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Marine
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Type:
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Document ID: DBAC352038
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Modification Service
Engine Documentation
RT-flex96C_WECS-9520_Dynex
Page No.
Modification
Date
Subject
(MM)
Page or
No.
Manual
new exch.
2008
2008
Tightening Values of
Important Screwed
Connections
0330-1/A1, B1
(26 and 27)
3303-2/A1
(1, 5 to 8)
1.09
Clearance Table
3303-3/A1, A2
1 to 5 (4)
7-67.364
Connecting Rod
7-67.364
Connecting Rod
3303-4/A1
3326-2/A1 (1)
Crosshead
3425-1/A1 (1)
7-65.977
Piston Rings
9403-5/A1
(21 and 26)
7-67.364
Tool List
2.09
0002-1/A1 (5)
Table of Contents
9403-5/A1 (52)
Tool List
x
x
12.09
2009
2010-07
x
x
x
x
x
x
Table of Contents
Clearance Table
Tightening Values
x
x
Index Gr. 0, 9
0330-1/A1 27
0352-1/A1 (1, 2,
5, 6, 8, 12, 13,
15, 16)
0352-1/A1 (8)
0352-2/A1 (1)
7-69.624
Tightening Values
0370-1/A1 (2)
7-69.800
7-78.356
Dimension: O-rings
0370-2/A1 (1)
7-77.791
Piston and Rod Seal 5556-1: former seal replaced with rod seal ring 70x3.53;
Rings
Material specification deleted
Maintenance Schedule 2745-1: relief valve to cylinder cover added; Gr. 8: General
remark concerning tightening of pipe holders and inspection of
vapor trap (fuel leakage system) added
Main Bearing
0380-1/A1 (2, 7)
1132-2/A1, A2
(13 or 16)
6.2 Lifting the crankshaft: remark for further lifting (0.8 mm) in
case of difficulties during removing lower bearing shell
1/6
31.3.2014
Modification Service
Engine Documentation
RT-flex96C_WECS-9520_Dynex
Page No.
Modification
Date
Subject
(MM)
Page or
No.
Manual
new exch.
2138-1/A2
2708-1/A1 (4)
7-73.638
2010-07
2708-2/A1
Lubricating Quill on
Cylinder Liner
Cylinder Cover
Cylinder Cover
Protection cap (11) added and lubricant for nuts (2) altered to
Never-Seez NSBT-8
Injection Valve (O.M.T. 1.General: 4th sentence added; 3. Judging an injection valve:
Test Bench)
revised; Remark concerning opening pressure of 375 bar and
reference dimension 'x1'= 49.5 mm in Fig. 'E' added
2722-1/A2
(1, 3, 5, 6)
Injection Valve (OBEL 1.General: 4th sentence added; 3. Judging an injection valve:
Test Bench)
revised; Remark concerning opening pressure of 375 bar and
reference dimension 'x1'= 49.5 mm in Fig. 'B' added
2751-1/A1
(4-6)
2751-2/A1
Exhaust Valve
3. Fitting: lubricant for studs (1) and nuts (2) altered to NeverSeez NSBT-8; Sec. 4: Replacement of waisted studs revised
Rotation device 94290 deleted and therefore dismantling and
assembling procedure revised
Rotation device 94290 deleted; new valve grinding device
94291 introduced and therefore grinding procedure revised
2722-1/A1
(1, 3, 6, 7)
7-77.818
Exhaust Valve
2751-3/A1
Replacing and
Grinding the Valve
Seat
2751-4/A1 (1)
3130-2/A1 (1)
Vibration Damper
Axial Damper
3146-1/A1 (4)
3403-3/A1 (6)
Piston
3425-1/A1 (1,
3)
4325-1/A1 (2)
Piston Rings
3130-1/A1
(1, 4)
7-72.925
5552-5/A1
5556-1/A3 (1, 2,
6-13, 15-17)
7-69.800
7-77.791
7-77.818
Fuel Pump
5556-2/A1
7-72.876
Fuel Pump
5564-1/A1 (3)
7-69.624
5612-1/A1
7-78.356
8733-1/A1
(1, 2)
8750-1/A2
7-77.538
8752-1/A1
(1, 4-6)
7-78.121
Intermediate Fuel
Accumulator
Fuel Pressure Piping
9403-5/A1
7-77.818
7-75.992
9403-5/A1
(1-5, 31, 38, 39,
40, 47, 49, 56)
7-77.818
7-78.121
EAAD082065
Tool List
x
x
2010-11
Table of Contents
Index Gr. 7
x
x
2/6
31.3.2014
Modification Service
Engine Documentation
RT-flex96C_WECS-9520_Dynex
Page No.
Modification
Date
Subject
(MM)
Page or
No.
Manual
new exch.
0380-1/A1
(7, 8)
7218-1/A1
0380-1/A1 (8)
Maintenance Schedule 7218-1: Procedure specified for checking gas (nitrogen) precharge pressure
8750-2 Fuel pressure control valve: Replace filter (control oil)
added and therefore on page 5 deleted
2010
Lubricating Pump
CLU4
2011-02
Maintenance Schedule 8744: Check of supply unit fuel drain pipings added:
8750: Check of non-return valves in IFA deleted
Lubricating Quill on
Test procedure of non-return valve modified (test medium
Cylinder Liner
altered to oil) and required tools added
Fuel Pump
Section 5: Oil flow check added
2138-1/A2
(1, 4)
5556-1/A3
(1, 20)
8750-2/A1 (3)
x
x
x
Fuel Pressure Control To prevent any clogging, new filter (35) is not secured with
Valve
LOCTITE, however fitted with oil and tightened with 10 Nm
2011-03
0002-1/A1
2722-1/A1 (6)
2722-1/A2
(5)
Table of Contents
Injection Valve (O.M.T. Fig. 'E': detail with spherical insert bush added
Test Bench)
x
x
Injection Valve (OBEL Fig. 'B': detail with spherical insert bush added
Test Bench)
8135-1/A1
Air supply to LLT valve altered from control air to air spring air;
and connection between actuator and butterfly valve by means
of a cardan rod introduced
8733-1/A1 (1)
7-77.538
7-77.630
Tool List
8733-1/A2
2011
9403-5/A1 (49)
2011-03 7-57.949
2751-2/A1
x
x
3403-1/A1
(1,4-8)
EAAD082346 Piston
6420-1/A1 (5)
Scavenge Air Receiver Opening pressure of relief valve (15) specified for TIER I and II
9403-5/A1 (28)
x
x
x
x
2011-05
Tightening Values
2124-1/A1
Cylinder Liner
2124-3/A1
2138-1/A2
2751-2/A1
3403-1/A1
(1,4-8)
EAAD082346 Piston
6420-1/A1 (5)
Scavenge Air Receiver Opening pressure of relief valve (15) specified for TIER I and II
9403-5/A1 (28)
x
x
x
x
2011-07
3/6
31.3.2014
Modification Service
Engine Documentation
RT-flex96C_WECS-9520_Dynex
Page No.
Modification
Date
Subject
(MM)
Page or
No.
Manual
new exch.
7218-1/A1
Lubricating Pump
CLU4
9403-5/A1(47)
Tool List
Table of Contents
New group 5610-1/A1 added; Tool list specified with new page
numbers
0330-1/A1 (26)
Clearance Table
0352-1/A1
(1, 4, 9, 10)
Tightening Values
0380-1/A1
(6, 8)
Maintenance Schedule 6735-1: Scavenge Air Waste Gate added; 8750-2: Interval of
36 000 Op.h changed to ''only necessary when PCV fails'';
9223-1: Work to be carried out and intervals revised
1903-1/A1
Tie Rod
2124-2/A1
(1, 5, 6, 7)
2138-1/A1
(1, 2, 3)
Cylinder Liner
EAAD083591 Lubricating Quill
(Pulse Jet)
Tensioning procedure altered to one step: 100 bar -> 1000 bar
with a tie rod elongation of 15.5 17.5 mm
Filling piece with waisted bolts deleted. Key of illustration and
numbering adapted
New lubricating quill with housing (11) and LEE non-return
valve introduced, tools 94720c, 94931, 94934h, 94934i and
94935 added
2138-1/A2
(1, 2, 3)
2722-1/A1
(1, 2)
2722-1/A2
(1, 2)
Lubricating Quill
(Pulse Feed)
Injection Valve with
O.M.T Test Bench
EAAD083679 Injection Valve with
OBEL Test Bench
Exhaust Valve
Exhaust Valve
2012-05
Index Gr. 5, 9
2751-1/A1
(1, 5)
2751-2/A1
(1, 2)
2751-4/A1 (2)
5556-1/A3 (7)
5610-1/A1
6420-1/A1
(1, 2, 3)
6545-1/A1
8750-2/A1
9223-1/A1
9403-5/A1
(3, 17, 28, 52)
x
x
2012-05 EAAD082712 Scavenge Air Receiver Relief valve with disc springs added. Opening pressure of RV
changed to 4.1 0.2 bar relative; section 3 added
Auxiliary Blower
All figures and items concerning execution 'Schmid' deleted.
7218-1/A1
2012
2012-05
Tool List
x
x
x
x
x
4/6
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Modification Service
Engine Documentation
RT-flex96C_WECS-9520_Dynex
Page No.
Modification
Date
Subject
(MM)
Page or
No.
Manual
new exch.
0380-1/A1 (5)
5610-1/A1
(1, 2)
2012-05
2012
x
x
2012-11
Injection Valve
Injection Control Unit
x
x
2013-02
Table of Contents
Index Gr. 9
1132-2/A1
(2, 19, 20)
1132-2/A2 (1,
2,3,17,24,25)
5552-5/A1
9403-3/A1 (6)
9403-5/A1 51,
(48, 49)
(50)
x
x
x
x
x
5552-5/A1
9403-5/A1 (16,
37, 50)
x
x
2013-08
Table of Contents
Index 3
0011-1/A1 (1)
0330-1/A1
(20, 21)
0370-2/A1 (5)
0380-1/A1
(2, 3)
x
x
(3, 8)
x
x
x
x
2722-1/A1
(1, 3, 5, 6, 9)
Injection Valve
(O.M.T. Test Bench)
2722-1/A2
(1, 3, 4, 8)
Injection Valve
(OBEL Test Bench)
(5, 6)
2728-1/A1
(1, 3)
CHECK: Periodical venting of starting air manifold (OM 03201) and monthly check of nut (18) on solenoid added
5/6
31.3.2014
Modification Service
Engine Documentation
RT-flex96C_WECS-9520_Dynex
Page No.
Modification
Date
Subject
(MM)
Page or
No.
Manual
new exch.
3103-1/A1
3206-1/A1 (2)
3425-1/A1
9403-5/A1
(55, 56)
Measuring Crank
Deflection
Turning Gear
Piston Rings
(Four Piston Rings)
Tool List
Tool List
x
x
x
x
2014-04
x
Date of publication 2014-04-02
6/6
31.3.2014
MM / RTflex / Register
General Information
Cylinder Lubrication
Piping
RT-flex96C
Maintenance
General Information
Group0
Group 0
General Guidelines
for Maintenance: Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 00111/A1
for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts, etc. . . . . . . . . . . . . . 00121/A1
Tightening Values
of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03521/A1
of Standard Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03522/A1
Masses (Weights): Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . 03601/A1
Dimensions
O-rings and Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03701/A1
Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03702/A1
Back-up Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03702/A1
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) . . . . . . . . 03801/A1
Engine Cross Section and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08031/A1
1/ 1
RTflex96C / MM / 201007
RT-flex96C
Maintenance
00001/A1
This manual is put at the disposal of the recipient solely for use in connection with
the corresponding type of diesel engine.
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 with Wrtsil Switzerland Ltd. This document
and parts thereof must not be reproduced or copied without their written permission, 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 Instructions or 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 parts should 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 Wrtsil Switzerland Ltd and correspond to the actual standard at the time of printing (year of printing is indicated on title page).
Those specifications and recommendations of the classification societies which
are essential for the design have been considered therein. It must be recognized
that such data, instructions and graphical illustrations may be subject 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 ensured that it will always be at the disposal of such personnel for the operation of the engines and/or for the required maintenance work.
This manual has been prepared on the assumption that operation and maintenance of the engines concerned will always be carried out by qualified personnel
having the special knowledge, training and qualifications needed to handle in a
workman-like manner diesel engines of the corresponding size, the associated
auxiliary equipment, as well as fuel and other operating media.
Therefore, generally applicable rules, which may also concern such items as
protection against danger, are specified 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 Wrtsil Switzerland Ltd nor their employees assume any liability under any legal aspect whatsoever, including possible
negligence in connection with this manual, its contents, or modifications
to it or in connection with its use.
Claims relating to any damage whatsoever or claims of other nature such as,
but not limited to, demands for additional spares supplies, service or others
are expressly excluded.
1/ 1
2008
RT-flex96C
Maintenance
00011/A1
Preface
Maintenance schedule
Design groups
Tool lists
The General Guidelines for Maintenance contain, in addition to recommendations on precautionary measures to be taken, also suggestions for carrying
out the work.
The above mentioned tables inform about normal and maximum acceptable
clearances, the tightening of important screwed connections, weights of individual engine components as well as the type and use of various sealing rings.
Tools and devices necessary to carry out maintenance are described in the
Tool Lists, and are generally supplied with 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!
1/ 1
2008
RT-flex96C
Maintenance
00021/A1
Table of Contents
Table of Contents
General Information
Group 0
General Guidelines
for Maintenance: Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 00111/A1
for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts, etc. . . . . . . . . . . . . . 00121/A1
Tightening Values
of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03521/A1
of Standard Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03522/A1
Masses (Weights): Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . 03601/A1
Dimensions
O-rings and Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03701/A1
Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03702/A1
Back-up Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03702/A1
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) . . . . . . . . 03801/A1
Engine Cross Section and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08031/A1
1/ 5
2013 -08
00021/A1
Maintenance
RT-flex96C
Table of Contents
Group 1
Main Bearing
Loosening and Tensioning of Waisted Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11321/A1
Removal and Fitting of a Main Bearing (6 and 7 Cylinder Engines) . . . . . . . . . 11322/A1
Removal and Fitting of a Main Bearing (8 14 Cylinder Engines) . . . . . . . . . . 11322/A2
Main Bearing Upside-down Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11323/A1
Thrust Bearing
Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12031/A1
Removal and Fitting the Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12241/A1
Engine Stays
with Friction Shims: Checking the Pre-tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 17151/A1
Hydraulic: Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17151/A2
Tie Rod: Checking the Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . 19031/A1
Group 2
Cylinder Liner
Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21241/A1
Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21242/A1
Removing the Wear Ridge, Re-dressing Lubricating Grooves
and Scavenge Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21243/A1
Lubricating Quill
and Accumulator: Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21361/A1
with Pulse Jet Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 21381/A1
with Pulse Feed Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . 21381/A2
Piston Rod Gland: Dismantling and Assembling, Measuring the Wear . . . . . . . . . 23031/A1
Cylinder Cover
Removal and Fitting of Cylinder Cover and Water Guide Jacket . . . . . . . . . . . . 27081/A1
Loosening and Tensioning of Cylinder Cover Waisted Studs . . . . . . . . . . . . . . . 27082/A1
Machining of Sealing Face for Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27083/A1
Injection valve
Checking, Dismantling, Assembling & Adjusting with O.M.T. Test Bench . . . . 27221/A1
Checking, Dismantling, Assembling & Adjusting with OBEL Test Bench . . . . . 27221/A2
Starting Valve: Removal, Fitting and Dismantling, Grinding-in & Assembling . . . . 27281/A1
Relief Valve for Cylinder Cover: Checking Blow-off Pressure . . . . . . . . . . . . . . . . . 27451/A1
2013-08
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RT-flex96C
Maintenance
00021/A1
Table of Contents
Exhaust Valve
Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs . . . . . . . . . 27511/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27512/A1
Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27513/A1
Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . 27514/A1
Group 3
Vibration Damper
Taking a Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31301/A1
Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31302/A1
Axial Damper: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31461/A1
Turning Gear: Checking the Toothing and Screwed Connections . . . . . . . . . . . . . . 32061/A1
Crankcase: Utilization of Working Platform and Ladder . . . . . . . . . . . . . . . . . . . . . . 33011/A1
Lower Platform: Platforms and Hatch Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33012/A1
Connecting Rod
Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . 33031/A1
Inspection, Removal and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . 33032/A1
Inspection, Removal and Fitting of Top End Bearing with Piston in Situ . . . . . . 33033/A1
Inspection, Removal and Fitting of Top End Bearing with Piston Removed . . . 33033/A2
Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33034/A1
Crosshead
Checking the Clearances and Fitting the Guide Shoes . . . . . . . . . . . . . . . . . . . . 33261/A1
Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33262/A1
Piston
Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34031/A1
Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34032/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34033/A1
Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34034/A1
Piston Rings: Checking Wear of Piston Rings and Ring Grooves . . . . . . . . . . . . . . 34251/A1
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2013 -08
00021/A1
Maintenance
RT-flex96C
Table of Contents
Group 4
Driving Wheels
Checking the Running and Backlash Clearances and Condition of Teeth . . . . 41031/A1
Removal and Fitting of Intermediate Wheel (610, 12 & 14 Cyl. Engines) . . . 41032/A1
Removal and Fitting of Intermediate Wheel (11 Cylinder Engines) . . . . . . . . . . 41032/A2
Replacing the Gear Wheel on Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41033/A1
Replacing the Gear Wheel on Crankshaft (Single Wall Column) . . . . . . . . . . . . 41033/A2
Shut-off Valve for Starting Air: Cleaning and Function Check . . . . . . . . . . . . . . . . . 43251/A1
Group 5
Supply Unit
Removal and Fitting of Dynex Servo Oil Pump and Servo Oil Pump Drive . . . 55521/A2
Removal and Fitting of Camshaft and Bearing Shells . . . . . . . . . . . . . . . . . . . . . 55522/A1
Removal and Fitting of Gear Wheel on Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 55523/A1
Removing and Fitting the Fuel Cams with Conical Bushes . . . . . . . . . . . . . . . . 55523/A2
Removal and Fitting of Intermediate Wheel to Camshaft . . . . . . . . . . . . . . . . . . 55524/A1
Lubrication of Supply Unit During Maintenance Works (Dynex SOP) . . . . . . . 55525/A1
Fuel pump
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55561/A3
Removal of a Jammed Pump Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55562/A1
Injection Control Unit: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55641/A1
Pressure Reducing Valve 8.111: Checking the Gas Pre-charge Pressure . . . . . 56101/A1
Exhaust Valve Drive: Removal, Fitting, Dismantling and Assembling . . . . . . . . . . . 56121/A1
Regulating Linkage: Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58011/A1
Group 6
Checking the Air Flaps and Cleaning the Scavenge Air Receiver . . . . . . . . . . . . . . 64201/A1
Auxiliary Blower: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65451/A1
Cylinder Lubrication
Group 7
2013-08
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Maintenance
00021/A1
Table of Contents
Piping
Group 8
Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81351/A1
Servo Oil Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . 84471/A1
Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding . . . . 84601/A1
Group 9
5/ 5
2013 -08
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00081/A1
Maintenance
General
Engine Numbering and Designations
General:
Turbocharger
1
Turbocharger 2
DRIVING
END
Cylinder
Numbering
FREE END
10
11
011.945/04
Rail Unit
FUEL SIDE
EXHAUST SIDE
Supply Unit
Clockwise
Rotation
013.059/05
1/ 2
2008
00081/A1
Maintenance
RT-flex96C
flex Parts:
Fuel Pump Row
Bank A
Pump A4
Pump A3
Pump A2
Pump A1
Counting Direction
Fuel Pumps
Actuator A2
Actuator A1
Pump B4
Pump B3
Pump B2
Pump B1
Supply Unit
Pump 3
Pump 2
Pump 1
Actuator B1
Actuator B2
Pump 4
Pump 5
Pump 6
Counting Direction
Servo Oil Pumps
DRIVING END
Pump 2
Pump 1
Sensor 1
(GT5126C)
FUEL SIDE
DRIVING
END
013.061/05
FREE END
FUEL SIDE
2008
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RT-flex96C
Maintenance
00111/A1
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautionary measures before beginning of
maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommendations for performing work . . . . . . . . . . . . . . . . .
1/4
1/4
2/4
3/4
4/4
General
The maintenance work which is required to be carried out on the engine at regular
intervals is described in the Maintenance Schedule 03801 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. Further details 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.
2.
It is the operators duty to assure that all personnel is familiar with all safety,
health as well as environment protection rules released for operating and
maintaining a diesel engine plant. In particular greatest attention 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 situations.
The operator has to nominate a person responsible for assigning work tasks
to every person who is participating in maintenance work.
Make sure that fluids or gases draining or escaping cannot cause accidents,
fires or explosions during maintenance work. Keep the engine and the surroundings clean. Cleanliness increases the quality of the work and helps to
prevent accidents.
Before beginning maintenance work on the diesel engine the corresponding
systems which are influenced by the maintenance work must be relieved of
pressure and/or drained if necessary. A protocol must be established evidencing these activities.
Certain media, i.e. fuels etc., are highly inflammable, therefore all precautionary measures have to be taken that they do not come into in contact with fires,
glowing or hot parts. Smoking in the engine room is strictly forbidden.
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 engine room while people are still inside. Emergency escapes are to be marked and personnel is to be instructed of 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 stepped on must be kept clean and dry.
Attention! Do not use water or any cleaning fluid to clean the WECS electronic
components and control boxes on the engine as well as on the rail unit. Damage
can occur if water goes into these electronic components or control boxes.
1/ 4
2013-08
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Maintenance
RT-flex96C
3.
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 clamps whenever the engine is running, even if this is only for a short time in order to
make temperature checks (e.g. after changing bearings during an overhaul,
etc.).
In the case of a fire in the engine having been extinguished by means of CO2,
the spaces affected must be well ventilated before work can be carried out
within them.
Attention! When performing electric welding near or on the engine, electromagnetic fields or peak voltage may occur, which may damage the electronic components of the WECS (Wrtsil Engine Control System).
Therefore, prior to performing electric welding in the vicinity of the mentioned components, the following precautions must be taken:
2008
8
If the welding point is within a radius of two metres from an electronic module
and/or a sensor, disconnect the modules and/or sensors.
Close the covers of all electric boxes and protect cables, sensors, etc. against
sparking and heat.
Shield the check and control units with a conductive material and connect
them to earth.
Run the welding cable from the welding apparatus directly to the welding point
without any unnecessary loops; also, avoid leading the welding cable parallel
to cables of the electronic control unit.
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Maintenance
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4.
Prior to turning the crankshaft with the turning gear, make sure and take notice:
that no person is inside the engine and no loose parts, tools or devices
can get jammed.
bear in mind that the coupled propeller turns too (danger in surroundings).
Prior to turning the crankshaft with the turning gear, make sure that no person
is inside the engine and no loose parts, tools or devices can get jammed. Also
bear in mind that the coupled propeller turns too (danger in surroundings).
At all times when somebody is inside the engine casing another person must
stand by in order that he can give the necessary aid if something unexpected
happens to the person inside the engine. The person who is inside the engine
casing must be equipped with all safety gears which are required to prevent
suffocation within the limited space and atmospheric conditions. Moreover an
antifall guard must be carried at dangerous places!
The allowed load capacity of the engine room crane, the lifting tools, ropes
and chains must be sufficient for the parts to be lifted (see 00121 and
03601).
Pay also attention to the weight distribution and attachment of the lifting 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 special edge guards which are placed between the part
and the rope or chain.
Always use gloves, a face shield and wear safety goggles when working with
hydraulic tools.
For your own safety keep away from under hanging loads, never undersling
hanging parts with your fingers or hands and never embrace lifting ropes with
your hands.
Remark: For further instructions see also Safety Precautions and Warnings (General Information) 02101 in the Operating Manual.
3/ 4
2008
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Maintenance
RT-flex96C
5.
For maintenance work on the engine use the tools and devices intended for
the particular job, which, as a rule, are supplied with the engine (see tool list at
the end of this manual).
Tools and devices must 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 etc. to prevent 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 (see Clearance Table 03301) have been reached or
even exceeded, these parts must be replaced.
Arrange to replace all parts taken from spares stock. When ordering new
parts refer to the Code Book, mention code numbers and description.
2008
When tightening studs, nuts or screws, take the utmost care not to damage
their thread. They must be screwed in by hand until metal to metal contact is
achieved. Always use the specified lubricants on the threads.
Adhere to tightening values wherever they are indicated. Use the specified
lubricant on the threads (see 03521 and 03522).
Locking devices of bolts, nuts, etc. must be fitted correctly and secured properly. Use locking plates and locking 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 takes place; they must conform in dimension and
quality to the specifications in the 03701.
The fitting of piston seal rings and rod seal rings requires the greatest of care
to prevent damage, over expansion or deformation. Before fitting the rings
heat them first in boiling water.
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Maintenance
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1.
General
The permissible capacities of the engine crane, lifting tools, ropes, chains, lifting
eye bolts, etc. must always correspond with the weights of the parts to be lifted
(see also Masses (Weights) 03601).
Remark: The admissible lifting (max. loading) capacity in kg corresponds to the
WLL = Working Load Limit.
For fitting and removal of engine components or their transportation, only the tools
which are in perfect condition and intended for this purpose may be used. Ropes
which have begun tearing or otherwise are defective and tools which are damaged
have to be exchanged.
For safe and proper handling of crane, suspension tools or transport of loads we
recommend to proceed as follows for safety reasons:
D
2.
Attachment elements
2.1
2.2
Span-sets
Span-sets have the advantage of easy and simple handling. The code and the
colour normally indicate the maximum admissible total load. Loops and knots in
the span-sets reduce their lifting capacity by one third.
2.3
1/ 5
2008
00121/A1
Maintenance
RT-flex96C
single-strand
double-strand (45)1)
45 _
M8
140
100
M10
230
170
M12
340
240
M16
700
500
M20
1200
860
M24
1800
1290
M30
3200
2300
M36
4600
3300
M42
6300
4500
M48
8600
6100
M56
11 500
8300
Remarks: The details listed in the table above are based on DIN 580 &
582:200308, requiring that the eye bolt or the eye nut:
2.4
was checked for visible damages (e.g. corrosion, deformation) before using it.
1) Full load is only permissible in the direction of the ring, therefore the
eye bolts or eye nuts must be brought to the right position, if necessary by using distance rings.
If there are through holes, a washer should be placed from the opposite side
under the nut or screw head.
Whenever possible, do not apply an angle of inclination bigger than 45 (in all
directions with regard to the ring level), and especially avoid lateral pulling!
For varying use on different objects to be carried, eye nuts or eye bolts with
thread diameters one size higher should be used.
2008
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RT-flex96C
00121/A1
Maintenance
they must be completely screwed down, lying fully on the seating surfaces.
they are hand-screwed with their own star-profile wrenches (do not use any
extension).
In order that after tightening the ring of the RUD-eye bolt is freely rotatable, the
star-profile wrench must be removed from the inner hexagon of the screw as
shown in Fig. A.
Prior to loading the RUD-eye bolt adjust it in force direction (RUD-eye bolts
are not suitable to be turned under load).
FORCE
DIRECTION
FORCE
DIRECTION
FORCE
DIRECTION
Ring
Star-profile
wrench
Screw
013.444/05
3/ 5
2008
00121/A1
Maintenance
RT-flex96C
they must be completely screwed down, lying fully on the seating surfaces.
Prior to loading the RUD-swivel lug adjust it in force direction (Fig. C and D).
FORCE
DIRECTION
FORCE
DIRECTION
FORCE
DIRECTION
013.445/05
2.5
Shackles
Only those shackles may be used which are in accordance with American Standard RRC271A or which fulfil or exceed these values, including the safety factor.
All calculations for components and tools where shackles are used are laid out accordingly and based on the mentioned standards.
Normally, the permissible lifting capacity of the shackles is specified for one single
strand.
Attention! If tools are combined (e.g. beams with shackles, RUD-eye bolts or
RUD-swivel lugs and ropes, etc.), it is always the weakest element which determines the maximum lifting capacity (see details in Tools List 94035).
2008
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RT-flex96C
Maintenance
00121/A1
3.
Distribution of load:
four strands carry each one quarter of the load weight if the load is distributed equally.
Angle of strand:
the flatter the strand angle, the more the strand is stressed
the more acute the strand angle is, the less the strand is stressed.
Place a soft-wood board between rope and engine component, because the
ropes tend to slide on smooth surfaces (e.g. tubes, shafts).
Wrapping the rope twice increases friction and adhesion in such a manner
that even a smooth, oily shaft is sliding less.
Hemp rope strands, wrapped around the hook, prevent sliding. Do not wrap
steel cables, but cross them instead.
Danger of injuries! For your own safety never stand beneath loads!
Hold the ropes in the flat of your hands and keep your fingers stretched out. Never
seize the load at the bottom, but always lead it laterally. Always put down the loads
on a perfect ground, and use sufficiently sized bases.
5/ 5
2008
RT-flex96C
Maintenance
03301/A1
Clearance Table
Overview
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/27
Crankshaft and Thrust Bearing (6 & 7 Cyl. Engines) . . . 2, 3/27
Crankshaft and Thrust Bearing (8 14 Cyl. Engines) . . 4, 5/27
Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . 6, 7/27
Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9/27
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11/27
Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13/27
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15/27
Top and Bottom End Bearings to Connecting Rod . . . 16, 17/27
Piston Cooling and Crosshead Lubricating Link . . . . . 18, 19/27
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21/27
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . 22, 23/27
Supply Unit with Dynex Servo oil Pumps . . . . . . . . . . . 24, 25/27
Fuel Pump (V4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27/27
General
The clearances listed in the column Nominal dimension of the following table correspond to design and manufacturing values or to the settings on the new engine.
The values listed in the column Maximum clearance, dimension are such values
as may be reached after a lengthy operating period, which however may not be
allowed to be exceeded or fall below. On components where the clearance is adjustable by modifying the thickness of shims, discs, spacers etc. the value given as
Normal Clearance should always be arrived at, or striven to attain. Where this is
not possible, worn parts must be replaced by standard new ones or reconditioned
by suitable material buildup.
If, during an overhaul, clearances are measured which have almost reached the
permissible limit, it must be left to individual judgement to decide whether a component part should be replaced or remain fitted till the next overhaul. This depends for
example on the duration of the next operation period till the next overhaul and what
wear has to be expected based on experience gained.
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2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Crankshaft and Thrust Bearing
001.404/96
001.404/96
001.404/96
2008
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RT-flex96C
03301/A1
Maintenance
Clearance Table
Crankshaft and Thrust Bearing
Key No.
Group
Description
1132
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
width
425
per side
15.5
Main bearing
Bearing shell
1
1203
Lateral clearance
Thrust bearing
1224
Thrust bearing pad
2
thickness
0.5
0.6
120
axial (total)
0.81.3
total
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2.5
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Crankshaft and Thrust Bearing
8 14 Cylinder Engines
001.404/96
1
3
011.332/03
2008
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RT-flex96C
03301/A1
Maintenance
Clearance Table
Crankshaft and Thrust Bearing
Key No.
Group
Description
1132
8 14 Cylinder Engines
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
width
425
per side
15.5
Main bearing
Bearing shell
1
1203
Lateral clearance
Thrust bearing
1224
Thrust bearing pad
2
thickness
0.5
0.6
120
axial (total)
0.81.3
total
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2.5
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Crankshaft and Main Bearing
30 mm
30 mm
50 mm
6 2
50 mm
7 3
3
008.298/01
008.298/01
MAIN BEARINGS
No. 2 ...
MAIN BEARING
No. 1
001.404/96
2008
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RT-flex96C
03301/A1
Maintenance
Clearance Table
Crankshaft and Main Bearing
Key No.
Group
Description
1132
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Crankshaft
outer
Main bearing
inner
990
Bearing clearance
vertical
0.30.6
*2
Lateral clearance
total
0.91.2
*3
Lateral clearance
total
0.50.8
**4
vertical
max. 0.3
1132
990
0.75
Crankshaft
outer
Main bearing
inner
990
Bearing clearance
vertical
0.30.6
*6
Lateral clearance
total
1.01.3
*7
Lateral clearance
total
0.81.1
**8
vertical
max. 0.3
990
0.75
All main bearing clearances are only valid with tie rods and main bearing studs
tightened.
**
The difference between the two values (positional tolerance) must not be
greather than 0.3 mm when the studs are tightened!
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2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Crosshead Guide
EXHAUST SIDE
6
8
7
014.087/06
4
5
2008
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RT-flex96C
03301/A1
Maintenance
Clearance Table
Crosshead Guide
Key No.
Group
Description
3326
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
1430
Crosshead guide
1
transverse
Guide shoe
transverse
*3
1430
0.20
0.35
0.201.10
1.4
Cylinder No. 1
4
Guide rail
longitudinal
977.5978.5
T.D.C.
1.11.7
B.D.C.
1.11.3
0.30.9
Guide rail
outer
550
0.05
0.10
inner
550
+ 0.07
0
longitudinal
978.30979.30
total
0.601.80
longitudinal
0.200.40
Bearing clearance
radial
0.050.17
2.2
0.30
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2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Cylinder Liner
2
3
approx. 220240 mm
014.090/06
2008
10/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Cylinder Liner
Key No.
Group
Description
2124
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Clearance
total
Clearance
total
Clearance
total
Clearance
total
+ 0.70
0.50
1425 +
0.801.20
+ 0.70
0.50
1290 +
0.801.20
+ 0.70
0.50
1360 +
0.701.10
+ 0.70
0.50
1425 +
0.701.10
2124
Clearance
total
1181.5
+ 0.20
0
1.01.4
Cylinder jacket
Cylinder jacket
6
2124
Clearance
1150
+ 0.20
0
total
2.202.60
radial
960
Cylinder liner
*7
966.7
11/ 27
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Piston Rod Gland
4
5
1
6
1
7
2
7
99.7406
011.333/03
2008
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RT-flex96C
03301/A1
Maintenance
Clearance Table
Piston Rod Gland
Key No.
Group
Description
2303
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Ring width
radial
31
min. 25
*2
Ring width
radial
24
min. 22.20
*3
Ring width
radial
min. 3.20
Ring clearance
axial
0.100.26
0.50
Ring clearance
axial
0.100.26
0.50
Ring clearance
axial
0.050.16
0.40
Ring clearance
axial
0.100.17
0.40
Ring wear
The differential value between nominal dimension and max. wear is equal for all
rings, i.e. also for undersize rings.
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Maintenance
RT-flex96C
Clearance Table
Exhaust Valve
VALVE SPINDLE
L = LENGTH
~ 1/3 L
~ 2/3 L
GUIDE BUSH
001.400/97
011.334/03
2008
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Maintenance
Clearance Table
Exhaust Valve
Key No.
Group
Description
2751
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Valve spindle
1
2751
Spindle
outer
95
0.35
0.40
94.50
Guide bush
*2
Bore
inner
95
+ 0.035
0
95.50
*3
Bore
inner
95
+ 0.035
0
96.50
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Maintenance
RT-flex96C
Clearance Table
Top and Bottom End Bearings to Connecting Rod
10 mm
10 mm
50 mm
10 mm
001.399/97
2008
16/ 27
001.399/97
RT-flex96C
03301/A1
Maintenance
Clearance Table
Top and Bottom End Bearings to Connecting Rod
Key No.
Group
Description
3303
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
3326
0
0.10
Crosshead pin
outer
Bearing
inner
900
Bearing clearance
vertical
0.500.90
*2
Lateral clearance
total
0.751.05
*3
Lateral clearance
total
0.600.85
Axial clearance
total
0.40.8
3303
900
1.05
1.2
Crankshaft
outer
Bearing
inner
990
Bearing clearance
vertical
0.500.80
*6
Lateral clearance
total
0.520.74
*7
Lateral clearance
total
0.751.0
Axial clearance
total
34
990
0.95
17/ 27
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Piston Cooling and Crosshead Lubricating Link
3
2
3
3
4
4
003.314/00
003.314/00
2008
18/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Piston Cooling and Crosshead Lubricating Link
Key No.
Group
Description
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
outer
72
Bearing clearance
radial
0.030.09
Bearing
width
173
Lateral clearance
total
min. 1.0
Lateral clearance
total
2.0
19/ 27
0.20
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Piston and Piston Rings
2
3
9
10
11
2013-08
20/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Piston and Piston Rings
Key No.
Group
Description
3403
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Piston crown
1
Crown
outer
951.7
Crown
outer
956.7
3403
3425
+ 0.50
0.45
vertical
20 +
vertical
20 +
Groove depth
3425
radial
+ 0.40
0.35
31
Piston rings
Ring height
vertical
20
0
0.03
Point A
Point B
Ring clearance
vertical
0.440.52
0.75
0.95
Ring clearance
vertical
0.350.43
0.65
0.80
Ring width
radial
30 0.45
3403
Piston skirt
9
Skirt
outer
958.9
0
0.2
10
Rubbing ring
outer
959.3
0
0.1
outer
370
3403
min. 957
Piston rod
11
Rod
0.062
0.119
min. 368.80
Used piston rings may be refitted if they will keep within their min. ring width until
the next overhaul (for judging and reusing piston rings see also 34251).
For evaluating and reusing piston heads see 34251).
21/ 27
2013-08
03301/A1
Maintenance
RT-flex96C
Clearance Table
Driving Wheels for Supply Unit
6
4
1
5
011.501/04
2008
22/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Driving Wheels for Supply Unit
Key No.
Group
Description
4103
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Intermediate wheel
1
Shaft
outer
340
Bearing clearance
vertical
0.1820.288
0.40
*3
Axial clearance
total
0.61.5
1.9
Tooth backlash
0.400.62
0.85
Tooth backlash
0.540.78
1.00
Tooth backlash
0.400.59
0.80
23/ 27
2008
03301/A1
Maintenance
Clearance Table
Supply Unit
RT-flex96C
3 2
5
4
014.096/06
10
2008
24/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Supply Unit
Key No.
Group
Description
5552
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Supply unit
1
Pinion
outer
120
0
0.022
Bearing (fitted)
inner
120
+ 0.23
+ 0.14
Bearing clearance
radial
0.140.252
Axial clearance
total
0.250.54
5552
0.7
Camshaft unit
Cam shaft
Bearing clearance
radial
0.220.34
Axial clearance
total
0.30.6
Tooth backlash
*8
Minimum clearance
5552
outer
0
0.032
300
0.8
0.160.29
3
Intermediate wheel
9
Bearing clearance
radial
0.220.34
10
Axial clearance
total
0.30.6
0.8
Minimum clearance between cam and roller with fuel pump cut out.
25/ 27
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Fuel Pump
29
A
B
149
73 mm
C
1
D
4
3
PLUNGER & CYLINDER
46
33
A
B
145
C
73 mm
5
WCH00832
014.104/06
2012-05 / V4
26/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Fuel Pump
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
radial
0.0350.038
0.045
radial
0.0250.028
0.035
radial
0.0350.038
0.045
radial
0.0250.028
0.035
radial
0.0400.043
0.5
Guide piston
outer
185
Lower housing
inner
185
Key No.
Group
Description
5556
Fuel pump
Plunger (42 mm)
1
Clearance
radial
0.220.68
0.8
axial
0.120.24
0.3
axial
0 .50.7
5556
0.8
Roller guide
Pin
outer
80
0
0.013
inner
80
+ 0.04
+ 0.01
Clearance
radial
0.0100.053
axial
0.260.54
0.08
0.7
Plunger conically machined in range CD; i.e. clearance increases in diameter of 0.015 mm.
27/ 27
V4 / 2010-07
RT-flex96C
03521/A1
Maintenance
Group
Description
Thread
Tightening values
1
[bar]
2
[Nm]
Lubricant
3
[_; mm]
1
1106
M36
2090
Oil
M56
4970
Oil
M64
11121
11321
17151
19031
Tie rod
1000
1st
MOLYKOTE G
M64x6
1000
M64
200
MOLYKOTE G
1000
MOLYKOTE G
M140x6
(130_)
Oil
2
2106
21242
*
*
M64
M64
M24
30
no additional
lubricant required
M48
30
no additional
lubricant required
M24
400
see details in
21242
Oil
Oil
10
21361
11
M16x20
50
see details in
21361
21381
12
M8x150
10
see details in
21381/A1
21381
12
M22x1.5
30
see details in
21381/A2
27082
13
M110x6
1
2
3
1000
(390_)
Never-Seez
NSBT-8
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
1/ 18
2012-05
03521/A1
Maintenance
RT-flex96C
Group
Description
Thread
Tightening values
1
[bar]
27221
14
M12
M65x1.5
27281
16
2
[Nm]
Lubricant
3
[_; mm]
Never-Seez
NSBT-8
Never-Seez
NSBT-8
30_
M36x3
(1215)
50_
MOLYKOTE G
(1340)
85_
Never-Seez
NSBT-8
(230_)
Never-Seez
NSBT-8
M33
27511
18
M110x6
27512
19
1000
M20
250
Oil
20
M36
21
M30
22
M56
20_
MOLYKOTE G
23
M85x4
50_
no additional
lubricant required
24
M85x4
55_
MOLYKOTE G
31302 *
25
M85x4
40_
MOLYKOTE G
25
M42x3
90_
MOLYKOTE G
26
M85x4
35_
MOLYKOTE G
27
M36
50_
MOLYKOTE G
130 Nm
Oil
30_
2nd step
1200
Oil
3
3103
3114
31461
1
2
3
(2300)
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
2010-07
2/ 18
RT-flex96C
03521/A1
Maintenance
Group
Description
Thread
Tightening values
1
[bar]
32061
28
M52
2
[Nm]
1000
Lubricant
3
[_; mm]
(60_)
Oil
33031
29
M80x6
1000
Oil
(30_)
M110x6
1000
Oil
1st
33261
31
(80_)
M36
2000
(30_)
MOLYKOTE G
(60_)
Oil
(115_)
Oil
34031
32
M52
1000
1st
34033
M48x3
1000
33
34
M20
35
M56
50_
MOLYKOTE G
36
M42x3
80_
see details in
41032
1st step 60 Nm
1st
step to
2nd
step
40_
no additional
lubricant required
4
41032
41033
37
M48x3
38
M42x3
80_
see details in
41033
no additional
lubricant required
1
2
3
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
3/ 18
2008
03521/A1
Maintenance
RT-flex96C
Group
Description
Thread
Tightening values
1
[bar]
2
[Nm]
Lubricant
3
[_; mm]
5
55521
39
M24
55522
40
M42
1000
Oil
55523
41
M42
1000
Oil
117
Camshaft Bolt
M42
140
Oil
42
M16
170
Oil
43
M36
(2100)
44
M56
45
M42
(2850)
46
M24
320
Never-Seez
NSBT-8
46
M27
480
Never-Seez
NSBT-8
47
M30
(1250)
48
M12
70
Never-Seez
NSBT-8
49
Non-return valve
M36x2
450
Never-Seez
NSBT-8
50
Nipple
M36x2
400
Never-Seez
NSBT-8
51
Screw plug
M27x2
300
Never-Seez
NSBT-8
52
M27x2
300
Never-Seez
NSBT-8
53
Pressure transmitter
M14x1.5
25
Never-Seez
NSBT-8
54
M16x100
150
Never-Seez
NSBT-8
55524
5553
55561
5562
1
2
3
600
Oil
47_
Oil
1000
Oil
60_
Oil
64_
Oil
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
2012-05
4/ 18
RT-flex96C
03521/A1
Maintenance
Group
Description
Thread
Tightening values
1
[bar]
5562
5564
5571
1
2
3
3
[_; mm]
55
M16
150
Never-Seez
NSBT-8
56
M10
35
Never-Seez
NSBT-8
57
M16
190
Never-Seez
NSBT-8
58
M8
20
Never-Seez
NSBT-8
59
M10
25
Never-Seez
NSBT-8
60
M12
75
Never-Seez
NSBT-8
61
M14
145
Never-Seez
NSBT-8
62
M16
110
Never-Seez
NSBT-8
63
M4
2.5
Never-Seez
NSBT-8
64
M42x2
700
Never-Seez
NSBT-8
65
Connecting nipple
M42x2
350
Never-Seez
NSBT-8
66
M10
35
Oil
67
M24x1.5
60
Oil
68
Drain screw
M24x2
200
Oil
69
Transmitter
25
Oil
70
M10
35
Oil
71
M18x1.5
67
Oil
72
Nipple
M30x2
220
Oil
73
M18x1.5
70
Oil
74
Drain screw
M24x2
200
Oil
55641
5566
2
[Nm]
Lubricant
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
5/ 18
2010-07
03521/A1
Maintenance
RT-flex96C
Group
Description
Thread
Tightening values
1
[bar]
5571
5610
2
[Nm]
Lubricant
3
[_; mm]
75
M22x1.5
80
Oil
76
M28x1.5
120
Oil
77
M16
170
Oil
78
M16
130
Oil
79
M16
130
Oil
80
M20
260
Oil
81
M16
170
Oil
118
Elastic bolt
M16x120
270
Oil
82
25
Oil
83
M16
130
Oil
84
M16
170
Oil
85
M12
60
Oil
86
Elastic bolt
Housing support, nut
M20x282
M20
20
350
no additional
lubricant required
56121
Oil
87
60
Oil
88
M20
350
Oil
119
Oil filter
120
Oil
89
M16
130
Oil
90
M16
170
Oil
91
M30x2
200
Oil
92
Non-return valve
80
see details in
84471
93
M12
40
Never-Seez
NSBT-8
8
8447
84471
87331
1
2
3
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
2010-07
6/ 18
RT-flex96C
03521/A1
Maintenance
Group
Description
Thread
Tightening values
1
[bar]
8750
2
[Nm]
Lubricant
3
[_; mm]
94
M16
190
Never-Seez
NSBT-8
95
M16
190
Never-Seez
NSBT-8
96
M10
35
Never-Seez
NSBT-8
97
M16
190
Never-Seez
NSBT-8
98
M16
190
Never-Seez
NSBT-8
87511
99
Relief valve
M30x2
300
Never-Seez
NSBT-8
87521
100
M12
60
Never-Seez
NSBT-8
101
M20
100
Never-Seez
NSBT-8
102
Non-return valve
80
see details in
87521
103
M10
35
MOLYKOTE G
104
M16
140
MOLYKOTE G
105
Shaft nut
M40x1.5
25
MOLYKOTE G
106
Shaft nut
M35x1.5
25
MOLYKOTE G
107
M8
16
MOLYKOTE G
108
M12
60
MOLYKOTE G
109
M12
60
MOLYKOTE G
9
9923
92231
1
2
3
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
7/ 18
2008
03521/A1
Maintenance
RT-flex96C
Group
Description
Thread
Tightening values
1
[bar]
92231
9314
M12
60
MOLYKOTE G
111
M10
35
MOLYKOTE G
112
15
Oil
113
Oil
114
M30
500
no additional
lubricant required
115
M20
450
no additional
lubricant required
116
M24
800
no additional
lubricant required
*
*
2
3
3
[_; mm]
110
66061
2
[Nm]
Lubricant
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
2010-07
8/ 18
RT-flex96C
03521/A1
Maintenance
ENGINE STAY
(FRICTION TYPE)
9
012.385/04
012.376/04
114
12
012.377/04
11
13
33
10
34
7
29
113
112
30
28
3
017.616/08
9/ 18
2012-05
03521/A1
Maintenance
RT-flex96C
12
11
32
31
36
35
37
26
38
A
25
017.617/08
24
2012-05
22
23
10/ 18
27
RT-flex96C
03521/A1
Maintenance
21
19
18
20
17
14
93
16
15
93
014.647/08
64
FUEL PRESSURE
PIPINGS
100
014.648/06
11/ 18
2008
03521/A1
Maintenance
RT-flex96C
95
98
99
97
95
101
96
91
94
89
48
47
46
40
014.641/06
43
117
74
41
42
76
75
014.642/06
73
2010-07
12/ 18
RT-flex96C
03521/A1
Maintenance
FUEL RAIL
I
57
63
101
56
II
54
54
55
II
51
50
53
49
52
61
58
59
60
62
102
014.581/06a
65
13/ 18
2010-07
03521/A1
Maintenance
RT-flex96C
SERVO OIL
90
90
90
014.582/06
39
44
45
2008
14/ 18
RT-flex96C
03521/A1
Maintenance
86
III
77
78
III
79
84
81
85
I
II
82
I
III - III
88
80
87
119
118
II
118
83
91
92
014.583/06a
15/ 18
2010-07
03521/A1
Maintenance
RT-flex96C
II
CONTROL OIL
SUPPLY
71
II
III
II - II
III
72
67
66
CONTROL OIL
SUPPLY
012.375/04a
69
2010-07
68
70
16/ 18
RT-flex96C
03521/A1
Maintenance
I
106
I-I
104
I
010.293/02
109
107
105
008.566/01
103
108
111
110
B
008.750/01
008.567/01
17/ 18
2008
03521/A1
Maintenance
RT-flex96C
116
115
014.643/06
2010-07
18/ 18
RT-flex96C
03522/A1
Maintenance
1.
