pressure pipe 'L' to the crosshead bearing. The connecting flange has to beconnected via an oil pressure hose to a lubricating pump 'P'. The pump has to be filled with the above mentioned oilmixture or special oil. The lubricating pump 'P' has to be operated from time to time, until oil is pouring out from thebearing side faces. Before the engine is put back into operation, the oil pressure pipe 'L' must be mounted backagain. The remainder of the above mentioned special oil or oil mixture may remain in the engine oil system.

5.92


1989


Documents

Maintenance Manualmaytau.ut.edu.vn/userfiles/files/RTA84C-Maintenance.PART...RTA84C Maintenance 0001/1.1 Preface The instructions contained in this "Maintenance Manual" are intended