Standard screws
This table is valid for all screws that are not considered in 03521.
It is recommended to lubricate the threads for screws which come into contact with
hot parts like exhaust pipings, expansion pieces, etc. with a heat-resisting lubricant, e.g. THREAD GARD or Never-Seez NSBT-8, etc.
Attention! These tightening instructions are valid only if:
Standard thread
Fine thread
M8
M8 x 1
20
M10
M10 x 1.25
40
M12
M12 x 1.25
70
M14
M14 x 1.5
110
M16
M16 x 1.5
170
M18
M18 x 1.5
250
M20
M20 x 1.5
350
M22
M22 x 1.5
450
M24
M24 x 2
600
M27
M27 x 2
900
M30
M30 x 2
1200
M33
M33 x 2
1600
M36
M36 x 3
2100
M39
M39 x 3
2500
M42
M42 x 3
2900
M45
M45 x 3
3300
M48
M48 x 3
3700
M52
M52 x 3
4100
M56
M56 x 4
4600
M60
M60 x 4
5200
1/ 2
2010-07
03522/A1
Maintenance
RT-flex96C
2.
Waisted studs
Waisted studs must be tightened according to the values in the following diagram.
D
Before fitting a waisted stud clean its thread and corresponding tap hole. The
sealing faces must be degreased (e.g. using white spirit) and subsequently
primed.
Screw in the waisted stud without lubricant on the thread right to the bottom of
the tap hole, and tighten. Always utilize a stud driver or two nuts.
Tools like a pipe wrench etc. which would damage the stud shank must never be
used.
D
For the protection of the waisted stud in the cylinder jacket and cylinder cover,
fill the annular space above the thread with a non-hardening jointing compound (see 27511).
3500
3000
400
2500
300
2000
1500
200
1000
100
500
001.769/97
0
10
20
30
40
50
60
2008
2/ 2
RT-flex96C
03601/A1
Maintenance
Masses (Weights)
Individual Components per Piece in kg
Group
Component
Execution
kg
1
1134
184234
1137
850949
1224
119161
1717
Casing
Casing
1720
1903
Tie rod
Tie rod nut
Intermediate ring for tie rod nut
driving end
free end
812
2044
585
306
complete
1335
49
2244
2
2106
166
2120
Supporting ring
3580
2124
Cylinder liner
9058
2130
2303
2708
453
complete
368
complete
88
6893
10 547
2722
Injection valve
complete
26.6
2728
Starting valve
complete
104
2751
Exhaust valve
complete
2927
2754
234
3122
Flywheel
40707800
3122
Counterweight
3140
3206
4521718
2-part
1/ 3
1992
22552356
2008
03601/A1
Maintenance
RT-flex96C
Group
3303
Component
Connecting rod
Waisted stud with nut for bottom end
bearing
Waisted stud with nut for top end
bearing
Execution
complete
kg
7900
79
29
3306
5330
3309
3310
3312
854
3315
202
3326
Crosshead
Crosshead with guide shoes
Guide shoe
complete
1226
91
complete
complete
4680
7417
1325
3403
complete
5444
1420
361
3287
256
3603
complete
208
4106
1-part
2-part, complete
2315
3517
4108
complete
3216
160
4120
1697
4325
497
5550
853
5551
227
2008
2/ 3
RT-flex96C
03601/A1
Maintenance
Group
Component
Execution
5552
complete
5556
Fuel pump
complete
408
5564
complete
207
5572
complete
222
5612
complete
235
6506
Turbocharger
Turbocharger
TPL85B11
MET83SEII
6545
complete
6606
GEA240/48/24
6708
Water separator
6735
complete
235
DN 1000
150
DN 500
142
complete 6, 7 Cyl.
compl. 810 Cyl.
compl. 1114 Cyl.
6, 7 cylinder
810 cylinder
1114 cylinder
kg
934
387
2869
3269
3613
725
975
1169
150
6
10 527
10 500
13802005
6301170
4550
3000
550
550
400
50
800
8
8138
8139
3/ 3
2008
RT-flex96C
03701/A1
Maintenance
Dimensions
O-rings and Round Rubber Rings
Group
Thickness
[mm]
Inner
[mm]
1903
Tie rod
6.99
129.54
2106
1130
Cylinder liner
Cylinder liner water guide jacket
Cylinder liner water guide jacket
Cylinder liner supporting ring
Cylinder liner cylinder jacket
9
9
9
9
1320
1380
1130
1110
2136
3.53
36.09
2138
2138
5.33
3.53
69. 22
36.09
2303
6.99
6.99
6.99
658.88
658.88
481.46
2708
Cylinder cover
Cylinder cover water guide jacket
Cylinder cover water guide jacket
9
9
1240
1380
2722
3.53
36.09
2728
Starting valve
Starting valve housing cylinder cover
Connection pipe starting valve
Starting valve cover 5/2-way valve
6.99
1.78
2
151.77
14
12
Exhaust valve
Valve cage cylinder cover
Valve seat cylinder cover
Valve seat valve cage
Guide bush valve cage
Lower housing valve cage
Lower housing intermediate flange
Bush to leakage passage valve cage
Piston valve spindle
Lower housing valve stroke sensor
Upper housing intermediate flange
Vent screw upper housing
Damper upper housing
7
6.99
6.99
5.33
6.99
5.33
3.53
5.33
5.33
5.33
2.62
5.33
685
608.08
456.06
129.54
417.96
291.47
37.69
94.62
28.17
291.47
23.47
91.44
1100
Piston
Piston rod oil pipe
Piston rod spraying plate
Piston crown spraying plate
6.99
9
9
151.77
620
630
2124
2751
3130
3403
Place of application
1/ 5
201007
03701/A1
Maintenance
RT-flex96C
Group
Thickness
[mm]
Inner
[mm]
6.99
6.99
3.53
2.62
1.78
2
253.37
227.97
56.74
13.94
6.07
10
2.4
1.78
20.30
6.86
Supply unit
Flange servo oil pump
3.53
202.79
5552
3.53
3.53
3.53
3.53
28.17
18.64
47.22
202.79
5554
3.53
202.79
Fuel pump
Lower housing housing of supply unit
Upper housing lower housing
Valve block upper housing
Valve block pump cover
Connection pin lower spring carrier
Adapter piece lower and upper housing
Pump cover flange
Guide pin lower housing
Flange upper housing
6.99
6.99
5.33
5.33
2.62
3.53
5.33
3.53
1.78
227.97
227.97
158.12
158.12
15.54
9.12
59. 69
37. 69
34. 65
Fuel rail
Flange heating pipe
Spindle guide valve block
Non-return valve
Drain screw valve block
5.33
3.53
1.5
1.78
59.69
32.92
16
12.42
3.53
3.53
1.78
40.87
40.87
5.28
2.62
1.5
1.78
1.78
15.54
16
14
9.25
4325
4605
5551
5556
5562
5564
5566
201007
Place of application
2/ 5
RT-flex96C
03701/A1
Maintenance
Group
Thickness
[mm]
Inner
[mm]
1.78
1.78
2.62
1.5
3.53
2.62
3.53
14
9.25
15.54
16
50.39
32.99
44.04
Oil return
Oil pipe pressure retaining valve
Valve valve block
Non-return valve
Drain screw valve block
5.33
2.62
1.5
1.78
132.72
29.82
16
12.42
3.53
3.53
3.53
1.78
1.5
2.62
1.78
3.53
32.92
32.92
85.32
5.28
16
59.99
6.07
72.62
6420
7206
3.53
40.87
8310
6.99
227.97
8446
3.53
3.53
50.39
26.57
3.53
3.53
3.53
3.53
2.62
1.78
1.78
1.78
47.22
37.69
47.22
47.22
15.54
75.92
75.92
33.05
5.33
5.33
75.57
85.09
5571
5610
5612
8447
8453
Place of application
3/ 5
201007
03701/A1
Maintenance
RT-flex96C
Group
Place of application
Inner
[mm]
8460
5.33
129.54
8704
2.62
15.54
2.62
3.53
3.53
3.53
37.77
37.69
32.92
31.34
3.53
5.33
5.33
3.53
40.87
59.69
148.49
32.92
3.53
3.53
1.78
1.78
2.62
2.62
2.62
1.78
2.62
2.62
2
2.62
3.53
3.53
1.4
50.39
32.92
20.35
6.07
113.97
18.72
15.54
6.07
64.77
61.60
10
3.63
18.64
66.27
69.60
5.33
5.33
5.33
5.33
46.99
66.04
66.04
66.04
9223
3.53
72.62
9258
Measuring instruments
Pressure switch and transmitter
1.78
6.07
8733
8750
201007
Thickness
[mm]
4/ 5
RT-flex96C
03701/A1
Maintenance
Group
Place of application
Thickness
[mm]
Inner
[mm]
9434
Tools
94349: Pressure testing device for piston
6.99
342.27
9455
2.62
34.59
8484
3.53
47. 22
5/ 5
201007
RT-flex96C
03702/A1
Maintenance
Dimensions
Piston and Rod Seal Rings
Group
Place of application
Ring
type
Dimension [mm]
4325
PSR
RSR
5556
RSR
24 x 26 x 1.8
RSR
70 x 3.53
Tools
94424: Hydr. jacking tool
PSR
65 x 61 x 3.8
940810
Cylinder
Bush
O-ring
Seal ring
Seal ring
O-ring
Piston
Rod
i
1/ 6
2010-07
03702/A1
Maintenance
RT-flex96C
Group
Place of application
Ring
type
Dimension [mm]
2751
RSR
110.1 x 95 x 6.1
00.7384
Rod
di
da
da = Groove diameter
di = Rod diameter
b = Groove width
2010-07
2/ 6
RT-flex96C
03702/A1
Maintenance
Group
Place of application
Ring
type
Dimension [mm]
2751
PSR
Cylinder
b
Seal ring
O-ring
Piston
di
da
da = Cylinder diameter
di = Groove diameter
b = Groove width
3/ 6
2010-07
03702/A1
Maintenance
RT-flex96C
Tool
No.
Part
Back-up ring
O-ring
(slotted)
Dimension [mm]
o x i x t
94145
94252
94314
94315
94340
94556
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
O-ring
i x s
123.19 x 5.33
94.62 x 5.33
266.07 x 6.99
148.49 x 5.33
240.67 x 6.99
170.82 x 6.99
177.17 x 6.99
126.37 x 6.99
113.67 x 5.33
78.74 x 5.33
6.99 x 135.89
5.33 x 85.09
Back-up ring
i
o
002.696/98
2013-04
4/ 6
RT-flex96C
03702/A1
Maintenance
Part
Back-up ring
O-ring
(un-slotted)
Dimension [mm]
o x i x t
94114
94215a
94215b
94346
94180
Tie rod
94557
94595
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
piston
O-ring
i x s
110.49 x 5.33
66.04 x 5.33
253.37 x 6.99
145.42 x 6.99
91.44 x 5.33
78.97 x 3.53
354.97 x 6.99
240.67 x 6.99
104.14 x 5.33
69.44 x 3.53
100.97 x 5.33
Back-up ring
s
o
i
o
011.032/03
5/ 6
2013-08
03702/A1
Maintenance
RT-flex96C
Group
8453
Place of application
Part
O-ring
Back-up ring
O-ring
(un-slotted)
Dimension [mm]
o x i x t
i x s
68 x 59.4 x 1.7
56.52 x 5.33
68 x 59.4 x 1.7
56.52 x 5.33
Back-up ring
014.687/06
2010-07
6/ 6
RT-flex96C
03801/A1
Maintenance
Maintenance Schedule
Inspection and Overhaul Intervals (Guidelines)
Group
Component
Intervals
0
Lubricating oil
Laboratory analysis
Cooling water
weekly
Bedplate
12 000 Op. h
Crankcase
Visual examination
100 Op. h after overhaul works
15003000 Op. h
Main bearing
according to
classification society
60008000 Op. h
60008000 Op. h
1
11121
11322
12031
Thrust bearing
12241
17151
60008000 Op. h
19031
Tie rod
Cylinder liner
as required
Replace O-rings
at every removal
as required
as required
Replace O-rings
6000 Op. h
2
21241
21242
21243
21361
Lubricating quill
and accumulator
1/ 9
2008
03801/A1
Maintenance
RT-flex96C
Group
Component
21381
Lubricating quill
(Pulse lubrication)
Intervals
Replace O-Rings
23031
27081
Cylinder cover
27221
Injection valve
3000 Op. h
weekly
60008000 Op. h
monthly
6000 Op. h
18 000 Op. h
27281
Starting valve
27451
Relief valve to
cylinder cover
as required
27511
to
Exhaust valve
Check piston seal ring / air spring & rod seal ring /
guide bush
18 000 Op. h
18 000 Op. h
according to
classification society
27514
3
31031
Crankshaft
2013-08
2/ 9
RT-flex96C
03801/A1
Maintenance
Group
Component
Intervals
31301
Torsional
vibration damper
acc. to instructions of
damper manufacturer
31302
31461
Axial damper
32061
Turning gear
acc. to instructions of
turn. gear manufacturer
12 000 Op. h
60008000 Op. h
33032
33033
Check clearances
60008000 Op. h
Remove crosshead
as required
after refitting
34033
as required
34034
5001000 Op. h
15003000 Op. h
15003000 Op. h
15002000 Op. H
Connecting rod
bearings
33261
Guide shoe,
crosshead pin
33262
34031
Piston
Piston underside
34251
Piston rings
3/ 9
2013-08
03801/A1
Maintenance
RT-flex96C
Group
Component
Intervals
41031
Start interlock
quarterly
Driving wheels
60008000 Op. h
60008000 Op. h
Vent
18 000 Op. h
Drain filter
weekly
Clean filter
6000 Op. h
Starting air
shut-off valve
43251
2008
4/ 9
RT-flex96C
03801/A1
Maintenance
Group
Component
Intervals
5
55521
24 000 Op. h
3000 Op. h
24 000 Op. h
3000 Op. h
12 000 Op. h
36 000 Op. h
18 000 Op. h
18 000 Op. h
18 000 Op. h
18 000 Op. h
36 000 Op. h
36 000 Op. h
Distributor block
36 000 Op. h
Replace hoses
56101
Pressure
reducing valve
56121
Exhaust valve
control unit
18 000 Op. h
Replace filter
18 000 Op. h
3000 Op. h
Supply unit
55522
55561
55641
5571
5610
58011
Fuel pump
Injection control
unit
Regulating
linkage
5/ 9
2012-05
03801/A1
Maintenance
RT-flex96C
Group
Component
Intervals
6
64201
Scavenge air
receiver
Exhaust gas
turbocharger
Air filter
65451
66061
67081
67351
2012-05
Auxiliary blower
Scavenge air
cooler
Water separator
Scavenge Air
Waste Gate
40006000 Op. h
Clean receiver
40006000 Op. h
15003000 Op. h
Check filter
half yearly
as required
Replace ball-bearing
as required
daily
15003000 Op. h
quarterly
Vent
daily
as required
daily
15003000 Op. h
15003000 Op. h
as required
Check function
(see Operating Manual 67351)
half yearly
6/ 9
RT-flex96C
03801/A1
Maintenance
Group
Component
Intervals
7
Cylinder
lubricating pump
72181
8
81351
Exhaust Waste
Gate (LLT)
according to instruction
of valve manufacturer
Servo oil
automatic filter
Collector block
36 000 Op.h
6000 Op.h
84471
as required
84601
Hydraulic piping
to exhaust valve
as required
Starting air
piping
Drain (de-water)
Pressure gauges
and pyrometers
60008000 Op.h
Fuel and
lubricating oil
filters
as required
Pipe holders
as required
8447
7/ 9
2011-07
03801/A1
Maintenance
RT-flex96C
Group
Component
Intervals
as required
87331
Fuel pressure
piping (on
cylinder cover)
as required
8744
6000 Op.h
87501
Relief valve
(fuel overpressure
safety valve)
18 000 Op.h
87502
Fuel pressure
control valve
(PCV)
3000 Op. h
Function check
(see Operating Manual 55561)
6000 Op. h
General overhaul
18 000 Op. h
Fuel pressure
piping
as required
Crank angle
sensor unit
3000 Op.h
24 000 Op.h
48 000 Op.h
48 000 Op.h
(only if new soft belt is
applied from beginning)
half yearly
WECS electronic
components
Check cabling
quarterly
87521
9
92231
2013-08
8/ 9
RT-flex96C
Maintenance
03801/A1
Heavy fuel oil and lubricating oil qualities (see Operating Manual 07101 and
07501)
Engine load
Fuel, lubricating oil and cooling water care (see Operating Manual 07201
and 07601)
Engine monitoring
On the engine sectional drawings 08031, those parts are marked with group
numbers, as they are found in the Maintenance Manual.
Group numbers exist of the following engine components, although these parts
are not marked on the sectional drawings:
Engine component
Group No.
9/ 9
2008
RT-flex96C
08031/A1
Maintenance
Cross Section:
84601
87331
27281
27221
55641
56121
65451
84471
64201
87521
87501
55561
55562
33012
66061
55521 to
55525
67081
41031 to
41033
33011
11121
013.297/05
1/ 2
2008
08031/A1
Maintenance
RT-flex96C
Longitudinal Section:
27511 to
27514
27081 to
27083
21361
21381
34251
21241 to
21243
19031
34031 to
34034
43251
23031
33261
33262
33031 to
33034
31461
11321
11322
32061
92231
31031
12031
12241
31301
31302
011.860/04
2008
2/ 2
RT-flex96C
Maintenance
Group1
Group 1
Main Bearing
Loosening and Tensioning of Waisted Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11321/A1
Removal and Fitting of a Main Bearing (6 and 7 Cylinder Engines) . . . . . . . . . 11322/A1
Removal and Fitting of a Main Bearing (8 14 Cylinder Engines) . . . . . . . . . . 11322/A2
Main Bearing Upside-down Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11323/A1
Thrust Bearing
Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12031/A1
Removal and Fitting the Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12241/A1
Engine Stays
with Friction Shims: Checking the Pre-tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 17151/A1
Hydraulic: Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17151/A2
Tie Rod: Checking the Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . 19031/A1
1/ 3
RTflex96C / MM / 2008
RT-flex96C
11121/A1
Maintenance
1.
Key to Illustrations:
Feeler gauge
Pre-tensioning jack
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
HP hose
94122
94145
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
7
8
9
10
Pin
Vent screw
Cylinder
Piston
Sealing ring
Nut
Bedplate
Foundation bolt
Foundation fitted stud
Bush
11
12
13
14
15
EV
KO
RS
SA
Sleeve
Chock
Ships foundation plate
Nut
Conical socket
Relief valve
Slot
Round bar
Gap
General
The pre-tension of the foundation bolts (holding down studs) must be checked at
longer intervals e.g. during overhauls (see 03801).
In the area of the thrust bearing the bedplate may be fastened with foundation bolts
8, bushes 10 and sleeves 11 (Fig. A) or with foundation fitted studs 9 (Fig. B).
The remaining area is fastened with foundation bolts 8 and bushes 10 (Fig. C),
however without sleeves 11.
Remark: Pay attention to General Application Instructions 94034 for hydraulic
pre-tensioning jacks.
6
8
10
9
10
7
11
014.286/06
014.285/06
8
10
12
13
014.287/06
15
14
1/ 3
2008
11121/A1
Maintenance
RT-flex96C
2.
Check with feeler gauge through slot KO if there is any clearance between nut 6
and its seating.
If there is no clearance, this means that the tightening condition of the foundation bolt has remained unchanged since the last check. The pressure can be
released to zero with relief valve EV and the pre-tensioning jack removed.
Should a clearance be found, nut 6 must be tightened down onto its seating
with round bar RS while the pressure is kept at 1000 bar (check with feeler
gauge). Subsequently lower the pressure to zero.
D
94932a
94935a
94934e
94934a
2
1
94935
94932
5
6
RS
KO
EV
94931
10
8(9)
014.295/06
Remark: If the foundation bolts have completely loosened and have to be tensioned again, then all foundation bolts have to be pre-tensioned first with 600 bar
(1st step) and subsequently tensioned with 1000 bar (2nd step).
2008
2/ 3
RT-flex96C
11121/A1
Maintenance
3.
E
94932a
94935a
94934e
94934a
2
1
4
3
5
94935
94932
6
SA
EV
94931
10
8(9)
014.297/06
4.
Tensioning of the foundation bolts must be carried out in two steps without exception, for both metal & synthetic chocks, i.e. tension all foundation bolts first
with 600 bar (1st step), then finish tensioning with 1000 bar (2nd step).
3/ 3
2008
RT-flex96C
11321/A1
Maintenance
Main Bearing
Loosening and Tensioning of Waisted Studs
Tools:
2
1
1
1
1
1
1
2
1
Key to Illustrations:
94114
94122
94123
94126
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
Waisted stud
Main bearing cover
Nut
Round nut
Piston
Cylinder
Cover
Tension sleeve
Distance sleeve
Main bearing girder
Vent screw
KO Slot
RS Round bar
1.
General
The double pre-tensioning jacks 94114 must always be used for loosening as well
as for tensioning the waisted studs 1 for the main bearing.
Prior to screwing the nuts onto the waisted studs, threads and the nut seating surfaces must be clean. Apply oil to the threads. Pay attention to the free movement of
the nuts.
Remark: Pay attention to General Application Instructions 94034 for hydraulic
pre-tensioning jacks.
2.
The pistons are fully down on the cylinders when distance L1 is about 13 mm,
measured from the top of the piston to the upper edge of cover 7.
Check the oil level in hydraulic unit 94942.
Close vent screw.
Subsequently loosen all round nuts 4 by about to 1 turn.
Raise the pressure to 1020 bar at the hydraulic unit.
Unscrew nuts 3 by one turn with round bar RS.
Release the pressure to zero at the hydraulic unit and then remove both
double pre-tensioning jacks.
1/ 3
2008
11321/A1
Maintenance
RT-flex96C
3.
CHECK
Place both double pre-tensioning jacks 94114 onto waisted studs 1 for the
main bearing as described under section 2 (Fig. C).
Connect both double pre-tensioning jacks by HP hoses 94935 and 94935a,
hydr. distributor 94934a and pressure gauge 94932a with hydraulic unit
94942 (arrangement see Fig. C).
Open vent screw 11.
Screw on round nuts 4 of the double pre-tensioning jacks till piston 5 fully seat
on cylinders 6 (Fig. B).
The pistons are fully down on the cylinders when distance L1 is about 13 mm,
measured from the top of the piston to the upper edge of cover 7.
Check the oil level in hydraulic unit 94942.
CHECK
A
y
1ST STEP
2ND STEP
CHECK
98.7672
TIGHTENING
ANGLE
Check if all the nuts have been turned by about the same value, i.e. the tightening angle should be 130_ between the 1st and 2nd step (Fig. A). If bigger
differences occur the tensioning procedure must be repeated.
Finally check the horizontal and vertical clearances by means of special feeler
gauge 94123 (see Clearance Table 03301 Crankshaft and main bearing).
Recheck distances a1 and a2. If the difference exceed 0.3 mm, loosen the waisted
studs, adjust the bearing cover correspondingly and repeat the tensioning procedure.
Remark: All main bearing clearance values are valid only with tightened tie rods
and waisted studs.
2008
2/ 3
RT-flex96C
11321/A1
Maintenance
94114
L1
11
5
6
8
RS
3
011.639/04
94935
94934a
94932a
94935a
94942
94935a
a1
a2
94114
10
011.638/04
3/ 3
2006
RT-flex96C
11322/A1
Maintenance
Main Bearing
Removal and Fitting of a Main Bearing
Tools:
Key to Illustrations:
1 Lifting tool
2 Roller supports
1 Turning-out device
for narrow bearing shell
1 Turning-out device
for broad bearing shell
1 Turning-out device
for last bearing shell at free end
1 Lifting yoke
1 Lifting eye bolt
2 Ropes with shackle
(300 mm)
1 Rope with shackle
(500 mm)
1 Rope with shackle
(600 mm)
1 Rope with shackle
(800 mm)
1 Rope with shackle
(1000 mm)
1 Rope with shackle
(1200 mm)
1 Rope with shackle
(1500 mm)
1 Rope with shackle
(1600 mm)
1 Rope with shackle
(1700 mm)
1 Rope with shackle
(1900 mm)
1 Rope with shackle
(2000 mm)
1 Rope with shackle
(2200 mm)
1 Rope with shackle
(2800 mm)
1 Rope with shackle
(3200 mm)
2 Ropes with 2 shackles (1000 mm)
1 Special feeler gauge
1 Support
1 Working platform
1 HP oil pump
1 Hydr. distributor
1 HP hose
2 HP hoses
2 Hydraulic jacks
94116
94117
94118b
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
94118c
94118d
94119
94120a
94120b
94120c
94120d
94120e
94120f
94120g
94120h
94120i
94120k
94120l
94120m
94120n
94120o
94120p
94120q
94123
94141
94142
94931
94934a
94935
94935a
94936
HO
HZ
H1...
OB
RC
RC1
RC2
Crankshaft
Main bearing cover
Main bearing shell
Locating dowel pin
Groove
Key
Flywheel
Main bearing girder
Guide shoe middle part
Support
Waisted stud
Nut
Axial damper
Support
Intermediate wheel
Spur-geared chain block
Connecting rod
Blank flange
Jack
Suspension eye
Suspension eye
Strap
Wooden board
Lifting tackle
Lifting tackles
Oil bore
Eye bolt M24
Eye bolt M20
Eye bolt M20
Overview
1.
2.
3.
4.
5.
6.
7.
1/ 22
2008
11322/A1
Maintenance
RT-flex96C
12
2
11
2
6
4
1
6
3
8
3
008.871/01
1.
Type A
Type B
Type D
Type E
Wide bearing cover and bearing shell with shot peened surface at
the back side
DF 11352
DF 11304
DF 11342
DF 11344
DF 11377
DF 11302
DF 11365
DF 11365
DF 11353
DF 11343
DF 11343
DF 11343
DF 11300
TYPE OF MB
B
D or E
D or E
D or E
D or E
D or E
FREE
END
DRIVING
END
Cyl. #1
Cyl. #2
Cyl. #3
THRUST BEARING
LOCATION
2013-02
2/ 22
RT-flex96C
11322/A1
Maintenance
15
10
H2
H1
7
b
a
94120a
RC
2
014.584/06
Detach rope a.
I-I
D
21 H6
20
H5
H2
RC
2
014.585/06
3/ 22
2008
11322/A1
Maintenance
RT-flex96C
II - II
Remove upper part of oil baffle at the
driving end.
Turn corresponding crank to exhaust
side approx. 90_after T.D.C.
Install working platform 94142.
Remove oil piping from thrust bearing.
Loosen nuts 12 to waisted studs 11
(Fig. A) hydraulically (see 11321).
94117
H1
RC
a e
2
94142
014.586/06
II
10
H2
H1
9
a
15
94117
RC
017.862/08
PROTECTION
014.587/06
II
2008
4/ 22
RT-flex96C
Maintenance
11322/A1
6 and 7 Cylinder Engines
H2
H1
014.588/06
H
Screw two eye bolts RC1 and RC2
laterally into the bearing cover.
Connect rope f (94120q) with eye
bolts RC1 and rope d.
H2
H1
d
RC1
e
f
RC2
014.589/06
5/ 22
2008
11322/A1
Maintenance
RT-flex96C
H2
H1
RC
e
d
94120a
H3
The further removal of the bearing cover is carried out analogously as described for Fig.
KM.
RC2
014.590/06
94117
RC
22 HZ H1
014.591/06
2008
6/ 22
RT-flex96C
11322/A1
Maintenance
H4
Guide the bearing cover to fuel side
with ropes g and e until rope h
(94120m) can be connected with lifting tackle H4 and eye bolt RC.
h
g
RC
014.592/06
014.593/06
94142
7/ 22
2008
11322/A1
Maintenance
RT-flex96C
4.
9
94117
9
H2
H1
94117
e
PROTECTION
94120a
H3
RC
RC2
008.889/01
2008
8/ 22
RT-flex96C
11322/A1
Maintenance
O
Fasten lifting tackle HZ to strap 22.
Connect rope g (94120e) with eye
bolts RC and lifting tackle HZ.
Lift the bearing cover carefully over
the crank web with ropes e and f towards middle of cylinder (Fig. I) and
pull it with rope g (Fig. O) to fuel
94117
side at the same time.
RC
H1
22 HZ
014.599/06
P
H4
RC
014.600/06
9/ 22
2008
11322/A1
Maintenance
RT-flex96C
Q
Place bearing cover on working platform 94142.
Remove rope e.
Lift the bearing cover out of the crankcase using ropes g and h.
h
014.601/06
94142
5.
H2
9
H1
18
94117
e d
13
PROTECTION
RC
014.602/06
2008
10/ 22
RT-flex96C
Maintenance
11322/A1
6 and 7 Cylinder Engines
S
Lift the bearing cover carefully as much as
possible with ropes d and e and detach
rope d from eye bolt RC.
H2
H1
e
RC
014.613/06
T
Screw two eye bolts RC1 and RC2 laterally into the bearing cover.
Fasten lifting eye bolt 94120a to the column
(see detail concerned in Fig. C).
Connect rope d with eye bolt RC2 and lifting tackle H2.
H2
94120a
e
H3
RC1
RC2
The further removal of the bearing cover is carried out analogously as described for Fig.
OQ.
014.603/06
11/ 22
2008
11322/A1
Maintenance
RT-flex96C
The same lifting tackles are used for the removal of the corresponding bearing
shells as for the removal of the corresponding bearing covers.
For the removal of bearing shells No. 1 and 2 the flywheel must also be
pressed up with the additional hydraulic jack 19. To protect the flywheel toothing, put a copper or aluminium plate between the hydraulic jack and the flywheel (Fig. Z).
6.1
94936
94141
8
I
94942
I-I
94931
94935
94934a
94935a
94936
94141
008.894/01
2008
12/ 22
RT-flex96C
11322/A1
Maintenance
8
004.844/98
6.3
CHECK
The same ropes and arrangement are used for turning out and lifting of the
bearing shells, however, rope 94120g must be replaced by rope 94120h.
The same ropes and arrangement are used for turning out and lifting of the
bearing shell, however, rope 94120i must be replaced by rope 94120l, and
rope 94120g must be replaced by rope 94120h.
The same ropes and arrangement are used for turning out and lifting of the
bearing shells, however, rope 94120i must be replaced by rope 94120l.
The same ropes and arrangement are used for turning out and lifting of the
bearing shells, however, rope 94120i must be replaced by rope 94120l, and
rope 94120d must be replaced by rope 94120f.
The turning-out procedure is the same for all bearing shell as described for
Fig. X.
DRIVING
END
008.872/01
94118b
94118c
13/ 22
94118d
2010-07
11322/A1
Maintenance
RT-flex96C
I-I
94117
94117
H2
H1
x
H2
94117
H1
e x
II
94119
94119
III
3
3
94936
94141
014.605/06
014.604/06
III
II
x
94118c
94119
008.900/01
2008
14/ 22
008.901/01
RT-flex96C
11322/A1
Maintenance
6.4
I-I
22
HZ
H1
94117
H1
H2
94120a
H3
II
014.606/06
94116
x e
94116
014.607/06
II
94116
3
008.913/01
15/ 22
2008
11322/A1
Maintenance
RT-flex96C
6.5
I
21 H6
15
20
10
H2
H5
H2
b
a
94116
94120a
H3
94116
3
7
19
014.609/06
014.608/06
PROTECTION
2008
16/ 22
RT-flex96C
11322/A1
Maintenance
6.6
A1
I-I
15
10
H2
94117
H1
a
94120a
H3
H1
94117
22
HZ
94116
a e
94116
3
014.611/06
014.610/06
PROTECTION
17/ 22
2008
11322/A1
Maintenance
RT-flex96C
6.7
B1
I-I
22 HZ
14
H1
H2
94117
94117
94120a
H3
94116
94116
ed
014.627/06
014.612/06
2008
18/ 22
RT-flex96C
11322/A1
Maintenance
7.
Prior to fitting a new bearing shell or bearing cover pay attention to the Arrangement and characteristics of the main bearings on page 2, and to the upset down test 11323.
Remark: All bearing shells are marked with their proper code numbers (see table
on page 2). In addition bearing shells and bearing covers are laterally marked with
DRIVING END. Therefore, they must be fitted correspondingly.
Attention! Always fit bearing shells No. 1 and 2 in direction of arrow as shown in
Fig. D1.
Furthermore refer to Service Bulletin RT141.
D
Bearing shell and bearing cover should be fitted into the bearing girder in their
original positions.
Oil bore OB in the bearing girder must be clean and without particles of white
metal.
Crankshaft journal, girder bore for main bearing and all parts to be fitted must
be clean and undamaged!
C1
014.690/06
I-I
STEPPED
KEYS
I
014.689/06
014.694/06
D1
TYPE OF MB
B
D or E
D or E
D or E
D or E
D or E
FREE
END
DRIVING
END
Cyl. #1
Cyl. #2
Cyl. #3
THRUST BEARING
LOCATION
19/ 22
2013-02
11322/A1
Maintenance
RT-flex96C
E1
Type B:
Narrow, asymetrical
and conical
Type A:
Narrow, asymmetrical
DRIVING
END
F1
369
369
Type D or E:
Wide
425
014.629/06
OB
2013-02
OB
20/ 22
RT-flex96C
11322/A1
Maintenance
The fitting of bearing shell and bearing cover is carried out analogously but in reverse sequence to the removal.
Directly before fitting (turning in) bearing shell 3 apply a very thin layer of
MOLYKOTE paste G to the back of it.
The crankshaft journal and the running surface of the main bearing shell must
be thoroughly lubricated with clean engine oil.
7.1
G1
Connect ropes x and e with lifting yoke
94119.
Lead both ropes of turning-out device
94118c below of the crankshaft journal to
the fuel side and connect them with lifting
yoke 94119.
D
H2
H1
END OF ROPE
94119
3
Be careful that keys 6 mesh with the corresponding keyways in bearing cover 2 (Fig.
A).
014.630/06
CHECK
The bearing clearances and the crank deflection must be measured after a new
bearing shell has been fitted and the bearing cover has been tightened (see
03301 and 31031).
After assembly, check if lubricating oil is supplied to the main bearing with the oil
pump in operation!
21/ 22
2008
11322/A1
Maintenance
RT-flex96C
Remark: Should the crankshaft need to be turned before the bearing cover is
fitted, then care must be taken that the bearing shell does not turn. Therefore,
bearing shell 3 must be blocked with two suitable wooden boards HO.
H1
12
HO
11
1
3
8
008.925/01
2008
22/ 22
RT-flex96C
11322/A2
Maintenance
Main Bearing
Removal and Fitting of a Main Bearing
8 14 Cylinder Engines
Tools:
Key to Illustrations:
1 Lifting tool
2 Roller supports
1 Turning-out device
for narrow bearing shell
1 Turning-out device
for broad bearing shell
1 Turning-out device
for bearing shell at free end
1 Lifting yoke
1 Lifting eye bolt
2 Ropes with shackle
(300 mm)
1 Rope with shackle
(500 mm)
1 Rope with shackle
(600 mm)
1 Rope with shackle
(800 mm)
1 Rope with shackle
(1000 mm)
1 Rope with shackle
(1200 mm)
1 Rope with shackle
(1500 mm)
1 Rope with shackle
(1600 mm)
1 Rope with shackle
(1700 mm)
1 Rope with shackle
(1900 mm)
1 Rope with shackle
(2000 mm)
1 Rope with shackle
(2200 mm)
1 Rope with shackle
(2800 mm)
1 Rope with shackle
(3200 mm)
2 Ropes with 2 shackles (1000 mm)
1 Special feeler gauge
1 Support
1 Working platform
1 HP oil pump
1 Hydr. distributor
1 HP hose
2 HP hoses
2 Hydraulic jacks
94116
94117
94118b
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
94118c
94118d
94119
94120a
94120b
94120c
94120d
94120e
94120f
94120g
94120h
94120i
94120k
94120l
94120m
94120n
94120o
94120p
94120q
94123
94141
94142
94931
94934a
94935
94935a
94936
HO
HZ
H1...
OB
RC
RC1
RC2
Crankshaft
Main bearing cover
Main bearing shell
Locating dowel pin
Groove
Key
Flywheel
Main bearing girder
Guide shoe middle part
Support
Waisted stud
Nut
Vibration damper
Support
Intermediate wheel
Spur-geared chain block
Connecting rod
Blank flange
Jack
Suspension eye
Cover
Casing, upper part
Oil baffle, upper part
Suspension eye
Strap
Wooden board
Lifting tackle
Lifting tackles
Oil bore
Eye bolt M24
Eye bolt M20
Eye bolt M20
Overview
1.
2.
3.
4.
5.
6.
7.
8.
1/ 27
2013-02
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
12
2
2
6
4
11
1
6
3
8
3
008.871/01
1.
Type A
Type B
Type C
Type D
Type E
Wide bearing cover and inner diameter of shell double conically machined
(MB No. 5 on 1114 Cyl. engines
only)
DF 11352
DF 11304
DF 11351
DF 11342
DF 11344
DF 11379
DF 11378
DF 11377
DF 11302
DF 11377
DF 11365
DF 11365
DF 11365
DF 11365
DF 11353
DF 11343
DF 11343
DF 11343
DF 11343
DF 11343
DF 11343
DF 11300
2013-02
2/ 27
Type F
Type G
RT-flex96C
11322/A2
Maintenance
8 14 Cylinder Engines
B
CENTRE DRIVE
D or E
D or E
DRIVING
END
Cyl. #1
Cyl. #2
D, E, F or G
D or E
D or E
FREE
END
TYPE OF MB
Cyl. #3
THRUST BEARING
LOCATION
3/ 27
2013-02
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
H2
RC
2
1
014.650/06
I-I
D
24 H6
20
H2
H5
RC
2
014.585/06
2008
4/ 27
RT-flex96C
11322/A2
Maintenance
8 14 Cylinder Engines
II - II
2
94142
RC
b e
II
Remove cover 21 from casing upper
part 22.
Fasten lifting tackle H2 to the inner side
of the casing upper part.
Connect rope b (94120b) with lifting
tackle H2 and eye bolt RC.
Provide protection for the crank web.
21
9
22
H2
b
RC
94117
017.862/08
PROTECTION
23
014.656/06
II
Wrtsil Switzerland Ltd
5/ 27
2008
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
H1
H2
e
b
014.657/06
e
f
H3
RC2
014.658/06
2008
6/ 27
RT-flex96C
11322/A2
Maintenance
8 14 Cylinder Engines
I
Fasten lifting tackle HZ to strap 25.
Connect rope g (94120e) with eye
bolts RC and lifting tackle HZ.
Lift the bearing cover carefully over
the crank web with ropes e and f towards middle of cylinder (Fig. H) and
pull it with rope g (Fig. K) to fuel side
94117
at the same time.
RC
H1
25 HZ
014.599/06
K
H4
RC
014.600/06
7/ 27
2008
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
L
Place bearing cover on working platform 94142.
Remove rope e.
Lift the bearing cover out of the
crankcase using ropes g and
h.
014.601/06
94142
2008
8/ 27
RT-flex96C
11322/A2
Maintenance
8 14 Cylinder Engines
9
94117
9
H2
H1
94117
e
PROTECTION
94120a
H3
RC
RC2
008.889/01
9/ 27
2008
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
I-I
Turn the corresponding crank to ex
haust side approx. 90_ after T.D.C.
Install working platform 94142.
Loosen nuts 12 for waisted studs 11
(Fig. A) hydraulically (see 11321).
Fasten roller support 94117 to guide
shoe middle part 9 as shown in Fig. N
O and detail concerned in Fig. F.
Screw eye bolt RC into bearing cover
94117
RC
H1
2
94142
a e
014.586/06
I
Fasten lifting eye bolt 94120a to the
column (see detail concerned in Fig
H).
Provide protection for the crank web.
15
9
H1
94120a
H2
94117
a
e
RC
PROTECTION
014.663/06
I
2008
10/ 27
RT-flex96C
Maintenance
11322/A2
8 14 Cylinder Engines
H1
e
H2
014.664/06
Screw two eye bolts RC1 and RC2 laterally into the bearing cover.
Connect rope f (94120q) with eye bolt RC1
and rope d.
Lift the bearing cover carefully onto the
crank web with ropes d, f and e.
Subsequently remove ropes d and f.
H1
H2
d
f
RC2
RC1
014.665/06
11/ 27
2008
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
I
Fasten lifting eye bolt 94120a to the column
(see detail concerned in Fig. H).
Connect rope f (94120q) with eye bolt
RC2 and lifting tackle H3.
H1
RC
94120a
H3
RC2
014.666/06
I-I
H1
25 HZ
94117
RC
g
014.591/06
2008
12/ 27
RT-flex96C
11322/A2
Maintenance
8 14 Cylinder Engines
H4
Guide the bearing cover to fuel side
with ropes g and e until rope h
(94120m) can be connected with lifting tackle H4 and eye bolt RC.
h
g
RC
014.592/06
014.593/06
94142
13/ 27
2008
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
9
H1
94117
PROTECTION
e d
14
H2
18
13
RC
2
014.670/06
H2
H1
e
RC
PROTECTION
014.660/06
2008
14/ 27
RT-flex96C
Maintenance
11322/A2
8 14 Cylinder Engines
X
Screw two eye bolts RC1 and RC2
laterally into the bearing cover.
Fasten lifting eye bolt 94120a to the
column (see detail concerned in Fig.
H).
H2
94117
H1
94120a
H3
RC1
e
f
RC2
PROTECTION
014.661/06
15/ 27
2008
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
The same lifting tackles are used for the removal of the corresponding bearing
shells as for the removal of the corresponding bearing covers.
For the removal of bearing shells No. 1 and 2 the flywheel must also be
pressed up with the additional hydraulic jack 19. To protect the flywheel toothing, put a copper or aluminium plate between the hydraulic jack and the flywheel (Fig. D1).
7.1
94936
94141
8
I
94942
I-I
94931
94935
94936
94934a
94935a
94141
008.894/01
2008
16/ 27
RT-flex96C
11322/A2
Maintenance
8 14 Cylinder Engines
6.2
8
004.844/98
7.3
CHECK
D
Bearing No. 2, see Fig. E1:
Bearing No. 3, see Fig. C1:
D
The same ropes and arrangement are used for turning out and lifting of the
bearing shells, however, rope 94120i must be replaced by rope 94120l.
The turning-out procedure is the same for all bearing shell as described for
Fig. B1.
A1
CENTRE DRIVE
FREE
END
DRIVING
END
008.928/01
94118b
94118c
94118b
17/ 27
94118c
94118d
2013-02
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
I-I
B1
94117
94117
H2
H1
H2
94117
H1
x
e
e x
II
94119
94119
III
3
3
94936
94141
014.605/06
014.604/06
III
II
x
94118c
94119
008.900/01
2008
18/ 27
008.901/01
RT-flex96C
11322/A2
Maintenance
7.4
8 14 Cylinder Engines
I-I
C1
25
HZ
H1
94117
H1
H2
94120a
H3
II
014.606/06
94116
x e
94116
014.607/06
II
94116
3
008.913/01
19/ 27
2008
11322/A2
Maintenance
RT-flex96C
7.5
8 14 Cylinder Engines
D1
I-I
24 H6
20
10
H2
H5
H2
94116
94116
3
7
19
014.662/06
2008
014.609/06
PROTECTION
20/ 27
RT-flex96C
11322/A2
Maintenance
7.6
8 14 Cylinder Engines
E1
I-I
25
HZ
H1
94117
H1
H2
94120a
H3
014.651/06
19
94116
3
b e
014.659/06
PROTECTION
21/ 27
2008
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
F1
7.7
15
94117
H1
94120a
H2
94116
3
014.685/06
I-I
F2
H1
94117
25 HZ
g
94116
3
a e
014.667/06
2008
22/ 27
H3
014.668/06
RT-flex96C
11322/A2
Maintenance
7.8
8 14 Cylinder Engines
G1
I-I
25 HZ
14
H1
H2
94117
94117
94120a
H3
e d
94116
94116
ed
014.627/06
014.612/06
23/ 27
2008
11322/A2
Maintenance
RT-flex96C
8.
8 14 Cylinder Engines
Prior to fitting a new bearing shell or bearing cover pay attention to the Arrangement and characteristics of the main bearings on page 2, and to the upset down test 11323.
Remark: All bearing shells are marked with their proper code numbers (see table
on page 2). In addition bearing shells and bearing covers are laterally marked with
DRIVING END. Therefore, they must be fitted correspondingly.
Attention! Always fit bearing shells No. 1 and 2 in direction of arrow as shown in
Fig. I1.
Furthermore refer to Service Bulletin RT141.
D
Bearing shell and bearing cover should be fitted into the bearing girder in their
original positions.
Oil bore OB in the bearing girder must be clean and without particles of white
metal.
Crankshaft journal, girder bore for main bearing and all parts to be fitted must
be clean and undamaged!
H1
I-I
014.690/06
I
014.689/06
014.694/06
I1
CENTRE DRIVE
TYPE OF MB
B
D or E
D or E
DRIVING
END
Cyl. #1
Cyl. #2
D, E, F or G
D or E
D or E
FREE
END
STEPPED
KEYS
Cyl. #3
THRUST BEARING
LOCATION
2013-02
24/ 27
RT-flex96C
11322/A2
Maintenance
8 14 Cylinder Engines
K1
Type B:
Narrow, asymetrical
and conical
Type A:
Narrow, asymmetrical
DRIVING
END
L1
369
369
Type D or E:
Wide
425
014.629/06
OB
OB
M1
N1
Type C:
Narrow, asymmetrical
(both sides of centre drive)
Type F or G:
Wide, double conical shell
(1114 Cyl. only)
369
369
425
014.653/06
OB
25/ 27
OB
2013-02
11322/A2
Maintenance
RT-flex96C
8 14 Cylinder Engines
The fitting of bearing shell and bearing cover is carried out analogously but in reverse sequence to the removal.
Directly before fitting (turning in) bearing shell 3 apply a very thin layer of
MOLYKOTE paste G to the back of it.
The crankshaft journal and the running surface of the main bearing shell must
be thoroughly lubricated with clean engine oil.
8.1
O1
Connect ropes x and e with lifting yoke
94119.
Lead both ropes of turning-out device
94118c below of the crankshaft journal to
the fuel side and connect them with lifting
yoke 94119.
D
H2
H1
END OF ROPE
94119
3
Be careful that keys 6 mesh with the corresponding keyways in bearing cover 2 (Fig.
A).
014.630/06
CHECK
2008
The bearing clearances and the crank deflection must be measured after a new
bearing shell has been fitted and the bearing cover has been tightened (see
03301 and 31031).
After assembly, check if lubricating oil is supplied to the main bearing with the oil
pump in operation!
26/ 27
RT-flex96C
11322/A2
Maintenance
8 14 Cylinder Engines
Remark: Should the crankshaft need to be turned before the bearing cover is
fitted, then care must be taken that the bearing shell does not turn. Therefore,
bearing shell 3 must be blocked with two suitable wooden boards HO.
P1
12
HO
11
1
3
8
008.925/01
27/ 27
2008
RT-flex96C
11323/A1
Maintenance
Main Bearing
Main Bearing Upside-down Test
Tools:
Key to Illustrations:
1 Measuring device
1 Template
1 Feeler gauge
1.
94113
94113a
94122
1 Key
2 Main bearing cover
3 Main bearing shell
General
The main bearing upside-down test is best carried out on all main bearings before
fitting them in the engine.
If a conical shell is fitted in main bearing No. 2 , with a non-matching cover (conical
or standard, new or used), then an upside-down test must be carried out before
fitting (see also 11322, Characteristics of main bearings).
2.
A
3
014.689/06
017.024/08
Attention! Lift off the shell from the cover carefully so that both keys 1 slip out at
the same time. Otherwise there is a risk of damaging the keys.
1/ 4
2008
11323/A1
Maintenance
RT-flex96C
2.1
94113a
X
30 mm
017.024/08
2008
2/ 4
RT-flex96C
11323/A1
Maintenance
2.2
2.3
C
RUN-OUT
LENGTH
017.023/08
3/ 4
2008
11323/A1
Maintenance
RT-flex96C
3.
TOUTCH POINT ON
BEARING SHELL
TOUTCH POINT ON
BEARING SHELL
94122
94113
min. 1080.42 mm
1080.22 mm
max. 1080.66 mm
1080.48 mm
The values in the table represent the normal range for new parts. The outside diameter of the bearing shell can be lower when the shell has been used.
2008
If the outside diameter is not within the limits in the above table, then correct
the outside diameter by fitting offset keys. If offset key is oversized, then machine it to the correct size.
4/ 4
RT-flex96C
Maintenance
12031/A1
Thrust Bearing
Checking the Axial Clearance
Tools:
Key to Illustrations:
1 Inside micrometer
1 Feeler gauge
1 Dial gauge with magnetic base
1.
94101
94238
1
2
3
4, 4a
5
6
Coupling flange
Oil baffle, upper part
Oil baffle, lower part
Holder
Thrust flange
Crankshaft
Measuring method 1
The total displacement which results from pushing the crankshaft axially both
ways until it contacts the thrust bearing pads AHEAD and ASTERN, is measured
with a dial gauge. This is then checked against the figure marked on the sheet
Check Dimensions in the engine documents supplied (see also Clearance Table
03301 Crankshaft and main bearing).
An increase compared with the nominal figure signifies wear of the thrust bearing
pads.
2.
Measuring method 2
Displace the crankshaft axially until it rests on the engine side thrust bearing
pads (AHEAD) and then fix it in this position.
Measure the distance between the coupling flange and the upper part of the
oil baffle with the inside micrometer 94101 at the position indicated (see Fig.
C). The amount by which distance X is smaller than that given on the sheet
Check Dimensions corresponds to the wear of the engine side thrust bearing
pads (AHEAD).
Displace the crankshaft axially until it rests on the thrust bearing pads for
ASTERN. Determine the total axial clearance with the inside micrometer.
Remark: After major works have been carried out in the thrust bearing space dismantle cover 8 for a check-up on the thrust bearing housing. Remove any foreign
matters through the opening.
1/ 3
2008
12031/A1
Maintenance
RT-flex96C
2
4
4a
6
THRUST
8
7a
7
3
0.81.3 mm
014.162/06
14 CYL. ENGINES
2
4
5
4a
6
9
THRUST
7a
7
3
2008
2/ 3
RT-flex96C
12031/A1
Maintenance
011.344/04
I-I
001.495/97
94101
3/ 3
2008
RT-flex96C
12241/A1
Maintenance
Thrust Bearing
Removal and Fitting the Thrust Bearing Pads
Tools:
Key to Illustrations:
1 Turning-out device
for 6 and 7 Cyl. engines,
with 1-part gear wheel
1 Turning-out device
for 6 and 7 Cyl. engines,
with 2-part gear wheel
1 Turning-out device
for 812 and 14 Cyl. engines
94155
1
2, 2a
3
4
5
6
7
8
94155a
94155b
1.
Removal
Loosen both holders 4 above thrust bearing pads 2 or 2a to be removed.
In addition, to ensure a better access for the removal of thrust bearing pads 2
(ASTERN), the upper part of oil baffle 7 (Fig. B and D) is also to be removed.
Remove temperature sensors 8 from their bores (page 5) on 812 cylinder
engines.
Insert and laterally fasten turning-out device 94155 or 94155a or 94155b respectively to the gear wheel or the thrust bearing flange as illustrated on Fig.
B or D.
The crankshaft is then to be turned with the turning gear until an eye bolt M16
can be screwed into a pad which can then be lifted up and removed one by
one.
Remark: When only a few thrust bearing pads of a row are to be removed the
crankshaft is located in its axial position by the remaining pads. When all thrust
bearing pads must be removed then the crankshaft must be prevented from sliding
axially. Therefore, insert a piece of hardwood of the same thickness in place of the
thrust bearing pad.
1/ 5
2008
12241/A1
Maintenance
RT-flex96C
2.
Fitting
CHECK
Make absolutely sure that all the thrust bearing pads are meticulously clean
and smeared with fresh engine oil; the thrust bearing pads must all be replaced in their original position. Note also numbering of the individual pads!
For fitting the thrust bearing pads tool 94155 or 94155a or 94155b respectively can also be utilized. Note in this respect that the first pad, when pushed in,
rests against the tool. The following thrust bearing pads can then be fitted one
after the other while simultaneously turning the crankshaft. The thrust bearing
pads should slide in without effort to their end position.
With all the thrust bearing pads in position, the distances from the outermost pads
on fuel side and exhaust side to the upper edge of the bedplate must be equal to be
able refitting holders 4. Subsequently check the clearance between holder and
thrust bearing pads 2 and 2a (see Clearance Table 03301 Crankshaft and thrust
bearing).
D
Prior to fitting screws 5 clean threads, tap holes and coat screw threads with
LOCTITE No. 222.
Attention! After fitting the thrust bearing pads immediately remove tool 94155 or
94155a or 94155b respectively.
Remark: When fitting new or remetalled thrust bearing pads, care must be taken
that their thickness (final dimension) corresponds exactly with the neighbouring
pads.
When replacing a complete row of new or remetalled thrust bearing pads the clearance must be adjusted to the original values (see Clearance Table 03301 Crankshaft and thrust bearing and 12031).
2008
2/ 5
RT-flex96C
12241/A1
Maintenance
A
6
4
5
FUEL SIDE
EXHAUST SIDE
2/2a
001.490/97
II - II
I-I
II
II
1
2/2a
94155
94155a
3
1
2a
001.490/97
94155
94155a
001.490/97
3/ 5
2008
12241/A1
Maintenance
RT-flex96C
C
6
4
5
FUEL SIDE
EXHAUST SIDE
2/2a
012.075/04
II - II
D
I-I
II
II
1
2/2a
94155b
1
2a
94155b
2008
4/ 5
RT-flex96C
12241/A1
Maintenance
ASTERN
016.725/08
ASTERN
AHEAD
SUPPORT SURFACE
014.063/06
DRIVING END
ENGINE SIDE
PROPELLER THRUST
ASTERN
PROPELLER THRUST
AHEAD
003.685/95
5/ 5
2008
RT-flex96C
17151/A1
Maintenance
Key to Illustrations:
Feeler gauge
Pre-tensioning jack
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
HP hose
1.
94122
94145
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
7
8
Engine stays
Friction shims
Screw
Nut
Disc spring
Vent screw
Pin
Piston
9 Cylinder
10 Sealing ring
EV
KO
PP
RS
Relief valve
Slot
Closing piece
Round bar
General
Two friction type stays 1 are installed on the exhaust side of the engine (Fig. A).
CHECK
FREE END
EXHAUST SIDE
II
011.408/03
II
SHIP SIDE
3
4
1/ 2
008.312/01
2008
17151/A1
Maintenance
RT-flex96C
2.
Check with feeler gauge through slot KO if there is any clearance between nut 4
and its seating.
If there is no clearance, this means that the tensioning condition of the screw
has remained unchanged since the last check. The pressure can be released
to zero and the pre-tensioning jack removed.
Should a clearance be found, nut 6 must be tightened down onto its seating
with round bar RS while the pressure is kept at 200 bar (check with feeler
gauge). Subsequently lower the pressure to zero.
94935a
94932a
94145
94934e
6
7
8
94934a
94935
94932
9
4
10
3
KO
1
RS
94931
EV
2
5
011.674/04
3.
2008
2/ 2
RT-flex96C
17151/A2
Maintenance
1.
5 Ball valve
6 Plug 3/8 NPT
7 Pressure gauge
General
Two hydraulic type stays 1 are installed each on the exhaust side and fuel side of
the engine.
CHECK
The oil pressures on the pressure gauges of the hydraulic cylinders must be
checked and compared with each other at regular intervals.
If one of the hydraulic cylinders shows a pressure below 30 bar, which could be
caused by defective O-rings, leaking valves or screwed connections, the opposite
hydraulic cylinder must also be released of its pressure till 30 bar.
The defective engine stays must be repaired at the first opportunity. Afterwards the
oil pressure must be readjusted to the required value on all the engine stays,
whereby the detailed instructions of the respective maker must be considered.
I
1
1
EXHAUST SIDE
FREE END
II
014.577/06
II
SHIP SIDE
004.078/98
1/ 1
2008
RT-flex96C
19031/A1
Maintenance
Tie Rod
Checking the Pre-tension and Tensioning the Tie Rods
Tools:
1
2
1
1
1
2
1
Feeler gauge
Pre-tensioning jacks
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
Key to Illustrations:
94122
94180
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
12
Cylinder jacket
Upper intermediate ring
Upper tie rod nut
Cylinder
Piston
Round nut
Vent screw
Tie rod
Protection cover
Bore for solvent
Clamp screw
Column
13
14
15
16
17
AN
BN
KO
MS
RS
SA
Bearing girder
O-ring
Lower intermediate ring
Lower tie rod nut
Bush
Drain slot
Limiting groove
Slot
Measuring place
Round bar
Gap
Overview
1.
2.
3.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
Checking the pre-tension of tie rods . . . . . . . . . . . . . . . . . . . . . 1/5
Loosening and tensioning the tie rods . . . . . . . . . . . . . . . . . . . 3/5
General
We recommend that about one year after commissioning the engine all tie rods are
checked for their correct pre-tensioning and if necessary to tension them to the
specified value. Later it is sufficient to make random checks during major overhauls, or the pre-tension of all tie rods has to be checked within four years.
Remark: For such checks it is not required to loosen the waisted studs of the main
bearings nor the clamp screws 11 (Fig. D).
Pay attention to General Application Instructions 94034 for hydraulic pre-tensioning jacks.
2.
1/ 5
2012-05
19031/A1
Maintenance
RT-flex96C
6
7
94935a
SA
x
94932a
5
4
94934a
BN
10
3
RS
KO
94935
MS
1
8
94942
PRE-TENSIONING JACK
PLACED FOR TENSIONING
CHECK
011.663/04
PRE-TENSIONING JACK
PLACED FOR LOOSENING
Using the feeler gauge 94122 inserted through slot KO, on the measuring place
MS, check whether tie rod nut 3 rests on intermediate ring 2 without any clearance.
If any clearance exists, tighten the tie rod nut with round bar RS until it rests
firmly on the intermediate ring (check with feeler gauge). Subsequently release the pressure to 0 bar at the hydraulic unit. If no clearance exists, the
pressure can immediately be released and the pre-tensioning jacks removed.
Check all the tie rods in this manner and, wherever necessary, tighten the tie
rod nut.
Protect the tie rod threads against corrosion by coating them with non-acidic
grease after the checking has been completed. Fit and fasten the protection
cover 9 (Fig D).
Remark: If the tie rod nut 3 is blocked/seized, it may be attempted to press in oil or
solvent through the bore 10 (G x 4 mm) with the pre-tensioning jacks placed
and pressurized so that the tie rods are lifted. At the same time insert a brass or
copper bar into a hole in the tie rod nut through the slotted aperture of cylinder 4
and first loosen, then tighten the nut with several heavy hammer blows. Make sure,
however, that the edge of the hole is not seriously deformed or it will be impossible
to remove the pre-tensioning jack. Seal off the bore 10.
2012-05
2/ 5
RT-flex96C
Maintenance
19031/A1
3.
Never move piston 5 of the pre-tensioning jack further up than to the red limiting
groove BN (Fig. A).
D
3.1
If the tie rods have been newly tightened, then the waisted studs of the main
bearings also have to be checked for correct pre-tensioning (see 11321).
Loosening
The procedure for loosening the tie rods is the same as the one described in section 2 Checking the pre-tension, except that round nuts 6 must be turned back by
four turns after being completely screwed down the pre-tensioning jacks (gap SA
in Fig. A). At this starting point connect the jacks with hydraulic unit 94942 and
operate it until a pressure of approx. 1030 bar is reached.
Turn the tie rod nuts 3 up until they fully seat on the pistons of the pre-tensioning jacks and then screw back them by four turns with round bar RS.
Release the pressure to 0 bar and remove the pre-tensioning jacks.
3.2
Tensioning
Preliminary works:
D
Clean the seating surface for upper intermediate ring 2 and upper tie rod nut 3
and smear them with MOLYKOTE G paste.
Smear the tie rod thread for upper tie rod nut 3 lavishly with MOLYKOTE G
paste and screw the nut on (check for easy threading).
Screw the eye bolt into the tie rod and lift carefully until the lower tie rod nut
rests snugly against the bearing girder.
Risk of accident! Use a manual ratchet hooked onto the crane, with which the tie
rod can be lifted manually until the lower nut is snug on its seating, as with the crane
alone the landing of the nut cannot easily be felt and the rope might break.
In this position tighten the upper tie rod nut with round bar RS until firmly
seated on the intermediate ring, and separate the manual ratchet from the tie
rod.
CHECK
There must now be no clearance between bearing girder and lower tie rod nut and
the lower tie rod nut must be flush with the tie rod end (Fig. D).
Place pre-tensioning jacks 94180 onto the tie rods a/a.
Turn the pre-tensioning jacks so that the holes in tie rod nuts 3 are accessible.
Tighten round nuts 6 until there is only little or no clearance at x (Fig. A).
3/ 5
2012-05
19031/A1
Maintenance
RT-flex96C
Tie Rod
Checking the Pre-tension and Tensioning the Tie Rods
Tensioning in one procedure:
Connect the pre-tensioning jacks with the hydraulic unit 94942 (see Fig. A).
Actuate the hydraulic unit until bubble-free oil flows out through the vent
screws 7. Close the vent screws.
Raise the pressure to 100 bar, keep it constant and firmly tighten the two upper tie rod nuts 3 with the round bar RS.
Measure and record the distance L (the measurements can be taken directly
on the mounted pre-tensioning jacks, i.e. from the top edge of the tie rod 8 to
the cylinder 4).
Subsequently tension the tie rods with 1000 bar, keep it constant and firmly
tighten the two upper tie rod nuts 3 with the round bar RS.
Never move pistons 5 of the pre-tensioning jacks further up than to the red limiting
grooves BN (Fig. A).
Measure again the distance L and record it as L1.
The tie rods are correctly tensioned with 1000 bar when the following reference
value of a total elongation L (L1L) is measured:
L = 15.5 ... 17.5 mm
Release the pressure to 0 bar.
Proceed in the same way by following the required sequence for all tie rods
b/b, c/c, d/d ect.
After completing the tensioning, smear the protruding thread portions of all the
tie rods lavishly with an acid-free grease and fit the protection cover 9 (Fig D).
TIE ROD
ELONGATION
SEQUENCE
L1
FREE END
DRIVING END
4
RS
3
DRAWN FOR 8 CYLINDERS
011.665/04
011.663/04
2012-05
4/ 5
RT-flex96C
19031/A1
Maintenance
Tie Rod
Checking the Pre-tension and Tensioning the Tie Rods
D
IV
IV
III - III
8
9
11
10
II
17
12
II
17
III
III
11
1
I
13
8
13
14
AN
16
I
FLUSH
011.665/04
15
5/ 5
2012-05
RT-flex96C
Maintenance
Group2
Group 2
Cylinder Liner
Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21241/A1
Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21242/A1
Removing the Wear Ridge, Re-dressing Lubricating Grooves
and Scavenge Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21243/A1
Lubricating Quill
and Accumulator: Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21361/A1
with Pulse Jet Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 21381/A1
with Pulse Feed Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . 21381/A2
Piston Rod Gland: Dismantling and Assembling, Measuring the Wear . . . . . . . . . 23031/A1
Cylinder Cover
Removal and Fitting of Cylinder Cover and Water Guide Jacket . . . . . . . . . . . . 27081/A1
Loosening and Tensioning of Cylinder Cover Waisted Studs . . . . . . . . . . . . . . . 27082/A1
Machining of Sealing Face for Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27083/A1
Injection valve
Checking, Dismantling, Assembling & Adjusting with O.M.T. Test Bench . . . . 27221/A1
Checking, Dismantling, Assembling & Adjusting with OBEL Test Bench . . . . . 27221/A2
Starting Valve: Removal, Fitting and Dismantling, Grinding-in & Assembling . . . . 27281/A1
Relief Valve for Cylinder Cover: Checking Blow-off Pressure . . . . . . . . . . . . . . . . . 27451/A1
Exhaust Valve
Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs . . . . . . . . . 27511/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27512/A1
Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27513/A1
Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . 27514/A1
1/ 1
RTflex96C / MM / 2008
RT-flex96C
21241/A1
Maintenance
Cylinder Liner
Measuring Bore Wear
Tools:
1 Inside micrometer
1 Ladder
1 Measuring gauge
Key to Illustrations:
94101
94224
94225
1 Cylinder liner
2 Antipolishing ring
ST Setting screw
The cylinder liner wear is to be determined after every piston removal with the cylinder liner
in situ.
000.786/99
To permit comparisons with previous measures always carry out measuring in the same
place and note down the values in a log.
Always use the properly adjusted measuring
gauge 94225.
CHECK
Check setting screw ST. Its lower protruding length must correspond to the
mean thickness of the built-in compression shims. This ensures that the topmost
measuring point is located between the top
ring wear ridge and the antipolishing ring.
The unrun position must be thoroughly
cleaned from any deposits or lacquer before
measurement.
94101
CHECK
For maximum permissible inside diameter refer to Clearance Table 03301 Cylinder liner.
014.242/06
1/ 1
2011-05
RT-flex96C
21242/A1
Maintenance
Cylinder Liner
Removal and Fitting
Tools:
1 Device
Key to Illustrations:
94201(a)
consisting of:
1
2
2
2
2
4
1
1
1
1
1
1
2
2
Lifting gear
Plates
Guide elements
Suspension straps
Special screws
Suspension straps
Lifting hook
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydr. jacks
94202(a)
94202b
94202c
94206(a)
94207
94208
94209
94931
94932
94932a
94934a
94935
94935a
94936
1
2
3
4
5
6
7
8
9
10
11
Screw
Water guide jacket
Supporting ring
Cylinder liner
Cylinder jacket
Allen screw
Centring pin
Centring pin
Cylinder cover
Screw
Lifting ring
12
13
13a
14
15
16
Antipolishing ring
O-ring
O-ring
O-ring
O-ring
Bush
AF
EV
HU
RC
Seating surface
Relief valve
Wooden underlay
Eye bolt M16
Overview
1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Laying down and raising cyl. liner (w. small crane hook) . . 8/9
10.
Laying down and raising cyl. liner (w. big crane hook) . . . . 9/9
1/ 9
2012-05
21242/A1
Maintenance
RT-flex96C
2.
2.1
10
94202a
94206a
94207
4
012.061/04
94202c
94202b
2008
2/ 9
RT-flex96C
Maintenance
21242/A1
3.
3.1
10
94202
94206
94207
4
003.333/00
3/ 9
2008
21242/A1
Maintenance
RT-flex96C
4.
C
FUEL SIDE
001.465/97
94935a
94203 94936
I-I
4
94932a
94934a
94932
001.465/97
94931 EV
2008
94935
94935a
4/ 9
94936
RT-flex96C
21242/A1
Maintenance
Before fitting, clean seating surfaces on antipolishing ring and cylinder liner.
Smear the antipolishing ring lightly with oil.
Further pay attention that one of the holes for fastening the suspension straps
lies on fuel side.
94209
94208
12
4
012.073/04
6.
6.1
Removal
Supporting ring 3 (Fig. E and G) is fastened with three Allen screws 6 and
Bush 16 to cylinder jacket 5 and located on fuel side by centring pin 7. For the
removal of the supporting ring the three Allen screws 6 can be used as jacking
screws (see Fig. F).
6.2
Fitting
The sealing surfaces on supporting ring and cylinder jacket must be cleaned
and then smeared with a non-hardening sealing compound (e.g. silicone).
Place the supporting ring.
Oil threads of screws 6, fit them with bushes 16 and apply a torque of 400 Nm.
3
16
7
5
004.087/98
5
016.844/08
5/ 9
004.087/98
2012-05
21242/A1
Maintenance
RT-flex96C
8
1
II
I-I
II
III
2
8
III
AF
3
000.785/99
008.325/01
000.785/99
EXHAUST SIDE
II - II
IV
1
FUEL SIDE
9
2
14
15
1
IV
4
3
000.785/99
3
4
13
008.326/01
13a
5
WCH00860
2012-05
6/ 9
RT-flex96C
Maintenance
21242/A1
7.
8.
7/ 9
2012-05
21242/A1
Maintenance
RT-flex96C
Laying down and raising cylinder liner (with small crane hook)
Place lifting gear 94202a as described in paragraph 2.1.
Connect rope a (lifting capacity 10 000 kg) with crane and lifting ring 11. Lay
down the cylinder liner as shown below and secure it against rolling away.
Raising the cylinder liner is carried out in reversed sequence.
Risk of accident! Laying down and raising a cylinder liner must not be done
in any other way than as shown in the figures!
11
94202a
HU
HU
012.065/04
9.1
J
RC
94202a
HU
012.065/04
2008
8/ 9
RT-flex96C
21242/A1
Maintenance
10.
Laying down and raising cylinder liner (with big crane hook)
Place lifting gear 94202 as described in paragraph 3.1.
Connect rope a (lifting capacity 10 000 kg) with crane and lifting gear. Lay
down the cylinder liner as shown in Fig. L to N and secure it against rolling
away.
D
Risk of accident! Laying down and raising a cylinder liner must not be done
in any other way than as shown in the figures, i.e. in longitudinal direction of
lifting gear 94202!
a
94202
HU
HU
9/ 9
HU
012.066/04
2008
RT-flex96C
21243/A1
Maintenance
Cylinder Liner
Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports
Tools:
Key to Illustrations:
1.
1
2
3
4
5
6
7
8
Roller support
Holder
Holder
Spacer roller
Pipe (column)
Grinder
Air hose
Hose oiler
9
10
11
12
Thread nozzle
Carbide milling cutter
Cylinder liner
Top piston ring
SI Scavenge port
SN Lubricating grooves
SN1 Collection / pressure reducion
grooves
General
Due to wear in the cylinder liner a ridge is formed on top to where the piston rings do
not reach. By that also the lubricating grooves in the cylinder liner lose their depth,
and the corner radii of the scavenge port edges become smaller.
After every piston removal measure the bore of the cylinder liner (see 21241) and
remedy any irregularities. For that the following points are of importance:
2.
Protect the space below the cylinder liner from falling particles.
After completing the reconditioning clean the bore of the cylinder liner thoroughly (particularly the lubricating grooves).
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 away any metal dust.
3.
4.
1/ 3
2011-05
21243/A1
Maintenance
RT-flex96C
I-I
III
SN
III
I
I
II
II
003.267/00
II-II
SI
SN1
III-III
I
WCH00442
011.350/04
2011-05
2/ 3
RT-flex96C
21243/A1
Maintenance
94299
11
10
10
2
3
T.D.C.
2 3 mm
1 mm
12
11
009.004/01
3/ 3
2008
RT-flex96C
21361/A1
Maintenance
24
23
22
Accumulator cylinder
Spring
Accumulator piston
Cap nut
Diaphragm
Accumulator casing
Cap nut
Backing screw
Copper sealing rings
Cylinder liner
Lubricating quill
Passage for lubricating quill
Filling pin
Steel ball
21
20 19
16
15
16
17
18
19
20
21
22
23
24
DF Sealing surface
LB Leak oil bore
LB
1
2
3
4
5
6
14
15
7
8
014.252/06
17 11
DF
1.
General
1.1
Function check
10
13
18
12
Actuate the cylinder lubricating pump until oil emerges from all the lubricating
points in the bore of the corresponding 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 (correct setting is
recorded on the acceptance records). Whatever the settings, make sure that on all
the lubricating points of the same row of lubricating grooves the oil outflow quantity
is equal.
1/ 2
2008
21361/A1
Maintenance
RT-flex96C
1.2
Check of accumulator
During a major overhaul check at random several accumulators or if there are oil
leakages through bores LB (Fig. A), open the relevant accumulators. Check the
condition of the diaphragms and defective or brittle ones must be replaced. Do not
use any sharp-edged objects for fitting new diaphragms!
1.3
014.253/06
2.
If only the passage for lubricating quill 12 has to be removed, with cylinder liner fitted, then the protecting bush may remain in place.
When refitting the passage for lubricating quill take care that sealing surface
DF between cylinder liner and passage for lubricating quill is absolutely
clean. Sealing surface DF must seal metallically and the use of gaskets is
prohibited!
Remark: The design of the lubricating quills for the upper and the lower row of lubricating grooves is the same.
Non-return valves are only supplied complete with filling pin as replacement parts.
2008
2/ 2
RT-flex96C
21381/A1
Maintenance
Lubricating Quill
Removal and Fitting
Tool:
Key to Illustrations:
1 Tool box
with fittings for
charging accumulator
1 HP oil pump
1 Hydr. distributor
(with pr. gauge 0...25 bar)
1 Connection nipple (G)
1 HP hose
1.
94720c
1
2
3
4
5
6
7
8
9
10
11
94931
94934h
94934i
94935
Cylinder liner
Lubricating pump
Screw-in union
Union nut
Angle union
Lubricating oil pipe
Supporting ring
Lubricating quill
Nozzle tip
Non-return valve
Housing
12
13, 13a
14
15
16
17
18
19
21, 22
Bush
Flange
Joint
Screw M8x40
Screw M8x100
4/2-way solenoid valve
Sink plunger
Pin (tool)
O-ring
DF Sealing surface
General
If only the lubricating quill must be removed, with cylinder liner in situ, then bush 12,
flanges 13 and 13a may remain in place. Therefore, the cylinder cooling water
must not be drained.
In order to remove cylinder liner 1 or supporting ring however, all lubricating quills
and bushes must be dismantled, whereby the cylinder cooling water must be
drained on the relevant cylinder (see 27081 Removal of cylinder cover).
Remark: For the additional lubrication of exhaust valve spindle see detailed instructions in the Operating Manual 72181.
2.
I
43
6
2
1/ 4
CLU4 / 2012-05
21381/A1
Maintenance
RT-flex96C
Lubricating Quill
2.
When refitting the lubricating quill, the sealing surface DF must be clean and
undamaged, as it seals metallically. Moreover, the proper seat angles in the
cylinder liner (120_) and on the nozzle tip (114_) differs slightly. Therefore, do
not use any gasket between cylinder liner 1 and nozzle tip 9!
I-I
12
7 13a 13
15
16
3
I
II
I
DF
21
14 22
11
II
9
11
WCH00857
2012-05
2/ 4
RT-flex96C
21381/A1
Maintenance
Lubricating Quill
3.
3.1
Test procedure
D
Instead of screw-in union, fit connection nipple 94934i into lubricating quill.
If the non-return valve does not open at 4.25 bar, it does not function properly
or it is damaged.
C
94934i
94931
WCH00859
10
94934h 94935
3/ 4
2012-05
21381/A1
Maintenance
RT-flex96C
Lubricating Quill
4.
If all cylinder lubricating oil pipes are vented and afterwards properly tightened
again, actuate the cylinder lubrication module until cylinder oil emerges from
all lubricating points in the bore of the respective cylinder liner. This visual inspection of the lubrication process is carried out through the scavenge ports at
piston underside and the piston is therefore at T.D.C. position.
If there are signs of irregularities with nozzle tips 9 , they must be replaced!
17
18
19
015.438/07
2008 / CLU4
4/ 4
RT-flex96C
21381/A2
Maintenance
Lubricating Quill
Removal and Fitting
Tool:
Key to Illustrations:
1 Tool box
with fittings for
charging accumulator
1 HP oil pump
1 Hydr. distributor
(with pr. gauge 0...25 bar)
1 Connection nipple (G)
1 HP hose
1.
94720c
94931
94934h
94934i
94935
1
2
3
4
5
6
7
8
9
10, 10a
11
Cylinder liner
Lubricating pump
Accumulator
Supporting ring
Passage for lubricating quill
Bush
Screw-in union
Non-return valve
Filling pin
Flange
Joint
12
13
14
15
16
17
18
19
Screw
Adjustable angle union
Pipe bracket
Lubricating oil pipe
4/2-way solenoid valve
Sink plunger
Pin (tool)
O-ring
DF Sealing surface
General
If only the lubricating quill (i.e. screw-in union 7, non-return valve 8 and filling pin 9)
must be removed, with cylinder liner in situ, then bush 6, flanges 10 and 10a may
remain in place. Therefore, the cylinder cooling water must not be drained.
In order to remove a cylinder liner 1 or supporting ring 4 however, all lubricating
quills and bushes must be dismantled, whereby the cylinder cooling water
must be drained on the relevant cylinder (see 27081 Removal of cylinder
cover).
Remark: For the additional lubrication of exhaust valve spindle see detailed instructions in the Operating Manual 72181.
12
13
EXHAUST
SIDE
15
3 2
14
1/ 4
017.087/08
CLU4 / 2012-05
21381/A2
Maintenance
RT-flex96C
Lubricating Quill
2.
When refitting the lubricating quill take care that sealing surface DF is absolutely clean, as it seals metallically. Therefore, do not use any gaskets between cylinder liner 1 and passage for lubricating quill 5!
Oil and tighten passage for lubricating quill 5 with a torque of 30 Nm.
10 10a
7 (AF24)
13
DF
15
WCH00440
2012-05
19
2/ 4
11
12
5 (AF32)
RT-flex96C
21381/A2
Maintenance
Lubricating Quill
3.
Non-return valve
Remark: Always replace a non-return valve completely, i.e. screw-in union 7 with
fitted non-return valve 8 and filling pin 9.
Oil and tighten screw-in union with a torque of 30 Nm.
WCH00441
1 mm
8
9
3.1
3.2
Test procedure
Instead of screw-in union, fit connection nipple 94934i into screw-in union 7.
Connect and vent the lubricating quill as shown below.
Vent the lubricating quill.
Apply a pressure of 2 bar and increase it in steps of 1 bar till the non-return
valve opens.
Note down the opening pressure.
Remark: The opening (cracking) pressure should be at least 4.25 bar for correct
functioning.
With an opening pressure below 4.25 bar the non-return do not function properly or
it is damaged and must be replaced.
D
94934i
WCH00440
001.547/97
94931
94934h 94935
3/ 4
2012-05
21381/A2
Maintenance
RT-flex96C
Lubricating Quill
4.
If all cylinder lubricating oil pipes are vented and afterwards properly tightened
again, actuate the cylinder lubrication module until cylinder oil emerges from
all lubricating points in the bore of the respective cylinder liner. This visual inspection of the lubrication process is carried out through the scavenge ports at
piston underside and the piston is therefore at T.D.C. position.
TO LUBRICATING
QUILLS
SERVO OIL
16
17
18
015.438/07
2008 / CLU4
4/ 4
RT-flex96C
23031/A1
Maintenance
Key to Illustrations:
94344
94345
94345b
94345c
94345e
94345f
94350
1
2
3
4
5
6
7
7a
8
9
10
11
Housing (2-part)
Scraper ring
Sealing ring
Sealing ring
Ring support
Scraper ring
Locating pin
Locating pin
Tension spring
Tension spring
Screw
Screw
12
13
13a
14
15
16
17
18
19
20
21
22
Overview
1.
2.
2.1
2.2
2.3
3.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, dismantling and assembling (variant 1) . . . . . . .
Removing a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, dismantling and assembling (variant 2) . . . . . . .
1/7
2/7
2/7
2/7
4/7
6/7
General
The removal of the piston rod gland (hereafter called gland) can be carried out in
two different ways, i.e. removing the gland together with the piston (variant 1) or
removing the gland downwards into the crankcase leaving the piston in situ and
using the dismantling device 94344 (variant 2).
On every piston overhaul, the gland must also be dismantled and inspected. Excessively worn or damaged parts are to be replaced.
It is important that the gland be in perfect condition when assembled. A possible
earlier than planned inspection of the gland with a piston in situ can only be carried
out under difficult conditions and with the help of the dismantling device 94344.
1/ 7
2008
23031/A1
Maintenance
RT-flex96C
2.
Removing a gland
17
94345
20
011.405/04
2.2
Dismantling a gland
Place the piston in piston supporting device 94350. For this 2-part housing 1
of the gland must rest on the two hinged covers 19 of the device.
Loosen screws 10, 11 and remove 2-part ring 17 (Fig. B).
Loosen and remove screws 13 and fitted bolts 13b to 2-part housing.
Push the two gland housing halves away from the piston rod.
Remove all tension springs, scraper rings, sealing rings and ring supports.
On the following parts wear has to be measured (see Fig. D):
Scraper rings
Sealing rings
2008
2 and 6
3 and 4
If necessary remove scraper rings 6 from ring supports 5 and replace them
with new ones.
2/ 7
RT-flex96C
23031/A1
Maintenance
I-I
II
1
22
10 17
15
16
21
13a 13
20
21
18
FUEL SIDE
II
11
13a
16
17
10
14
15
011.451/04
3/ 7
2008
23031/A1
Maintenance
RT-flex96C
11 mm
94345f
2
3
4
3
4
19 mm
009.655/02
19
94345f
009.654/02
94345b
94350
94345b
11 mm
5
94345f
009.655/02
20
011.468/04
94345
017.874/08
2.3
Assembling a gland
Place the piston in piston supporting device 94350, its hinged covers 19 must
be folded down.
Attach clamp ring (2-part) 94345b resting on the hinged cover to piston
rod.
Place the three parts of a ring support 5 on the clamp ring with scraper rings 6
fitted. Distribute the distances evenly.
Use assembly tool 94345e (see 94035) for fitting tension spring 9.
Place two distance pieces 94345f (11 mm) on ring support 5 and fit another
ring support with scraper ring 6 and tension spring 9 as described above.
D
2008
4/ 7
RT-flex96C
23031/A1
Maintenance
D
2
GROOVE a
7a
3
GROOVE b
4
3
4
GROOVE c
GROOVES
di
9
1
011.485/04
18
After assembly of the ring supports for grooves d i (Fig. D), place two distance pieces 94345f (19 mm) on the uppermost ring support 5 and fit sealing
rings 3, 4 and tension spring 8 for groove c.
D
Take care that one segment is always provided with two horizontal locating
pins 7a lying side by side on sealing ring 4. These locating pins must fit into the
corresponding bores in sealing ring 3. Remove possibly existing vertical locating pins 7.
The remaining three segments are provided only with one horizontal locating
pin each.
Place two distance pieces 94345f (19 mm) on the assembled sealing ring 3
and fit again sealing rings 3, 4 and scraper ring 2 with tension spring 8 for
groove b.
D
Proceed in the same way as mentioned above for sealing rings 3 and 4, however, a vertical locating pin 7 in sealing ring 3 must fit into the respective recess
in scraper ring 2.
No vertical locating pin may be fitted in the scraper ring.
Place two distance pieces 94345f (11 mm) on the assembled scraper ring 2
and fit the two uppermost scraper rings 2 with tension springs 8 for groove a.
No vertical locating pin may be fitted in the uppermost scraper ring.
5/ 7
2008
23031/A1
Maintenance
RT-flex96C
E
Remove all distance pieces 94345f and clamp ring
94345b.
CHECK Check the proper position of all rings with gauge
94345c resting on hinged cover 19.
Smear piston rod as well as all rings with bearing
oil.
94350
94345c
19
20
94345
When fitting the gland into the cylinder jacket distance holders 94345 must be mounted on the piston rod foot.
017.875/08
3.
2008
6/ 7
RT-flex96C
23031/A1
Maintenance
F
1
94345b
17
18
94344
20
94345b
94344
Clamp 2-part clamp ring 94345b to
piston rod 20 lying on housing 1.
Turn the piston slowly to B.D.C.
again and pay attention that the
gland slides out of the gland bore in
the cylinder jacket without jamming.
2-part ring 17 remains on cylinder
jacket 18.
D
CHECK
I-I
94344
011.495/04
7/ 7
2008
RT-flex96C
27081/A1
Maintenance
Cylinder Cover
Removal and Fitting of Cylinder Cover and Water Guide Jacket
Tools:
1
2
3
1
Suspension device
Spec. (nut) eye bolts
Protection caps
Cradle
Key to Illustrations:
94265(c)
94265a
94265b
94266
1
2
2a
3
4
5
5a
6
Cylinder cover
Nut
Cylinder cover stud
Cyl. cooling water outlet
Leak oil drain
Exhaust valve cage
Stud to exhaust valve cage
Connection for valve
shank lubrication
7 Hydraulic piping
8 Air inlet for air spring
9 Water guide jacket
10
11
12
13
14
15
16
17
18
Allen screw
Screw M20x200
Platform support
Fixing screw
Plug
Control box
Fuel pressure piping
O-ring
O-ring
DB Through hole
RC Eye bolt
Overview
Removal of cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport of cylinder cover (with big crane hook) . . . . . . . .
Transport of cylinder cover (with small crane hook) . . . . . .
Fitting of cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of water guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting of water guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.
2.
3.
4.
5.
6.
1.
1/7
2/7
3/7
4/7
5/7
7/7
16
15
14
1/ 7
2008
27081/A1
Maintenance
RT-flex96C
2.
C
94265
94265a
5a
94265b
2a
003.307/00
2008
008.328/01
2/ 7
RT-flex96C
27081/A1
Maintenance
3.
E
94265c
94265a
5a
94265b
2a
012.026/04
3/ 7
2008
27081/A1
Maintenance
RT-flex96C
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 water guide jacket 9 which is screw fastened to the cylinder cover as well as the respective guide surface at the collar of the cylinder
liner must be clean and smeared with bearing oil.
Place new O-rings into the grooves of the cylinder liner and smear these with
bearing oil.
The threads of the cylinder cover studs, nuts and their seating surfaces must
be clean and smeared with Never-Seez NSBT-8.
Place three protection caps 94265b on cylinder cover waisted studs (see Fig.
C and E).
When these conditions are all met, lower the cylinder cover, attached to suspension device 94265 or 94265c, slowly over the cylinder cover studs, whereby a centring pin assures the correct position (see 21242).
Screw all nuts by hand onto the cylinder cover studs, paying attention to easy
turning.
Pre-tension the studs with hydraulic pre-tensioning device 94215 in accordance with 27082.
Reconnect all connections to cylinder cover and exhaust valve.
Finally shut drain and vent cock, and reopen the cocks for cooling water inlet
and outlet.
Remark: Concerning the fitting of the expansion piece between exhaust valve and
exhaust manifold see 27511.
8
1
2
FUEL SIDE
2a
3
7
RC
6
5
5a
4
011.535/04
201007
4/ 7
RT-flex96C
27081/A1
Maintenance
5.
5.1
II
ENGINE SIDE
II
11
94266
12
94266
5.2
5
ENGINE SIDE
011.765/04
94266
13
94266
5
1
5/ 7
2008
27081/A1
Maintenance
RT-flex96C
5.3
K
1
1
GL
13
10
13
94266
011.767/04
2008
6/ 7
RT-flex96C
27081/A1
Maintenance
6.
L
17
18
13
M
1
GL
9
DB
10
13
94266
011.768/04
7/ 7
2008
RT-flex96C
27082/A1
Maintenance
Cylinder Cover
Loosening and Tensioning of Cylinder Cover Waisted Studs
Tools:
Key to Illustrations:
94215
consisting of:
94215a, b
94215c
94215d
1
1
1
2
1
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94932a
94934a
94935
94935a
94942
1.
General
1
2
3
4
5
6
7
8
9
10
11 Protection cap
12 Screw M16
MO Emplacement for round
nuts 5 when not in use
RO Emplacement for round
bars RS when not in use
BN Limiting groove
RS Round bar
SA Gap
2.
When the pistons are resting on the cylinders there should be little or no clearance
at x.
Remark: For loosening the waisted studs, screw back the round nuts by approx.
1 turns.
For tensioning the waisted studs the round nuts must lie on piston 4.
1/ 4
2010-07
27082/A1
Maintenance
RT-flex96C
3.
Loosening
Place the pre-tensioning jacks as mentioned already. Open vent screws 3 of
the pre-tensioning jacks.
Start up hydraulic unit 94942.
Close vent screws 3 on the jacks as soon as oil flows bubble-free.
Actuate hydraulic unit until a pressure of 1020 bar is indicated on its pressure
gauge and on pressure gauge 94932a.
Never move piston 4 of the pre-tensioning jack further up than to the red limiting
groove BN (Fig. C).
Turn all nuts 2 upwards till the stop, using round bar RS. Store round bar RS
in emplacement RO while not in use (see Fig. B).
Release pressure to zero.
Disconnect and remove HP hoses 94935a from both device halves.
Unscrew round nuts 5 and remove them together with the pre-tensioning
jacks.
4.
Tensioning
Smear threads of cylinder cover studs 1, nuts 2 and their seating surfaces with
Never-Seez NSBT-8.
CHECK
Tighten all nuts down with round bar RS till fully seated (check with feeler gauge).
Mark position of all nuts, with a line on nuts and cylinder cover, with a felt-tip
pen (this will serve for a later check).
Set-up of the pre-tensioning jacks as mentioned already. Open vent screws 3
of the pre-tensioning jacks.
Start up hydraulic unit 94942.
Shut vent screws 3 on the pre-tensioning jacks as soon as oil flows bubblefree.
Actuate hydraulic unit until a pressure of 1000 bar is indicated on its pressure
gauge and on pressure gauge 94932a.
Never move piston 4 of the pre-tensioning jack further up than to the red limiting
groove BN (Fig. C).
CHECK
While keeping this pressure constant tighten all nuts 2 with round bar RS till fully
seated on the cylinder cover (check seating with feeler gauge), verify while tightening that all nuts can be turned by about the same angle of 390_.
Where it is found that a nut can be turned considerably less than the others, it must
be assumed that the respective cylinder cover stud has become insufficiently tensioned.
2010-07
2/ 4
RT-flex96C
27082/A1
Maintenance
Possible causes:
Piston 4 jams.
Repeat tensioning procedure after the cylinder cover studs have been loosened again.
When all nuts have been tightened by practically the same angle, release the
oil pressure to zero.
Disconnect and remove HP hoses 94935a from both device halves.
Unscrew round nuts 5 and remove them together with the pre-tensioning
jacks.
CHECK
5.
Verify by the previously applied marks that all nuts have been turned equally by an
angle of about 390_.
A
12
11
1
2
WCH0069
3/ 4
2010-07
27082/A1
Maintenance
RT-flex96C
94935
94934a
94932a
94935a
94935a
EXHAUST
SIDE
I
94942
I
94215d
94215c
MO
RO
94215c
94215b
94215a
94215b
3 94215a
6
5
RS
BN
10
SA
9
2
1
017.869/08
PRE-TENSIONING JACK
PLACED FOR TENSIONING
2010-07
PRE-TENSIONING JACK
PLACED FOR LOOSENING
4/ 4
RT-flex96C
Maintenance
27083/A1
Cylinder Cover
Machining of Sealing Face for Injection Valve
Tools:
Key to Illustrations:
1 Overhauling device
1 Ring spanner AF 24
1.
94270
1
2
3
4
5
Cylinder cover
Milling cutter holder
Guide flange
Setscrews
Profiling cutter
6 Centring mandril
7 Screw
General
The seat sealing face in the cylinder cover must be clean and undamaged as the
sealing is metallic.
Should any blow-by of combustion gases have been noticed during engine operation, the spring packets with their screws of the injection valve are not, under any
circumstances, to be tightened further as a counter measure.
2.
Dirty or slightly damaged sealing faces can be re-conditioned on the spot by using overhauling device 94270.
Carefully insert the profiling cutter, bolted to the milling cutter holder, into the hole in the cylinder cover.
Fasten guide flange 3 with screws 7.
When the tool is being used, the centring mandril on
the profiling cutter on the one hand and the guide
flange on the other, give the tool the necessary stability and direction.
Cutting is done by pressing down lightly with the
hand on the milling cutter holder at the same time as
turning the hexagon evenly with the other hand using the ring spanner.
Try to remove as little material as possible but sufficient, however, to obtain the desired standard for
the seating area.
D
1/ 1
2008
1
4
5
6
003.512/00
RT-flex96C
27221/A1
Maintenance
Injection Valve
Checking, Dismantling, Assembling and Adjusting
Tools:
1 Protection cap
1 O.M.T. test bench
Key to Illustrations:
94271
94272
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Allen screw
Spring guide
Cup spring (spring packet)
Nozzle holder
Collar nut
Spring tensioner
Nozzle tip
Tappet carrier
Tappet
Retaining nut
Compression spring
Nozzle needle
Nozzle body
Retaining sleeve
Snap ring
16
17
18
19
20
21
22
23
24
25
26
27
Dowel pin
Dowel pin
Holding angle
Support
HP hose
Torque beam
Dowel pin
Spring cage
Circlip
Shim ring
Shim
O-ring
LF Leakage fuel
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Judging an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the opening pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling a spring cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting an injection valve in cylinder cover . . . . . . . . . . . . . . .
Storage and handling of injection valve . . . . . . . . . . . . . . . . . .
1/9
2/9
3/9
4/9
5/9
5/9
7/9
7/9
8/9
8/9
9/9
General
For checking, dismantling, assembling and adjusting the injection valve, test
bench 94272 as well as test & calibration fluid has to be used (e.g. Shell Calibration
Fluid S.9365) complying with the data according to the following table:
Physical characteristics for test & calibration fluid:
Kinematic Viscosity
ASTM D445
at 40 _C
mm2/s
Density at 15 _C
kg/m3
ISO 12185
827
_C
ISO 3016
27
Pour Point
2.6
Remark: Clean diesel oil (gas oil) can be used if no calibration fluid is available.
The use however is not recommended, if the injection valve will be stored and not
directly installed on the engine (corrosion reasons).
On some injection valves the leakage flow amount might be bigger than on others.
In case of the test bench flow is not sufficient to open the nozzle needle, a clean
additive-type crankcase (system) oil of the SAE 30 viscosity grade (for additional
data see 07501 System oil in the Operating Manual) can be used for testing
instead of the above mentioned fluids.
1/ 9
2013-08
27221/A1
Maintenance
RT-flex96C
2.
From time to time check the pressure gauges of the test bench with a master pressure gauge and adjust them if necessary.
Remark: The work station must be clean; welding and grinding should not be done
nearby!
Remove combustion residues and clean nozzle tip externally with a brass
wire brush.
Fit injection valve with nozzle tip pointing downwards into holding angle 18 of
test bench 94272 and fasten it with two Allen screws 1 and spring cages 23.
Support 19 must also be fitted for this.
Connect high pressure hose 20 of test bench with fuel inlet of injection valve.
Start test bench following the instructions of the test bench makers.
Bring the injection valve to spray with a few short pump jerks, and then observe at what pressure the injection valve opens, applying slow, equal pump
jerks.
Danger of injuries! Never hold fingers or hands directly before the spray holes of
the nozzle tip!
A
I-I
1
21
23
20
18
18
94272
19
001.437/97
2012-05
2/ 9
011.353/04
RT-flex96C
3.
27221/A1
Maintenance
Spray pattern: Fuel will spray mainly from the holes in the first level of the
nozzle tip at the specified opening pressure. No fuel should drip from nozzle
tip when injection is finished.
In order to test tightness between the nozzle needle and needle seat, keep the
pressure in the test bench constant at approx. 20 bar below the opening pressure. During a time period of 30 seconds no dripping should occur at the
nozzle tip.
The spray holes of nozzle tip 7 must not be flushed out unduly.
3/ 9
2013-08
27221/A1
Maintenance
4.
RT-flex96C
Remove spring tensioner 6 with collar nut 5, compression spring 11 and tappet 9
and inspect their condition.
Remark: If only a nozzle tip 7 has to be replaced, then to this end only snap ring 15
has to be removed, see section 5. All other parts are not to be dismantled.
Never interchange nozzle needle 12 and nozzle body 13! Each nozzle needle belongs to its mated nozzle body into which it has been individually fitted with greatest precision.
B
94272
21
10
18
008.329/01
2008
4/ 9
RT-flex96C
27221/A1
Maintenance
5.
C
SCREW DRIVER
5.1
16
Removal
Using two screw drivers inserted between both recesses in retaining nut 10, press snap ring 15 out
of the groove in the retaining nut, whereby the retaining sleeve can be withdrawn (Fig. C).
Watch that the snap ring does not jump off unexpectedly.
Remove nozzle tip.
14
15
10
13
5.2
Fitting
004.072/98
6.
94271
004.070/98
5/ 9
2013-08
27221/A1
Maintenance
RT-flex96C
I-I
II - II
6
5
27
INSERT BUSH
WITH SPHERICAL
SEALING SURFACE
x1
1
2
3
23
22
11
8
10
17
12
13
14
15
16
DESIGNATION
OF NOZZLE TIP
MANUFACTRER x IDNO. x
EXECUTION x CHARG. NO.
LF
II
II
2013-08
014.117/06
6/ 9
RT-flex96C
7.
27221/A1
Maintenance
The fitting position of nozzle tip 7, nozzle body 13 and nozzle holder 4 is given
by dowel pins 16 and 17 (Fig. E).
Make sure that the sealing faces are in perfect condition and that no lubricant
is applied.
Fit the nozzle tip in accordance with section 5.
D
If tappet 9, compression spring 11 and spring tensioner 6 with collar nut 5 are
already fitted, the spring tensioner must be screwed by approx. one turn only,
in order to prevent the compression spring from being under tension in any
case, otherwise nozzle body 13 does not lie flat on nozzle holder 4 during assembly.
Apply a thin layer of Never-Seez NSBT-8 to the thread and the seating face of
retaining nut 10.
First tighten retaining nut 10 to 100 Nm using the hydraulic tightening (or loosening) device of the test bench 94272 (Fig. B). Starting from this position,
tighten the retaining nut by a further angle of 30_.
CHECK
8.
After assembling the injection valve must be checked and judged according to sections 2 and 3.
7/ 9
2010-07
27221/A1
Maintenance
RT-flex96C
9.
F
24
2
The spring packet consists of three packs composed of three cup springs which are arranged as
shown in Fig. F.
In order to maintain an equal contact force when screwing down the injection valve, distance x must be
adjusted to 1.6 0.1 mm with shims 26 .
25
26
23
011.473/04
10.
Clean the seating surface of the injection valve in the cylinder cover and check for
damages.
If necessary recondition the seating surface using the special tool supplied with the
tools set (see 27083).
The sealing must be metal-to-metal, i.e. no joint must be put in between.
Place the injection valve carefully in the cylinder cover. Dowel pin 22 assures
the correct position.
FLUSH
1
2
23
3
22
011.472/04
2008
8/ 9
RT-flex96C
Maintenance
11.
27221/A1
with O.M.T. Test Bench
9/ 9
2013
RT-flex96C
27221/A2
Maintenance
Injection Valve
Checking, Dismantling, Assembling and Adjusting
Tools:
1 Protection cap
1 OBEL test bench
1 Adapter piece
Key to Illustrations:
94271
94272
94272g
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Injection valve
Allen screw
Spring guide
Cup spring (spring packet)
Nozzle holder
Collar nut
Spring tensioner
Nozzle tip
Tappet carrier
Tappet
Retaining nut
Compression spring
Nozzle needle
Nozzle body
Retaining sleeve
16
17
18
19
20
21
22
23
24
25
26
27
28
Snap ring
Dowel pin
Dowel pin
Cylinder cover
Support
HP hose
Receiver
Dowel pin
Spring cage
Circlip
Shim ring
Shim
O-ring
LF Leakage fuel
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Judging an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the opening pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling a spring cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting an injection valve in cylinder cover . . . . . . . . . . . . . . .
Protecting a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage and handling of injection valve . . . . . . . . . . . . . . . . . .
1/8
2/8
3/8
4/8
4/8
6/8
6/8
7/8
8/8
7/8
9/9
General
For checking, dismantling, assembling and adjusting the injection valve, test
bench 94272 as well as test & calibration fluid has to be used (e.g. Shell Calibration
Fluid S.9365) complying with the data according to the following table:
Physical characteristics for test & calibration fluid:
Kinematic Viscosity
ASTM D445
at 40 _C
mm2/s
Density at 15 _C
kg/m3
ISO 12185
827
_C
ISO 3016
27
Pour Point
2.6
Remark: Clean diesel oil (gas oil) can be used if no calibration fluid is available.
The use however is not recommended, if the injection valve will be stored and not
directly installed on the engine (corrosion reasons).
On some injection valves the leakage flow amount might be bigger than on others.
In case of the test bench flow is not sufficient to open the nozzle needle, a clean
additive-type crankcase (system) oil of the SAE 30 viscosity grade (for additional
data see 07501 System oil in the Operating Manual) can be used for testing
instead of the above mentioned fluids.
1/ 8
2013-08
27221/A2
Maintenance
2.
RT-flex96C
From time to time check the pressure gauges of the test bench with a master pressure gauge and adjust them if necessary.
Remark: The work station must be clean; welding and grinding should not be done
nearby!
Remove combustion residues and clean nozzle tip externally with a brass
wire brush.
Place injection valve 1 with nozzle tip pointing downwards into support 20 of
test bench 94272 and fasten it with two Allen screws 2 and spring cages 24.
Tighten high pressure hose 21 of the test bench with the adapter piece
94272g.
Start the test bench following the proper manufacturers instructions.
Bring the injection valve to spray with a few short pump jerks, and then observe at what pressure the injection valve opens, applying slow, equal pump
jerks.
Danger of injuries! Never hold fingers or hands directly before the spray holes of
the nozzle tip!
A
21
94272g
2
24
1
20
22
94272
2
24
94272g
WCH00862
2012-05
017.086/08
2/ 8
RT-flex96C
3.
27221/A2
Maintenance
Spray pattern: Fuel will spray mainly from the holes in the first level of the
nozzle tip at the specified opening pressure. No fuel should drip from nozzle
tip when injection is finished.
In order to test tightness between the nozzle needle and needle seat, keep the
pressure in the test bench constant at approx. 20 bar below the opening pressure. During a time period of 30 seconds no dripping should occur at the
nozzle tip.
The spray holes of nozzle tip 8 must not be flushed out unduly.
3/ 8
2013-08
27221/A2
Maintenance
4.
RT-flex96C
5.
The fitting position of nozzle tip 8, nozzle body 14 and nozzle holder 5 is given
by dowel pins 17 and 18 (Fig. B).
Make sure that the sealing faces are in perfect condition and that no lubricant
is applied.
Fit the nozzle tip in accordance with section 7.
D
If tappet 10, compression spring 12 and spring tensioner 7 with collar nut 6 are
already fitted, the spring tensioner must be screwed by approx. one turn only,
in order to prevent the compression spring from being under tension in any
case, otherwise nozzle body 14 does not lie flat on nozzle holder 5 during assembly.
Apply a layer of Never-Seez NSBT-8 to the thread and the seating surface of
retaining nut 11.
First tighten retaining nut 11 to 100 Nm using a torque wrench. Starting from
this position, tighten the retaining nut by a further angle of 30_ by means of the
hydraulic tightening (or loosening) device of the test bench.
CHECK
2008
After assembling the injection valve must be checked and judged according to sections 2 and 3.
4/ 8
RT-flex96C
27221/A2
Maintenance
I-I
II - II
7
6
28
INSERT BUSH
WITH SPHERICAL
SEALING SURFACE
x1
2
3
4
24
23
12
19
9
10
11
18
13
14
15
16
17
DESIGNATION
OF NOZZLE TIP
MANUFACTRER x IDNO. x
EXECUTION x CHARG. NO.
LF
II
II
014.117/06
5/ 8
2013-08
27221/A2
Maintenance
RT-flex96C
6.
7.
C
7.1
SCREW DRIVER
Using two screw drivers inserted between both recesses in retaining nut 11, press snap ring 16 out of
the groove in the retaining nut, whereby the retaining sleeve can be withdrawn (Fig. C).
Watch that the snap ring does not jump off unexpectedly.
17
15
16
11
Removal
14
Fitting
5
004.072/98
2010-07
6/ 8
RT-flex96C
27221/A2
Maintenance
8.
D
25
3
The spring packet consists of three packs composed of three cup springs which are arranged as
shown in Fig. D.
In order to maintain an equal contact force when screwing down the injection valve, distance x must be
adjusted to 1.6 0.1 mm with shims 27 .
26
27
24
011.473/04
9.
Clean the seating surface of the injection valve in the cylinder cover and check for
damages.
If necessary recondition the seating surface using the special tool supplied with the
tools set (see 27083).
The sealing must be metal-to-metal, i.e. no joint must be put in between.
Place the injection valve carefully in the cylinder cover 19. Dowel pin 23 assures the correct position.
FLUSH
2
3
24
4
23
19
011.472/04
7/ 8
2008
27221/A2
Maintenance
RT-flex96C
10.
94271
11.
2013-08
8/ 8
RT-flex96C
27281/A1
Maintenance
Starting Valve
Removal, Fitting and Dismantling, Grinding-in and Assembling
Tools:
Key to Illustrations:
2 Jacking screws
1.
1
2
3
4
5
6
7
8
9
10
11
Nut
Cover
Intermediate ring
Casing
Cylinder cover
Self-locking nut
Piston
Valve spindle
Allen screw
Compression spring
Joint ring
12
13
14
15
16, 17
18
19
Control valve
Connecting pipe
Piston ring
Spindel guide
O-rings
Solenoid
Nut with locking washer
General
Should functional difficulties occur with the starting valves when starting, or should
a starting air pipe near to the connection become noticeably hotter in operation
than on the neighbouring cylinders, 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 check and to overhaul the other starting valves in frequencies determined by such checking.
CHECK
2.
Periodical venting of the starting air manifold under higher pressure must be
provided as mentioned in the Operating Manual 03201. In addition, regular
checks must be carried out to make sure, that nut 18 on solenoid 17 is tight (see
also Maintenance Schedule 03801).
3.
When the removal is carried out with the cylinder cover fitted on the engine,
the vacated opening must be immediately covered by suitable means to prevent the possibility of foreign particles entering the combustion space.
Lift cover 2 with mounted control valve 12 off casing 4. Take care that during
lifting, the cover does not get jammed, whereby connecting pipe 13 risks being damaged.
1/ 3
2013-08
27281/A1
Maintenance
RT-flex96C
4.
Grinding-in
D
Badly worn seat faces must first be machined and then ground in (lapped)
manually.
Remark: The valve spindle has an angle of 61_, however, the valve seat angle
amounts to 60_.
5.
Assembling
Assemble the valve in reverse sequence to the dismantling.
Clean all parts and smear them lightly with oil.
Apply MOLYKOTE paste G to the thread of valve spindle 8, however not in the
area of the locking ring of the self-locking nut 6.
Tighten the not greased, clean self-locking nut with 1215 Nm or by a tightening angle of 50_.
Place new, lightly oiled, O-rings 16 and 17 into the groove in casing 4 and connecting pipe 13 respectively.
CHECK
After completing the assembly (without cover 2) check the easy movement of the
valve spindle by moderately tapping the upper end of the valve spindle several
times with a lead block in an axial direction; the valve spindle must jump every time
back on the seat.
If the valve seat have been ground/machined several times, check the clearance
x (see figure) with a depth gauge from the upper edge of intermediate ring 3 onto
the piston 7.
Clearance x must be minimum 1 mm.
Fit cover 2 and tighten it with Allen screws 9. Take care that when assembling
cover 2, connecting pipe 13 does not interfere.
6.
2008
2/ 3
RT-flex96C
27281/A1
Maintenance
II
I-I
II - II
RC
1
14
14
4
7
III
IV
16
CA
IV
13
10
011.357/04
III
III - III
IV - IV
2
11
9
17
13
17
4
17
18
3/ 3
2013-08
RT-flex96C
27451/A1
Maintenance
1.
Key to Illustrations:
94272
94272c
94931
94934a
94935
1
2
3
4
5
6
7
8
9
Cylinder cover
Relief valve
Indicator valve
Adapter piece
Protection plate
Flange
Adapter
Sleeve
Allen screw
10 Receiver
11 Gasket
12 Gasket
EV Relief valve
MD Metallic sealing
RB Relief bore from
compression chamber
General
Each cylinder cover is provided with an indicator valve combined, depending on
Class requirements, with a relief valve, which is connected by relief bore RB to the
compression chamber. An inadmissible high pressure peak in the compression
chamber opens the valve and the over-pressure is immediately reduced.
A relief valve which has blown off or valves leaking during engine operation
must be replaced at the first opportunity (with engine stopped only).
A relief valve can not be repaired nor adjusted any more after having blownoff!
Relief valves require no maintenance, however they should be checked in general
at every major engine overhaul. Basically leaking or damaged valves should be
returned to the manufacturer for inspection and repair.
BLOW-OFF PRESSURE
STAMPED IN
2
5
12
11
4
12
9
6
7
MD
8
1
RB
017.671/08
1/ 2
2008
27451/A1
Maintenance
RT-flex96C
2.
Blow-off pressure
[bar]
140143
200
1441471)
205
148151
210
152155
220
156160
225
1)
B
94935
94934a
94272c
2
10
017.670/08
013.484/05
94931
3.
94272
EV
013.486/05
2008
2/ 2
RT-flex96C
27511/A1
Maintenance
Exhaust Valve
Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs
Tools:
1
1
1
1
2
1
1
1
2
1
1.
Dismantling tool
Hydr. tensioning device
Valve protector
Suspension device
Lifting lugs
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
Key to Illustrations:
94008aM100
94252
94262
94265(c)
94811
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
Waisted stud
Nut
Vent screw
Piston
Round nut
Pin
Sealing ring
Sealing ring
9
10
11
12
13
Cylinder
Expansion piece
Protection pipe
Valve cage
Valve spindle
KO Slot
RS Round bar
General
Prior to the removal of an exhaust valve, drain first the cylinder cooling water from
the respective cylinder (see 27081), and close the air inlet to the air spring at the
control air supply.
The exhaust valve can be removed from the cylinder cover or transported as whole
unit (without cylinder cover) with suspension device 94265 or with 94265c for
cranes provided with small hooks (see also 27081).
The valve cage must be suspended as shown in Fig. A.
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
General Application Instructions 94034 for hydraulic pre-tensioning jacks.
D
94265(c)
12
13
94262
008.330/01
003.352/00
1/ 6
2012-05
27511/A1
Maintenance
RT-flex96C
Removal
Remove all connected pipes. Removal of hydraulic piping see 84601.
Expansion piece 10 (Fig. C) has to be removed with the aid of lifting lug 94811
and suspension device 94265(c). Therefore, two screws of each suspension
strap have to be screwed into the expansion piece flange. After removing the
connecting screws from the expansion piece flanges the expansion piece can
be taken out in the engine longitudinal direction.
94265(c)
94811
10
10
I
12
I
94811
I-I
94811
003.723/95
11
003.723/95
6
RS
4
7
8
2
9
RS
KO
008.331/01
2008
10
2/ 6
RT-flex96C
27511/A1
Maintenance
94252
94935a
94932a
94934a
94935
94935a
014.774/06
94252
94942
Turn all nuts 2 upwards till the stop, using round bar RS.
Release pressure to zero at the hydraulic unit.
Disconnect HP hoses to hydr. tensioning device 94252 and remove the latter.
Unscrew round nuts 5 from the waisted studs.
Suspend the hooks of suspension device 94265 (Fig. A) into the eye bolts of
valve gage 12 and pull the complete exhaust valve out of the cylinder cover.
3/ 6
2008
27511/A1
Maintenance
RT-flex96C
3.
Fitting
D
Before fitting the exhaust valve into the cylinder cover, the sealing surfaces
must be checked for cleanliness and possible damage.
Make sure that the soft iron gasket of 2 mm thickness lies flat in its recess in
the cylinder cover.
The correct position of the exhaust valve cage is determined by the cylindrical
dowel pin set in the cylinder cover.
Clean threads of the waisted studs, nuts and their seating surfaces, and
smear them with Never-Seez NSBT-8.
CHECK
Fit nuts 2 and tighten them firmly with round bar RS till fully seated before mounting the pre-tensioning jacks (check seating with feeler gauge).
Mark position of the nuts on a corner and their position on valve cage 12 with a
felt-tip pen (for later checks).
Place hydr. tensioning device 94252 consisting of two pre-tensioning jacks on
the two waisted studs 1 (Fig. D) which have to be loosened (arrangement
according to Fig. E).
Open vent screw 3 of each pre-tensioning jack.
Screw round nuts 5 onto waisted studs 1 until there is no or very little clearance at x.
Connect the pre-tensioning jacks by HP hoses 94935 and 94935a as well as
hydr. distributor 94934a with hydraulic unit 94942 as shown in Fig. E.
CHECK
CHECK
Keep this pressure constant and tighten nuts 2 with round bar RS till firmly seated
on exhaust valve cage 12 (check seating with a feeler gauge through the slot KO).
After tightening the nuts ascertain that these have been turned by about the same
angle of 230_.
If bigger differences occure the tensioning procedure must be repeated.
Release pressure to zero and remove both pre-tensioning jacks.
Remark: When fitting expansion piece 10 smear its flange surfaces and connecting screws lightly with a heat resisting lubricant. The expansion piece has to be
fitted in such a way that protection pipe 11 of the expansion piece comes to lie in the
flow direction i.e. on the valve cage side, as shown in Fig. C.
2010-07
4/ 6
RT-flex96C
27511/A1
Maintenance
4.
4.1
F
JOINTING
COMPOUND
ANNULAR
SPACE
SEALING
SURFACE
1
94008aM100
CYLINDER
COVER STUD
WCH00836
003.465/00
5/ 6
2012-05
27511/A1
Maintenance
RT-flex96C
4.2
Hardener
Adhesive
primer
Elastosil
RT 622 A
RT 622 B
G 790
Silcoset
105 RTV
Manufacturer
Wacker-Chemie Gmbh
Geschftsbereich Silicone
Hanns-Seidel-Platz 4
D-81737 Mnchen
Silcoset
Silcoset Primer AMBERSIL LTD
Curing Agent A
Wylds Rd
Bridgwater
Somerset
TA6 4DD
Uk-Great Britain
Remark: Mixing and applying of the jointing compounds must be done according
to the instruction of the respective manufacturer.
Products of other manufacturers are also allowed when fulfilling the below specification:
2010-07
Resistant to oil, marine diesel oil, heavy fuel oil and water at a permanent temperature of approximately 100 _C.
Short age hardening time, i.e. at least 24 hours under ISO standard reference
conditions.
Well flowing to properly fill out the annular space, in order to avoid the creation
of any hollow space.
The jointing compound must remain elastic, as a cylinder cover stud may be
removed at any given time.
6/ 6
RT-flex96C
27512/A1
Maintenance
Exhaust Valve
Dismantling and Assembling
Tools:
1
2
2
1
Key to Illustrations:
Depth gauge
Retaining screws
Jack screws
Torque wrench
94124
94259
94263
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Valve cage
Lower housing
Screw
Nut
Upper housing
Outside piston
Inside piston
Thrust piece
Valve spindle
Screw plug
Piston guide
Flange
Screw
Measuring cone
Head screw
Valve cotter
Piston
Piston seal ring
Disc spring
Distance ring
Head screw
Guide bush
23
24
25
26
27
28
29
30
31
32
33
34
3544
Vent screw
Valve seat
Rod seal ring
Non-return valve
Bush
Air pipe
Screw
Valve stroke sensor
Screw
Housing
Damper
Shim
O-rings
BO
HH
HU
OB
OB1
Bore
Hydr. HP pipe
Wooden underlay
Oil bore
Oil bath for valve
spindle lubrication
RC Eye bolt
Overview
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling of exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling of exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling of valve drive and blocking exhaust valve . .
1.
2.
3.
4.
RC
1.
1/10
3/10
5/10
9/10
General
There are in minimum two complete exhaust
valves on board, as recommended by the International Association of Classification Societies
(IACS). Therefore, they must be used as a replacement in any case of difficulties appeared
during operation.
4
10
2
3
1/ 10
2012-05
27512/A1
Maintenance
RT-flex96C
RC
33
35
34
009.716/02
43
7
5
23
13
33
11
BO
12
37
14
15
16
18
38
17
2
3
19
39
21
OB1
20
22
20
25
40
2
1
014.456/06
22
9
41
1
42
24
WCH00438
2012-05
2/ 10
RT-flex96C
27512/A1
Maintenance
2.1
2.2
15
14
16
17
18
38
19
1
HU
014.539/06
3/ 10
2011-05
27512/A1
Maintenance
RT-flex96C
2.3
Check and measure inner diameter of the guide bush according to Clearance
Table 03301 Exhaust Valve.
94263
21
25
20
1
1
22
40
014.540/06
2.4
Check oil bores OB in guide bush and valve cage for free passage.
Replace O-ring 40.
Oil guide bush and press it into the valve cage up to the stop using jack screws
94263.
94263
OB
40
1
22
014.540/06
2011-05
4/ 10
RT-flex96C
27512/A1
Maintenance
CHECK
21
HU
014.541/06
5/ 10
2010-07
27512/A1
Maintenance
RT-flex96C
3.2
In this position fill oil bath OB1 liberally with system oil (see Fig. B).
Take care of bush 27 and O-ring 44 when fitting (Fig. J, section I-I).
H
33
3.3
34
4
15
36
32
30
31
2
3
WCH00438
2011-05
6/ 10
RT-flex96C
27512/A1
Maintenance
3.4
Setting of damper
Setting of damper 33 is necessary only after a valve spindle or valve seat has been
replaced, and after one of the valve seating faces has been ground. Setting is to be
carried out, after assembling of the exhaust valve as shown in Fig. I.
3.5
94124
H 0.5
34
5
7
Measure H
0.5 mm
Total
thickness h
222 mm
2 mm
221 mm
3 mm
220 mm
4 mm
219 mm
5 mm
218 mm
6 mm
217 mm
7 mm
216 mm
8 mm
014.543/06
7/ 10
2011-05
27512/A1
Maintenance
RT-flex96C
3.6
3.7
I-I
2
27
44
LEAKAGE
OIL
II
I
II
I
26
29
II - II
28
014.544/06
2011-05
8/ 10
RT-flex96C
27512/A1
Maintenance
4.
4.1
L
RC
HH
5
4
2
RC
6
13
7
12
014.546/06
9/ 10
2010-07
27512/A1
Maintenance
RT-flex96C
4.2
94259
94259
4.3
014.547/06a
2011-05
10/ 10
RT-flex96C
27513/A1
Maintenance
Exhaust Valve
Replacing and Grinding the Valve Seat
Tools:
1
1
1
1
Key to Illustrations:
Feeler gauge
Valve seat fitting and dismantling device
Gauge
Valve grinding device
94122
94261
94279
94291
1 Valve seat
2 Valve cage
3 O-ring
AF Seating face
HA Hammer
RC Eye bolt
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grinding the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/5
1/5
2/5
3/5
5/5
General
Valve seats of which the seat surfaces are badly damaged, or on which the wear
limit has been reached through frequent grinding, must be replaced.
The most advantageous position for replacing the valve seat is to bring the valve
cage in a vertical position as shown in Fig. A.
Remark: When the valve seat must be removed with the valve cage in the inverted
upside down position, it must be suspended on the engine room crane slightly
above a wooden underlay. Device 94261 can then be attached from below and the
valve seat carefully withdrawn until it drops caused by its own weight (142 kg).
Therefore, the valve seat must be properly secured with additional wooden underlays. The distance to the wooden underlay is to be kept as small as possible to
avoid any accidents or damage.
2.
Should a valve seat be removed for any reason, it must be reground by means
of valve grinding device 94291 before refitting.
94261
2
008.336/01
1/ 5
201007
27513/A1
Maintenance
RT-flex96C
3.
Through the control openings in the valve seat fitting and dismantling device check
with feeler gauge 94122 all around the circumference that no clearance remains at
AF.
1
94122
94261
2
008.337/01
201007
2/ 5
AF
RT-flex96C
27513/A1
Maintenance
4.
When the seat surface on the valve seat is badly damaged (impacts, corrosion scars).
94291
016.773/08
3/ 5
201007
27513/A1
Maintenance
RT-flex96C
CHECK
The grinding allowance on the valve seat is maximum 3 mm. The wear condition
can be checked efficiently with gauge 94279 in combination with feeler gauge
94122. Possible burn scars at the inside of the valve seat must not exceed 15 mm.
The depth of the burn scars can also be verified with the gauge 94279 as shown in
Fig. D.
D
Valve seats which exceed the above mentioned values must be replaced.
94279
003.458/00
max. 15 mm
201007
4/ 5
RT-flex96C
Maintenance
27513/A1
5.
RC HA
CHECK
003.457/00
F
30 _ + 2
0
50100%
003.456/00
S = 0.14 0.18 mm
003.455/00
5/ 5
2008
RT-flex96C
Maintenance
27514/A1
Exhaust Valve
Grinding the Seating Surface on the Valve Head
Tools:
1 Feeler gauge
1 Valve grinding device
1 Gauge
1.
94122
94291
94292
General
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 94291 be made available.
Remark: 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 has cooled down.
The machines from the makers HUNGER and CHRIS - MARINE are well proven
for valve grinding and can also be ordered directly from Wrtsil Switzerland Ltd,
Winterthur.
2.
+20
+18
Remark: For the application of the grinding device refer to the operating instructions.
94291
016.744/08
1/ 2
2010-07
27514/A1
Maintenance
RT-flex96C
CHECK
The wear condition can be checked at any time with gauge 94292 and feeler gauge
94122.
D
Where the precise angle required has been obtained during grinding, a check
with marking blue with the valve on the reground valve seat in the valve cage
will show only a line contact or a very narrow band (extent of contact) starting
from the smaller diameter as shown in Fig. B.
See also remarks in 27513 regarding the valve behaviour at running temperature.
max. 3 mm
94292
003.454/00
2012-05
max. 12 mm
2/ 2
003.454/00
RT-flex96C
Maintenance
Group3
Group 3
Vibration Damper
Taking a Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31301/A1
Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31302/A1
Axial Damper: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31461/A1
Turning Gear: Checking the Toothing and Screwed Connections . . . . . . . . . . . . . . 32061/A1
Crankcase: Utilization of Working Platform and Ladder . . . . . . . . . . . . . . . . . . . . . . 33011/A1
Lower Platform: Platforms and Hatch Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33012/A1
Connecting Rod
Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . 33031/A1
Inspection, Removal and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . 33032/A1
Inspection, Removal and Fitting of Top End Bearing with Piston in Situ . . . . . . 33033/A1
Inspection, Removal and Fitting of Top End Bearing with Piston Removed . . . 33033/A2
Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33034/A1
Crosshead
Checking the Clearances and Fitting the Guide Shoes . . . . . . . . . . . . . . . . . . . . 33261/A1
Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33262/A1
Piston
Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34031/A1
Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34032/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34033/A1
Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34034/A1
Piston Rings: Checking Wear of Piston Rings and Ring Grooves . . . . . . . . . . . . . . 34251/A1
1/ 3
RTflex96C / MM / 2030-08
RT-flex96C
31031/A1
Maintenance
Crankshaft
Measuring Crank Deflection
Tool:
Key to Illustrations:
1.
94305
1 Flywheel
2 Pinion
General
Regular crankweb deflection measurements according to the intervals defined by
the class rules are sufficient. Detailed alignment measurements might become necessary only in case of abnormalities, like
after replacing main bearing shells and again after approx. 100 service hours.
2.
The ship must be floating freely and lying in the water as horizontal as
possible.
2.1
1
2
014.254/06
TURNING GEAR
ON FUEL SIDE
Influences on measuring
Strong sunshine.
It is recommended to include these data in the records.
3.
Measuring procedure
Despite the ordinary rotation direction of the engine, the
crankshaft must always be turned in such a manner that
flywheel 1 and pinion 2 of the turning gear are rotating as
indicated by the arrows.
1/ 3
2013-08
31031/A1
Maintenance
RT-flex96C
3.1
The last value at B.D.C. is for checking. With correctly carried out measuring
procedure it should be again nearly zero. If it deviates more than 0.06 mm
from the first reading, then the measuring must be repeated.
VIEW FROM
DRIVING END
COUNTERCLOCKWISE ROTATION
EXHAUST SIDE
T.D.C.
B.D.C.
FUEL SIDE
B.D.C.
CRANK DEFLECTION
SIGN ON DIAL GAUGE
+
94305
OR
APPROX. 18 mm
CENTER PUNCH MARK
FOR DIAL GAUGE 94305
2013-08
2/ 3
RT-flex96C
31031/A1
Maintenance
4.
STROKE
C
94305
B.D.C
T.D.C
The difference between the indicated values shows the amount of crank deflection
during one revolution (Fig. B).
Where values are measured which lie above the maximum permissible limits, the
cause has to be found and the necessary remedial measures taken (defective
main bearing, engine stay altered due to hull deformation, loose holding-down
bolts, defective propeller shaft bearings or checking equipment 94305, etc.).
The limits are valid for any condition of ship service after ship delivery, i.e.:
The ships draught and trim are within the limits for normal operation.
Cylinder No. 2
to penultimate
cylinder
0.76
0.76
0.54
0.54
Horizontal
Last cylinder
(Free end)
1)
2)
0.54
0.54
0.54
0.76
All cylinders
0.25
0.25
1)
For engine without torsional vibration damper or front disc or free end PTO.
2)
For engine with torsional vibration damper or front disc or free end PTO.
Contact Wrtsil Switzerland, if the final measurements exceed the limits given in
the above table.
3/ 3
2013-08
RT-flex96C
31301/A1
Maintenance
Vibration Damper
Taking a Silicone Fluid Sample
Key to Illustrations:
1
2
3
4
5
6
1.
Casing trough
Casing cover
Screw plug
O-ring
Sealing ring
Coupling bolts
7 Crankshaft
8 Cap nut
General
Viscous vibration dampers manufactured by Hasse & Wrede, Metaldyne International UK, STE Schwingungstechnik and Geislinger can be mounted at the free
end of the crankshaft and in case of RTA engines as well at the free end of the camshaft.
The service life of a vibration damper is largely dependent on the speed range in
which the engine is run. Wear of the inner parts as well as changes in the silicone
oil properties can reduce the effectiveness of the damper. By periodic examination
of the silicone oil the makers of the vibration damper can draw conclusions on its
condition.
The silicone oil must be examined for the first time after about 15 00018 000 operating hours. Future intervals for examinations depend on the result of these first
findings.
Special sample containers PB (Fig. B) can be obtained from the vibration
damper makers.
7
3
2
3
3
009.739/02
1/ 4
2010-07
31301/A1
Maintenance
RT-flex96C
2.
Leave the damper in the mentioned position for at least two hours.
(If the oil sample is to be withdrawn from a removed vibration damper the
same conditions apply as regards the positions and the waiting time).
Using a flat caulker, hammer back the squeezed material in the corresponding
slot, which serves as locking means of screw plug 3.
Loosen the screw plug, but do not unscrew it yet, it must still seal.
3.
Prepare sample container PB, i.e. remove both cap nuts 8 and examine the bore
which must be meticulously clean.
Remark: Two different threads are used for the sample bores of the Simpson International and STE vibration dampers. Therefore, the ends of the sample container are provided with different threads.
Remove the previously loosened screw plug 3, and screw in the sample container PB instead.
After fully screwing in the sample container, screw it back by one turn to prevent it from touching the flywheel inside the vibration damper.
Wait until the silicon fluid appears at the open end of the sample container.
Depending on the viscosity of the fluid, this may take some seconds only, or
much longer.
As soon as the silicon fluid flows out of the sample container, close its open
end with the respective cap nut.
Unscrew the sample container from the vibration damper housing (taking care
not to let escape the fluid), then immediately set in screw plug 3 with a new
O-ring 4 or sealing ring 5. (Avoid any leaking of silicon fluid.)
Screw the second cap nut on the sample container and tighten it moderately.
For the different vibration dampers tighten screw plugs 3 as follows:
with 20 Nm
STE
Finally secure the screw plugs with centre punch mark KS (Fig. B).
2008
2/ 4
RT-flex96C
31301/A1
Maintenance
SAMPLE
CONTAINERS
Metaldyne
and STE
8
3/8BSF (M16)
M10x1
PB
PB
M10x1
5/16BSF (M10)
007.964/97
4
KS
KS
Remove the opposite screw plug, connect a compressed air supply and apply
about 3.5 bar pressure.
D
Only dried and filtered air may be used (connections and air hose must be
clean, free from any fouling).
As soon as fluid reaches open end of sample container shut off compressed
air supply and then fit one of the two cap nuts 8 to the sampling container.
Disconnect compressed air supply. Remove sample container and fit the
other cap nut 8.
Re-fit the corresponding screw plugs to all withdrawal openings.
Tighten and lock the screw plugs as already mentioned under Taking the
sample.
Remark: The special sample container permits drawing a specific quantity of silicone oil from the damper. The total number of samplings should be limited to 10.
3/ 4
2008
31301/A1
Maintenance
RT-flex96C
201007
Engine type
Engine No.
Ship name
4/ 4
RT-flex96C
31302/A1
Maintenance
Vibration Damper
Inspection (GEISLINGER Vibration Damper)
Key to Illustrations:
1
2
3
4
5
1.
Damper casing
Vent nozzles
Sealing rings
Oil supply piping
Crankshaft
6 Coupling bolt
7 Coupling disc
(crank angle sensor unit)
8 Vibration damper
9 Sealing ring
General
Depending on the design execution of an engine, a vibration damper of GEISLINGER make may be mounted at the free end of the crankshaft.
The service life of a vibration damper depends largely on the speed range in which
the engine is operated. Water, in particular sea-water, in the lubricating oil leads to
increased wear and loss of damping action.
2.
Check
D
The engine filters should regularly be checked for steel or bronze chippings. If
such chippings are found also in the damper housing, the damper supplier is
to be informed accordingly.
Until the reasons for such findings are not clarified and rectified, it is not allowed to
put the damper back into service.
D
Should the oil pressure drop below 1 bar, it may not be corrected by adjustment of the adjustable throttle in the supply piping. Instead, the cause of the
pressure drop must be investigated (defective oil supply piping 4).
Attention! If the oil supply to the damper is interrupted, the engine must be
stopped immediately, otherwise the damper may be seriously damaged. The oil
supply has to be reestablished before restarting the engine.
D
Should damage be noticed on the engine bearings which is due to water contamination of the lubricating oil, then the vibration damper must also be inspected for possible damage at the very earliest opportunity.
To check the inner spring tips and groove flanks the inspection cover on the
face of damper casing 1 (Fig. B) can be removed (with stopped engine). For
wear limits refer to the manual of the damper manufacturer.
Dismantling of a vibration damper should only take place if there is a reasonable suspicion that the damper is damaged or wear rates have exceeded their
limits. In this case contact the damper manufacturer for further instructions.
Attention! Adjustments on the vibration damper may only be carried out by a specialist, with simultaneous torsional vibration measurements.
Prior to removing a vibration damper and balance weight mark their positions with
reference to the crankshaft.
D
Remark: For the test run after the first commissioning, as well as the normal
checking and servicing intervals, refer to the manual of the damper manufacturer.
Contact address for GEISLINGER vibration dampers:
Geislinger GmbH
A-5300 Hallwang / Salzburg
Austria
1/ 2
201007
31302/A1
Maintenance
RT-flex96C
B
8
1
8
6
9
FREE END
OIL SUPPLY
7
011.669/04
2008
2/ 2
RT-flex96C
31461/A1
Maintenance
Axial Damper
Dismantling and Assembling
Tools:
Key to Illustrations:
1.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Locking screw
Locking plate
Diaphragms
Oil inlet pipe
Main bearing cover
Crankshaft
Main bearing shell
HZ Lifting tackle
RC Eye bolt
Dismantling
Prior to any overhaul work being started on an axial damper, switch off the bearing
oil pump. Then remove the upper half of the two-piece crankshaft casing at the free
end.
Remove oil inlet pipe 15.
Pull out both taper pins locating the upper and lower part of cylinder 2 and 1
respectively. For this purpose the taper 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.
10
12
15
14
10
11
16
16
5
1
4
6 7
17
18
001.420/97
1/ 3
001.420/97
2008
31461/A1
Maintenance
RT-flex96C
HZ
RC
1
16
001.522/97
17
Screw in two eye bolts RC (Fig. B) into the upper part of cylinder and fit lifting
tackle HZ on the platform support at the free end. Join the eye bolts by steel
ropes and the lifting tackle.
For removal of two-part seal rings 6 and 7, loosen first self-locking nuts 8 and
remove Allen screws 9. The sealing rings can then be turned out of their
grooves in the lower part of cylinder 2 without any problems.
9
8
6 (7)
003 718/95
2008
2/ 3
RT-flex96C
Maintenance
31461/A1
2.
12
13
D
10
14
004.156/99
If it becomes necessary to unscrew or replace a spindle for any reason, then the
distance x must be measured first (Fig. D). The spindle has to be adjusted to the
same distance on reassembling.
The spindle must not be turned back by more than 16 turns , that corresponds to a
stroke of x = 48 mm.
D
When the above check brings to light any defect of throttling valve 10 then diaphragms 14 (Fig. A) screwed into the throttling valve must also be checked
for possible damage and replaced if necessary.
Attention! The engine must not be operated with spindle 11 removed or with the
oil supply to the axial damper interrupted!
3.
Assembling
Remark: The seal rings normally have no signs of wear, therefore no dimension
due to wear is indicated. However, worn or damaged seal rings 6 and 7 due to contamination must be replaced. See also 31461 Monitoring system in the Operating Manual.
D
The seal rings are fastened by two Allen screws 9 and self-locking nuts 8. Immediately before fitting the seal rings smear them with clean engine oil.
Newly fitted seal rings must allow radial movement when fitted.
Before tightening screws 3 as well as 4 and 5 fit the taper pins for the upper
part and lower part of the cylinder.
Remark: Apply MOLYKOTE and tighten screw 4 between axial damper and bedplate with a tightening angle of 50_ (see also 03521).
3/ 3
201007
RT-flex96C
32061/A1
Maintenance
Turning Gear
Checking the Toothing and Screwed Connections
Tools:
1
1
1
1
1
1
1
1
1
1.
Feeler gauge
Pre-tensioning jack
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
HP hose
Key to Illustrations:
94122
94340
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
7
8
Turning gear
Pinion
Toothing of flywheel
Support
Screw
Nut
Spacer ring
Cylinder
9 Piston
10 Vent screw
11 Pin
EV
KO
RS
SA
Relief valve
Slot
Round bar
Gap
General
Before putting the turning gear into operation, the condition of the tooth flanks, i.e.
the lubricant of pinion 2 and toothing of flywheel 3 must always be checked. See
also 07501 in the Operating Manual.
For maintenance of the turning gear the instructions recommended by the
manufacturer must be followed.
The pre-tension of screws 5 for turning gear 1 must be checked in accordance with
Maintenance Schedule 03801.
Remark: Pay attention to General Application Instructions 94034 for hydraulic
pre-tensioning jacks.
1
3
2
4
014.254/06
1/ 5
2008
32061/A1
Maintenance
RT-flex96C
2.
2.1
Application instruction
The lubricant needs to be spread evenly in a very thin layer over the tooth flanks
of pinion 2 and flywheel 3 in order to prevent it from being thrown off at full engine
speed.
Brand
2.2
Application picture
Remark
1 LE 5182
PYROSHIELD
2 Klberfluid
CF 3 ULTRA
Re-lubrication intervals
According to visual inspection results, when hardly any lubricant is left any more on
the highest loaded tooth flank areas, i.e. before the tooth flanks nearly run dry:
Approximately every 2000 operating hours of the diesel engine, or more frequently, as required.
2.3
Recommended suppliers
2013-08
2/ 5
RT-flex96C
32061/A1
Maintenance
3.
Check with feeler gauge through slot KO if there is any clearance between nut 6
and spacer ring 7.
If any clearance does exist, tighten the nut with round bar RS till it rests firmly
on the spacer ring (check with feeler gauge). Subsequently release the pressure to 0 at the HP oil pump. If no clearance exists, the pressure can immediately be released and the pre-tensioning jack removed.
Check all the screws in this manner and, wherever necessary, tighten the nut.
4
7
KO
RS
94932a
94934a
x
9
94934e
94932
11
012.106/04
10
94935a
3/ 5
94935
EV
94931
2008
32061/A1
Maintenance
RT-flex96C
4.
4
6
7
SA
RS
94932a
94934a
9
94934e
94932
94935
EV
11
10
94935a
2008
4/ 5
94931
012.107/04
RT-flex96C
32061/A1
Maintenance
5.
1st step with 600 bar in the required sequence a f as shown in Fig. D
view II.
I-I
D
I
2
1
5
4
7
6
b e
II
3
I
012.108/04
II
c
f
TENSIONING
SEQUENCE
5/ 5
2008
RT-flex96C
33011/A1
Maintenance
Crankcase
Utilization of Working Platform and Ladder
Tools:
Key to Illustrations:
2 Working platforms,
consisting of 3 grids each
2 Working supports
1 Ladder
1.
94142
1
2
3
4
94143
94147
General
To avoid accidents, the grids of working platform 94142, working supports 94143
and ladder 94147 should be used for inspections or work in the crankcase. The
grids must always be fitted in such a way that their U-profiles come to lie between
engine longitudinal beam 1 and that the opposite end rests on crank web 2, as
shown in Fig. A.
Working support 94143 can be fitted between the columns at the desired height,
on steps 3. These are safeguarded against falling down by shoving straps 4
against the steps.
Never rotate crankshaft while grids, working supports or the ladder are in position.
I-I
I
3
94143
94143
4
FUEL SIDE
EXHAUST SIDE
94147
94142
94142
1
011.662/04
1/ 1
009.307/01
2008
RT-flex96C
33012/A1
Maintenance
Lower Platform
Platforms and Hatch Covers
Key to Illustrations:
1
2
3
4
5
6
7
8
9
10
11
12
1.
Supply unit
Lateral hatch cover
Upper platform
Hatch cover
Hatch cover
Column
Bolting device
Lower platform
Lower platform
Front centre part
Rear centre part
Screw
General
In order to meet the different requirements during removal and fitting of engine
components, the upper and lower platforms as well as the hatch covers can be
opened respectively removed at the (main) lower platform.
Risk of accident! Prior to opening platforms and hatch covers, the access to the
area to be opened must always be barricaded without fail!
1
5
4
2
014.140/06
1/ 6
2008
33012/A1
Maintenance
RT-flex96C
014.141/06
5
4
014.142/06
2008
2/ 6
RT-flex96C
33012/A1
Maintenance
014.143/06
HZ
RC
014.144/06
3/ 6
2008
33012/A1
Maintenance
RT-flex96C
6
3
7
12
014.145/06
11 10
014.146/06
2008
4/ 6
RT-flex96C
Maintenance
33012/A1
10
11
014.147/06
014.148/06
5/ 6
2008
33012/A1
Maintenance
RT-flex96C
8
9
014.149/06
2008
6/ 6
RT-flex96C
33031/A1
Maintenance
Connecting Rod
Loosening and Tensioning the Connecting Rod Studs
Tools:
1
2
2
1
1
1
2
1
Key to Illustrations:
Feeler gauge
Pre-tensioning jacks
Pre-tensioning jacks
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94122
94314
94315
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
KO Slot
RS Round bar
SA Gap
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening the stud of bottom end bearing . . . . . . . . . . . . . . .
Tensioning the stud of bottom end bearing . . . . . . . . . . . . . .
Loosening the stud of top end bearing . . . . . . . . . . . . . . . . . .
Tensioning the stud of top end bearing . . . . . . . . . . . . . . . . . .
1/5
2/5
3/5
4/5
5/5
General
For loosening and tensioning clean the threads of connecting rod studs 1 and
the area around nuts 2 and lubricate the threads.
CHECK
4
3
5
6
2
RS
SA
KO
011.360/03
011.359/03
PRE-TENSIONING JACK
PLACED FOR LOOSENING
PRE-TENSIONING JACK
PLACED FOR TENSIONING
1/ 5
2008
33031/A1
Maintenance
RT-flex96C
2.
94314
94935a
94932a
Attention should be paid to ensure that pins 3 always protrude slightly compared with pistons 5 on
the pre-tensioning jacks!
94934a
94935
008.450/01
94942
2008
2/ 5
RT-flex96C
Maintenance
33031/A1
3.
Tighten the nuts first with round bar RS by hand with a smart jerk.
Check whether the nuts rest flush on the connecting rod shank.
CHECK
Equally distribute the clearance between the bearing halves (bearing projection).
Screw pre-tensioning jacks 94314 onto connecting rod studs 1 until these rest
against the connecting rod shank. Moreover, open slightly vent screws 4 so
that pistons 5 can slide back to their initial position, i.e. there is no or little clearance at x (Fig. A).
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. B.
Actuate the hydraulic unit and set pressure to 300 bar (1st step) and keep
pressure constant.
Start up hydraulic unit till bubble-free oil flows out through vent screws 4. Shut
the vent screws.
D
Tighten the nuts with round bar RS and check with the feeler gauge through slot
KO (Fig. A) that no clearance remains between nut and supporting surface.
Check with the feeler gauge that no clearance remains between bearing cover and
connecting rod shank.
(Should clearance remain, loosen the fastening and compare the bearing projection with the nominal value as indicated in 33032).
CHECK
Fig. a
Fig. b
Finally check the vertical bearing clearance (see Clearance Table 03301 Top and bottom end bearings to connecting rod).
98.7700
TIGHTENING ANGLE
3/ 5
2008
33031/A1
Maintenance
RT-flex96C
4.
Remark: For loosening the studs always follow the sequence shown in Fig. C i.e. a + a and b + b.
I
b
94315
a
94935a
Attention should be paid to ensure that pins 3 always protrude slightly compared with pistons 5 on
the pre-tensioning jacks!
94932a
94934a
94935
003.347/00
94942
2008
4/ 5
RT-flex96C
Maintenance
33031/A1
5.
Tighten the nuts first with round bar RS by hand with a smart jerk.
Check whether the nuts rest flush on the bearing cover.
CHECK
Equally distribute the clearance between the bearing halves (bearing projection).
Screw pre-tensioning jacks 94315 diagonally onto two connecting rod studs 1
until these rest against the bearing cover. Moreover, open slightly vent screws
4 so that pistons 5 can slide back to their initial position, i.e. there is no or little
clearance at x (Fig. A).
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. C.
Start up hydraulic unit till bubble-free oil flows out through vent screws 4. Shut
the vent screws.
Actuate the hydraulic unit and set pressure to 600 bar (1st step) and keep
pressure constant.
Attention should be paid to ensure that pins 3 always protrude slightly
compared with pistons 5 on the pre-tensioning jacks!
Tighten the nuts with round bar RS and check with the feeler gauge through slot
KO (Fig. A) that no clearance remains between nut and supporting surface.
Check with the feeler gauge that no clearance remains between bearing cover and
connecting rod shank.
(Should clearance remain, loosen the fastening and compare the bearing projection with the nominal value as indicated in 33033).
CHECK
Fig. a
CHECK
x
Fig. b
CHECK
y
Finally check the vertical bearing clearance (see Clearance Table 03301 Top and bottom end bearings to connecting rod).
98.7700
x
TIGHTENING ANGLE
5/ 5
2008
RT-flex96C
33032/A1
Maintenance
Connecting Rod
Inspection, Removal and Fitting of Bottom End Bearing
Tools:
2
2
4
1
1
1
1
2
2
2
2
2
1
1.
Key to Illustrations:
Working platforms
Working supports
Retaining pins
Device
Lifting beam
Suspension
Lifting support
Washers
Eye bolts (M64)
Eye bolts (M24)
Ropes with shackles (1060 mm)
Ropes with shackles (1200 mm)
Rope with shackle (1600 mm)
94142
94143
94323a
94326
94334a
94334b
94334c
94334d
94334e
94334f
94334g
94334h
94334i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Screw
Strap
Handle
Pin
Support
Screw
Bush
Spherical discs
AF Seating surface
H1 ... Lifting tackles
HZ Lifting tackle
Attention! Never turn the crankshaft as long as the pre-tensioning jacks are
mounted on the connecting rod studs!
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
Utilization of Working Platform and Ladder 33011.
1.1
H1
H2
94334f
6
3
11
10
12
6
014.301/06
1/ 8
1.09
33032/A1
Maintenance
RT-flex96C
1.2
I
H1
94334h
H2
94334b
94334a
94334d
14
94334h
13
94334b
I
014.303/06
6 94334c
2008
94334c
94334a
2/ 8
RT-flex96C
33032/A1
Maintenance
H3
H1
94334i
H1
94334c
94334e
94334c
94334h
94334g
94334i
15
H4
94334e
15
H4
H3
94334h
94334g
94334b
94334b
014.311/06
014.313/06
3/ 8
2008
33032/A1
Maintenance
RT-flex96C
H3
014.315/06
014.317/06
I
94334g
94334b
94334h
014.320/06
2008
4/ 8
RT-flex96C
33032/A1
Maintenance
1.3
GUIDE SHOE
AF
19
63 mm
21
20
19
018.037/09
20
17
18
16
0.10.3 mm
5/ 8
1.09
33032/A1
Maintenance
RT-flex96C
I
018.037/09
1.4
D
HZ
H6
94323a
014.321/06
H7
b
1.5
a
94326
94142
014.326/06
1.09
6/ 8
RT-flex96C
33032/A1
Maintenance
a
HZ
94326
d
c
94142
94326
a
HZ
c
94142
014.346/06
014.343/06
2.
Fitting
The fitting of bearing shell 10 and bearing cover 6 is carried out analogous to removal but in reverse sequence.
D
The running surfaces have to be lavishly smeared with clean bearing oil.
Attention! Always fit toggle lever 4 in such a way that its curvature stands upwards.
After completing the work all retaining pins 94323a must be removed without fail.
7/ 8
1.09
33032/A1
Maintenance
RT-flex96C
3.
For fitting a bearing shell to the bottom end bearing, the surface of the
crankpin must be in perfect condition.
While fitting a bearing shell pay attention to prevent dirt or foreign particles
from entering between the shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be free from any damage. Immediately before inserting the bearing shells they have to be wiped
with a slightly oily hand, so that a trace of oil is on them.
The bearing shell should be placed in the connecting rod head such that it protrudes by the same distance at both ends of the separating face.
x2
x1
Protrusion of a new
bottom end bearing shell:
x1 + x2 = approx. 0.56 0.64 mm
008.458/01
Remark: Above measuring checks must be carried out when fitting new bearing
shells. For this the bearing shells are placed in position the bearing cover fitted and
the nuts tightened by hand with a round bar.
Prior to final assembly smear the running surfaces lavishly with clean bearing oil.
Should, however, the engine have to be frequently turned after the fitting of the
bearing, or should a re-start of the engine not be immediately planned, 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, the
latter can be post-lubricated by means of a lubricating pump (see 33033).
1.09
8/ 8
RT-flex96C
33033/A1
Maintenance
Connecting Rod
Inspection, Removal and Fitting of Top End Bearing
Tools:
1
2
2
1
2
2
2
1
Working platform
Retaining pins
Roller supports
Carrying roller
Suspension straps
Wire rope slings with hooks
Eye bolts
Connecting flange
94142
94323a
94331
94332
94333a
94333b
94333c
94336
1
2
3
4
5
6
7
8
9
10
11
12
Crankshaft
Toggle lever
Connecting rod
Guide way
Crosshead pin
Nut
Connecting rod stud
Threaded hole
for eye bolt
Cylindrical pin
Bearing shell
Allen screw
Bearing cover
13
14
15
16
17
18
19
DL
HZ
H1...
OP
RC
Guide shoe
Guide segment
Bolt with nut
Supporting sheet
Piston rod foot
Platform
Spur-geared chain block
Oil pressure pipe
Lifting tackle
Lifting tackles
Lubricating pump
Eye bolt
Overview
1.
2.
3.
4.
5.
1.
1/9
3/9
5/9
7/9
9/9
A
Turn crank of the corresponding cylinder to B.D.C.
HZ
Loosen and remove all nuts 6 of connecting rod studs 7 to top end bearing
as instructed in 33031.
Loosen the screws fastening toggle
lever 2 of the crosshead lubrication
and piston cooling, and separate the
toggle lever from connecting rod 3.
6
94142
3
1
014.367/06
1/ 9
1.09
33033/A1
Maintenance
RT-flex96C
Take care that cylindrical pins 9 and connecting rod studs 7 slide out
through the bores without jamming!
Risk of accident! The piston may not be removed in this position without securing
the bearing cover against falling down.
13
94323a
018.037/09
12
5
9
7
15
13
94323a
RC
16
4
014.368/06
94331
1.09
2/ 9
94332
RT-flex96C
33033/A1
Maintenance
C
Turn the crank to max. 85_ after
T.D.C. as shown in Fig. C.
Install working platform 94142.
CHECK
94331
94142
014.370/06
2.
94331
H2
RC
H1
3
94332
014.375/06
3/ 9
1.09
33033/A1
Maintenance
RT-flex96C
2.1
H3
H2
H4
c
94331
10
3
014.376/06
F
2.2
H3
H2
H4
10
3
014.378/06
1.09
4/ 9
RT-flex96C
33033/A1
Maintenance
G
12
7
11
14
14
14
10
014.379/06
3.
Check whether the surface of the crosshead pin is in perfect condition before fitting
the bearing shell.
D
While fitting a bearing shell pay attention to prevent dirt or foreign particles
from entering between the shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be free from any damage. Immediately before inserting the bearing shell they have to be wiped with
a slightly oily hand, so that a trace of oil is on them.
The bearing shell should be placed in the connecting rod head such that it protrudes by the same distance at both ends of the separating face (Fig. H).
The tensioning of the connecting rod studs must be carried out as instructed in
33031.
When fitting the bearing shell, as well as the crosshead pin, pay attention not
to damage the white metal of the two guide segments 14 (Fig. G).
Attention! Always fit toggle lever 2 in such a way that its curvature stands upwards.
Retaining pins 94323a, roller supports 94331 and carrying roller 94332 must be
removed immediately after completing the work.
5/ 9
2008
33033/A1
Maintenance
RT-flex96C
H
3.1
x1
12
Proceed as described in section 3, however protrusion x1 + x2 must be measured prior to tension connecting rod studs 7.
x2
004.148/99
3.2
DL
2
EXHAUST SIDE
94336
OP
014.395/06
2008
6/ 9
RT-flex96C
33033/A1
Maintenance
4.
K
I
94333c
94333b
94333a
RC
12
17
012.131/04
L
Turn crank to B.D.C.
Loosen and remove all nuts 6 (Fig. A) to connecting
rod studs 7 (see 33031).
RC
12
014.380/06
7/ 9
2008
33033/A1
Maintenance
RT-flex96C
4.1
After opening platform 18, the bearing cover can further be transported by
means of spur-geared chain block 19 (see also 33012).
19
HZ
H5
H5
a
2
18
3
1
d
12
014.392/06
014.391/06
2008
RC
12
8/ 9
RT-flex96C
33033/A1
Maintenance
4.2
HZ
H5
H5
a
RC
12
d
5
3
1
014.394/06
014.393/06
5.
Before fitting smear the running surfaces lavishly with clean bearing oil.
Tightening of the nuts for the connection of crosshead pin 5 and piston rod foot
17, see 34031.
9/ 9
2008
RT-flex96C
33033/A2
Maintenance
Connecting Rod
Inspection, Removal and Fitting of Top End Bearing
Tools:
1
4
1
2
1
1
Working platform
Retaining pins
Lifting plate
Eye bolts
Holder
Connecting flange
94142
94323a
94324
94334e
94335
94336
1
2
3
4
5
6
7
8
9
10
11
Crankshaft
Toggle lever
Connecting rod
Guide way
Crosshead pin
Nut
Connecting rod stud
Cylindrical pin
Bearing shell
Allen screw
Bearing cover
12
13
14
15
16
17
DL
HZ
H1...
OP
Guide shoe
Guide segment
Waisted stud
Nut
Platform
Spur-geared chain block
Oil pressure pipe
Lifting tackle
Lifting tackles
Lubricating pump
Overview
1.
2.
3.
4.
5.
1.
1/8
3/8
5/8
7/8
8/8
A
Turn crank of the corresponding cylinder to B.D.C.
Install working platform 94142.
Loosen and remove all nuts 6 (Fig.
G) of connecting rod studs 7 to top
end bearing as instructed in 33031.
Screw in eye bolts 94334e on either
side of the connecting rod head.
H1
H2
94334e
94334e
94142
Connect lifting tackles H1 and H2 (lifting capacity 4000 kg each) with eye
bolts and column straps.
014.433/06
1/ 8
1.09
33033/A2
Maintenance
RT-flex96C
II
14 94335
15
11
II
94324
014.434/06
12
94323a
018.037/09
H1
H2
014.435/06
1.09
2/ 8
RT-flex96C
33033/A2
Maintenance
2.
D
HZ
2
H2
014.436/06
E
2.1
H4
c
Lift the bearing shell out of the crankcase using ropes c, d and lifting
tackle H4.
014.437/06
3/ 8
1.09
33033/A2
Maintenance
RT-flex96C
F
2.2
Lift the bearing shell out of the crankcase using ropes c, d and lifting
tackle H4.
014.438/06
G
11
6
7
13
13
10
13
9
001.688/97
1.09
4/ 8
RT-flex96C
Maintenance
3.
33033/A2
with Piston Removed
Check whether the surface of the crosshead pin is in perfect condition before fitting
the bearing shell.
D
While fitting a bearing shell pay attention to prevent dirt or foreign particles
from entering between the shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be free from any damage. Immediately before inserting the bearing shell they have to be wiped with
a slightly oily hand, so that a trace of oil is on them.
The bearing shell should be placed in the connecting rod head such that it protrudes by the same distance at both ends of the separating face (Fig. H).
The tensioning of the connecting rod studs must be carried out as instructed in
33031.
When fitting the bearing shell, as well as the crosshead pin, pay attention not
to damage the white metal of the two guide segments 13 (Fig. G).
Attention! Always fit toggle lever 2 in such a way that its curvature stands upwards.
5/ 8
2008
33033/A2
Maintenance
RT-flex96C
H
3.1
x1
11
Proceed as described in section 3, however protrusion x1 + x2 must be measured prior to tension connecting rod studs 7.
x2
004.148/99
3.2
DL
2
EXHAUST SIDE
94336
OP
014.395/06
2008
6/ 8
RT-flex96C
33033/A2
Maintenance
4.
4.1
17
HZ
H5
a
H5
b
c
RC
11
2
5
16
3
1
d
11
014.441/06
014.442/06
7/ 8
2008
33033/A2
Maintenance
RT-flex96C
4.2
HZ
H5
H5
RC
11
5
3
1
11
014.443/06
5.
014.444/06
2008
Before fitting smear the running surfaces lavishly with clean bearing oil.
8/ 8
RT-flex96C
33034/A1
Maintenance
Connecting Rod
Removal and Fitting
Tools:
1
2
1
2
1
1.
Working platform
Retaining pins
Lifting device
Roller supports
Carrying roller
Key to Illustrations:
94142
94323a
94330
94331
94332
1
2
3
4
5
6
7
8
9
10
Crankshaft
Toggle lever
Connecting rod
Support
Guide way
Crosshead pin
Bearing cover
Guide shoe
Nut
Guide segment
11
12
13
14
15
Waisted stud
Suspension beam
Spur-geared chain block
Upper platform
Lower platform
HZ Lifting tackle
H1... Lifting tackles
RC Eye bolt
General
A connecting rod can be removed from or fitted to the engine without removing the
piston and crosshead pin.
D
The bearing cover for the bottom end bearing must be removed (see 33032).
Risk of accident! Should the piston have been removed prior to the removal of the
connecting rod then lifting plate 94324 for the crosshead pin (see 33262) must be
installed or bearing cover 7 secured by steel ropes. In this way the bearing cover of
the top end bearing is prevented from turning around and dropping down after lowering the connecting rod.
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
Utilization of Working Platform and Ladder 33011.
2.
Removal
Turn crank of the corresponding cylinder to B.D.C.
HZ
Loosen and remove all nuts 9 of connecting rod studs 7 to top end bearing
as instructed in 33031.
94142
3
1
1/ 8
1.09
33034/A1
Maintenance
RT-flex96C
7
9
11
10
10
10
3
014.379/06
Fit two retaining pins 94323a (pay attention to paragraph 1.3 in 33032) and
roller supports 94331, as well as carrying roller 94332 in the same manner as
described for Inspection, Removing and Fitting of Top End Bearing 33033.
Turn crankshaft carefully max. 85_ after T.D.C. towards exhaust side (Fig.
C). Follow instructions in 33033.
Attach lifting tackle H1 and rope a (lifting capacity 3000 kg each) and sling the
latter around the connecting rod (Fig. C).
Tighten rope a till the carrying roller is slightly lifted off the roller support.
Dismantle carrying roller 94332.
Attach lifting tackle H2 and rope b (lifting capacity 4000 kg each), screwing
eye bolt RC into the connecting rod head. Tighten rope b and remove rope
a.
Lower the connecting rod head till column opening, using rope b (Fig. D).
D
D
7
6
8
94331
HZ
b
94323a
2
RC
H1
94332
014.416/06
014.415/06
1.09
2/ 8
RT-flex96C
33034/A1
Maintenance
H4
Remove rope b.
H3
94330
014.417/06
H4
H5
Remove rope c.
RC
H3
94330
014.418/06
3/ 8
1.09
33034/A1
Maintenance
RT-flex96C
G
Attach lifting tackle HZ (lifting capacity 3000 kg) and connect it to lifting
device 94330.
HZ
014.420/06
H
2.1
H4
H6
12
d
RC
HZ
014.421/06
1.09
4/ 8
RT-flex96C
33034/A1
Maintenance
H5
H7 H6
PROTECTION
12
014.422/06
K
Remove rope e.
H5
H7 H6
13
RC
014.423/06
5/ 8
1.09
33034/A1
Maintenance
RT-flex96C
L
Move connecting rod 3 in such a position that it can be taken over by spurgeared chain block 13.
13
3
014.424/06
M
2.2
H5
14
12
H6
15
d
RC
HZ
014.425/06
1.09
6/ 8
RT-flex96C
33034/A1
Maintenance
N
Attach lifting tackle H7 (lifting capacity
4000 kg) to the inner hole on suspension beam 12 and connect it to lifting
device 94330.
13
H5
f
PROTECTION
H7
12
15
H6
RC
94330
014.430/06
O
Remove rope e.
H5
014.431/06
7/ 8
1.09
33034/A1
Maintenance
RT-flex96C
P
Move connecting rod 3 in such a position that it can be taken over by spurgeared chain block 13.
13
014.432/06
3.
Fitting
Fitting the connecting rod is carried out analogously to the removal but in reverse
sequence, whereby attention must be paid to instructions 33031 to 33033.
For the assembly bearings and bearing pins must be in perfect condition. They
must be smeared lavishly with fresh bearing oil.
Remark: When fitting the crosshead pin, pay attention not to damage the two
guide segments 10 to the crosshead pin (Fig. B) if they are already fitted. The two
white metal lined guide segments are fitted to the front sides of the connecting rod
head.
Attention! Always fit toggle lever 2 in such a way that its curvature stands upwards.
After completing the work retaining pins 94323a, roller support 94331 and carrying
roller 94332 must be removed immediately.
1.09
8/ 8
RT-flex96C
33261/A1
Maintenance
Crosshead
Checking the Clearances and Fitting the Guide Shoes
Tools:
1
1
1
1
1
1
1
1
1
1
1
1.
Feeler gauge
HYTORC torque machine
Reaction arm
Socket wrench insert
HP hose
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
Key to Illustrations:
94238
94339
94339a
94339b
94339c
94931
94932
94932a
94934a
94934e
94935
1
2
3
4
5
Crosshead pin
Guide shoe
Retaining cover
Guide way in engine column
Top end bearing
of connecting rod
6
7
8
9
Guide rail
Middle part
Screw
Screw
EV Relief valve
General
On the occasion of an overhaul or when a crosshead has been removed, the opportunity should be taken to measure the various running clearances and to
compare them with the values found in the Clearance Table 03301 Crosshead
Guide, so that possible wear may be discovered.
A
4
2
4
2
7
3
4
3
9
6
4
FUEL SIDE
1/ 4
4
000.784/99
2008
33261/A1
Maintenance
RT-flex96C
Clearance
Clearance
Clearance
90 BEFORE OR
AFTER T.D.C.
013.784/06
2008
2/ 4
RT-flex96C
33261/A1
Maintenance
3.
94339
2 9
94339b
TIGHTENING
94339
94339a
001.509/97
94339c
94339a
LOOSENING
94339c
94932a
94934e
94932
94934a
94935
001.509/97
001.509/97
94931 EV
3/ 4
2008
33261/A1
Maintenance
RT-flex96C
Check with feeler gauge 94238 that there is no clearance between the surfaces of
guide shoe 2 and middle part 7.
D
2008
4/ 4
RT-flex96C
33262/A1
Maintenance
Crosshead
Removal and Fitting of a Crosshead Pin
Tools:
1
2
1
2
2
2
1.
Key to Illustrations:
Working platform
Retaining pins
Lifting plate
Holders
Guide pieces
Roller supports
94142
94323a
94324
94325
94325a
94331
1
2
3
4
5
6
7
8
9
10
Crosshead pin
Guide shoe
Retaining cover
Screw
Guide way
Guide rail
Middle part
Screw
Crank
Neighbouring cylinder
11
12
13
14
15
Suspension girder
Support
Upper platform
Lower platform
Spur-geared chain block
HZ Lifting tackle
H1... Lifting tackles
RC Eye bolt
General
If a crosshead pin has to be removed, the piston of the cylinder concerned must
first be pulled out (see 34031).
In addition, the covers for top & bottom end bearings and the connecting rod must
be removed from the crankcase. Follow the instructions in 33032 to 33034.
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
Utilization of Working Platform and Ladder 33011.
2.
Preparation
A
D
94323a
94331
94142
014.180/06
1/ 7
1.09
33262/A1
Maintenance
RT-flex96C
B
CRANK ANGLE
7 Cyl.
ENGINE
6 Cyl.
NEIGHBOURING CYL.
AFTER T.D.C.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
1
2
3
4
5
6
2
1
2
3
4
5
270_
90_
90_
270_
90_
90_
1
2
3
4
5
6
7
2
1
2
5
4
5
6
270_
90_
90_
90_
270_
90_
90_
8 Cyl.
CRANK ANGLE
9 Cyl.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
1
2
3
4
5
6
7
8
2
1
2
5
6
5
6
7
270_
90_
90_
90_
90_
270_
90_
90_
1
2
3
4
5
6
7
8
9
2
3
4
3
4
5
8
9
8
90_
90_
270_
90_
90_
90_
90_
90_
270_
10 Cyl.
CRANK ANGLE
CRANK ANGLE
11 Cyl.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
1
2
3
4
5
6
7
8
9
10
2
1
2
3
4
5
6
7
8
9
270_
90_
90_
90_
90_
90_
90_
90_
90_
90_
CRANK ANGLE
2
1
2
3
6
7
8
9
8
9
10
270_
90_
90_
90_
90_
90_
90_
270_
90_
90_
90_
CRANK ANGLE
1
2
3
4
5
6
7
8
9
10
11
14 Cyl.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
1
2
3
4
5
6
7
8
9
10
11
12
2
1
2
3
4
5
8
7
8
11
10
11
270_
90_
90_
90_
90_
90_
270_
90_
90_
270_
90_
90_
1
2
3
4
5
6
7
8
9
10
11
12
13
14
2
1
2
5
4
7
6
9
8
9
12
13
12
13
90_
270_
270_
270_
90_
270_
90_
90_
90_
270_
270_
90_
270_
270_
12 Cyl.
2008
CRANK ANGLE
2/ 7
CRANK ANGLE
RT-flex96C
33262/A1
Maintenance
3.
Removal
3.1
I-I
b
HZ
94325a
94324
RC
94325a
RC
2
7
2
9
1
HZ
HZ
5
10
014.511/06
3/ 7
2008
33262/A1
Maintenance
RT-flex96C
11
12
REMOVAL OUTSIDE OF
AREA OF SUPPLY UNIT
REMOVAL BELOW
SUPPLY UNIT
H1
12
b
11
H1
014.515/06
014.516/06
F
5
5
2
7
4
2
5
8
6
5
014.517/06
FUEL SIDE
2008
4/ 7
RT-flex96C
33262/A1
Maintenance
3.2
G
I
5 94325
4
3
10
014.518/06
5/ 7
2008
33262/A1
Maintenance
RT-flex96C
3.3
H
REMOVAL OUTSIDE OF
AREA OF SUPPLY UNIT
REMOVAL BELOW
SUPPLY UNIT
15
HZ
11
H2
12
13
12
e
f
1
11
H2
014.519/06
2008
e
f
94324
H2
14
014.521/06
6/ 7
014.522/06
RT-flex96C
Maintenance
33262/A1
4.
Fitting
Fitting procedure is analogous to the removal, but in reverse sequence.
D
Fit only crosshead pins which have a perfect, undamaged running surface.
Before fitting the crosshead pin clean all guide and bearing surfaces carefully
and smear them lavishly with bearing oil.
Attention! Always fit toggle lever to crosshead lubrication and piston cooling in
such a way that its curvature stands upwards.
CHECK
After completing the work check that all tools and foreign bodies are removed from
the crankcase, and that all the screwed fastenings are tightened to specification
and locked accordingly.
Check crosshead clearances according to Clearance Table 03301 Crosshead
Guide.
Check with lubricating oil pump running that crosshead and connecting rod bottom
end bearings are lavishly supplied with oil.
7/ 7
2008
RT-flex96C
34031/A1
Maintenance
Piston
Removal and Fitting
Tools:
1
2
1
2
2
1
2
1
1
1
1
1
1
2
1
Key to Illustrations:
94338
94340
94341(a)
94341c
94341d
94342a(b)
94345
94345d
94348
94350
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
Piston rod
Crosshead pin
Waisted stud
Nut
Vent screw
Pin
Piston
Platform support
Support
Hinged cover
Piston rod gland
12
13
14
15
16
Screw connection
Centring pin
Compression shim
Cylinder liner
Slotted countersunkhead screw
17 Protection
KO Slot
RS Round bar
SA Gap
Overview
1.
2.
3.
4.
5.
6.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening the waisted studs of piston foot fastening . . . . .
Tensioning the waisted studs of piston foot fastening . . . .
Removal of piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/8
1/8
3/8
4/8
7/8
8/8
General
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
Utilization of Working Platform and Ladder 33011.
General Application Instructions 94034 for hydraulic pre-tensioning jacks.
D
The piston may not be transported with built-on piston rod gland (gland for short).
Attention! The supporting device 94350 can be used for piston overhauling
work at calm sea only, however, in no case this may serve as storage place
during the voyage!
Moreover, always bear in mind, that the passage between engine and supporting
device is limited (e.g. as possible escape route) on the platform.
2.
1/ 8
2011-05
34031/A1
Maintenance
RT-flex96C
CHECK
Release pressure to zero at the hydraulic unit and then remove pre-tensioning
jacks and the nuts.
D
The same procedure is to be applied for loosening the other two waisted
studs.
94340
13
94340
3
4
14
94935a
94932a
94934a
94942
94935
94935a
008.480/01
2008
2/ 8
RT-flex96C
34031/A1
Maintenance
B
Clean the threads of waisted studs 3
and the area around nuts 4 (Fig. A).
6
7
CHECK
Mark position of nuts to seating surface with a felt tipped pen (Fig. a).
4
RS
KO
SA
012.167/04
Fig. a
Attention should be paid to ensure that pins 6 always protrude slightly compared with pistons 7 on
the pre-tensioning jacks!
x
Fig. b
CHECK
3/ 8
2008
98.7700
TIGHTENING
ANGLE
34031/A1
Maintenance
RT-flex96C
4.
Removal of piston
4.1
94341c
94341d
II
II
x
II - II
014.686/06
94341
16
4.2
WCH00439
FREE
END
17
2011-05
4/ 8
RT-flex96C
34031/A1
Maintenance
4.3
Removal of piston
Remark: Loosen and remove all screws for the screwing gland / cylinder jacket
(see 23031).
Remove antipolishing ring as described in 21242.
Screw fasten both distance holders 94345 to the piston foot (Fig. E).
Turn crank to T.D.C. whereby the gland is pushed out of its seating in the cylinder jacket by distance holders 94345 (Fig. F).
Use tap 94348 to clean threaded holes of combustion residue in the piston
crown.
Mount suspension device 94341(a) to the piston crown.
D
Before pulling the piston out, the crosshead pin and the top end bearing must
be protected, so that entry of dirt into the top end bearing is absolutely prevented.
94341(a)
FUEL
SIDE
94341(a)
94350
11
8
11
94345
94345
017.876/08
5/ 8
2011-05
34031/A1
Maintenance
RT-flex96C
9
12
11
10
94350
8
017.877/08
2011-05
6/ 8
RT-flex96C
Maintenance
34031/A1
5.
Determine the height of the piston ring grooves (see Clearance Table 03301
Piston and piston rings).
Clean piston rings and measure them.
Remarks: For refitting of used and new piston rings, follow strictly instructions in
34251.
CHECK
When refitting used piston rings be sure to fit them in the same grooves
as before.
Fit the piston rings in such a manner that their marking TOP is on top.
Gland and both distance holders 94345 must be mounted on the piston rod
(see 23031).
Suspension device 94341(a) must be fastened to the top of the piston crown.
Remarks: 2-part insertion funnel 94342b has the advantage that a half can be removed, if required.
H
94342a(b)
15
003.351/00
7/ 8
2011-05
34031/A1
Maintenance
RT-flex96C
5.1
Fitting
Slightly lift piston by crane. Loosen screw connection 12 of supports 9 (Fig. G) and push both supports outwards. Then lift the piston including gland
11 so far that the two hinged covers 10 can be
turned up.
94342a(b)
Slowly lower the piston further till its piston rod foot
has arrived just above the crosshead pin. While
one person directs the further lowering of the piston from the top, another directs the piston rod
progress from the engine interior and how it must
be turned to guide the piston rod foot, without jamming, into the centring pins 13 (Fig. A) in the
crosshead pin.
94345
Slacken the crane rope a bit and remove the suspension device.
Turn piston to B.D.C. and direct the insertion of the
gland into its seating bore in the cylinder jacket
(see 23031).
Loosen and remove both distance holders from
the piston foot.
Firmly tighten all screws fastening the gland housing.
014.039/06
Tension the waisted studs for the piston foot fastening as described above.
Remark: Refit antipolishing ring as described in
21242 and reinstall protections 17.
6.
Leak test
A leak test must be carried out after every fitting of a piston in the cylinder. For this,
start the bearing lubrication pump and set the bearing lubricating pressure. Check
through the scavenge space on the fuel side in the cylinder jacket (piston underside) whether cylinder liner running surface and piston rod remain dry.
Any increase in the dirty oil level in the scavenge air space may be caused by a
faulty O-ring in the piston.
2011-05
8/ 8
RT-flex96C
Maintenance
34032/A1
Piston
Changing the Compression Shims
Tools:
Key to Illustrations:
4 Supports
2 Eye bolts
1.
94347
1 Ring, 2-part
2 Piston rod
3 Piston rod foot
4 Crosshead pin
5 Piston
6 Compression shim
5
94347
I
1
Loosen the nuts of the waisted studs for the screwing of piston rod foot 3 and crosshead pin 4, as described in 34031.
Open the door to the piston underside of the corresponding cylinder on fuel side.
Fasten four supports 94347 to the 2-part ring 1 of
the gland housing as shown in the figure.
CHECK
2
3
For fitting the new compression shim proceed in reverse sequence to the removal.
008.533/01
I-I
94347
1
008.534/01
1/ 1
2008
RT-flex96C
34033/A1
Maintenance
Piston
Dismantling and Assembling
Tools:
1
4
1
2
2
1
1
1
2
4
1
1
Key to Illustrations:
Suspension device
Pre-tensioning jacks
Piston supporting device
Jacking screws
Jacking screws
Hydr. distributor
Connection block
HP hose
HP hoses
HP hoses
Hydraulic unit
Torque wrench
94341(a)
94346
94350
94363
94364
94934a
94934c
94935
94935a
94935b
94942
1
2
2a
3
4
5
6
7
8
9
10
11
12
Piston crown
Spraying plate with oil pipe
Nozzle to spraying plate
Vent screw
Piston
Cylinder
Nut
Waisted stud
Piston rod
Piston skirt
Rubbing ring
Centring pin
Elastic screw
13
14
15
16
17
18
Locating pin
Locating pin
Waisted screw
O-ring
O-ring
O-ring
BN
EV
KO
RS
SA
Limiting groove
Relief valve
Slot
Round bar
Gap
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening the waisted studs of piston crown . . . . . . . . . . . .
Tensioning the waisted studs of piston crown . . . . . . . . . . .
Dismantling of a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling of a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/6
2/6
3/6
4/6
6/6
General
Should the dismantling of a piston become necessary (cleaning the cooling chamber, reconditioning the ring grooves etc.), then this can be carried out as described
below. For this purpose the piston is to be placed in the piston supporting device
94350 according to 34031.
Attention! When dismantling or assembling a piston take particular care that the
nozzles to spraying plate 2a are not damaged.
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
General Application Instructions 94034 for hydraulic pre-tensioning jacks.
1/ 6
2008
34033/A1
Maintenance
RT-flex96C
2.
A
Clean the threads of waisted studs 7 and the
area around nuts 6.
94346
3
I-I
94934c
94935b
94346
94935a
94932a
94934a
017.878/08
94935
2008
2/ 6
94942
RT-flex96C
34033/A1
Maintenance
LOOSENING
BN
x
CHECK
4
Mark position of nuts to seating surface with a felt tipped pen (Fig. a).
RS
KO
SA
KO
TENSIONING
SEQUENCE
Fig. a
Fig. b
y
x
y
CHECK
TIGHTENING
ANGLE
011.675/04
3/ 6
2008
34033/A1
Maintenance
RT-flex96C
4.
Dismantling of a piston
Insert both jacking screws 94363 into the two opposite bores for centring pins
11 in the piston rod head (Fig. G), and drive them in till they press against the
centring pins (Fig. E).
Equally tighten the two jacking screws in small steps, till the piston crown is
separated from the piston rod.
Lift piston crown 1 by crane and take particular care not to damage nozzles 2a
of spraying plate 2.
Remove both jacking screws from piston rod head.
Following the removal of piston crown separate piston skirt 9 from piston rod 8 as
described below:
Loosen and remove both elastic screws 12 (Fig. G).
Using two jacking screws 94364 (Fig. F) the piston skirt can be separated
from the piston rod.
D
While raising the piston skirt pay attention that locating pin 13 does not jam.
94341(a)
1
2a
8
SEPARATING OF
PISTON CROWN
SEPARATING OF
PISTON SKIRT
1
2
94364
2
11
8
94363
017.879/08
2008
4/ 6
RT-flex96C
34033/A1
Maintenance
I-I
II - II
V
1
2a
IV
15
II
II
16
13
9
10
17
14
V
IV
I
FUEL SIDE
6
7
IV - IV
1
8
11
9
8
17
V
III
1
12
III
8
6
7
014.274/06
5/ 6
2008
34033/A1
Maintenance
RT-flex96C
5.
Assembling of a piston
For assembling the piston the following points must be observed:
CHECK
Whenever possible always use new O-rings, they must conform in dimensions and quality to our specifications (see 03701).
All cylindrical guide portions and O-rings must be smeared with oil before
the assembly.
Attention must be paid to locating pin 13 when assembling piston skirt 9 with
piston rod 8.
201007
For the assembly of piston crown 1 with piston rod 8 make sure that the two
centring pins 11 (Fig. G), serving also as guides, mate with the corresponding bores in the piston skirt 9 and the piston rod.
6/ 6
RT-flex96C
Maintenance
34034/A1
Piston
Checking Piston Top Surface
Tools:
1 Feeler gauge
1 Template
1 Template
94122
94366
94366a
CHECK
Every time a piston is pulled the piston top surface contour must be checked with
the checking template 94366 and with feeler gauge 94122. The template is placed
on the topmost piston ring and rotated around the piston axis (see Fig. A).
D
Where burn scars are only slight it is sufficient to grind them over and to
smooth sharp-edged zones with emery cloth. Where, however, burn scars exceed x = 10 mm the original material thickness must be restored by surface
welding. This entails the removal of the piston crown.
Before re-starting the engine, the reason for such heavy burns should be established. The causes must be remedied.
Causes of heavy burn scars may be:
A
94366
Poor combustion
Worn nozzles
PISTON RING
003.321/00
94366a
003.321/00
1/ 1
2008
RT-flex96C
34251/A1
Maintenance
Piston Rings
Checking Wear of Piston Rings and Ring Grooves
Tools:
Key to Illustration:
1 Inside micrometer
1 Feeler gauge
1 Piston ring tensioning device
94101
94122
94338
1 Equipment case
with instruments for
measuring chrome layers
1 Micrometer (030 mm)
1 Calliper gauge
94356
1
2
3
4
Piston ring
Cylinder liner
Piston head
Claw
94357
Overview
1.
2.
3.
4.
5.
6.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determine wear rate of piston rings . . . . . . . . . . . . . . . . . . . . .
Measuring piston ring grooves . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage and handling of piston rings . . . . . . . . . . . . . . . . . . . .
1/7
1/7
4/7
6/7
7/7
7/7
General
For judging and evaluating the condition of cylinder liner, piston and piston rings
the following guidelines serve for a condition-based Maintenance for piston and
cylinder liner overhaul.
Wear rates strongly depend on operational factors, such as fuel in use, engine load
profile, ambient conditions etc.
By visual inspections, critical conditions of cylinder liners and piston rings can be
detected at an early stage. Further information to monitor the cylinder liner and piston ring conditions are given in the Operating Manual 07501 Lubricating Oils.
The information regarding measuring piston ring grooves helps to define if the
wear on piston ring grooves is within the given limits or if the piston head must be
reconditioned. For the maximum wear data see Clearance Table 03301 Piston
and Piston Rings.
2.
1/ 7
2013-08
34251/A1
Maintenance
RT-flex96C
2.1
RECOMMENDED
MINIMUM
P9
1
P1
P9
P1
94356
P7
P3
2
P5
WCH01145
2.2
P5
Wear rate
The chrome-ceramic coating is a lifetime coating. However, the actual wear depends on operating conditions. When during a piston underside inspection a piston ring with a partially worn chrome-ceramic coating is found, we recommend
overhauling the unit at next opportunity (Fig. B).
With regular done measuring you can determine the specific wear rate for each
piston ring.
The piston rings can still be used, if the remaining chrome-ceramic coating is
above the following limits:
2013-08
2/ 7
RT-flex96C
34251/A1
Maintenance
2.3
Lifetime calculation
Calculate the wear rate and the remaining lifetime of a piston ring.
Use the formula below to calculate the wear rate:
WR = (D1D2) x 1000
T2T1
WR = Wear rate [mm/1000 h]
T2 = Actual running hours [h]
T1 = Running hours at previous measurement [h]
D2 = Actual coating thickness [mm]
D1 = Coating thickness at previous measurement [mm]
Example for wear rate calculation:
D1
D2
T1
T2
WR
0.382
0.367
0 (new)
1500
0.01
0.351
0.340
3500
5000
0.0073
Use the formula below to calculate the remaining piston ring lifetime according to
the latest condition setting:
LT =
D2
Dmin
T1
T2
WR
LT
0.382
0.367
0.05
0 (new)
1500
0.01
31700
0.351
0.340
0.05
3500
5000
0.007333
39545
3/ 7
2013-08
34251/A1
Maintenance
RT-flex96C
3.
3.1
Check all dimensions and record them (see Clearance Table 03301 Piston and
piston rings). These records are important for later evaluation of the running gear.
They should encompass all dimensions, the date of overhaul and operating hours
of the various components and of the engine itself.
1
3
3
1
x1
3
1
(C2)
x2
A
94122
WCH02244
WEAR STEP ON
CHROMIUM LAYER (C3)
POSSIBLE WEAR
SHAPE ON GROOVE
1
3
2013-08
WCH02244
4/ 7
RT-flex96C
34251/A1
Maintenance
WCH02244
94357
POSSIBLE WEAR
SHAPE ON GROOVE
Measuring method with a piece of a piston ring:
Measure the thickness of piece of a piston ring (1).
Place piece of piston ring into the piston ring groove.
Measure gap x2 between the face of piston ring and groove with feeler gauge
94122.
Evaluate the piston ring clearance with the following data:
CL = GH RT (mm)
CL =
CLearance
GH =
RT =
x2
E
3
(1)
94122
WCH02244
If the clearance at point A and/or B exceeds the permitted value, the piston head
has to be reconditioned. For the maximum wear data see Clearance Table 03301
Piston and Piston Rings.
A piston head with clearances close to the maximum value may not be further used
as the expected remaining lifetime is too short.
5/ 7
2013-08
34251/A1
Maintenance
RT-flex96C
4.
1
4
94338
017.681/08
2013-08
6/ 7
RT-flex96C
34251/A1
Maintenance
4.
When reusing piston rings, only rings in perfect condition may be fitted, however in the same position and groove as removed.
Ring type
Uppermost piston ring a
1 x SCP1CC 20
Coating / material
Application
chrome-ceramic
coated
chrome-ceramic
coated
1 x GTP1CC 20 (GasTight) 1
Piston rings b d
3 x SCP2CC 20
3 x SCP2CC20 1
1
Additional execution
I-I
G
TOP
5.
CHROMIUM
PLATING
CHROMIUM
PLATING
CHROMIUM
PLATING
CHROMIUM
PLATING
r2
r2
TOP
I
r2
r2
GasTight
003.831/96
7/ 7
2013-08
RT-flex96C
Maintenance
Group4
Group 4
Driving Wheels
Checking the Running and Backlash Clearances and Condition of Teeth . . . . 41031/A1
Removal and Fitting of Intermediate Wheel (610, 12 & 14 Cyl. Engines) . . . 41032/A1
Removal and Fitting of Intermediate Wheel (11 Cylinder Engines) . . . . . . . . . . 41032/A2
Replacing the Gear Wheel on Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41033/A1
Replacing the Gear Wheel on Crankshaft (Single Wall Column) . . . . . . . . . . . . 41033/A2
Shut-off Valve for Starting Air: Cleaning and Function Check . . . . . . . . . . . . . . . . . 43251/A1
1/ 2
RTflex96C / MM / 2008
RT-flex96C
41031/A1
Maintenance
Driving Wheels
Checking the Running and Backlash Clearances and Condition of Teeth
Tools:
1
1
1
1
1.
Feeler gauge
Micrometer
Dial gauge
Lead wire 1.5 mm
Key to Illustrations:
94122
06 Tooth profile
a, b, c Lead wires
TF Driving flanks
General
Gear wheels of new engines have to be checked visually during the running-in period after about 12 operating hours. The same applies to old engines which have
been equipped with new gear wheels.
2.
Check
Rotate crankshaft with the turning gear until all the teeth have been inspected.
Check with running lubricating oil pump, whether all the spray nozzles are delivering oil freely.
Check whether all the screws are correctly locked, and whether any irregularities can be detected.
After the running-in period check the gear wheels periodically every three
months in the manner described above. Should in this time faults appear, then
these can in certain cases be remedied by an experienced engineer.
3.
Should noises be heard in the region of the gear train, search for its cause.
Replace defective gear wheels as soon as ever possible, to prevent damage
to the mating gear wheels.
When the gear wheels have run well for an initial running period of 60008000
hours the above-mentioned inspection may be carried out annually.
For the checking of clearances and tooth impressions the tie rods and the
waisted studs of the main bearings must be tightened.
3.1
3.2
1/ 2
2008
41031/A1
Maintenance
RT-flex96C
Checking the Running and Backlash Clearances as well as Condition of the Teeth
15 mm
=
=
15 mm
3.3
a1
a3
b1
b3
b
c
000.653/93
The admissible deviation of tooth profile parallelity amounts to max. 0.2o/oo across the
width of the tooth.
B
0
1
2
3
4
6
...
...
...
000.653/93
4.
f1
f2
TF
000.653/93
2008
2/ 2
RT-flex96C
41032/A1
Maintenance
Driving Wheels
Removal and Fitting of Intermediate Wheel
Tools:
1 Feeler gauge
6 Adjusting devices
Withdrawing device
for taper pins
94122
94410
1
2
3
4
5
6
7
8
9
9a
10
11
Intermediate wheel
Cover
Cover
Pipe bend
Support
Gear wheel on crankshaft
Waisted screw
Cover
Screw plug for taper pin
Screw plug
Taper pin
Bearing
12
13
14
15
16
17
18
19
20
Bearing journal
Locking strap
Double column
Wheel hub
Gear rim
Lubricating oil pipe
Self-locking nut
Strap
Suspension beam
HZ Lifting tackle
H1... Lifting tackles
Overview
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of intermediate wheel . . . . . . . . . . . . . . . . . . . . . . .
Replacement of a gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.
2.
3.
4.
5.
1.
1/6
2/6
4/6
5/6
6/6
General
The turning gear must be engaged.
Risk of accident! Precautions must be taken that, while removal work is in progress, the running gear can on no account be put into motion.
Remark: Pay attention to General Guidelines for Lifting Tools 00121.
014.066/06
1/ 6
2008
41032/A1
Maintenance
RT-flex96C
2.
Removal
B
6 and 7 cylinder engines:
Fasten lifting tackle HZ to pipe bend
4 and connect it to cover 3.
Fasten lifting tackle H1 (lifting capacity 4000 kg) to strap 19 and connect it
to cover 3.
Loosen and remove the cover.
I
HZ
3
H1
H1
19
4
HZ
014.069/06
C
810, 12 and 14 cylinder engines:
Fasten lifting tackle HZ to support 5
and connect it to cover 3.
Fasten lifting tackle H1 (lifting capacity 4000 kg) to suspension beam 20
and connect it to cover 3.
Loosen and remove the cover.
I
HZ
H1
20
H1
HZ
014.068/06
2008
2/ 6
RT-flex96C
41032/A1
Maintenance
D
Remove lubricating oil pipes 17 to intermediate wheel 1, where necessary.
Fasten lifting tackle H2 (lifting capacity 4000
kg) to cover 2.
Connect one rope a (lifting capacity 4000
kg) with intermediate wheel and lifting tackle
H2.
2
a
H2
012.183/04
II - II
16
15
11 13
II
17
14
7
8
001.639/97
III
III
II
9a
III - III
12
9a
7
8
9
10
012.185/04
001.639/97
3/ 6
2008
41032/A1
Maintenance
RT-flex96C
H2
b
H1
H3
6
012.184/04
3.
Fitting
Fitting the intermediate wheel is carried out analogously to the removal but in
reverse sequence, whereby attention must be paid as follows:
Remark: When fitting bearings 11 they must first be lavishly smeared with bearing
oil. Both bearings are basically equal, they may, however, only be refitted in their
original place, as their position has been dowelled with taper pins 10 when building
the engine.
D
Fit intermediate wheel so that marking DRIVING END appears when viewed
from the driving end of the engine.
Intermediate wheel may be fitted arbitrarily with respect to the tooth position.
2008
4/ 6
RT-flex96C
41032/A1
Maintenance
Screw in the remaining waisted screws and tighten them all slightly and
evenly by hand with a wrench.
In this position mark the screws with a line and tighten them crosswise until an
angle of 50 is obtained.
CHECK
As a safeguard check the tooth backlash between the gear wheels (see also Clearance Table 03301 Driving Wheels for Supply Unit).
Fit screw plugs 9 with LOCTITE No. 0222 and screw them in till the stop at the
taper pins.
Lock all waisted screws 7 in pairs with locking wire.
4.
D
CHECK
After a new adjustment of the intermediate wheel the tooth backlash (see Clearance Table 03301 Driving Wheels for Supply Unit), as well as the tooth flank contact pattern have to be checked (see 41031).
If a new adjustment of the bearings is required, the pin holes pre-bored in the
column must be used.
II - II
14
14
I
II
I
8
94410
II
11
94410
012.186/04
5/ 6
001.639/97
2008
41032/A1
Maintenance
5.
RT-flex96C
The replacement of a damaged 2-part gear wheel may only be done in exchange for a complete gear wheel i.e. gear rim 16 must be screw fastened to
wheel hub 15 and the bearing journal fitted.
This is necessary as the final machining of the gear teeth has been carried out
in this mounted condition at the makers works and guarantees the required
perfect true running of the complete gear wheel.
For this reason a split design gear wheel may only be installed if the final
machining of the teeth had been carried out with assembled hub / gear
rim.
After the final machining of the teeth the gear rim may not be separated from the
wheel hub.
D
Should the damage be limited to the toothing (gear rim), then the hub may be
reused, provided a new rim, on which the teeth are not finish-machined, is
fitted to the hub, screw-fastened and dowelled. Then its teeth can be finishmachined.
Apply LOCTITE 262 and then tighten self-locking nuts 18 until an angle of 80_
is obtained.
16
18
15
012.185/04
2008
6/ 6
RT-flex96C
41032/A2
Maintenance
Driving Wheels
Removal and Fitting of Intermediate Wheel
Tools:
1 Feeler gauge
6 Adjusting devices
1 Suspension device
Withdrawing device
for taper pins
11 Cylinder Engines
Key to Illustrations:
94122
94410
94411
1
2
3
4
5
6
7
8
9
9a
10
11
Intermediate wheel
Cover
Cover
Pipe bend
Support
Gear wheel on crankshaft
Waisted screw
Cover
Screw plug for taper pin
Screw plug
Taper pin
Bearing
12
13
14
15
16
17
18
19
20
Bearing journal
Locking strap
Double column
Wheel hub
Gear rim
Lubricating oil pipe
Self-locking nut
Strap
Strap
HZ Lifting tackle
H1... Lifting tackles
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of the intermediate wheel . . . . . . . . . . . . . . . . . . .
Replacement of a gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/6
2/6
4/6
5/6
6/6
General
D
Risk of accident! Precautions must be taken that, while removal work is in progress, the running gear can on no account be put into motion.
Remark: Pay attention to General Guidelines for Lifting Tools 00121.
6
014.078/06
1/ 6
2008
41032/A2
Maintenance
RT-flex96C
2.
11 Cylinder Engines
Removal
Fasten lifting tackle HZ to pipe bend 4 and
connect it to cover 3.
H2
19
H1
3
HZ
I
4
HZ
014.079/06
II - II
16
15
11 13
14
17
III - III
II
7
8
9a
9a
10
12
001.639/97
III
001.639/97
III
II
012.185/04
2008
2/ 6
RT-flex96C
41032/A2
Maintenance
11 Cylinder Engines
D
Lower intermediate wheel 1 completely onto
the gear wheel on crankshaft 6 by means of
rope a, and turn it out to exhaust side while
following up with rope b.
Fasten lifting tackle H3 (lifting capacity 4000
kg) to cover 2.
Connect rope b (lifting capacity 4000 kg)
with intermediate wheel and lifting tackle H3.
Remove rope a.
H2
b a
H3
1
6
014.086/06
E
Fit suspension device 94411 to the intermediate wheel as shown in view I.
Fasten lifting tackle H4 (lifting capacity 4000
kg) to straps 20 and connect it to the suspension device.
Lift the intermediate wheel out of the double
column with rope b and lifting tackle H4.
I
b
20
H4
H4
H3
1
6
94411
014.080/06
3/ 6
2008
41032/A2
Maintenance
RT-flex96C
11 Cylinder Engines
F
Connect lifting tackle H1 and rope d (lifting
capacity 4000 kg each) with intermediate
wheel 2.
Pull out the intermediate wheel by means of
lifting tackle H4 and rope d and then remove
lifting tackle H4.
D
H4
H1
d
014.081/06
3.
Fitting
Fitting the intermediate wheel is carried out analogously to the removal but in
reverse sequence, whereby attention must be paid as follows:
Remark: When fitting bearings 11 they must first be lavishly smeared with bearing
oil. Both bearings are basically equal, they may, however, only be refitted in their
original place, as their position has been dowelled with taper pins 10 when building
the engine.
D
Fit intermediate wheel so that marking DRIVING END appears when viewed
from the driving end of the engine.
Intermediate wheel may be fitted arbitrarily with respect to the tooth position.
2008
4/ 6
RT-flex96C
41032/A2
Maintenance
11 Cylinder Engines
Screw in the remaining waisted screws and tighten them all slightly and
evenly by hand with a wrench.
In this position mark the screws with a line and tighten them crosswise until an
angle of 50 is obtained.
CHECK
As a safeguard check the tooth backlash between the gear wheels (see also Clearance Table 03301 Driving Wheels for Supply Unit).
Fit screw plugs 9 with LOCTITE No. 0222 and screw them in till the stop at the
taper pins.
Lock all waisted screws 7 in pairs with locking wire.
4.
D
CHECK
After a new adjustment of the intermediate wheel the tooth backlash (see Clearance Table 03301 Driving Wheels for Supply Unit), as well as the tooth flank contact pattern have to be checked (see 41031).
If a new adjustment of the bearings is required, the pin holes pre-bored in the
column must be used.
II - II
14
14
I
II
I
8
94410
II
11
94410
012.186/04
5/ 6
001.639/97
2008
41032/A2
Maintenance
RT-flex96C
5.
11 Cylinder Engines
The replacement of a damaged 2-part gear wheel may only be done in exchange for a complete gear wheel i.e. gear rim 16 must be screw fastened to
wheel hub 15 and the bearing journal fitted.
This is necessary as the final machining of the gear teeth has been carried out
in this mounted condition at the makers works and guarantees the required
perfect true running of the complete gear wheel.
For this reason a split design gear wheel may only be installed if the final
machining of the teeth had been carried out with assembled hub / gear
rim.
After the final machining of the teeth the gear rim may not be separated from the
wheel hub.
D
Should the damage be limited to the toothing (gear rim), then the hub may be
reused, provided a new rim, on which the teeth are not finish-machined, is
fitted to the hub, screw-fastened and dowelled. Then its teeth can be finishmachined.
Apply LOCTITE 262 and then tighten self-locking nuts 18 until an angle of 80_
is obtained.
16
18
15
012.185/04
2008
6/ 6
RT-flex96C
41033/A1
Maintenance
Driving Wheels
Replacing the Gear Wheel on Crankshaft
Tools:
Key to Illustrations:
1 Feeler gauge
1 Hydraulic tightening device
consisting of:
1 Clamping fork with extension
1 Impact ring spanner
1 Forked piece
1 Hydraulic ram
1 Retaining wrench
1 HP oil pump
1 Pressure gauge
1 Pressure gauge
1 Hydr. distributor
1 Plug piece
1 HP hose
1 HP hose
94122
94412
94412a
94412b
94412c
94412d
94412e
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
Gear wheel
Crankshaft flange
Waisted stud
Castle nut
Base
Flange screw
7
8
9
10
Distance sleeve
Self-locking nut
Dowel pin
Column
EV Relief valve
Overview
1.
2.
3.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/7
Preparing the assembly of the gear wheel . . . . . . . . . . . . . . . 2/7
Assembly of the gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/7
6
1
4
5
3
9
5
4
001.173/97
1/ 7
2008
41033/A1
Maintenance
RT-flex96C
1.
General
Usually, the gear wheel on the crankshaft (from now on referred to as gear wheel)
is executed in one part and fitted as such on the crankshaft. If a damaged gear
wheel in the engine is to be replaced, it must be separated into two halves for dismantling. In order to avoid damages, especially to the crankshaft, please obtain the necessary instructions and recommendations for executing such dismantling work from the engine supplier or from Wrtsil Switzerland Ltd.
For dismantling as well as for assembling a new gear wheel, dismount the intermediate wheel (41032) to the supply unit drive.
The spare gear wheel is designed in two parts and must be fitted as described below.
Remark: When ordering a two-part spare wheel, please indicate the engine type,
the engine No., as well as the engine supplier. This data is necessary because the
centring diameter of the crankshaft is registered for mounting the gear wheel, and
the center hole of the two-part spare wheel is manufactured according to these dimensions.
2.
CHECK
DEGREASE
If the undersize is not within the mentioned tolerance, the gear wheel must not be assembled, but
the center hole of the gear wheel has to be given an
appropriate aftertreatment (remachine / possibly
bore and flame-spray, and machine to obtain the
correct diameter).
2/ 7
1
000.697/98
DRIVING END
MIDDLE OF ENGINE
DEGREASE
1
000 697/98
2008
RT-flex96C
41033/A1
Maintenance
Remark: The assembly of the gear wheel must be carried out carefully, since relatively small faults could have a negative influence on the operating performance of
all gear wheels of the drive.
3.
C
4
MOLYKOTE
LOCTITE 262
DEGREASE
SPLINT PIN
5
3
1
5
001.168/97
Turn the crankshaft so that the mark on the crankshaft flange is approximately horizontal with regard to the crankshaft centre line.
D
6
1
3
001.167/97
Work sequence
3/ 7
2008
41033/A1
Maintenance
RT-flex96C
E
3
001.167/97
GAP 0
F
CHECK
001.166/97
6
1
6
001.166/97
CHECK There must be no clearance on the seating surfaces between the gear wheel and the crankshaft flange check!
001.166/97
2008
4/ 7
RT-flex96C
Maintenance
41033/A1
CHECK
After fitting the gear wheel on the crankshaft and assembling the intermediate
wheel, check the correct positioning of the driving wheels (see 41032).
Check all driving wheels as specified in 41031 after assembling them.
5/ 7
2008
41033/A1
Maintenance
RT-flex96C
10
94412a
94412d
94412b
94412c
000.696/98
2008
6/ 7
RT-flex96C
41033/A1
Maintenance
10
I-I
94412a
1
3
94412d
94935a
94412e 4 2
LOCTITE 262
MOLYKOTE
I
94932a
94934e
94934a
94935
012.093/04
94932
7/ 7
EV
94931
2008
RT-flex96C
41033/A2
Maintenance
Driving Wheels
Replacing the Gear Wheel on Crankshaft
Tools:
Key to Illustrations:
1 Feeler gauge
1 Hydraulic tightening device
94122
94412
consisting of:
1
1
1
1
1
1
1
1
1
1
1
1
1
94412b
94412c
94412d
94412e
94412f
94412g
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
7
Gear wheel
Crankshaft flange
Waisted stud
Castle nut
Base
Flange screw
Distance sleeve
8
9
10
11
Self-locking nut
Dowel pin
Column
Screw
EV Relief valve
Overview
1.
2.
3.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/7
Preparing the assembly of the gear wheel . . . . . . . . . . . . . . . 2/7
Assembly of the gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/7
6
1
4
5
3
9
5
4
001.173/97
1/ 7
2008
41033/A2
Maintenance
1.
RT-flex96C
General
Usually, the gear wheel on the crankshaft (from now on referred to as gear wheel)
is executed in one part and fitted as such on the crankshaft. If a damaged gear
wheel in the engine is to be replaced, it must be separated into two halves for dismantling. In order to avoid damages, especially to the crankshaft, please obtain the necessary instructions and recommendations for executing such dismantling work from the engine supplier or from Wrtsil Switzerland Ltd.
For dismantling as well as for assembling a new gear wheel, dismount the intermediate wheel (41032) to the supply unit drive.
The spare gear wheel is designed in two parts and must be fitted as described below.
Remark: When ordering a two-part spare wheel, please indicate the engine type,
the engine No., as well as the engine supplier. This data is necessary because the
centring diameter of the crankshaft is registered for mounting the gear wheel, and
the center hole of the two-part spare wheel is manufactured according to these dimensions.
2.
CHECK
DEGREASE
If the undersize is not within the mentioned tolerance, the gear wheel must not be assembled, but
the center hole of the gear wheel has to be given an
appropriate aftertreatment (remachine / possibly
bore and flame-spray, and machine to obtain the
correct diameter).
2/ 7
1
000.697/98
DRIVING END
MIDDLE OF ENGINE
DEGREASE
1
000.697/98
2008
RT-flex96C
41033/A2
Maintenance
Remark: The assembly of the gear wheel must be carried out carefully, since relatively small faults could have a negative influence on the operating performance of
all gear wheels of the drive.
3.
C
4
MOLYKOTE
LOCTITE 262
DEGREASE
SPLINT PIN
5
3
1
5
001.168/97
Turn the crankshaft so that the mark on the crankshaft flange is approximately horizontal with regard to the crankshaft centre line.
D
6
1
3
001.167/97
Work sequence
3/ 7
2008
41033/A2
Maintenance
RT-flex96C
E
3
001.167/97
GAP 0
F
CHECK
001.166/97
6
1
6
001.166/97
CHECK There must be no clearance on the seating surfaces between the gear wheel and the crankshaft flange check!
001.166/97
2008
4/ 7
RT-flex96C
Maintenance
41033/A2
Single Wall Column
CHECK
After fitting the gear wheel on the crankshaft and assembling the intermediate
wheel, check the correct positioning of the driving wheels (see 41032).
Check all driving wheels as specified in 41031 after assembling them.
5/ 7
2008
41033/A2
Maintenance
RT-flex96C
II - II
I
I
94412g
94412g
94412f
94412d
94412c
94412b
015.091/07
2008
6/ 7
RT-flex96C
41033/A2
Maintenance
I-I
II
94412g
94412f
11
III
94935a
94412c
MOLYKOTE
LOCTITE 262
III - III
1
3
1
94932a
III
94934e
94934a
94412e
4 2
94935
II
94932 EV 94931
7/ 7
2008
RT-flex96C
43251/A1
Maintenance
1.
Valve seat
Cover
Spring
Valve
Valve seat
Valve guide
Spring
Valve body
Control valve
Piston seal ring
Piston
Valve
Screw plug
Spring
Screw plug
Liner bush
Screw
18
19
20
21
22
23
24
Spindle
Spindle guide
Handwheel
Locking lever
Common start valve
O-ring
O-ring
General
The shut-off valve must be dismantled, cleaned and inspected according to Maintenance Schedule 03801.
Remark: To avoid accumulation of water in the main starting air piping open for a
short time water drain pipe on the main starting air piping after each starting operation.
Risk of accident! Before starting work on the shut-off valve for starting air it is essential to manually close the stop valves on the starting air receivers.
The turning gear must be engaged.
The venting valve 2.21 to connection EV as well as the valve 2.27 must be open
for venting and draining the main starting air piping on the engine (see Control Diagram 40032 in the Operating Manual).
2.
2.1
Dismantling
If the valve seat 1 is to be grind in, first loosen the screws to cover 2.
Withdraw spring 3 together with valve 4 and spindle 18 as an unit.
Unscrew spindle guide 19 and remove the valve from the spindle.
If valve seat 5 of the non-return valve is to be grind in, then the shut-off valve
must be completely dismantled.
After dismantling valve guide 6 and spring 7 remove valve body 8 of the nonreturn valve.
D
When the above mentioned items are being checked, control valve 9 has also
to be dismantled and cleaned.
1/ 4
2006
43251/A1
Maintenance
RT-flex96C
2.2
Assembly
Before reassembling all items replace corroded springs by new ones.
Replace damaged or much worn piston seal ring 10.
Check equalizing bores EB for free passage.
Before reassembling spindle 18, the threads in valve 4 and spindle guide 19
are to be thoroughly degreased and then smeared with LOCTITE. Insert the
spindle and fully tighten the spindle guide.
For the assembly smear all the parts lightly with MOLYKOTE paste.
Check to ascertain that clearance S between piston 11 and valve 12 of control
valve 9 amounts to about 1 mm.
CHECK
24 6
17
7
8
13
5
1
EB
S1
DT
EV
19
10
4
16
23
14
12
TV
2
SL
15
9
11
21
22
019.238/10
18
20
011.670/04
201007
2/ 4
RT-flex96C
Maintenance
43251/A1
3.
Function check
After completing the assembly carry out a function check, for which the following
precautions have to be taken:
3.1
3.2
Initial position
D
The stop valves of the starting air receivers must still be closed.
The engine has to be completely assembled, ready to start and the turning gear must be in the disengaged position.
The area of flywheel, propeller shaft and propeller must be free of persons or
objects.
During the functional check the reversing must remain in position STOP and
START may not be actuated under any circumstances.
Tightness
Close venting valve 2.27 in the main starting pipe.
Open the stop valve of a starting air receiver slowly.
CHECK
3.3
Check whether the automatic shut-off valve is airtight, i.e. verify that no air escapes
from the bore of screw plug 14.
Manual opening
Open the shut-off valve slowly with the help of handwheel 20 till locking lever
21 is in the position OPENED (by hand). The discharging air at the bore for
screw plug 13 indicates that valve 4 of the shut-off valve and valve body 8 of
the non-return valve are open.
Risk of accident! Great care must be taken for this operation. To prevent accidents from compressed air suddenly escaping out of the bore for screw plug 13 a
sufficient distance has to be kept.
3.4
Automatic closing
Turn handwheel 20 to position CLOSED till locking lever 21 engages in position AUTOMATIC.
In this position the shut-off valve should, through the spring resistance, be automatically closed. No more air should come out at the bore for screw plug 13.
In this position the valve closes positively only if there is a clearance S1 (in
new condition min. 2 mm max. 5 mm) between spindle 18 and spindle guide
19.
3/ 4
2006
43251/A1
Maintenance
RT-flex96C
CHECK
3.5
By turning the spindle carefully to position OPENED, the contact with spindle guide
19 can be felt. The clearance S1 can thus be determined externally and it shall be
min. 2 mm corresponding to 1/3 turn of the spindle.
D
By opening test valve 2.06, which is fitted in piping TV, the same effect is obtained as when actuating control valve 9.
Upon opening test valve 2.06 the shut-off valve opens automatically. The air
now escaping at the bore for screw plug 13 indicates that valve 4 of the shutoff valve and valve body 8 of the non-return valve have opened.
Automatic opening
Risk of accident! Great care must be taken for this operation. To prevent accidents from compressed air suddenly escaping out of the bore for screw plug 13 a
sufficient distance has to be kept to the shut-off valve.
D
After shutting test valve 2.06 no air must escape from bore for screw plug 13.
After completing these checks fit and tighten screw plug 13, and close the
shut-off valve with handwheel 20 to position CLOSED (by hand).
2006
4/ 4
RT-flex96C
Maintenance
Group5
Group 5
Supply Unit
Removal and Fitting of Dynex Servo Oil Pump and Servo Oil Pump Drive . . . 55521/A2
Removal and Fitting of Camshaft and Bearing Shells . . . . . . . . . . . . . . . . . . . . . 55522/A1
Removal and Fitting of Gear Wheel on Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 55523/A1
Removing and Fitting the Fuel Cams with Conical Bushes . . . . . . . . . . . . . . . . 55523/A2
Removal and Fitting of Intermediate Wheel to Camshaft . . . . . . . . . . . . . . . . . . 55524/A1
Lubrication of Supply Unit During Maintenance Works (Dynex SOP) . . . . . . . 55525/A1
Fuel pump
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55561/A3
Removal of a Jammed Pump Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55562/A1
Injection Control Unit: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55641/A1
Pressure Reducing Valve 8.111: Checking the Gas Pre-charge Pressure . . . . . 56101/A1
Exhaust Valve Drive: Removal, Fitting, Dismantling and Assembling . . . . . . . . . . . 56121/A1
Regulating Linkage: Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58011/A1
1/ 5
RTflex96C / MM / 2012-05
RT-flex96C
55521/A2
Maintenance
Supply Unit
Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive
Tools:
1 Device
1 Lifting plate
1.
Dynex Pumps
Key to Illustrations:
94561
94435
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
3133
Foot
Guide
Flange
Screw
Flange
Screw
Wing nut
Shut-off valve
Collector block
Screw
Drain screw
Screw
O-ring
HZ Lifting tackle
MA Mark
RC Eye bolt
General
Concerning the maintenance of the servo oil pump observe the instructions from
the manufacturer. The servo oil pump drive must be checked in accordance with
the Maintenance Schedule 03801 Supply Unit.
2.
19
94435
014.464/06
1/ 5
2008
55521/A2
Maintenance
RT-flex96C
Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive
10
11
10 5
Dynex Pumps
MA
2.1
Removal of pinion
2
3
33
014.465/06
RC
Fit guide bush 17 as shown in Fig. C.
Fit eye bolts RC.
17
014.465/06
I-I
18
11
18
014.465/06
19
20
20
014.474/06
2008
2/ 5
RT-flex96C
55521/A2
Maintenance
Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive
Dynex Pumps
Turn stop rod 18 till its mark TOP pointing upwards (view I).
Fasten flanges 23 to flange 21 by means of screws 24.
Push flange 21 (mark TOP pointing upwards) over stop rod 18 to guide bush
17 and fasten it by means of screws 22.
Fit and tighten wing nut 25 to the stop rod.
Connect lifting tackle HZ with eye bolt RC and remove pinion 6 (see Fig. F).
11
RC
22
I
I
25
23
24
21
014.473/06
18
17
014.475/06
HZ
F
RC
94561
014.467/06
3/ 5
2008
55521/A2
Maintenance
RT-flex96C
Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive
3.
Dynex Pumps
Spray nozzles
Two spray nozzles 12 are provided for each pinion; they are located in such a manner that oil is sprayed between pinion 6 and gear wheel 8.
The tap holes in the housing of the supply unit are properly arranged ensuring correct fitting of the spray nozzles.
The spray nozzles can be removed each time the engine and the lubricating pump
are stopped.
3.1
CHECK
Spray nozzle 13 for intermediate wheel 9 can only be unscrewed after removal of cover 16 (Fig. H).
G
I
I-I
12
32
12
31
23
14
6
8
12
014.468/06
2008
4/ 5
RT-flex96C
55521/A2
Maintenance
Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive
Dynex Pumps
I-I
16
13 15
4.
014.470/06
Fitting
I
Fitting is carried out analogously to the removal but in reverse sequence, whereby attention
must be paid to the following:
27
26
29
1
30
Remark: Bores for bearing bushes 10 in housing 11 and pump support 4 are machined together and marked accordingly. Therefore,
never interchange the pump supports and take
special care of marks MA on assembly!
D
CHECK
During fitting the clearances are to be determined in accordance with Clearance Table
03301 Supply Unit.
Open shut-off valves 26 and tighten their
spindles with 200 Nm.
014.472/06
5/ 5
2008
RT-flex96C
55522/A1
Maintenance
Supply Unit
Removal and Fitting of Camshaft and Bearing Shells
Tools:
Devices
Key to Illustrations:
94430
1
1
1
1
1
1
1
1
1
1
2
2
1
2
2
2
1
1
1
1
1
2
1
Lifting support
Lifting support
Lifting support
Lifting plate
Fork lever consisting of:
Face plate
Rocker arm
Nut
Bolt
Web
Pre-tensioning jacks
Sleeves
Socket wrench
Round bars
Supports
Tension nuts
Assembly template
Pipe
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94553
94553a
94553b
94553c
94554
94554a
94554b
94554c
94554d
94554e
94557
94558
94559
94560
94566
94566a
94567
94567a
94932
94934a
94935
94935a
94942
1
2
3
4
5
6, 6a
7, 7a
8
9
10
11
12
13
14
15
16
17
17a
18
19
20
21, 21a
22
23
24
25
26
BN
BO
HK
HZ
H1...
SA
Gear wheel
Push rod
Nut
Bolt
Guide
Dowel pin
Flange
Distance plate
O-ring
Limiting groove
Bore
Wooden wedge
Lifting tackle
Lifting tackle
Gap
Overview
1.
2.
3.
4.
1.
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/16
Removal of camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . 5/16
Removal of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/16
Fitting of bearings and camshaft . . . . . . . . . . . . . . . . . . . . . . 13/16
Preparation
Stop the engine and main lubricating pump.
Remove the casing plates from servo oil pumps.
Cut out fuel pumps 3 (Fig. A or D) by means of devices 94430 (see 55562 in
the Operating Manual).
Remove servo oil pumps 1 which are placed in front of camshaft wheel and
the corresponding pinions (see 55521).
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
General Application Instructions 94034 for hydraulic pre-tensioning jacks.
1/ 16
2008
55522/A1
Maintenance
RT-flex96C
A
1.1
Removal of covers
Remove cover 2.
5
011.824/04
I
94553
HZ
HZ
94553
4
I
94553
94553c
4
017.865/08
011.829/04
2008
2/ 16
RT-flex96C
55522/A1
Maintenance
H1
HZ
HZ
94553a
II - II
I
94553a
II
I
24
5
5
014.092/06
011.836/04
3/ 16
II
2008
55522/A1
Maintenance
RT-flex96C
D
1.2
Removal of cover 5
(6 and 7 Cyl. engines)
Remove cover 2.
2
014.091/06
E
HZ
I
H1
5
94553b
24
94553b
I
5
2008
014.094/06
014.093/06
4/ 16
RT-flex96C
55522/A1
Maintenance
2.
2.1
94932
94935a
94557
10
94935a
94934a
13
BN
11
SA
14
94558
94935
6
7
94560
11
94942
011.837/04
5/ 16
2008
55522/A1
Maintenance
RT-flex96C
2.2
Till the removal of pre-tensioning jacks the further procedure is the same as
described in paragraph 2.1.
Nuts 7a are turned out with socket wrench 94559 as shown in Fig. H.
Remark: For safety reasons do not unscrew nuts 7a before the corresponding
bearing cover will be removed!
10
12
13
8 BN SA
13
7a
6a
94557
94935a
94932
94934a
94559 12
011.861/04
94935
I-I
94942
7a
2008
6/ 16
94560
RT-flex96C
55522/A1
Maintenance
2.3
Numbering of bearings
Bearing No. 1 is designed as thrust bearing.
Remark: All bearing covers 12 are machined together with housing 11, therefore
never interchange them! They must be marked accordingly before their removal.
12
11
12
7/ 16
2008
55522/A1
Maintenance
RT-flex96C
2.4
HZ
For bearing covers 12 the removal procedure is the same as described for
cover 4 in paragraph 1.1.1.
II
94553
13
23
II
12
011.854/04
HZ
H1
For bearing covers 12 the removal procedure is the same as described for
cover 5 in paragraph 1.2.
II
94553b
13
II
23
25
12
014.095/06
2008
014.106/06
8/ 16
RT-flex96C
55522/A1
Maintenance
M
2.4.3 Removal of bearing shell No. 1
Move camshaft 14 till there is a clearance on
both sides of thrust bearing ring halves 15.
Push thrust bearing ring halves out and remove them.
I
18
11
4
18
14
15
15
17a
14
I-I
94554
94554b
16
94554e
94554c
011.855/04
94554a 6a
I
Wrtsil Switzerland Ltd
9/ 16
94554d
2008
55522/A1
Maintenance
RT-flex96C
O
Place assembly template 94567 on lower
bearing shell 17, so that its pin fits into the corresponding bore of the bearing shell.
14
17a
17
94567
94567a
16
P
Insert pipe 94567a into the other pin and turn
lower bearing shell upwards till assembly
template stops at housing 11.
11
94567
94567a
Q
Turn screw 16 out of gear with face plate
94554a, lift and remove rocker arm 94554b.
Remove lower bearing shell.
17a
16
94554e
2008
94554b
94555a
011.858/04
10/ 16
RT-flex96C
55522/A1
Maintenance
3.
Removal of camshaft
Push support 94566 over waisted bolt 6a and fasten it with tension nut 94566a
as shown in Fig. R.
Attention! Heads of bolts 21 and 21a must point towards the free end when fitting
support 94566 as shown in Fig. R.
By means of turning nut 20, extend push rod 19 till it touches camshaft 14.
I-I
14
19
21a
21
20
94566a
94566
6a
S
Screw the bearing cover and bearing shell
down to bearing No. 3 as described in paragraph 2.4.4.
Fit support 94566 and extend push rod 19
as described for Fig. R.
4
Remove the bearing covers and lower bearing shells 17 from the remaining bearings.
011.864/04
11/ 16
2008
55522/A1
Maintenance
RT-flex96C
94430
14
19
94566
HK
HK
011.865/04
2008
12/ 16
RT-flex96C
55522/A1
Maintenance
V
Pull out bolt 21a. Lift and remove
guide 22.
94430
17a
21a
011.868/04
4.
for the assembly smear bearing shells, thrust bearing ring halves and camshaft with oil.
fit bearing shells, so that their bores provided for dowel pins 23 in the bearing
covers point to the same side (Fig. K or L).
Align bearing shells laterally and their mating surfaces with housing 11.
fit lower bearing shell 17 laterally aligned with upper bearing shell 17a.
take care of the bearing cover numberings and meshing of dowel pins 13 and
23 (Fig. K).
apply oil to the threads of nuts 7, 7a and tighten nuts 7a with socket wrench
94559 till there is no clearance at y (Fig. W).
13/ 16
2008
55522/A1
Maintenance
RT-flex96C
4.1
10
X
x
12
BN
7a
6a
7a
94557
94559
y
94935a
94934a
011.867/04
94935
I-I
94942
7a
2008
14/ 16
94560
RT-flex96C
55522/A1
Maintenance
4.2
Y
94932
94935a
94557
10
94935a
94934a
13
BN
11
14
94558
6
94935
7
94560
11
011.866/04
94942
15/ 16
2008
55522/A1
Maintenance
RT-flex96C
4.3
Final assembly
CHECK
Determine radial and axial clearances, see clearance table 03301 Supply Unit.
Put O-ring 26 in cover 5 (Fig. C).
Apply sealing compound to sealing faces of covers 4, 5 and fit the latter.
Fit servo oil pumps (see 55521).
Install all pipings.
Cut in the fuel pumps and remove tools 94430 (see 55562 in the Operating
Manual).
CHECK
After assembly, turn the engine and check if lubricating oil is supplied to all lubricating points and bearings with the oil pump in operation!
Attention! Prior to commissioning or after maintenance works and exchange of
Bosch servo oil pumps, they must be filled up with system oil (see 55521 Fitting).
2008
16/ 16
RT-flex96C
55523/A1
Maintenance
Supply Unit
Removal and Fitting of Gear Wheel on Camshaft
Tools:
2
2
1
1
1
2
1
2
1
1.
Pre-tensioning jacks
Sleeves
Round bar
Pressure gauge
Hydr. distributor
Connecting elements
HP hose
HP hoses
Hydraulic unit
Key to Illustrations:
94557
94558
94560
94932(a)
94934a
94934d
94935
94935a
94942
1
2
3
4
5
6
7
8
9
Camshaft
Fuel cam
Nut
Vent screw
Cylinder
Piston
Shaft
Gear wheel
Camshaft wheel
10 Waisted bolt
11 Withdrawing screw
BN
HU
HZ
RS
SA
Limiting groove
Wooden underlay
Lifting tackle
Round bar
Gap
1/ 5
2008
55523/A1
Maintenance
RT-flex96C
1.1
A
x
4
94558
10
1
BN SA
94557
94934d
2008
10
94560
94932a
94942
014.229/06
94935a
94935
2/ 5
94934a
RT-flex96C
55523/A1
Maintenance
1.2
B
I
HZ
11
012.211/04
10 3
11
Hold camshaft wheel 9 with two nuts 3 (Fig. B) provisionally on the shaft 7.
Place the unit on wooden underlays HU.
11
Remove nuts 3.
HU
3/ 5
2008
55523/A1
Maintenance
RT-flex96C
2.
Waisted bolt 10 itself has to be tightened with a torque of 140 Nm providing oil
on its thread.
10
3
13
8
HU
2008
4/ 5
RT-flex96C
55523/A1
Maintenance
2.1
E
x
4
94558
10
1
BN
94557
94934d
10
94560
94932a
94942
014.264/06
94935a
94935
5/ 5
94934a
2008
RT-flex96C
55523/A2
Maintenance
Supply Unit
Removing and Fitting the Fuel Cams with Conical Bushes
Tools:
1 Hydr. jacking tool
1 Adapter piece
Cam adjusting gear
Key to Illustrations:
94424
94426a
94562
consisting of:
1
1
1
1
1
1
1
1
1
1
2
1
1
Angle rail
Guide tube
Positioning unit
Distance holder
Distance holder
Distance holder
HP oil pump
Pressure gauge
Hydr. distributor
Plug piece
HP hoses
HP hose
Hydraulic unit
94562a
94562e
94562f
94563
94563a
94563b
94931
94932(a)
94934a
94934e
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Camshaft
Fuel cam
Washer
Fitted bolt
Camshaft wheel
Screw M8x20
Conical bush
Screw
Vent screw
Ring piece
Piston supporting plate
Piston
Shaft
Driving wheel for servo oil pumps
EV Relief valve
GL Taphole
Overview
1.
2.
3.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/10
Removing the 2-part fuel cam . . . . . . . . . . . . . . . . . . . . . . . . . . 2/10
Fitting the 2-part fuel cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/10
General
The following instructions apply to supply units which are providing 2-part fuel
cams, i.e. with conical bushes (bush for short).
The camshaft must be removed from the supply unit for removing and fitting the
fuel cams and gear wheels on the camshaft (see 55522). To be able to work appropriately, it is recommended to put the camshaft on suitable pedestals.
Prior to fitting the fuel cams, it must be ensured that the fuel cams, bushes and
camshaft are absolutely clean and in perfect condition.
HP oil pump 94931 and hydraulic unit 94942 have to be filled with engine oil having
a viscosity of SAE30 to SAE40 before starting them up. In exceptional cases hydraulic unit 94942 may be filled with cylinder lubricating oil.
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
General Application Instructions 94034 for hydraulic pre-tensioning jacks.
1/ 10
2008
55523/A2
Maintenance
RT-flex96C
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
2.
A
12
11 2
10
94424
94426a
94935
94935a
94932
94934a
94942
94931
2008
EV
94932a
94934e
94935
2/ 10
RT-flex96C
55523/A2
Maintenance
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
3.
3.1
The numbering starts with fuel cam No. 1 , which is next to the camshaft
wheel 5.
Setting the distances of the fuel cams to each other is carried out with the aid
of distance holders 94563, 94563a and 94563b.
Setting the positioning angles of the fuel cams to each other is carried out with
the aid of cam adjusting gear 94562, i.e. angle rail 94562a, guide tube 94562e
and positioning unit 94562f.
The appropriate tool is delivered for each engine.
The positioning angles of the fuel cams to the camshaft wheel is undefined.
Remark: A fuel cam 2 and its bush 7 (Fig. A) form one unit and must not be interchanged! If necessary, both parts must therefore be replaced at the same time;
moreover they are only supplied together.
6 and 7 CYLINDERS
94563a
94564
94563
94562
GL
1
5
x2
x1
3/ 10
2008
55523/A2
Maintenance
RT-flex96C
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
8 to 10 CYLINDERS
94563b
94564
94563a
94563
94562
x1
x2
x3
11 to 14 CYLINDERS
1
94563a
94563b 94563a
x2
3
2
94563
94564 94562
2008
x3
x2
x1
4/ 10
RT-flex96C
55523/A2
Maintenance
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
3.2
E
I
12
11 2 94563
10
94424
94426a
94935
94935a
94932
94934a
94942
94931
EV
94932a
94934e
94935
5/ 10
2008
55523/A2
Maintenance
RT-flex96C
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
Actuate HP oil pump 94931 till oil flows bubble-free at vent screw 9; then close
the latter.
Actuate hydraulic unit 94942, and when oil is squeezing out on the whole circumference between bush 7 and fuel cam 2, operate also the HP oil pump.
Pull the fuel cam onto the bush by means of the HP oil pump while keeping the
hydraulic unit running. During this process pay attention that oil is continuously squeezing out between bush and fuel cam.
Attention! The oil pressure in hydr. jacking tool 94424 may not exceed 250 bar.
When fuel cam 2, is flush with piston supporting plate 11, release the pressure
to zero at the hydraulic unit and approx. 30 seconds later also at the HP oil
pump.
Remove all tools.
Remark: Mark camshaft together with bush and fuel cam by means of a nonwashable colour in order to ascertain a possible deviation of the marks, i.e. twisting
of the parts.
F
14
11 2
I
94424
94563
94426a
94935
94935a
94932
94934a
94942
94931
2008
EV
94932a
94934e
94935
6/ 10
RT-flex96C
55523/A2
Maintenance
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
;
3.3
3.3.1 Preparation
Fasten angle rail 94562a with fitted bolts 4 and washer 3; and guide tube
94562e at 25 mark with screws 8 to fuel cam No. 1 .
Push bush 7 together with fuel cam No. 2 onto the oiled camshaft.
Fit positioning unit 94562f with its shaft 13 into one of the three tapholes on the
relevant side of fuel cam No. 2 .
Put distance holder 94563a onto the camshaft and push it against fuel cam
No. 1 .
Push and turn the bush with fuel cam so that shaft 13 meshes in guide tube
94562e.
I-I
G
4
94424
94563a 94562
III
94563a
94426
14
2
8
94562a
III
3, 4
x1
III - III
SEE ALSO FIG. I AND K
x3
x2
017.855/08
94562f
13
94562e
94562a
Push bush 7 together with fuel cam 2 till the bush rests on distance holder
94563a (Fig. G).
Push hydr. jacking tool 94424 on bush 7 and fasten it to the fuel cam using six
screws 8 (evenly tighten screws slightly by hand only).
Connect the hydr. jacking tool to HP oil pump 94931, however one side of
hydr. distributor 94934a must be plugged with plug piece 94934e.
Open vent screw 9 and relief valve EV.
Tighten screws 8 evenly by hand till ring piece 10 rests on piston supporting
plate 11.
Close relief valve EV.
Screw adapter piece 94426a into fuel cam 2 and connect it to hydraulic unit
94942 as shown in Fig. E.
7/ 10
2008
55523/A2
Maintenance
RT-flex96C
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
H
BEFORE DRAWING UP
AFTER DRAWING UP
2
94424
8
94563a
10 12
2008
11
8/ 10
RT-flex96C
55523/A2
Maintenance
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
3.4
I
94563b
94562
II
II
I-I
II - II
III
III
8
94562a
94563a
94562a
III
III
3, 4
3, 4
94563b
9/ 10
2008
55523/A2
Maintenance
RT-flex96C
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
3.5
K
94563a
94562
II
II
II
II
I
I-I
II-II
3, 4
94563b
94563a
III
8
94562a
8
III
III
3, 4
III
2008
10/ 10
RT-flex96C
55524/A1
Maintenance
Supply Unit
Removal and Fitting of Intermediate Wheel to Camshaft
Tools:
1
2
1
1
1
2
2
1
8
1
1
1
1
1
2
1
Feeler gauge
Pre-tensioning jacks
Assembly template
Pipe
Rail
Screws
Washers
Carriage
Screws
Support (left)
Support (right)
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
Key to Illustrations:
94122
94556
94567
94567a
94571
94571a
94571b
94571c
94571d
94571e
94571f
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Intermediate wheel
Housing
Intermediate shaft
Cover
Screw plug
Screw
Spray nozzle
Housing
Screw
Bush
Screw
Securing bolt
Waisted bolt
Nut
Vent screw
Cylinder
Piston
18
19
20
21
21a
22
23
24
25
Pin
Bearing cover
Jack
Lower bearing shell
Upper bearing shell
Locating pin
Locating pin
Thrust bearing ring halves
Bearing pin
AF
BO
HU
RC
RS
SA
ZA
Seating face
Bore
Wooden underlay
Eye bolt M10
Round bar
Gap
Pin
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/10
Removal of housing with intermediate wheel . . . . . . . . . . . . 2/10
Removal of bearing shell and intermediate wheel . . . . . . . 7/10
Fitting bearing shell and intermediate wheel . . . . . . . . . . . . 8/10
Fitting housing with intermediate wheel . . . . . . . . . . . . . . . 10/10
General
Removing intermediate wheel 1 is only possible after the camshaft has been removed too (see 55522).
The intermediate wheel must be removed together with its housing from the supply
unit.
Remark: Pay attention to:
General Guidelines for Lifting Tools 00121.
General Application Instructions 94034 for hydraulic pre-tensioning jacks.
011.926/04
1/ 10
2013-05
55524/A1
Maintenance
RT-flex96C
2.
C
b
2
94571
I
6
2013-05
014.571/06a
2/ 10
RT-flex96C
55524/A1
Maintenance
D
b
a
I-I
94571a
I-I
12
94571b
8
94571
94571d
94571c
2
I
10
9
11
I
014.572/06a
3/ 10
2013-05
55524/A1
Maintenance
RT-flex96C
94571f
94571e
014.571/06a
Use the bolts from the supply unit cover to attach the supports 94571f and
94571e to the supply unit (Fig. F).
Fully tighten the screws 94571d on the carriage 94571c to lift up the intermediate wheel and the housing (Fig. G).
I-I
I-I
I
94571d
94571
94571c
1
2013-05
4/ 10
RT-flex96C
55524/A1
Maintenance
H
c
12
2
014.573/06a
5/ 10
2013-05
55524/A1
Maintenance
RT-flex96C
2.3
Turn back nuts 14 with round bar RS until they are almost touching the pistons of the pre-tensioning jacks.
Release pressure to zero and remove the pre-tensioning jacks and nuts.
18 15
x
94932a
94934a
17
16
13
RS
14
19
SA
94935a
94556
94935
HU
94942
011.936/04
2008
6/ 10
RT-flex96C
55524/A1
Maintenance
K
RC
19
23
3.
22
L
94567a
94567
21
25
21a
20
PROTECTION
011.937/04
ZA
7/ 10
2008
55524/A1
Maintenance
RT-flex96C
011.938/04
24
4.
BO
21
AF
For the assembly smear bearing shells and thrust bearing ring halves with oil.
Fit bearing shells, so that their bores BO provided for locating pins 22 in the
bearing covers (Fig. L) point to the same side (Fig. M).
Moreover align bearing shells laterally (they must not protrude in any case!)
with seating faces AF of thrust bearing ring halves 24.
Take care of the designations and meshing of locating pins 22 and 23 when
fitting the bearing covers.
Apply oil to the threads of nuts 14 and tighten them with round bar RS until
there is no clearance at y (Fig. N).
D
CHECK
2008
After tensioning of waisted bolts determine radial and axial clearances, see clearance table 03301 Supply Unit.
8/ 10
RT-flex96C
55524/A1
Maintenance
4.1
Keep pressure constant and tighten nuts 14 with round bar RS until firmly
seated.
CHECK
Using feeler gauge inserted through slot KO (Fig. N), check whether the nuts rest
on bearing cover without any clearance.
Release pressure to zero and remove the pre-tensioning jacks.
18 15
N
94932a
94934a
17
16
13
RS
14
19
KO
94935a
949556
14
94935
HU
94942
011.939/04
9/ 10
2008
55524/A1
Maintenance
RT-flex96C
5.
Check tooth backlash, see clearance table 03301 Driving Wheels for Supply
Unit.
Remove all tools.
8
10
9
11
6
7
I
014.574/06a
5.1
2013-05
10/ 10
RT-flex96C
Supply Unit
Lubrication of Supply Unit During Maintenance Works
Tools:
Lubricating device
Filling device A
Filling device B
Filling device C
Flexible hose
Cross union
Holder
1.
55525/A1
Maintenance
Key to Illustrations:
94844
94844a
94844b
94844c
94844d
94844e
94844f
1
2
2a
3
4a
4b
4c
Ball valve
Blind flange
Flange
Oil pipe
Lubrication bore
Lubrication bore
Lubrication bore
5 Hose clamp
6 Warning plate
7 Flange
General
Lubricating device 94844 has been provided to prevent bearing bushes of the servo oil pump drive from being damaged (dry running) due to turning the engine during overhaul works.
For this additional lubrication of the supply unit, system oil (bearing oil) is used (see
Operating Manual 07501).
Remark: Clean surroundings of the flanges which are opened up and take care
that no dirt or any kind of debris are entering to the supply unit.
2.
1/ 2
2013-05
55525/A1
Maintenance
RT-flex96C
A
94844f
6
94844
94844d
3
1
2
2a
94844e
3
94844a
94844b
94844c
94844a 94844b
94844c
4a
4c
4b
94844a
94844b
4mm
2013-05 / Dynex
5
2mm
2/ 2
RT-flex96C
55561/A3
Maintenance
Fuel Pump
Dismantling and Assembling
Tool:
1
1
1
1
1
1
2
4
4
2
1
2
2
1
Oil trough
Limiters
Screws
Screws
Screws
Assembly tool
Guide screws
Steel wires
Assembling device
1
1
2
1
4
1
1
1
2
1
Tool half
Tool half
Flat bars
Metal sheet
Screws
Mandrel
Mandrel
Impact wrench
Extensions
Socket spanner insert
Lifting tackles
Key to Illustrations:
94550
94551
94552
94555
94592
consisting of:
94592a
94592b
94592c
94592d
94592e
94581
94581a
94581b
94593
consisting of:
94593a
94593b
94593c
94593d
94593e
94597
94597a
94598
94598a
94598b
H1...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38, 38a
39
40
41
42
43
44, 44a
45
46
47
48
49
50
5157
58
DP
DS
GS
RC
Intermediate flange
Regulating (toothed) rack
Circlip
Ring
Head screw
Valve block
Valve body (NRV)
Compression spring
Retaining screw
Fluted seal rings
Intermediate disc
Circlip
Bush
Spindle
Rod seal ring
Seals
Oil inlet pipe
Oil drain pipe
Screw plug
Orifice
Cover
Locating pin
O-rings
Screw
Depository
Pressure piece
Handle screw
Eye bolt
Overview
1.
2.
3.
4.
5.
6.
7.
1.
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/20
Removal of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/20
Dismantling of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/20
Assembling of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/20
Fitting of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19/20
Oil flow check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20/20
Preserving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20/20
Preparation
Stop the engine and switch off the fuel supply pump and lubricating oil pump.
Close the shut-off valves to fuel inlet and outlet pipes (see 80191 in the Operating Manual).
Remove casings as far as necessary and the fuel inlet and outlet pipes.
Remove the fuel pressure piping (see 87521).
Switch of power supply to the actuators and disconnect the connecting element between regulating rack 30 and the regulating linkage (see 58011).
Remove oil inlet pipe 45 and oil drain pipe 46 from upprt housing 5.
Turn the engine till roller 8 rests on the cam base circle (Fig. O).
1/ 20
V4 / 2011-02
55561/A3
Maintenance
RT-flex96C
B
58
1
2
58
94552
4
30
017.706/08
012.387/04
2.
2.1
94552
94581a
94581
94581b
94581a
013.905/06
201007
2/ 20
RT-flex96C
55561/A3
Maintenance
E
H2
2.2
H1
94552
94581
BANK B
012.389/04
F
H2
H2
H1
94552
3/ 20
2008
55561/A3
Maintenance
RT-flex96C
H
H2
H1
H3
94581
012.390/04
I
H2
H2
H1
H3
2008
4/ 20
RT-flex96C
55561/A3
Maintenance
K
H2
H1
H3
94581
012.391/04
M
b
e
H4
H2
H4
5/ 20
H2
2008
55561/A3
Maintenance
RT-flex96C
N
94592c
DP (94592c)
45
46
94592b
94592
DP (94592e)
94592a
94592e
017.706/08
N1
201007 / V4
N2
6/ 20
RT-flex96C
55561/A3
Maintenance
I-I
33
4
STAMP AREA FOR:
VERSION
MANUFACTURER
DATA
SERIAL NO.
STAMP AREA FOR:
VERSION
MANUFACTURER
DATA
SERIAL NO.
PLUNGER
23
22
52
37, 38
25
27
26
24
16 54
44, 55
15
19
53
44a, 56
47, 38a
14, 56
48
17 18
51
41
21
7
9
12
10
11
13
019.325/10
7/ 20
V4 / 2012-05
55561/A3
Maintenance
RT-flex96C
P
3.1
94551
Risk of accident! Guide pin 9 must only be removed with fitting & dismantling device 94551!
7
8
9
GS
013.909/06
R
3.2
RC
42
94551
7
6
21
20
24
22
014.873/06a
201007 / V4
8/ 20
RT-flex96C
Maintenance
55561/A3
S
Push pump plunger 22 out from lower spring carrier
21.
Store pump plunger in a manner not to damage it.
Remove circlip 16 and push retaining ring 17 downwards.
Unscrew connection pins 18 with O-rings 54 by
means of an Allen wrench AF10, and remove lower
spring carrier.
18
54
17
16
21
22
T
13
RC
50
12
11
10
3.3
Removal of roller
15
9/ 20
V4 / 201007
55561/A3
Maintenance
RT-flex96C
30
3.4
Remove intermediate flange 29, and push out regulating rack 30.
I-I
29
28 30
49
32
019/236/10
57
31
43
V
33
36
35
34
23
3.5
39
40
52
37, 38
201007 / V4
10/ 20
RT-flex96C
55561/A3
Maintenance
3.6
M10x60
94550
STROKE
3 0.3 mm
34
94550
52
36, 35
40
39
019.235/10
11/ 20
V4 / 201007
55561/A3
Maintenance
RT-flex96C
4.
4.1
Preparation
Clean all parts and check their condition.
Damaged parts must be replaced.
Replace all O-rings, piston and rod seal rings.
Check the lubricating oil bores in the housings and in pump cylinder 23 for free
passage using compressed air.
X
4.2
23
37, 38
4.3
Check that the compression spring fits properly into the hole in the intermediate
disc by using a flashlight (see arrow in Fig. V).
Apply Never-Seez NSBT-8 to the threads and head seating surfaces of the
head screws 33 (M27), and tighten them crosswise in three steps with 100,
300 and finally to a torque of 480 Nm. Recheck all head screws 33, i.e. by applying the corresponding torque again!
201007 / V4
12/ 20
RT-flex96C
Maintenance
55561/A3
RC
4.4
10
8
44a
4.5
21
x
15
44
22
4.6
4.7
51
26
27
5
25
30 94555
012.413/06a
13/ 20
V4 / 201007
55561/A3
Maintenance
RT-flex96C
A1
4.8
CHECK
27
30
25
26
26
013.919/06a
4.9
B1
94593e
94593e
I-I
C1
94593a
94593a
24
51
5
I
94593b
013.920/06
2008
013.921/06
14/ 20
RT-flex96C
55561/A3
Maintenance
D1
21
Remark: Figures D1, E1, H1 and I1 are drawn
with former lower spring carrier and connection pin.
17
16
22
Oil pump plunger 22, sliding carefully into pump cylinder 23 and rest it on tool halves.
Guide retaining ring 17 and circlip 16 over lower
spring carrier 21 and push them onto the pump
plunger.
013.922/06
E1
94593d
17
16
013.923/06
15/ 20
201007
55561/A3
Maintenance
RT-flex96C
F1
21
55
09.276/10
15 44
6
56
14
21
56
7 44a
7
016.860/08
G1
I
94597
21, 6
55, 56
44, 44a
6
41
017.738/08
201007 / V4
016.860/08
16/ 20
RT-flex96C
Maintenance
55561/A3
H1
4.11 Final assembly
Oil guide piston 7 and fit it into lower housing 6.
42
94551
Turn pump plunger 22 till both drivers fit into the recesses of tool halves 94593a and 94593b.
Loosen equally screws 94593e and remove the tool
halves.
Remark: When loosening screws 94593e, make sure
that the pump plunger is not pushed up too!
17 18
21
94593a
16
54
22
94593e
17/ 20
201007
55561/A3
Maintenance
RT-flex96C
I1
Lower down carefully lower housing 6 together with
guide piston 7, ensuring that the drivers of pump
plunger 22 fit into the slot (guide) of regulating
sleeve 26.
Should this not be possible, the regulating sleeve
must be properly turned by means of regulating rack
30.
94551
Preload compression spring 24 with fitting & dismantling device 94551 till guide pin 9 can be inserted into the lower housing and guide piston with
handle screw GS.
Should this not be possible, the groove in the guide
piston must be aligned turning pressure piece DS
in the required direction.
21
J1
K1
30
DS
9
GS
013.929/06
013.928/06
2008
18/ 20
RT-flex96C
Maintenance
55561/A3
5.
Check whether the seating surfaces as well as the guide parts of the supply unit
housing and the fuel pump itself are in a faultless condition.
Fit remaining O-rings 45.
Oil the guide parts and fit the fuel pump, taking care of the locating pin and the
regulating shaft (do not use any jointing agent).
Fit screws 3 with oiled threads and head seating surfaces.
Tighten screws 3 to an angle of 64 using socket spanner insert 94598b, extensions 94598a and pneum. impact wrench 94598.
CHECK
L1
94598
94598a
94598b
3
013.930/06
19/ 20
2008
55561/A3
Maintenance
RT-flex96C
M1
48
46
45
7
OIL
FLOW
7.
Preserving
If a fuel pump has to be stored over a long period of time, the spaces carrying fuel
oil must be filled with Vaseline oil and plugged with plastic stoppers.
Furthermore, oil the fuel pump and protect it against humidity and soiling by wrapping it suitably.
Always store fuel pumps in upright position!
2011-02
20/ 20
RT-flex96C
55562/A1
Maintenance
Fuel Pump
Removal of a Jammed Pump Plunger
Tool:
1
1
1
1
2
1
1
1
Key to Illustrations:
Jack
Short tappet
Long tappet
Piston reset tool
Screws
HP oil pump
Pressure gauge
HP hose
1.
94595
94595b
94595c
94595d
94595e
94931
94932
94935
1
2
3
4
5
6
7
8
Upper housing
Lower housing
Pump plunger
Pump cylinder
Guide pin
Compression spring
Allen screw
Screw
9
10
11
12
13
14
Nut
Head screw (12xM27)
Piston
Vent screw
Spindle
Indicator
EV Relief valve
Preparatory works
Dismantle the fuel pump as far as possible (see 55561).
Check whether piston 11 is in the top position. If necessary push it fully back by
means of piston reset tool 94595d.
Insert short tappet 94595b.
Fasten jack 94595 onto upper housing 1 with head screws 10.
Remove first screw 8. Insert first screw 94595e and screw together with nut 9,
however keeping a clearance of 10 25 mm.
Remove second screw 8 from opposite side. Insert second screw 94595e and
screw together with nut 9, however keeping a clearance of 10 25 mm.
Remove both Allen screws 7.
I-I
11
10
94595
II
II
94595b
I
8
94595
1
1
2
11
94595d
13
9
94595e
014.181/06
WCH00075
7
2
x = 10 25 mm
II - II
1/ 3
201007
55562/A1
Maintenance
RT-flex96C
2.
Jacking-out procedure
Connect jack 94595 with HP oil pump 94931.
Shut relief valve EV and actuate HP oil pump till oil flows bubble-free at vent
screw 12.
Close the vent screw.
Attention! Take care during the jacking-out procedure that nuts 9 show always a
clearance of 10 25 mm, readjust repeatedly if required (Fig. A section II-II).
Press carefully till pump plunger 3 is jacked out by the spring force or till indicator 14 shows the stroke end, i.e. the indicator is flush with the housing.
D
If the pump plunger can now be taken out, remove jack 94595 and short tappet 94595b. Push the piston fully back by means of piston reset tool 94595d.
In case the pump plunger is still not loose, proceed as described in the following paragraph Jacking-out 2nd stage.
12
94595
11
94595d
14
94595b
FLUSH
13
94932
WCH00075
94935
201007
2/ 3
EV
94931
RT-flex96C
55562/A1
Maintenance
12
10
94595
94595c
14
1
FLUSH
94932
WCH00075
EV
94935
3/ 3
94931
201007
RT-flex96C
55641/A1
Maintenance
1.
Key to Illustrations:
94584
94589
94874
1
2
3
4
5
6
7
7a
8
9
10
Hose line
Hose line
Fuel leakage return
Fuel rail
Connection piece
Injection control unit
Screw
Screw
Pre-control valve
Screw
Intermediate plate
11
12
13
14
15
16
17
18
19
20
21
Lip seal
Position sensor
Countersunk screw
Nipple
Filter holder
Connecting nipple
Dowel pin
O-ring
O-ring
Oil filter
Circlip
General
When working on an injection control unit in principle the engine has to be stopped
and the fuel booster and bearing oil pumps switched off.
If it is necessary to replace an injection control unit, the engine must operate for a
minimum of 1.5 hours with marine diesel oil (MDO). For more data see Operation
Manual 02701.
Attention! There must be no pressure in fuel rail 4.
The corresponding drain (screws) valves must be opened as described in 05101
of the Operating Manual. Follow the detailed instructions without fail!
Maintenance on the injection control unit can be done only by the manufacturer as
a matter of principle. However, if troubles have been detected on the injection control unit during operation, it must be replaced by a revised unit, following the instruction below.
Remark: No maintenance work is provided for pre-control valve 8. If necessary it
must be replaced as a whole unit!
2.
Removal
A
3
5
7a
7
14
011.730/04
Remove fuel pressure pipings according to 87331 and unscrew connection pieces 5 from injection control unit 6 as shown in Fig. D (the
connection pieces are screwed into
the spare injection control unit).
1/ 4
2012-11
55641/A1
Maintenance
RT-flex96C
B
3
94584
12
4
9
8
011.954/04
2008
2/ 4
RT-flex96C
55641/A1
Maintenance
3.
Fitting
Insert lip seal 11.
Lower injection control unit 6 carefully onto the fuel rail and remove the lifting
plate.
Apply Never-Seez NSBT-8 to the threads of screws 7 and 7a (Fig. A).
First tighten screws 7a crosswise with a torque of 110 Nm and subsequently
screws 7.
Replace O-rings 18, if necessary.
Apply Never-Seez NSBT-8 to screws 9 and fasten pre-control valve 8 to injection control unit 6 with them.
Tighten screws 9 with a torque of 2.5 Nm.
15
21
16
20
FLOW
DIRECTION
II
11
4
17
II
13
18
10
9
014.279/06
3/ 4
201007
55641/A1
Maintenance
RT-flex96C
For restarting the injection see instructions 05101 in the Operating Manual!
I-I
94874
19
6
014.280/06
2008
4/ 4
RT-flex96C
56101/A1
Maintenance
Key to Illustrations:
1 Case
94720c
consisting of:
1.
1
2
3
4, 4a
5
Hydraulic accumulator
Protection cap
Pressure reducing valve
Hose (1m, 4 m)
Control unit with
valves A, B and C
7 Pressure gauge 060 bar
8 Valve block
9
10
11
12
13
14
15
Check the filling pressure at least once in the first week after start-up of the accumulator. If no loss of gas is observed, recheck after three months. If there is still no
change in pressure, an annual check might be sufficient, however, it is recommended to continue carrying out checks every three months.
Attention! Ensure that servo oil supply is shut off before starting accumulator
pressure checking and charging. Also no residual oil pressure in valve block must
be visible on pressure gauge 12 (PI2041L) of pressure reducing valve 8.111.
1.1
1.2
Preparation
Close stop valve 14 between rail unit and pressure reducing valve (Fig. C).
Checking procedure
Close the three valves A, B and C on control unit 5.
Connect accumulator 1 to control unit 5 using short hose 4.
Open valve A and read pressure from gauge 7.
Required gas pressure: min. 20 bar / max. 25 bar.
If gas pre-charge pressure is ok:
Close valve A and drain remaining pressure in control unit by opening valve B.
Disconnect short hose from accumulator.
Refit protection cap.
Remark: During every check a small amount of gas may be lost to the atmosphere. Therefore, make sure a gas bottle is available before a pressure check is
made in order to refill possible loss.
If gas pre-charge pressure is not ok:
Refill the accumulator.
1/ 4
2012
56101/A1
Maintenance
RT-flex96C
2.
2.1
Refilling procedure
Fit pressure reducing valve 3 to nitrogen bottle 15 and adjust the pressure to
approx. 30 bar.
Close the three valves A, B and C on control unit 5.
Connect pressure reducing valve with long hose 4a to the right side (C), and
accumulator with short hose 4 to the left side (A) of control unit.
Open valve A and read pressure from gauge 7.
Slowly open valve C and refill accumulator to the required pressure of 25 bar.
Close valves A and C and drain remaining pressure in control unit by opening
valve B.
Disconnect hoses 4, 4a and refit all protection caps.
2.2
2012
2/ 4
RT-flex96C
56101/A1
Maintenance
Case with measurement set 94720c for CLU4 and PRV 8.111:
Case 94720c
4, 4a
Arrangement of equipment:
B
PI2041L
12
13
7
A
C
15
8
1
4a
WCH00703
3/ 4
2012
56101/A1
Maintenance
RT-flex96C
C
14 (4.305)
9
PRESSURE REDUCING
UNIT
1, 2
10, 11
FREE
END
WCH00853
Details of servo oil rail 4.11 > pressure reducing valve 8.111 > lubricating pump 8.06:
8.06
RAIL UNIT
4.11
PI2041L
8.111
13
WCH00861
WCH00852
2012
4/ 4
RT-flex96C
56121/A1
Maintenance
1.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
3340
Slide rod
Lower cover
Piston
Screw plug
Filter holder
Filter
Circlip
Closing piece
Gasket
Screw
Non-return valve
Nipple
Screw
Screw
O-rings
KO Slot
OE Oil inlet
General
When working on the exhaust valve drive in principle the engine has to be stopped
and the bearing oil pump switched off.
Attention! Pipings for servo and control oil must be pressureless.
Follow the instruction in 05201 of the Operating Manual without fail!
2.
Removal
2
1
Remove piping.
10
5
6
4
7
Loosen nut 6.
8a
8
9
WCH00088
1/ 4
201007
56121/A1
Maintenance
RT-flex96C
3.
Fitting
It is recommended to pre-assemble the exhaust valve drive outside the rail unit.
The work station must be clean; welding and grinding should not be done nearby!
Remark: All screw and nut threads must be oiled, and all O-rings must be replaced
by new ones.
Place connecting piece 4 with O-ring 38 (Fig. B, view II) over the studs taking
care of the dowel pins and screw it down by hand, using nuts 6.
CHECK
Make sure that the connecting piece has metallic contact with the servo oil rail.
Place housing 1 together with 3/2-way valve 2 on servo oil rail 7.
Drag housing with 3/2-way valve by hand against connecting piece and tighten the four screws 5 by hand.
Loosen screws 10 slightly. Take care of O-ring 34.
Crosswise tighten connecting piece to the servo oil rail by means of nuts 6 with
a torque of 60 Nm.
Crosswise tighten connecting piece to 3/2-way valve by means of screws 5
with a torque of 170 Nm.
D
4.
For fitting the hydraulic piping to the exhaust valve drive see 84601.
201007
2/ 4
RT-flex96C
56121/A1
Maintenance
13
30
1
10
I
4
II
11
II
38
7
KO
4
011.827/04
5.
30
5.1
13
Removal
OE
5.2
Fitting
014.239/06
29
3/ 4
201007
56121/A1
Maintenance
RT-flex96C
6.
7.
I-I
26
3
28
10
37
31
15
16
17
18
33
12
13
19
36
25
22
34
39
40
74 mm
27
14
21
32
23
24
35 20
WCH00090
FLOW
DIRECTION
201007
4/ 4
RT-flex96C
58011/A1
Maintenance
Regulating Linkage
Adjusting
Key to Illustrations:
1
2
3
4
5
6
7
8
9
10
1.
Fuel pump
Actuator
Forked lever
Torsion spring
Pin
Adjusting screw
Limit lever
DU bush
Regulating (toothed) rack
Stop ring
11
12
13ae
14a, b
15
16
17
18
19
Flange
Holder
Connecting rods
Stop screws
Actuator lever
Actuator shaft
Regulating shaft
Intermediate wheel
Pointer
General
After overhauling the linkage or the fuel pumps, as well as after fitting a new fuel
pump or a new actuator, the setting of the linkage must be checked and, if necessary, adjusted.
A
Attention! The power to the actuators 2
must be interrupted first, before they are
disconnected from the regulating linkage
(see 93621 in the Operating Manual).
1
2
012.431/04
2.
I-I
2.1
3
8
17
011.776/04
1/ 4
2008
58011/A1
Maintenance
RT-flex96C
2.2
C
15
14a 16
14b
012.439/04
2008
2/ 4
RT-flex96C
58011/A1
Maintenance
2.3
13e 19
19
13b
2
13a
13d
13c
19
13e
012.401/04
19
E
I-I
13b
13a
15
13d
13c
17
11
13e
13e
18
11
012.402/04
3/ 4
2008
58011/A1
Maintenance
RT-flex96C
13b
13a
13d
13c
012.403/04
2.5
The admissible deviation between the individual fuel pumps is 0.1 mm.
If there are no pointers or incorrectly set ones fitted on the regulating shaft, an
easy alternative adjustment (cross check) can be carried out. I.e. a distance of
approx. 5 mm must result between pump housing and stop ring 10 with actuator shaft at pos. 0.
Rotate the actuator shafts while checking whether the fuel regulating linkages are
freely moveable over the whole regulating range.
Stop rings 10 must not touch the fuel pump housing in any of the end positions. A
possible correction can be carried out by adjusting screws 6.
CHECK
10
x
9
10
12
I
3
19
13e
012.432/04
2008
4/ 4
RT-flex96C
Maintenance
Group6
Group 6
Checking the Air Flaps and Cleaning the Scavenge Air Receiver . . . . . . . . . . . . . . 64201/A1
Auxiliary Blower: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65451/A1
1/ 4
RTflex96C / MM / 2008
RT-flex96C
64201/A1
Maintenance
1.
9
10
11
12, 12a
13
14
15
Screw
Locking plate
Distance ring
Stop plate
Pin
Drain
Relief valve
General
Depending on number of cylinders air flaps are arranged either as shown in Fig. B
or Fig C or there are both arrangements fitted in the same engine.
2.
In the course of periodic cleaning of the scavenge air receiver, air flaps 3 (Fig. B
and C) must be checked for damage, movability and fouling.
To check air flaps in scavenge air receiver 1, the two doors 4 arranged at the
end are to be opened and locked with pins 13 on the inner sides (Fig. A view
II).
To check upper air flaps, cover 7 must be opened and locked with one of
screws 8 (Fig. C view V).
To check air flaps for auxiliary blowers 5, the cover 6 on suction space 2 is to
be opened (Fig. B).
A
5
II
I
II
1
13
011.956/04
1/ 4
2012-05
64201/A1
Maintenance
RT-flex96C
Checking the Air Flaps and Cleaning the Scavenge Air Receiver
3.
For the removal of several air flaps, first screws 9 and their locking plates 10 as
well as stop plates 12 and 12a must be removed as shown in Fig. C. Subsequently the air flaps can be removed as single unit.
Check that the air flaps are freely moveable in fitted condition.
3
II
10
II
3
III
IV
III
12
11 12
9
10
IV
011.957/04
2012-05
2/ 4
RT-flex96C
64201/A1
Maintenance
Checking the Air Flaps and Cleaning the Scavenge Air Receiver
II
III
III
13
II
I
IV
V
12a
8
3
12
I-I
1
IV
VI
VI
12
3
VII
10
12
11
12
VII
011.958/04
3/ 4
2008
64201/A1
Maintenance
RT-flex96C
Checking the Air Flaps and Cleaning the Scavenge Air Receiver
4.
At this opportunity check whether drains 14 are not clogged, so that their function is
assured during operation (Fig. D).
During a major overhaul relief valve 15 must be checked. The valve is set to an
opening pressure of 4.1 $ 0.2 bar (relative).
Remark: Do not open the relief valve with disc springs! In case of any damages or
malfunctions please contact the manufacturer or Wrtsil Switzerland Ltd.
15
1
14
011.959/04
14
RELIEF VALVE WITH
COMPRESSION SPRING
178 mm
DISC SPRINGS
50 mm
MAX. STROKE
011 960/04
2012-05
4/ 4
RT-flex96C
65451/A1
Maintenance
Auxiliary Blower
Maintenance
Tools:
1 Spur-geared chain block
1 Dismantling device
Key to Illustrations:
94650
94651
1
2
3
4
5
6
7
8
consisting of:
1 Trolley
2 Centring studs
1.
94651c
94652
Electric motor
Motor plate
Spiral casing
Impeller
Support
Shim
Screw
Screw
9 Screw
10 Longitudinal beam
11 Exhaust manifold
BC Board crane
LA Strap
General
Remark: Auxiliary blowers which are out of service for a longer period should be
started up for a short time twice a month. Where this is not feasible, the impeller
should be turned by hand by several turns. This is necessary to protect the bearings from corrosion damage.
2.
3.
Removal
Separate electrical leads from electric motor 1.
Remove screws 8.
On 10 and 12 cylinder engines support 5 is welded on the receiver, therefore,
screws 9 must be removed.
A
3
1
6
8
011.699/04
1/ 3
2012-05
65451/A1
Maintenance
RT-flex96C
I
BC
11
LA
10
94651c
94650
94652
011.701/04
1
2012-05
2 4 94652
2/ 3
RT-flex96C
Maintenance
65451/A1
4.
Dismantling
For dismantling works and maintenance of the auxiliary blower please comply with
the instructions of the manufacturer.
The impeller is statically and dynamically balanced, and therefore must in no way
suffer damage. The impeller must be rebalanced in case of any damaged or replaced parts turning together with the motor shaft.
5.
Fitting
Fit both centring studs 94652.
With the aid of trolley 94651c and spur-geared chain block 94650 fit electric
motor 1 including impeller 4 into spiral casing 3 and firmly tighten screws 7
crosswise.
Remove centring stud and replace it by screws.
Connect electric motor to mains and check direction of rotation.
3/ 3
2012-05
RT-flex96C
66061/A1
Maintenance
Lifting device
Lifting device
Extension
Extension
Roller plate
Support
Beam
Swivel lugs
Wire rope sling*
Wire rope sling*
Wire rope sling*
Wire rope sling*
Wire rope sling*
Wire rope sling*
Key to Illustrations:
94660
94660a
94660b
94660c
94662
94663
94664
94665
94666
94666a
94666b
94666c
94666d
94666e
1
2
3
4
5
6
7
8
9
10
11
12
13
Butterfly valve
Cooling water inlet pipe
Cooling water outlet pipe
Drain pipe
Vent pipe
Connecting bend
Screw
Cover
Screw
Connection chamber
Receiver
Swivel lug
Spur-geared chain block
14
15
16
17
18
19
20
Cooler pre-stage
Main cooler
Screw
Rail
Roller
Plate
Plate
AH
DF
HZ
RC
ST
Stop lever
Sealing surface
Lifting tackle
Eye bolt
Set screw
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/18
Preliminary works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/18
Removal of cooler element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/18
Transport of cooler element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/18
Separating of cooler elements . . . . . . . . . . . . . . . . . . . . . . . . . 9/18
Assembly of cooler elements . . . . . . . . . . . . . . . . . . . . . . . . . . 9/18
Fitting of cooler element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/18
Removal of cooler pre-stage . . . . . . . . . . . . . . . . . . . . . . . . . . 12/18
Fitting of cooler pre-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/18
General
Risk of accident! Either only the cooler pre-stage alone or the cooler element
(consisting of main cooler and cooler pre-stage) may be removed.
Depending on the manner in which the cooler element or the cooler pre-stage are
carried away (upwards or downwards) after their removal, parts concerned must
be removed from the upper or lower platform (Fig. K). Therefore, always block or
cover the relevant openings for reason of safety!
Remark: Pay attention to General Guidelines for Lifting Tools 00121.
1/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
2.
Preliminary works
Stop the cooling water pump. Close butterfly valves 1 and drain coolers.
Remove drain and vent pipes 4 and 5.
Remove cooling water inlet and outlet pipes 2 and 3 above butterfly valve 1 of
the element to be dismantled.
Remove connecting bend 6 for the removal of cooler pre-stage 14.
14
5
I
3
2
I
I-I
5
6
4
1
011.870/04
2008
2/ 18
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
3.
II
11
7
9
10
II
14
011.872/04
3/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Remove plate 20 from roller plate 94662 (Fig. T).
Fasten roller plate with their screws to connection chamber 10 as shown in
Fig. C (view I).
Connect rope 94666b with eye bolts of the roller plate.
Connect rope 94666c with eye bolts RC (M20) fitted into the opposite side.
Connect ropes 94666b with 94666e.
Connect ropes 94666e with 94666c to lifting tackle HZ.
Press cooler element slightly upwards with set screws ST.
II
11
94666b 94666e
HZ
94666c
RC
ST
18
10
94662
17
ST
AH
II
011.873/04
2008
4/ 18
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Pull out the cooler element till the minimum length of lifting tackle HZ is
reached. Subsequently remove rope 94666e (Fig. C) and connect 94666b
directly to lifting tackle HZ.
Pull out the cooler element till stop a.
Place beam 94664 over cooler pre-stage 14.
Fasten lifting devices 94660 and 94660a to main cooler 15 as shown in Fig.
D.
Risk of accident! Swivel lugs 12 to the lifting devices must be hand-screwed using an open end wrench.
II
HZ
94666
94666a
94664
14
15
94660
94660a
a 94666b
HZ 94666c
II
SHIP SIDE
II
13
94666
94660a
12
94660
12
013.876/06
5/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Pull stop lever AH of roller plate 94662 upwards and draw the cooler element
till stop b. Follow up with spur-geared chain block 13 maintaining the ropes
tight at the same time.
Remove ropes 94666b with 94666c, lifting tackle HZ and roller plate 94662.
Lift cooler element slightly upwards with spur-geared chain block (Fig. F).
I
AH
I
013.877/06
b 94666b HZ 94666c
SHIP SIDE
F
13
013.878/06
2008
6/ 18
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
HZ
013.879/06
H
SHIP SIDE
K
13
013.880/06
013.882/06
013.881/06
7/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
4.
L
Place cooler element on the lower platform.
Loosen lifting gear 94660 from the cooler element and extend it by means of tools 94660b
and 94660c.
Refasten the extended lifting gear to the cooler element.
Transport the cooling element along the engine till it can be further handled by the crane.
013.883/06
94660b
94660c
013.884/06
2008
8/ 18
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
5.
N
I
16
16
14
15
19
013.885/06
I
94665
I
014.031/06
DF
6.
9/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
7.
Take care that the roller plate rests on stop b as shown in Fig. M.
94663
94666e
HZ
94666c
RC
HZ
ST
94666d
94663
94662
18
17
b
94666e
HZ
94663
013.886/06
2008
10/ 18
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Pull the cooler element into the receiver by approx. 110 mm.
Place beam 94664 over the cooler element and then remove all lifting tools.
Apply a high-temperature and non-hardening jointing compound to sealing
surfaces DF.
Remove beam 94664.
approx. 110 mm
ST
013.887/06
94666e
94666c
94664
DF
R
Pull the cooler element into the receiver till the
minimum length of lifting tackle HZ is
reached. Subsequently connect rope 94666e
and lifting tackle HZ directly to rope 94666c
as shown in Fig. R.
Pull the cooler element fully into the receiver.
Remove all tools and fasten the cooler element to the receiver.
Clean sealing surfaces DF of cover 8 and receiver (Fig. B) and apply a high-temperature
and non-hardening jointing compound.
Fit the cover.
Install all pipings and parts concerned to the
upper or lower platform.
011.910/04
HZ 94666c
CHECK
11/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
8.
II
11
7
9
10
II
14
011.872/04
2008
12/ 18
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Fasten roller plate 94662 with corresponding plate 20 to the flanges for connecting bends 6 of cooler pre-stage 14.
Connect rope 94666e with eye bolt of the plate.
Connect rope 94666b with eye bolts RC fitted into the opposite side.
Connect ropes 94666e with 94666b to lifting tackle HZ.
Press cooler pre-stage slightly upwards with set screws ST.
II
14
94662 94666e
HZ 94666b
RC
I
I-I
20
ST
94662
18
17
II
011.918/04
94666e
13/ 18
HZ 94666b
RC
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Pull out cooler pre-stage 14 till stop a.
Place beam 94664 over the cooler pre-stage.
Fasten swivel lugs 94665 to cooler pre-stage on both sides (see also Fig. N).
Connect rope 94666 and spur-geared chain block 13 with swivel lugs on engine side.
Hang lifting tackle HZ (lifting capacity 750 kg) on the lifting lug of rope 94666.
Connect rope 94666a with lifting tackle HZ and swivel lugs on ship side.
Tighten ropes 94666 and 94666a.
Remove beam 94664.
I
HZ
94666
94666a
94664
94665
14
94666b
a 94666e
HZ
I
SHIP SIDE
13
HZ
94666
94666a
94664
94665
94662
011.919/04
2008
14/ 18
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Pull out the cooler pre-stage till the minimum length of lifting tackle HZ is
reached. Subsequently remove rope 94666e (Fig. U) and connect roller support 94662 directly to lifting tackle HZ.
Pull stop lever AH of roller plate 94662 upwards and draw the cooler prestage till stop b. Follow up with spur-geared chain block 13 maintaining ropes
94666 and 94666a tight at the same time.
Remove rope 94666b, lifting tackle HZ and roller plate 94662.
V
13
I
AH
94666
94666a
I
b
94662
SHIP SIDE
HZ 94666b
13
Lift cooler pre-stage slightly upwards with
spur-geared chain block.
Turn the cooler pre-stage into vertical position by means of lifting tackle HZ.
In this position the cooler pre-stage can be
moved up or downwards and subsequently
returned into horizontal position.
HZ
011.920/04
15/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
9.
X
I
PROTECTION
94663
94666e
94666c
RC 14 DF
94666d
I
94666e
HZ
94663
011.921/04
2008
16/ 18
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Fit roller plate 94662.
D
Take care that the roller plate rests on stop b as shown in view I.
Y
I
94662
DF
94666c
Pull the cooler pre-stage into the receiver by approx. 110 mm.
Place beam 94664 over the cooler pre-stage and then remove all lifting tools
(ropes 94666, 94666a, lifting tackle HZ and swivel lugs 94665).
Remove the beam.
Apply a high-temperature and non-hardening jointing compound to sealing
surfaces DF.
Press cooler pre-stage slightly upwards to the correct height with set screws
ST (Fig. T).
Pull the cooler pre-stage into the receiver till the minimum length of lifting
tackle HZ is reached.
Z
HZ
94666
94666a
approx. 110
mm
011.922/04
94664
17/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
Remove 94666e (Fig. Y) and subsequently connect lifting tackle HZ directly
to support 94663 and rope 94666c as shown in Fig. A1.
Pull the cooler pre-stage fully into the receiver.
Remove all tools and fasten the cooler pre-stage to the receiver.
Fit cooler pre-stage 14 and plates 19 using screws 16 (Fig. N).
Clean sealing surfaces DF of cover 8 and receiver (Fig. B) and apply a hightemperature and non-hardening jointing compound.
Fit the cover.
Install all pipings and parts concerned to the upper or lower platform.
CHECK
A1
011.923/04
94663
2008
HZ
18/ 18
94663c
RT-flex96C
66061/A2
Maintenance
Lifting devices
Extension
Roller plate
Support
Support
Support
Supports
Catwalk
Swivel lugs
Discs
Wire rope sling*
Wire rope sling*
Wire rope sling*
Wire rope sling*
Key to Illustrations:
94660d
94661
94662
94663a
94663e
94663d
94663f
94664a
94665b
94665c
94666f
94666g
94666h
94666i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Butterfly valve
Cooling water inlet pipe
Cooling water outlet pipe
Drain pipe
Vent pipe
Connecting bend
Screw
Cover
Screw
Connection chamber
Receiver
Screw
Spur-geared chain block
Cooler pre-stage
Main cooler
Screw
Rail
Roller
Plate
Plate
Bottom plate
Support
Plate
24
25
26
27
28
29
30
31
32, 32a
33
34
35
36
37
Screw
Roller
Screw
Double spring clip
Bolt
Lower stay
Bolt
Upper stay
Bolt
Threaded rod
Roller support
Bolt
Roller
Swivel lug
AH
DF
HU
HZ
H1
RC
ST
Stop lever
Sealing surface
Wooden underlay
Lifting tackle
Lifting tackle
Eye bolt
Set screw
Overview
1.
2.
3.
4.
5.
6.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/18
Preliminary works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/18
Removal of cooler pre-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/18
Fitting of cooler pre-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/18
Removal of main cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/18
Fitting of main cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/18
General
Risk of accident! Cooler pre-stage and main cooler may be removed only one by
one. To prevent having a fall, immediately close the openings off after removing
bottom plates!
For every removal and fitting of a cooler, supports 22 (Fig. C) must always be provided and may be removed again only after completion of the works.
Remark: Pay attention to General Guidelines for Lifting Tools 00121.
1/ 18
2008
66061/A2
Maintenance
RT-flex96C
2.
Preliminary works
Stop the cooling water pump. Close butterfly valves 1 and drain coolers.
Remove drain and vent pipes 4 and 5.
Remove cooling water inlet and outlet pipes 2 and 3 above butterfly valve 1 of
the cooler to be dismantled.
Remove connecting bend 6 for the removal of cooler pre-stage 14 and main
cooler 15.
Remark: Depending on the situation, the corresponding pipings must also be removed from the opposite scavenge air cooler.
14
5
6
4
I
3
2
I
I-I
5
6
14
15
011.870/04
2008
2/ 18
RT-flex96C
66061/A2
Maintenance
3.
III
II
III
II
11
7
8
14
10
III - III
16
19
15
013.948/06
3/ 18
2008
66061/A2
Maintenance
RT-flex96C
3.1
II
22
14
94662
94666g
HZ RC
I-I
20
94662
ST
18
17
II
013.951/06
2008
94666g
4/ 18
HZ RC
RT-flex96C
66061/A2
Maintenance
I
AH
I
013.952/06
15
94663f
HZ
11
94665b
Hoist stop lever AH of roller plate 94662 and pull out the cooler pre-stage till
stop b.
Remark: If the cooler pre-stage does not touch stop b although lifting tackle HZ
has reached its minimum length, rope 94666h must be connected directly to swivel
lugs 94665b and the lifting tackle as shown in Fig. E. Subsequently the cooler prestage can be pulled out till stop b.
Remove the lifting tackle, rope and catwalk.
013.955/06
94665b 94666h
5/ 18
94664a b
HZ
2008
66061/A2
Maintenance
RT-flex96C
013.957/06
94663f
G
3.2
94662
21
14
013.958/06
013.959/06
2008
013.960/05
6/ 18
RT-flex96C
66061/A2
Maintenance
013.961/06
L
Turn cooler pre-stage 14 into horizontal position by means of the spur-geared chain
blocks as shown in Fig. L and M.
013.962/06
013.963/06
14
7/ 18
2008
66061/A2
Maintenance
RT-flex96C
4.
N
94663f
94663e
HZ
94666f
94666i RC
13
94664a
DF
94665b
94662
94666g
94663d
013.964/06
2008
8/ 18
RT-flex96C
66061/A2
Maintenance
Remove rope 94666f (Fig. N) and connect lifting tackle HZ to rope 94666i as
shown in Fig. O.
Pull out cooler pre-stage 14 till stop b and remove support 94663f.
013.965/06
HZ
94666i
94663f
Pull the cooler pre-stage fully into the receiver (Fig. P).
Remove all tools and fasten the cooler pre-stage to the receiver.
Fit cooler pre-stage 14 and plates 19 using screws 16 (Fig. B).
Clean sealing surfaces DF of cover 8 and receiver (Fig. B) and apply a hightemperature and non-hardening jointing compound.
Fit the cover.
Install all pipings and platform parts.
CHECK
013.966/06
9/ 18
2008
66061/A2
Maintenance
RT-flex96C
5.
Pay attention to section 1 General information and carry out the works as described under sections 2 & 3 Preliminary works and Removal of cooler prestage.
Q
I
11
9
10
15
013.967/06
R
I
ST
18
17
013.968/06
94661
2008
94662 10
10/ 18
RT-flex96C
66061/A2
Maintenance
S
5.1
24
23
5.1.1 Step 1
Withdraw double spring clip 27 and remove
pin 28 with roller 25.
013.969/06
26
15
26
25
27
28
5.1.2 Step 2
Connect lower stays 29 with plates 23 by
means of bolts 30 resp. 32.
32
23
31
29
30
I
x1
33
013.970/06
11/ 18
2008
66061/A2
Maintenance
RT-flex96C
5.1.3 Step 3
Connect lower stays 29 with roller support 34
by means of bolts 35.
31
013.971/06
32a
35 29
5.2
34
94661
94662
94666i
HZ RC
013.972/06
94661
2008
94666i
12/ 18
RT-flex96C
66061/A2
Maintenance
Pull out the main cooler till extension 94661 is situated in the receiver.
Press main cooler slightly upwards by turning threaded rod 33 (Fig. T view I).
Pull out the main cooler till the minimum length of lifting tackle HZ is reached.
Place catwalk 94664a over the main cooler.
Fasten both lifting devices 94660d to the main cooler.
D
Make sure that the swivel lugs 37 are screwed in at the top of the lifting devices.
Fit eye bolt RC on the opposite side and connect it to lifting tackle H1.
Connect rope 94666h to the swivel lugs and lifting tackle H1.
Tighten lifting tackle H1.
Remove lifting tackle HZ and rope 94666i.
W
I
37
94664a
94666h
H1
RC
94660d
94660d
013.973/06
94660d
94666i
HZ
13/ 18
2008
66061/A2
Maintenance
RT-flex96C
Hoist stop lever AH of roller plate 94662 (Fig. D view I) and pull out the main
cooler till stop b.
Remove rope 94666h and lifting tackle H1.
94666h
H1
013.974/06
Screw swivel lugs 37 into the lifting device 94660d on that side pointing to the
engine, and these on the opposite side in the middle of the lifting device (Fig.
Y view I).
Connect and tighten spur-geared chain blocks 13 to the swivel lugs of the lifting devices.
Remove extension 94661 and roller plate 94662.
13
37
37
013.975/06
94661
94662
2008
14/ 18
RT-flex96C
66061/A2
Maintenance
Z
13
5.3
013.976/06
A1
013.977/06
C1
B1
013.979/06
013.978/06
15/ 18
2008
66061/A2
Maintenance
RT-flex96C
D1
Turn the main cooler into horizontal position
by means of the spur-geared chain blocks 13
and place it on wooden underlays HU as
shown in Fig. D1 to F1.
F1
013.980/06
13
E1
013.981/06
HU
013.982/06
2008
16/ 18
RT-flex96C
66061/A2
Maintenance
6.
Make sure that the roller plate rests on stop b as shown in Fig. G1.
G1
13
94664a
DF
94663e
HZ
94666f
94661
94660d
ST
94666g
94663d
94662
94663a
I
17
013.987/06
17/ 18
2008
66061/A2
Maintenance
RT-flex96C
Pull the main cooler fully into the receiver till stop a.
D
Take care that the main cooler does not jam during fitting.
Remark: If the main cooler rests on stop a, rollers 25 should be in the receiver,
otherwise the main cooler must be further pulled in correspondingly.
Lift roller 36 of extension 94661 slightly off the receiver 11 by turning threaded
rod 33.
Pull the main cooler into the receiver till the minimum length of lifting tackle
HZ is reached. Subsequently connect rope 94666f and lifting tackle HZ directly to support 94663a.
H1
94662
94666f
013.988/06
I1
11 36
33
94663a
25
013.989/06
2008
18/ 18
RT-flex96C
67081/A1
Maintenance
Water Separator
Removal and Fitting of Water Separator
Tools:
1
1
1
1
1
*
1.
Key to Illustrations:
Carriage
Pulley device
Support
Lifting device
Wire rope sling*
94667
94668
94669
94672
94673
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Door
Pin
Cover
Cover
Receiver
Platform support
Platform support
Screw
Intermediate ring
Plate
Plate
Rail
Screw
Screw with washer
15
16
17
18
19
20
21
AC
HZ
KO
RC
TU
Water separator
Rail
Spur-geared chain block
Lock screw
Drain pipe
O-ring (round rubber ring)
O-ring (round rubber ring)
Chamfer
Lifting tackle
Slot
Eye bolt
Door opening
Preparation
Loosen doors 1, open up and lock it on the inside with pin 2.
Attach lifting tackle HZ (carrying capacity 1000 kg) to the lug on the platform
support (Fig. A and F).
Remove platform supports 6, 7 and the corresponding bottom plates which
hinder the removal of the water separator.
Attention! To prevent having a fall, immediately close the openings off after removing the bottom plates!
Remark: Pay attention to General Guidelines for Lifting Tools 00121.
HZ
I
6
2 1
1
011.966/04
1/ 8
2008
67081/A1
Maintenance
RT-flex96C
II
II
5
TU
III
III
1.1
012.559/04
IV
IV
15
11
14
III - III
15
11
14
10
13
12
20
AC
13
012.560/04
2008
21 12
IV
KO
2/ 8
SILICONE
RT-flex96C
67081/A1
Maintenance
1.2
V-V
III - III
V
15
11
14
10
20
15
SILICONE
012.561/04
2.
2.1
Both edges must be filled with silicone before fitting O-ring 21, which should
protrude on both sides.
When fitting plate 10 take into consideration that its longitudinal chamfer AC
presses O-ring 20 against the water separator.
D
2.2
After placing O-ring 21 on rail 12, the latter is bolted with plate 11.
The O-ring is pressed against receiver 5 by means of an appropriate blunt tool
through slot KO.
First fill up the gap between receiver 5 and water separator 15 on both ends
with silicone. Subsequently fit O-ring 21 and the remaining sealing elements.
3/ 8
2008
67081/A1
Maintenance
RT-flex96C
2.
Removal
Loosen screws 8 and remove them together with intermediate ring 9.
Put carriage 94667 on rail 16 and fasten it to water separator 15.
5
94667
15
16
15
012.562/04
19
2008
4/ 8
RT-flex96C
67081/A1
Maintenance
94667
15
94669
18
16
94667
011.968/04
16
18
b 94667
RC
HZ
15
94669
5/ 8
2008
67081/A1
Maintenance
RT-flex96C
HZ
15
94672
94667
G
17
HZ
94672
011.969/04
2008
6/ 8
RT-flex96C
67081/A1
Maintenance
3.
Fitting
CHECK
Prior to fitting the water separator, check drain pipes 19 (Fig. C) for free passage.
Move the water separator to the mounting place as shown in Fig. F and E for
the removal but in reverse sequence, and adjust it to the mounting height.
Mount support 94669 and carriage 94667.
Fit a lock screw 18 each into stop b on both rails 16 (view I).
Carefully lower water separator onto rails 16 and support 94669 as shown in
Fig. H.
D
Remark: When fitting the opposite water separator, lock screws 18 must be fitted
into stops a, and support 94669 has to be fastened directly below the water separator to be fitted (Fig. E).
Remove lifting device 94672 and disconnect lifting tackle HZ from carriage
94667.
I
94667
18
16
HZ
94672
18
b 94667
011.970/04
94669
7/ 8
2008
67081/A1
Maintenance
RT-flex96C
94668
94673
18
94667
HZ
RC
011.971/04
2008
8/ 8
RT-flex96C
67351/A1
Maintenance
Housing
Cover
Piston
Pressure reducing valve
Adjusting screw
(stroke limitation)
6 Seal (1 mm thickness)
1.
7
8
9
10
11
12
13
Lock nut
Screw
Guide ring
Piston seal ring
Compression spring
Solenoid valve
Silencer
2.
Assembling
Assembling is carried out analogously to dismantling but in reverse sequence.
Attention! Should seal 6 need to be replaced, attention must be paid to ensure
that a seal of the same thickness (1 mm) is refitted.
Before assembling smear all moving parts lightly with clean oil.
Remark: The retaining pressure is adjusted with pressure reducing valve 4.
10
11
6
12
2
7
5
8
13
1
014.132/06
014.131/06
1/ 1
2008
RT-flex96C
Maintenance
Cylinder Lubrication
Group7
Group 7
1/ 5
RT-flex96C
72181/A1
Maintenance
Key to Illustrations:
1 Case
94720c
consisting of:
1.
1
2
3
4
5
6
7
8
Hydraulic accumulator
Protection cap
Pressure reducing valve
Hose (1 m)
Hose (4m)
Control unit with valves A,B,C
Pressure gauge 0...60 bar
Lubricating pump (CLU4)
9
10
11
12
13
14
15
Check the pre-charge pressure directly after the installation of a new accumulator,
then at least once in the first week after start-up. Afterwards, check the pre-charge
pressure every three months.
Attention! Ensure that servo oil supply is shut off before starting accumulator
pressure checking and charging. Also no residual oil pressure in the servo oil supply line must be visible on pressure gauge PI2041L of pressure reducing valve
8.111.
1.1
Close the stop valve 4.305 on servo oil rail 4.11 (Fig. D).
Drain the servo oil system at screw plug 12 of pressure reducing valve 8.111
(Fig. E).
Remark: Screw plug 12 must remain open during the entire checking / refilling
procedure.
1.2
1/ 5
CLU4 / 2011-07
72181/A1
Maintenance
RT-flex96C
1.3
2011-07 / CLU4
2/ 5
RT-flex96C
72181/A1
Maintenance
2.
Final assembly
2.1
2.2
Required equipment:
3/ 5
CLU4 / 2011-07
72181/A1
Maintenance
RT-flex96C
Case 94720c
4, 5
Arrangement of equipment:
14
2011-07 / CLU4
4/ 5
RT-flex96C
72181/A1
Maintenance
13
15
9
10
SERVO
OIL
1
2
11
015.438/07
Details of servo oil rail 4.11 > pressure reducing valve 8.111 > lubricating pump 8.06:
8.06
RAIL UNIT
4.11
PI2041L
8.111
12
WCH00861
PRESSURE REDUCING
UNIT
5/ 5
WCH00852
CLU4 / 2012-05
RT-flex96C
Maintenance
Piping
Group8
Group 8
Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81351/A1
Servo Oil Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . 84471/A1
Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding . . . . 84601/A1
1/ 1
RTflex96C / MM / 2011-03
RT-flex96C
81351/A1
Maintenance
1.
General
The Low-Load Tuning concept is based on the combination of a specifically designed turbocharging system setup and appropriately adjusted engine parameters related to fuel injection and exhaust valve control. This allows enhancing the
performance of engines while operating at low part loads, in particular in the range
up to 70% load, by realizing considerably reduced fuel consumption as well as lower thermal load and thus improved engine reliability.
2.
Maintenance
D
Butterfly valve 1 does not require special maintenenace. For a general inspection however, the instructions of the valve manufacturer must be followed.
To carry out a function check see 81351 in the Operating Manual and Maintenance Schedule 03801.
11
10
4
9
2
8
12
6
7
2
3
WCH00395
WCH00349
Key to Illustrations:
1
2
3
4
5
6
Butterfly valve
Control actuator (one or two)
Feedback sensor ZS5372C
Orifice
Solenoid valve ZV7076C
Control air supply
7
8
9
10
11
12
1/ 1
2011-03
RT-flex96C
84471/A1
Maintenance
Key to Illustrations:
1.
94835
1
2
3
4
5
6,a,b
7
8
9
10
11
12
13
14,a,b
15
16
17
18
19
20
21
22
23
24
25
26
Screwed sleeve
Valve block
Intermediate piece
Shim
Shim
Connecting piece
Back-up ring
O-ring
O-ring
O-ring
O-ring
DF Sealing face
Removal
1.1
Preparatory works
19
7
14a
6
1
1.2
The ends of the servo oil piping must be protected from any damages.
5
14
I-I
10
11
9
8
014.447/06
1/ 4
2008
84471/A1
Maintenance
RT-flex96C
1.3
B
I
7
6a
1
2
I
17
14b
7
6a
II
IV
014.448/06
III
II
III-III
2
19
22 23
21
IV
22
23
20
III
6b
2008
14b
2/ 4
18
RT-flex96C
84471/A1
Maintenance
2.
Fitting
x = 10 mm
2.1
24
12
7
13
1, 2
25
014.449/06
2.2
Oil the threads of screws 6, a, b and tighten them crosswise with a torque of
170 Nm.
When fitting clamp pieces 9 tighten their screws 8 after all servo oil pipings
have been tightened!
After refitting the servo oil pipings open shut-off valves 4 and 5, and tighten
their spindles with 200 Nm.
3/ 4
2008
84471/A1
Maintenance
RT-flex96C
3.
Non-return valve
If a non-return valve 15 has been removed from valve block 17, O-rings 26 must be
replaced by new ones.
The proper flow direction must be maintained when refitting the non-return valve.
Apply LOCTITE 0222 to the screwed sleeve 16 and tighten it with a torque of
80 Nm.
17
26
16
15
FLOW
DIRECTION
4.
014.450/06
E
DF
D
1, 2
014.936/06
2008
4/ 4
RT-flex96C
84601/A1
Maintenance
Key to Illustrations:
1.
94835
1
2
3
4
5
6
7
8, 8a
9
10
Hydraulic piping
Stop valve
Drain screw
Pilot valve
Partition device
Screw
Screw
Housing
Sealing ring
Metallic hose
11
12
13
14
15
16
17
18
Screw
Holder
Screw
Gasket
Clamping flange
Clamping flange
Waisted screw
O-ring
DF Sealing face
Removal
When working on a hydraulic piping 1 the engine has to be stopped, and it is essential that instructions 05201 Exchange of a defective hydraulic piping in the Operating Manual be strictly followed.
CHECK
Before beginning dismantling works recheck whether stop valve 2 of the oil inlet
pipe is closed and drain screw 3 is removed.
17
16
15
8a
12
13
14
x
015.860/07
II
6
3
4
8
5
II
2
011.782/04
1/ 3
2008
84601/A1
Maintenance
RT-flex96C
Pay attention not to damage sealing faces DF when removing the hydraulic
piping.
All openings must be closed off immediately after removing the connections.
II
1
18 9
8a
6
8
11
011.783/04
2.
11
18
10
Fitting
CHECK
Check before assembly whether the inside of the hydraulic piping, sealing faces
DF of the piping ends, the seating surfaces of sealing rings 9 are clean and undamaged, and whether O-rings 18 (gaskets 14 if necessary) are in good condition.
D
Fitting together should be carried out axially, i.e. the objects to be connected
must not be moved closer together laterally, in order to avoid any damaging
of sealing faces DF.
Remark: If the hydraulic piping has been separated, the following must be additionally observed:
2008
Clean hydraulic piping and clamping flanges 15, 16 and fix them in such a
manner that clearance x is about 8 mm equally distributed after tightening
waisted screws 17.
Oil the threads and apply a torque of 70 Nm to the waisted screws and retighten these after 1000 operating hours.
After assembly open stop valve 2, fit and tighten drain screw 3.
2/ 3
RT-flex96C
84601/A1
Maintenance
3.
C
DF
D
014.936/06
3/ 3
2008
RT-flex96C
87331/A1
Maintenance
Key to Illustrations:
94870
1
2
3
4
5
6
7
8
9
10
consisting of:
1
1
1
1
Screw-on sleeve
Grinding tool
Lock nut
Template
94870a
94870b
94870c
94870d
1 Torque wrench
1.
Cylinder cover
Injection valve
Fuel pressure pipe
Injection control unit
Claw
Head screw
Flange
Thrust ring
Connection piece
Drain screw
11
12
13
14
15
1618
Pipe bracket
Holder
Angle steel
Pipe clip
Screw with nut & washer
O-rings
DF Sealing face
EC Emry cloth
HD Hand drill
Removal
When working on a fuel pressure pipe the engine has to be stopped, and it is essential that instructions 05101 in the Operating Manual be strictly followed.
Attention! Fuel leakage pipes are under pressure. Before removing them, they
must be depressurized by means of drain valve 3.65 (see 80191 Fuel leakage
system in the Operating Manual).
Loosen screws 15, remove pipe clips from pipe bracket 11 or angle steel 13.
Remove screws 6 from flange 7 on injection valve 2 and ICU 4.
Pay attention not to damage sealing faces DF when removing the fuel pressure pipes.
All connections must be closed off immediately and sealing faces DF must be
protected after removing fuel pressure pipes.
I
14,15
11
12
2
1
3
II
I
II
I
14,15
13
WCH00078
I
Wrtsil Switzerland Ltd
1/ 4
2011-03
87331/A1
Maintenance
RT-flex96C
2.
Fitting
Fitting procedure is analogous to the removal but in reverse sequence.
Before fitting fuel pressure pipe 3 check whether its claws 5 are screwed on properly, i.e. the fuel pressure pipe must protrude by x = 11 mm compared to the claw
as shown in Fig. C.
CHECK
Measurement x can be adjusted by turning the claw using an open end spanner.
Fit fuel pressure pipe and fasten it as stress-free as possible.
Apply Never-Seez NSBT-8 to threads of screws 6 and tighten them crosswise
with a torque of 40 Nm.
D
II - II
B
x
16
6
7
8
5
17
2
WCH00078
I-I
DF
16
6
8
7
10
5
17
9
18
4
011.815/04
DF
2010-07
2/ 4
RT-flex96C
Maintenance
87331/A1
3.
3.1
D
Place template 94870d on the back of emery cloth
EC .
94870d
EC
016.738/08
E
Shape the cut cloth in a manner to obtain a cone with
the grained face being turned inward.
94870b
GRAINED FACE
TIGHTENED
CONDITION
016.738/08
3/ 4
2008
87331/A1
Maintenance
RT-flex96C
F
1.
2.
94870c
94870a
G
Clamp grinding tool 94870b in hand drill HD.
Slide grinding tool into the screw-on sleeve
until it slightly touches the fuel pressure pipe.
016.739/08
94870b
HD
016.739/08
2008
4/ 4
RT-flex96C
87331/A2
Maintenance
1.
Key to Illustrations:
94872
1
2
3
4
5
6
7
8
9
10
Cylinder cover
Injection valve
Fuel pressure pipe
Injection control unit
Claw
Head screw
Flange
Thrust ring
Connection piece
Drain screw
11
12
13
14
15
1618
Pipe bracket
Holder
Angle steel
Pipe clip
Screw with nut & washer
O-rings
DF Sealing face
EC Emry cloth
HD Hand drill
Removal
When working on a fuel pressure pipe the engine has to be stopped, and it is essential that instructions 05101 in the Operating Manual be strictly followed.
Attention! Fuel leakage pipes are under pressure. Before removing them, they
must be depressurized by means of drain valve 3.65 (see 80191 Fuel leakage
system in the Operating Manual).
Loosen screws 15, remove pipe clips from pipe bracket 11 or angle steel 13.
Remove screws 6 from flange 7 on injection valve 2 and ICU 4.
Pay attention not to damage sealing faces DF when removing the fuel pressure pipes.
All connections must be closed off immediately and sealing faces DF must be
protected after removing fuel pressure pipes.
I
14,15
11
12
2
1
3
II
I
II
I
14,15
13
WCH00078
I
Wrtsil Switzerland Ltd
1/ 3
2011
87331/A2
Maintenance
RT-flex96C
Fuel Pressure Piping: Removing, Fitting and Regrinding of Spherical Sealing Faces
2.
Fitting
Fitting procedure is analogous to the removal but in reverse sequence.
CHECK
Before fitting fuel pressure pipe 3 check whether its claws 5 are screwed on properly, i.e. the fuel pressure pipe must protrude by x = 6 mm compared to the claw as
shown in Fig. C.
Measurement x can be adjusted by turning the claw using an open end spanner.
Fit fuel pressure pipe and fasten it as stress-free as possible.
Apply Never-Seez NSBT-8 to threads of screws 6 and tighten them crosswise
with a torque of 40 Nm.
D
II - II
16
7
8
6
7
8
5
17
2
DF
I-I
3
16
6
8
10
9
18
5
17
9
WCH00372
DF
2011
2/ 3
RT-flex96C
Maintenance
87331/A2
Fuel Pressure Piping: Removing, Fitting and Regrinding of Spherical Sealing Faces
3.
94872
DF
3
WCH00373
3/ 3
2011
RT-flex96C
87501/A1
Maintenance
Tools:
Key to Illustrations:
94272
1
2
3
4
5
6
7
8
9
10
11
Valve housing
Valve needle
Ball
Spring carrier
Disc spring (11 pieces)
Stop ring
Distance ring
Seating washer
Snap ring
Screw plug
Fuel overpressure
safety valve 3.52
12
12a
13
14
15
Flushing valve
Spindle
Adapter (test head)
Back-up ring
O-ring
AB Drain bore
EV Relief valve
MK Marking 3 mm
A
Y
10
OPENING PRESSURE STAMPED IN
3
4
015.499/07
AB
1.
7 15 14 MK 5
General
CHECK
Before dismantling a relief valve for overhaul (grinding in of the valve needle), distance X must be measured and recorded as X. For this purpose, distance ring 4
must be pressed against stop ring 3 by screw plug 10.
After grinding valve needle 2 into the seat of valve housing 1, thoroughly clean
all parts, lightly oil valve needle 2 and apply MOLYKOTE paste G to parts 6, 7,
9 and 11.
D
During assembly, care must be taken that disc springs 6 are correctly positioned (Fig. A).
1/ 2
2008
87501/A1
Maintenance
RT-flex96C
Open flushing valve 12 a little by spindle 12a at adapter 13. Operate the test
bench pump until pressure chambers are filled and diesel oil escapes bubblefree. Close spindle 12a.
Increase the pressure on the test bench and observe at what value the relief
valve opens. Correct opening pressure = 1250 bar.
Set required pressure by adjusting screw plug 10. Measure distance X and
note it as X1 (Fig. A).
Reduce height Y of the distance ring by the difference between distances X1
and X.
Reassemble relief valve with distance ring 4 and tighten screw plug until it is
fully down on distance ring.
CHECK
13
94272
11
12a
12
13
000.931/94
000.930/94
3.
2008
2/ 2
RT-flex96C
87501/A2
Maintenance
Tools:
1
1
1
2
2
1.
Key to Illustrations:
94272
94272a
94931
94934a
94935
1
2
3
4
5
6
7
8
9
10
Valve housing
Valve needle
Ball
Spring carrier
Disc spring (11 pieces)
Stop ring
Distance ring
Seating washer
Snap ring
Screw plug
11 Fuel overpressure
safety valve 3.52
12 Receiver
13 Back-up ring
14 O-ring
AB Drain bore
EV Relief valve
MK Marking 3 mm
General
A relief valve normally requires no maintenance, however the opening pressure
and the tightness should be checked according to Maintenance Schedule 03801.
Leaky or faulty valves have to be returned to the manufacturer or to a Wrtsil
Switzerland Ltd. authorized repair workshop for inspection and repair.
The opening pressure of the relief valve must be approved by IACS (International
Association of Classification Societies) and recorded on the Inspection Report.
Remark: To identify the new fuel overpressure safety valve (relief valve) 11, two
bores MK on one face have been provided as a marking.
AF80
AF41
OPENING PRESSURE
STAMPED IN
3
4
015.499/07
AB
2
6
2.
7 14 13 MK 5
8 9 10
Checking
In order to properly loosen the relief valve from the fuel accumulator, a spanner
AF80 must be used and placed on housing 1!
Test bench 94272 as well as test & calibration fluid has to be used (e.g. Shell Calibration Fluid S.9365) complying with the data according to the following table:
2.1
kg/m3
ISO 12185
827
_C
ISO 3016
27
Pour Point
ASTM D445
mm2/s
1/ 2
2.6
201007
87501/A2
Maintenance
RT-flex96C
2.2
2.3
No leakage is allowed!
+ 100
50
94934a
94935
94272a
11
12
013.484/05
94931
EV
94272
94934a
013.486/05
3.
201007
2/ 2
RT-flex96C
87502/A1
Maintenance
1.
15
16
17
18
19
20
21
22
23...25
BA Fuel outlet
BE Fuel inlet
OE Oil inlet pipe
General
To avoid any risk of failures related to the fuel pressure control valve (PCV),
Wrtsil recommends only performing the below mentioned maintenance. PCV
maintenance onboard is limited to:
Remark: In case the PCV was replaced on a previous occasion, Wrtsil offers a
new or remanufactured PCV which will be equipped and set according to the latest
technical specification with the correct pressure adjustment.
For detailed maintenance intervals of the PCV refer to the Maintenance Schedule
03801.
The engine has to be stopped when working on a PCV and the instructions 05151
in the Operating Manual must be strictly followed.
1 21
WCH00845
1/ 3
2012-05
87502/A1
Maintenance
RT-flex96C
2.
3.
I
1
18 19 20
16
17
15
WCH00845
2012-05
23
24
2/ 3
16
RT-flex96C
87502/A1
Maintenance
4.
14
12 13
8
9
OE
7
6
11
3
4
25 21 22
10
5
BE
WCH00763
BA
OIL
FUEL OIL
5.
Storage on board
The spare parts must be carefully protected against corrosion.
D
The PCV has to be free from any dirt, oil and grease.
Apply coating liquids (e.g. Tectil 506, ISOTEC 337 or similar) on the surfaces
to be preserved.
Especially consignments transported overseas must be well protected against adverse climatic conditions (intense cold, rain, high humidity, etc.) and kept in a
closed box.
3/ 3
2012-05
RT-flex96C
87521/A1
Maintenance
Key to Illustrations:
2 Regrinding devices
94870
consisting of:
1
1
1
1
Screw-on sleeve
Grinding tool
Lock nut
Template
94870e
94870f
94870g
94870h
1
1
1
1
Screw-on sleeve
Grinding tool
Lock nut
Template
94870i
94870j
94870k
94870l
1 Turnbuckle
1.
1
2
3
4
5
6
7
8
9,a,b
10,a
11
12
13
14
15
16
17
18
19
2022
Claw
Thrust ring
Drain screw
Valve block
Screwed sleeve
Non-return valve
Fuel pressure pipe
O-rings
DF Sealing face
94873
Removal
3
1.1
Preparation to removal
II
8
7
I
1
19
011.799/04
1/ 6
2010-07
87521/A1
Maintenance
RT-flex96C
The sealing faces DF at the pipe ends must be protected from any possible
damages.
B
I
10
15
9b
4
5
II
6
9a
10
II
11
III
15
12
10a
9
4
III
9
011.801/04
2008
2/ 6
10a 15
RT-flex96C
87521/A1
Maintenance
C
1.3
9b
4
94873
approx. 383 mm
011.810/04
Fitting
X = 16.5mm
2.
21
13
14
10
20
5, 6, 7
014.493/06
3/ 6
2008
87521/A1
Maintenance
RT-flex96C
3.
Non-return valve
If a non-return valve 18 has been removed from valve block 16, O-rings 22 must be
replaced by new ones.
The proper flow direction (see arrow engraved in valve block) must be maintained
when refitting the non-return valve.
Apply LOCTITE 0222 to screwed sleeve 17 and tighten it with 80 Nm.
I-I
16
014.451/06
FLOW
DIRECTION
22
18
4.
17
Before fitting fuel pressure pipe, check whether their claws are screwed on properly, i.e. fuel pressure pipe 19 must protrude by x = 13.4 mm compared to the claw.
19
WCH00084
2010-07
4/ 6
RT-flex96C
Maintenance
87521/A1
5.
5.1
G
Place template 94870h(I) on the back of emery cloth
EC .
94870h(I)
EC
016.738/08
H
Shape the cut cloth in a manner to obtain a cone with
the grained face being turned inward.
94870f(j)
GRAINED FACE
TIGHTENED
CONDITION
016.738/08
5/ 6
2010-07
87521/A1
Maintenance
RT-flex96C
2.
5,6,7,19 94870g(k)
94870e(i)
J
Clamp grinding tool 94870f(j) in hand drill
HD.
Slide grinding tool into the screw-on sleeve
until it slightly touches the fuel pressure
piping.
016.739/08
94870f(j)
HD
016.739/08
2010-07
6/ 6
RT-flex96C
Maintenance
Group9
Group 9
1/ 22
RTflex96C / MM / 2013-02
RT-flex96C
92231/A1
Maintenance
Key to Illustrations:
94122
94924
94925
1
2
3
4
5
6
7
8
9
10
11
12
13
13a
14
15(a)
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32(a)
33
34
35
36
Protection hood
Covering cap
Screw
Nut
Shaft
Crank angle sensor (CAS)
Holder
Screw
Toothed belt
Protection plate
Screw with locking plate
Angle holder
Outer shaft encoder
Inner shaft encoder
Bearing housing
Screw
Washer
Locking plate
Gear wheel
Gear wheel
Waisted screw
Screw with locking plate
Packing ring
Adjusting disc
Locking plate
Shaft nut
Locking plate
Shaft nut
Circlip
Retaining ring
Sealing ring
Distance ring
Ball bearing
Distance ring
Distance sleeve
Disc spring
Circlip
37
38
39
40
41
42
43
44
45
46
47
48
48a
49
50
51
52
53
54
55
56
57
58
59
60
Disc
Key
Packing ring
Locating pin
Inspection cover
Compression spring
Lever
Screw with locking plate
Throttle
Housing
Screw
Screw
Locking plate
Connecting unit
Locating pin
Coupling disc
Spring tensioner
Screw with locking plate
Adjusting screw
Clamp screw w. tab washer
Distance piece
Screw with locking plate
Locating pin
Spring balance
O-ring
GL
KD
KK
MB
MK
OE
SU
SH
SK
SR
Tap hole
Cable clamp
Terminal box
Magnetic base with dial gauge
Mark
Oil inlet
Collar
Protective sleeve
Sensor cable
Protective pipe
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1/ 22
2012-05
92231/A1
Maintenance
RT-flex96C
1.
1.1
Preparation
SR
OE
Unscrew cable clamps KD as well as protective sleeve SH and withdraw sensor cable
from protective pipes SR.
2
1
1.2
II - II
I
I-I
1 14 11
CLEARANCE
11 12 10
II
2
5 4
008.725/00
13
13a SH
II
2008
008.758/00
15a 15
2/ 22
KD SK
RT-flex96C
92231/A1
Maintenance
1.3
13a
008.727/00
008.726/00
SK
2.
Shaft encoder
Shaft encoders are only supplied complete. The crank angle sensor 6 is fastened
to the holder 7 and set by the manufacturer.
Attention! Never loosen screw 8!
008.728/00
3.
3.1
19
008.728/00
Slide shaft encoder along the guide plate to check that the shaft encoder is moving
freely.
Push shaft encoder inwards.
3/ 22
2012-05
92231/A1
Maintenance
RT-flex96C
3.2
Connect gear wheels 19 and 18 with toothed belt 9, paying attention to their
marks MK which must coincide according to Fig. G (zero position).
Push shaft encoder outwards till the toothed belt is lightly tensioned and
meshing properly with the gear wheels. Lightly tighten screws 15. Recheck
marks MK.
Fit screws 15a, washers 16 and locking plates 17. Apply MOLYKOTE paste G
to the threads and head seatings.
Align toothed belt exactly in running direction.
Attach spring balance 59 to the shaft encoder and slightly preload it according
to Fig. F.
Loosen all screws 15 and 15a, paying attention that the shaft encoder can still
move freely.
Tension toothed belt with 30 N indicated on spring balance, and fixate shaft
encoder with screws 15 and 15a.
Remark: Pull the spring balance exactly in tensioning direction, keeping the friction between the holder guide and screw surfaces as small as possible.
15
15a
13a
MK
59
SK
58
008.729/00
2012-05
4/ 22
17
16
15a
008.730/00
RT-flex96C
92231/A1
Maintenance
TOOTHED BELT
TENSIONED
G
9
18
15
TOOTHED BELT
LOOSE
H
I
15a 17
19
T.D.C. 1
T.D.C. 1
008.731/00
008.732/00
MK
16
17
008.731/00
15a
MK
3.3
Fitting the outer shaft encoder 13 is carried out analogously to the inner one.
Attention! When fitting shaft encoders, toothed belts
or crank angle sensor drive (section 7) always pay
attention to the following points:
58
SK
Mark MK (T.D.C. 1) of gear wheel 18 pointing upwards as shown in Fig. G and all other marks
aligned according to Fig. I.
008.733/01
5/ 22
2008
92231/A1
Maintenance
RT-flex96C
3.4
Final works
Fit angle holder 12 using screws 11 with their locking plates. Subsequently
install protection plates 10 in such a way that they contact each other at the
centre without overlapping and touching any moveable parts, using screws 3
with their locking plates.
Tighten and lock screws 3 and 11.
After assembling fit carefully the sensor cables SK. Pay attention to the clearance which must exist between sensor cables and housing (Fig. B, section
II).
Fit protection hood 1 together with covering cap 2.
3.5
3.6
2008
6/ 22
RT-flex96C
92231/A1
Maintenance
3.7
J
Crank Angle
CA 1/2 Offs.
Crank Angle
0.0 < _
0.0 < _
CA 1/2 Offs.
0.1 < _
-0.2 < _
359.8 <_
0.0 < _
0.0 < _
MK
T.D.C. 1
008.731/00
008.726/00
MK
7/ 22
2012-05
92231/A1
Maintenance
RT-flex96C
4.
I-I
21
22 21
II
5
4 20
23
I
008.735/01
SK
008.734/01
II
008.736/01
2008
8/ 22
RT-flex96C
92231/A1
Maintenance
18
24 25
GL
008.737/01
M
26 27 38
28
008.738/01
9/ 22
2008
92231/A1
Maintenance
RT-flex96C
N
14
34
35
Retaining ring 29 (using tap holes GL) together with sealing ring 30 and O-ring 60.
Circlip 36.
60
GL
31
29
30
008.739/01
36
2008
37 32a
33 32
10/ 22
RT-flex96C
92231/A1
Maintenance
6.
6.1
SU
SU
38
008.740/01
32a 34
32
31 27
14
Measure and note down distance b in housing 14.
According to the following formula determine thickness
x for distance ring 33 to be fitted:
x = a b 4.2 mm
Tolerance x amounts to " 0.2 mm.
008.741/01
11/ 22
2008
92231/A1
Maintenance
RT-flex96C
6.2
37 32a 14
008.742/01
6.3
R
14 34
34
35
35
33
31
14
008.744/01
II
31
30
29
II
14
33 32
008.743/01
2008
12/ 22
008.744/01
60
RT-flex96C
92231/A1
Maintenance
6.4
S
26 27
5
28
008.738/01
6.5
14
24 25
58
18
008.737/01
13/ 22
2008
92231/A1
Maintenance
RT-flex96C
7.
41
CHECK
7.1
39
40
43
Final works
22
21
I
43
5
40
5 20
4 20
42 58 23
008.745/01
44
NO CLEARANCE
008.734/01
2008
14/ 22
RT-flex96C
92231/A1
Maintenance
8.
47
46
8.1
Preparation
008.746/01
W
49
50
20
I-I
50
43
44
40
43
48a
48
51 48
008.748/01
51
008.747/01
15/ 22
44
2008
92231/A1
Maintenance
RT-flex96C
8.2
FITTING
POSITION
57
42
54
55
55
52
008.749/01
53
8.3
52
51
008.750/01
54
8.4
Y
x
008.751/01
52
54
Insert compression springs 42, fit spring tensioner with screws 53 and new locking plates,
applying MOLYKOTE paste G to threads and
seating surfaces.
Tighten screws 53 with a torque of 60 Nm and
lock them.
2008
16/ 22
RT-flex96C
92231/A1
Maintenance
8.5
50
40
II - II
II
42
008.752/01
II
56
43
55
54
008.749/01
8.6
Locating pin 40 and locating pin 50 must point upwards on Cyl. No.1 at T.D.C. according to Fig. W and Z!
17/ 22
2008
92231/A1
Maintenance
RT-flex96C
8.7
9.
Checks
The periodical checks must be carried out according to Maintenance Schedule
03801 Crank angle sensor unit.
9.1
I-I
A1
41
008.753/01
OIL OUTLET
B1
I
008.725/00
008.754/01
OIL SPRAY
2008
18/ 22
RT-flex96C
92231/A1
Maintenance
9.2
C1
II
II
OE
I
008.755/01
II - II
45
OIL INLET
008.724/00
008.756/01
19/ 22
2008
92231/A1
Maintenance
RT-flex96C
9.3
9.4
Eccentricity check
Remove the protection hood 1 of the CAS drive (see Fig.B).
Install the magnetic base with dial gauge MB.
D1
MB
18
Remark! The measuring point must be horizontally adjacent of the gear wheel 18.
Read the deviation on the dial gauge while turning the crankshaft with the
turning gear.
The average shaft eccentricity under normal working and assembly condition
must be less than 0.15 mm.
In case the measured value is out of the stated average eccentricity value, it is recommended to replace the CAS with a new one (see sections 5 and 7). A CAS drive
is available as a standard spare part.
2012
20/ 22
RT-flex96C
92231/A1
Maintenance
9.5
Checking the clearance between shaft and internal bearing of the CAS
In case the CAS is over five years in service or has more than 48 000 operating
hours, it is recommended to check the condition of the CAS before a new belt version is installed. The CAS condition is checked by measuring the clearance between the shaft and internal CAS bearing.
Procedure for measuring the clearance:
Remove the protection hood 1 of the CAS drive (see Fig.B).
Remove the protection plate 10.
After loosening the screws 15a and 15, remove first the toothed belt of the outer CAS and then the toothed belt of the inner CAS.
After removing the toothed belt, tighten the screws 15a and 15 again.
Install the magnetic base with dial gauge MB as shown below.
Push the gear wheel of the CAS to the left and right direction.
The measurements X and Y have to be done in fixed condition of the outer and
inner CAS but without the toothed belts.
Read the deviation on the dial gauge while pushing the gear wheel of the CAS.
The average CAS clearance under normal working and in assembly condition must be less than 0.05 mm.
E1
15a
9.6
15
10
MB
21/ 22
2012
92231/A1
Maintenance
RT-flex96C
10.
High shaft eccentricity: To verify the eccentricity, see the paragraph 9.3.
Before carrying out the replacement of a CAS drive which is available as a standard spare part, a new CAS drive must be ordered unless a repair kit is available on
board.
The spare parts order number is to be found in the Spare Parts Code Book, Group
9, Chapter 96011, within item Crank Angle Sensor Unit and named Shaft encoder drive, complete or Shaft encoder, complete (box).
Remark! According to IACS regulations, at least one Shaft Encoder Package box
containing the spring balance is part of the standard spare parts supply per ship.
2012
22/ 22
RT-flex96C
Maintenance
94031/A1
Tools
Explanation
1.
General
The tools required for erection and maintenance of the engine are divided into
three groups as per the following Tool List:
Standard tools
When ordering additional tools or replacements, the tool No. as well as the tool
description including engine type must be indicated (see 94035).
Detailed instructions on the arrangement and application, storing, servicing and
maintenance of the hydraulic pre-tensioning jacks are given in 94032 to 94034.
When oil must be added to the hydraulic pumps, the specification regarding oil
quality issued by the pump manufacturers must be followed. Utilize generally an
engine lub. oil having viscosities SAE 30 to SAE 40.
A cylinder lubricating oil also can be used in exceptional cases.
A separate set of tools is issued for certain components from sub-suppliers, which
should also be stored separately from the engine tools.
2.
Standard tools
... are tools and devices required for normal maintenance work on the engine. In
this respect take into consideration that, depending on the design execution of the
engine, certain tools and devices which are mentioned in the above sheets are not
required for specific maintenance work, and are therefore not part of the engine
tools supply.
3.
4.
1/ 1
2008
RT-flex96C
94032/A1
Maintenance
13 12 11 10
9
3
14
7
1
13 11
10
16 17
13
12
11
10
19
6
18 5
20
18
014.126/06
1/ 4
2008
94032/A1
Maintenance
RT-flex96C
13 12 11 10
8
9
14
13 11
F
17 16
14
7
10
13
12
11
10
24 18
20
17 16
20
18 24
19
6
18 5
18
10
22
17
21
18
G
014.127/06
2008
2/ 4
RT-flex96C
94032/A1
Maintenance
I
25
18 20
13 12 1110
18
7
17
18
10
19
5
28
28
14
14
6
13 11
13 12 11 10
23
9
3
14
13
12
11
27
11
26
014.133/06
15
I = Fitting / removing the 2-part fuel cam
K = Repositioning the driving wheel for servo oil pumps
014.138/06
3/ 4
2008
94032/A1
Maintenance
RT-flex96C
Tool
1 Hydraulic jack 1000 kN (100 t)
94936
94412d
94931
4 Hydraulic unit
94942
5 Hydraulic distributor
94934a
6 Pressure gauge
94932a
7 Plug piece
94934e
8 Pressure gauge
94932
9 Hydraulic distributor
10 Adapter
11 Closing valve
12 Coupling socket
13 Adapter
14 High pressure hose max. 2500 bar
94935
94935c
16 Adapter
17 Closing valve
18 Coupling socket
19 Safety valve
2008
94935a
94935b
22 Connection block
94934c
23 Connection piece
94426
24 Connecting element
94934d
94424
26 Valve holder
94272a
27 Jack
94595
28 Adapter piece
94426a
4/ 4
RT-flex96C
94033/A1
Maintenance
1.
General
The hydraulic pre-tensioning jacks forming part of the engine tool kit are to be
stored in their tool boxes when not in use, in a clean place, where they are protected from damage (after greasing them and closing the connections with dust
plugs). We recommend to always keep in stock a sufficient number of new O-rings,
back-up rings, piston seal rings and rod seal rings of the specified quality and dimensions.
When fitting new back-up rings, piston seal rings and rod seal rings proceed with
care, to avoid their damage; do not use any sharp edged utensils for assistance.
Heat unslit back-up and sealing rings which are used as piston seal rings in boiling
water before fitting them.
Tool 94114
1 Piston
8 Back-up ring
9 O-ring
2 Double cylinder
3
4
5
6
7
Distance sleeve
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
10
11
12
13
14
Sealing
ring
Cover
Nut
Screw
Tension sleeve
Eye bolt
14
11
12
10
6
7
1
2
9
8
13
3
009.318/01
008.308/01
4
5
1/ 9
2008
94033/A1
Maintenance
RT-flex96C
Tool 94314
Tool 94315
Tool 94340
Tool 94556
1
2
3
4
5
6
7
Piston
Cylinder
Vent screw
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
8
9
10
11
Back-up ring
O-ring
Allen screw
Pin
Sealing ring
5
10
11
6
7
9
8
1
2
003.902/96
2008
2/ 9
RT-flex96C
94033/A1
Maintenance
Piston
Cylinder
Vent screw
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
8
9
10
11
12
Back-up ring
O-ring
Nut
Screw
Disc spring
Sealing ring
11
12
5
10
3
6
9
8
017.025/08
3/ 9
2008
94033/A1
Maintenance
RT-flex96C
Piston
Cylinder
Vent screw
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
8
9
10
11
Back-up ring
O-ring
Nut
Pin
Sealing ring
10
3
11
6
9
8
003.902/96
2008
4/ 9
RT-flex96C
94033/A1
Maintenance
Piston
Cylinder
Vent screw
Adapter
Connection piece
6
7
8
9
Back-up ring
O-ring
Back-up ring
O-ring
Sealing ring
Sealing ring
3
4
6
7
2
9
8
012.100/04
5/ 9
2008
94033/A1
Maintenance
RT-flex96C
Piston
Cylinder
Vent screw
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
8
9
10
11
Back-up ring
Sealing ring
O-ring
Nut
Allen screw M10x97
11
10
5
4
3
1
6
7
9
8
012.101/04
2013-02
6/ 9
RT-flex96C
94033/A1
Maintenance
1 Piston
2 Cylinder
3 Vent screw
4 Adapter
5 Connection piece
6 Back-up ring
7 O-ring
Sealing
ring
8 Back-up ring
9 O-ring
Sealing ring
5
3
4
1
9
8
012.102/04
7/ 9
2008
94033/A1
Maintenance
RT-flex96C
Tool 94424
1
2
3
4
5
6
7
8
9
10
11
Allen screw
Ball
Screw
Screw plug
9
8
10
I-I
I
I
1
2
11
3
014.578/06
2008
8/ 9
RT-flex96C
94033/A1
Maintenance
Tool 94595
1
2
3
4
Piston
Cylinder
Push rod
Vent screw
5
6
7
8
6
5
Adapter
Connection piece
Back-up ring
O-ring
8
7
1
2
3
014.579/06
9/ 9
2008
RT-flex96C
Maintenance
94034/A1
1.
General
For distinct screwed connections different designs and sizes of waisted bolts or
waisted studs (bolts/studs) are used, which are pretensioned by hydraulic pre-tensioning jacks. The bolts/studs have threads which extend over the nut. The pretensioning jack is mounted on this thread end.
For each thread of the various bolts/studs a suitable pre-tensioning jack is supplied. Since the bolts/studs are pretensioned with the pre-tensioning jacks, the
nuts are threaded-on only manually until seated.
Prior to the mounting of the pre-tensioning jacks, their threads as well as the
threads of the waisted bolts/studs must be carefully cleaned. The threads must be
undamaged and freely working. Concerning utilization of lubricant for screwing on
nuts the instructions in 03521 must be followed.
Risk of accident! Always use gloves, a face shield and wear safety goggles when
working with hydraulic tools.
2.
Then, depending on the design of the pre-tensioning jack, turn it or the round
nut back by about to 4 turns. The clearance thus obtained between pre-tensioning jack and landing face of the part or piston and cylinder is essential,
before starting the pre-tensioning of the bolts/studs. It enables the loosening
of the nut till total relaxation of the bolts/studs in one single working sequence.
Connect the HP oil pump and pre-tensioning jack with the HP hose.
Open the vent screw on top of the pre-tensioning jack a little.
Shut relief valve at the HP oil pump and actuate it. As soon as oil flows out
bubble-free close the vent screw at the pre-tensioning jack.
D
When loosening attention should be paid that the pins of the pre-tensioning
jacks protrude slightly above the upper edges of the pistons (stroke limitation!).
Pre-tensioning jacks providing red limiting grooves on the pistons, the latter
must not exceed the indicated stroke limitation.
Raise the pressure about 2030 bar beyond the nominal pressure (see
03521). The nut is now slack, loosen it with a round bar, while keeping the
pressure constant.
Release the pressure at the HP oil pump and remove the pre-tensioning jack.
1/ 2
2008
94034/A1
Maintenance
RT-flex96C
3.
When tensioning attention should be paid that the pins of the pre-tensioning
jacks protrude slightly above the upper edges of the pistons (stroke limitation!).
Pre-tensioning jacks providing red limiting grooves on the pistons, the latter
must not exceed the indicated stroke limitation.
Raise the pressure with the HP oil pump, in accordance with the indication on
the tightening of important screwed connections (see 03521).
Maintain the oil pressure constant at the adjusted value and use the round bar
to tighten the nut onto its seating surface until firmly seated.
CHECK
Check with the feeler gauge whether actually no clearance remains between nut
and seating.
Check with the referenced markings, whether all the nuts of a screwed connection
have been turned by the same value as mentioned in 03521. If big differences are
noted their causes have to be investigated and the tensioning procedure must be
repeated.
Release the pressure at the HP oil pump and remove the pre-tensioning
jacks.
D
2008
For operation and maintenance of the HP oil pump we also refer to the
manufacturers documentation.
2/ 2
RT-flex96C
Maintenance
94035/A1
Tool List
Standard Tools
94000
9400036
9400041
9400046
9400050
9400055
9400060
Combination wrenches
2 Pieces . . . . AF36
2 Pieces . . . . AF41
2 Pieces . . . . AF46
2 Pieces . . . . AF50
2 Pieces . . . . AF55
2 Pieces . . . . AF60
94001
9400165
9400170
9400175
9400180
9400185
9400195
94001110
94001a110
000.385/93
000.384/93
93.7463
94002
9400227
9400230
9400232
9400236
9400241
9400246
9400250
9400255
9400260
9400265
9400270
9400275
9400285
9400295
94002110
000.382/93
1/ 62
2010-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
94003
940035
940036
940038
9400310
9400312
9400314
9400317
9400319
9400322
9400324
9400327
Allen keys
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
94004
9400410
9400412
9400425
Angle screwdrivers
1 Piece . . . . . b =
1 Piece . . . . . b =
1 Piece . . . . . b =
AF5
AF6
AF8
AF10
AF12
AF14
AF17
AF19
AF22
AF24
AF27
000.381/93
10 mm
12 mm
25 mm
b
94005
94005d
94005e
94005f
94005g
94005h
94005i
Rods
for pre-tensioning jacks
3 Pieces . . . . 7 mm
3 Pieces . . . . 7.5 mm
3 Pieces . . . . 9 mm
3 Pieces . . . . 15 mm
3 Pieces . . . . 20 mm
3 Pieces . . . . 33 mm
94006
9400611
9400612
9400614
9400617
9400619
9400622
9400627
94007
94007C8
94007C19
94007C40
Tongs
1 Piece . . . . . Type C 8
1 Piece . . . . . Type C 19
1 Piece . . . . . Type C 40
94007A10
94007A19
94007A40
1 Piece . . . . . Type A 10
1 Piece . . . . . Type A 19
1 Piece . . . . . Type A 40
94007A41
1 Piece . . . . . Type A 41
000.380/93
000.379/93
000.377/93
000.376/93
000.375/93
014.381/06
2010-07
2/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94008
Withdrawing gears
for taper & cylindrical dowels and pins
1 Piece . . . . . M4
1 Piece . . . . . M5
1 Piece . . . . . M6
1 Piece . . . . . M8
1 Piece . . . . . M10
1 Piece . . . . . M12
1 Piece . . . . . M16
1 Piece . . . . . M20
94008M4
94008M5
94008M6
94008M8
94008M10
94008M12
94008M16
94008M20
94008aM100
94009
94009M4
94009M5
94009M6
94009M8
94009M10
94010
94010a
94010b
94011
94012
94012a
94012b
94013a
9401319
9401320
9401321
9401322
9401324
9401327
9401330
9401332
94013b
9401346
9401355
Grip screw
2 Pieces . . . .
2 Pieces . . . .
2 Pieces . . . .
2 Pieces . . . .
2 Pieces . . . .
M4x150
M5x150
M6x150
M8x150
M10x150
X
WCH00836
000.372/93
1 Torque spanner
(Range of adjustment 225 Nm)
Adapter piece 3/8
Adapter piece 3/8
010.229/02
1 Torque spanner
(Range of adjustment 20200 Nm)
010.230/02
1 Torque spanner
(Range of adjustment 140760 Nm)
with extension tube and tool box
adapter piece -,
shell type ratchet -
1 Torque spanner
(Range of adjustment 20120 Nm)
with open end spanner inserts:
AF19
AF20
AF21
AF22
AF24
AF27
AF30
AF32
010.231/02
013.558/05
Torque spanner
(Range of adjustment 140620 Nm)
with open end spanner inserts:
AF46
AF55
3/ 62
2012-05
94035/A1
Maintenance
RT-flex96C
Standard Tools
94017
012.232/04
94022a
010.233/02
94022b
94022b46
94022g
94025
016.718/08
000.368/93
94026
94032
000.370/93
2010-07
4/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94045
94045M10
94045M12
94045M16
94045M20
94045M24
94045M30
94045M36
94045M42
94045M48
Eye bolts
8 Pieces
8 Pieces
8 Pieces
8 Pieces
8 Pieces
8 Pieces
8 Pieces
8 Pieces
4 Pieces
94045aM16
Eye screw
6 Pieces . . . . M16x145
....
....
....
....
....
....
....
....
....
M10
M12
M16
M20
M24
M30
M36
M42
M48
93.7472
93.7468
Eye nut
4 Pieces . . . . M48
(WLL 8600 kg, single-strand)
94046
94046M48
001.584/97
94050
94050a
94050b
94050c
94050d
94050e
94050f
94050g
94050h
5/ 62
002.552/98
2010-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
94101
1 Inside micrometer
(Measuring range 501010 mm)
with case
000.366/93
94101a 1 Extension
Length of 480 mm
94113
000.365/93
1 Measuring device
for checking external diameter of a main
bearing
X = 1150 mm
94113a 1 Template
for contact surface between main bearing
cover and shell
X = 300 mm
016.819/08
016.812/08
X
94114
012.234/04
94116
1 Lifting tool
for removal and fitting of
main bearing shell
X = 320 mm
(max. lifting capacity 250 kg)
008.541/01
X
94117
2008
2 Roller supports
for removal and fitting of main bearing
with screws M30x60 and washers 68 mm
X = 140 mm
(max. lifting capacity 1050 kg)
6/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
X
008.542/01
94119
1 Lifting yoke
for removal and fitting of
a main bearing shell
X = 390 mm
(max. lifting capacity 250 kg)
000.768/99
005.933/00
7/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
Rope ( 10 mm)
with a shackle for removal and fitting
of main bearing cover and shell
(max. lifting capacity 1050 kg)
94120b
94120c
94120d
94120e
94120f
94120g
94120h
94120i
94120k
94120l
94120m
94120n
94120o
94120p
2 Pieces . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
X = 300mm
X = 500mm
X = 600mm
X = 800mm
X = 1000mm
X = 1200mm
X = 1500mm
X = 1600mm
X = 1700mm
X = 1900mm
X = 2000mm
X = 2200mm
X = 2800mm
X = 3200mm
005.932/00
94122
008.551/01
1 Feeler gauge
000.361/93
94123
X
94124
1 Depth gauge
measuring range 250 mm
012.237/04
94126
1 Depth gauge
measuring range 700 mm
000.394/93
2008
8/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
X
94141
1 Support
for removal and fitting of
main bearing shells
X = 1430 mm
008.133/96
94142
2 Working platforms
consisting of 3 grids each
X = 1150 mm
000.392/93
94143
2 Working supports
X = 9201170 mm
009.323/01
94145
1 Pre-tensioning jack
for foundation bolts and engine stays,
including a metal box
X = 170 mm
008.132/96
9/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Ladder
for working in crankcase
X = 1550 mm
X
94147
000.706/97
94155
1 Turning-out device
with screws
for turning out thrust bearing pads
(for 6 & 7 cylinder engines,
with 1-part gear wheel)
X = 266 mm
003.973/96
004.036/96
94180
012.239/04
2008
10/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
1 Device
for fitting and transporting a cylinder
liner (with big crane hook)
(max. lifting capacity 9200 kg)
consisting of:
1 Lifting gear
X = 400 mm
94206
2 Suspension straps
with 2 screws each
X = 275 mm
94207
001.409/96
94202
94206
94202
94201
94207
94201a 1 Device
for fitting and transporting a cylinder
liner (with small crane hook)
(max. lifting capacity 9200 kg)
consisting of:
X
012.240/04
94202a
FASTENING HERE,
IF PLATES 94202b
ARE NOT USED
94202b 2 Plates
X = 164 mm
94202b
012.241/04
94206a
94207
94202c
94207
11/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94209
4 Suspension straps
with screws M20x25
for removal and fitting of the
antipolishing ring
X = 146 mm
(max. lifting capacity 30 kg)
94208
005.928/00
1 Lifting hook
for removal and fitting of the
antipolishing ring
X = 1000 mm
(max. lifting capacity 800 kg)
X
012.242/04
94215
94215d
94215c
2008
12/ 62
94215b
RT-flex96C
94035/A1
Maintenance
Standard Tools
94219
012.243/04
94224
1 Ladder
for measuring cylinder liner bore
X = 3600 mm
000.420/93
94225
94238
1 Measuring gauge
for measuring cylinder liner bore
(accessory for it:
inside micrometer tool 94101)
X = 3246 mm
000.419/93
1 Feeler gauge
(10-part)
for checking bearing clearances
Leaf length = 600 mm
000.418/93
13/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94252
012.245/04
94259
6 Retaining screws
for exhaust valve
X =
112 mm
X
012.246/04
94261
001.426/97
94262
1 Valve protector
(only to be applied for transporting a
complete exhaust valve)
X = 750 mm
001.425/97
94263
000.413/93
2008
14/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94265
1 Suspension device
for cylinder cover & exhaust valve cage
(with big crane hook)
X = 1000 mm
including:
a = 2 Special eye nuts
X = 365 mm
(max. lifting capacity 12 000 kg)
b = 3 Protection caps
X =
110 mm
b
a
a
003.971/96
012.247/04
b
a
a
003.971/96
15/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94266
1 Cradle
for removal and fitting of water guide
jacket
X = 1855 mm
012.248/04
94266a 4 Support
for cradle (Retrofit)
WCH01146
1 Device
for overhauling injection valve seat in
cylinder cover
X=
565 mm
X
94270
001.432/97
Protection cap
for injection valve
(1 piece each nozzle)
X=
110 mm
94271
705603/F101167d
2013-05
16/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94272
001.406/96
94272
Valve holder
for checking and adjusting relief valve
to cylinder cover
X = 66 mm
WCH00863
94272a
X
94272g
X
17/ 62
94272c
2012-05
86
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Gauge
for checking wear on exhaust valve
seat
X = 220 mm
94279
001.633/97
94292
1 Gauge
for checking wear on disc of exhaust
valve spindle
X = 290 mm
004.061/96
2010-07
18/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
1 Grinding device
for removing a built-up wear ridge at
top of cylinder liner running surface
X = approx. 600 mm
X
94299
000.463/93
94305
94314
2 Pre-tensioning jacks
for connecting rod studs to bottom end
bearing, including a metal box
X = 330 mm
94315
2 Pre-tensioning jacks
for connecting rod studs to top end
bearing, including a metal box
X = 245 mm
008.129/96
018.037/09
19/ 62
1.09
94035/A1
Maintenance
RT-flex96C
Standard Tools
94324
94325
012.263/04
2 Holders
for removal of a crosshead guide shoe
X =
70 mm
001.631/97
001.630/97
X
94326
1 Device
for removal and fitting of bottom end
bearing
X = 406 mm
(max. lifting capacity 100 kg)
012.265/04
2008
20/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94330
1 Lifting device
for removal and fitting of a connecting
rod
X = 1000 mm
001.627/97
2 Roller supports
for removal and fitting of a connecting
rod, and for inspection of bearing shell
to top end bearing
X = 1955 mm
94331
000.773/99
94332
1 Carrying roller
for removal and fitting of a connecting
rod, and for inspection of bearing shell
to top end bearing
X = 300 mm
001.625/97
21/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Lifting device
to piston for removal of top end bearing
cover
(max. lifting capacity 5000 kg)
consisting of:
94333
001.314/97
94334
1 Device
for removal and fitting of bottom end
bearing
consisting of:
012.266/04
94334b 1 Suspension
with screws M24x35
X = 560 mm
X
012.267/04
2008
22/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
012.268/04
94334d 2 Washers
X =
66 mm
012.269/04
005.932/00
X
94335
1 Holder
with screw M24x35
for fixing the crosshead
X = 494 mm
012.271/04
23/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
X
94338
94339
94339c 1 HP hose
working pressure max. 1000 bar
length approx. 3500 mm,
including a metal box
94339c
001.624/97
001.623/97
001.622/97
1.09
24/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94340
2 Pre-tensioning jacks
for piston rod screw connection and
screwed connection of turning gear,
including a metal box
X = 160 mm
705603/F101168
94341
001.408/96
94341d
94341c
25/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
005.923/00
012.664/05
2 Distance holders
for removal and fitting of piston rod
gland and piston
X = 600 mm
94345
001.407/96
2008
26/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94345c 1 Gauge
for fitting scraper rings
X = 400 mm
011.507/04
000.400/93
94345f
4 Distance pieces
for fitting rings
to upper gland group
2 pieces each 11 and 19 mm
X = 520 mm
005.655/99
94346
4 Pre-tensioning jacks
for waisted studs to piston crown
X = 126 mm
012.276/04
27/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Propping device
consisting of 4 supports for changing
compression shims
X = 700 mm
X
94347
008.552/01
94348
1 Tap M27
for cleaning carbon deposits in
threaded holes of piston crown
000.398/93
94350
1 Device
for supporting piston and removal of
piston rod gland
X = 1174 mm
Y = 1297 mm
2012-05
28/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94363
2 Jacking screws
for separating piston crown
from piston skirt
X = M20
94364
2 Jacking screws
for separating piston skirt
from piston rod
X = M24
705603/F101198
X
94366
1 Template
for shape of top of piston crown
X = 1030 mm
001.423/97
94366a 1 Template
for shape of top of piston crown
(for use with piston in situ)
X = 1115 mm
94410
001.422/97
6 Adjusting devices
for alignment of intermediate wheel
X = 270 mm
705603/F101217
X
94411
1 Suspension device
for removal and fitting of intermediate
wheel
(for 11 cylinder engines)
including: 2 Shackles
1 Screw with nut M36x340
X = 500 mm
014.384/06
29/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94412
1 Tightening device
(supplied only for engine equipped
with 2-part gear wheel on crankshaft)
X = 150 mm
consisting of:
94412e
94412a
94412c
94412b
1 Tightening device
(supplied only for engine equipped
with 2-part gear wheel on crankshaft)
consisting of:
94412e
94412f
015.227/07
94412d
94412c
94412b
1 Extension
X = 640 mm
015.202/07
2008
94412g
30/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94426
1 Connection piece
for repositioning the driving wheel of
servo oil pumps
X = 247 mm
004.027/96
X
94426a 1 Adapter piece
for removing and fitting 2-part fuel cam
X =
45 mm
94550
012.278/04
1 Lifting plate
for removal and fitting of Dynex servo
oil pump
X = 190 mm
(max. lifting capacity 280 kg)
94435
94430
019.235/10
94551
94552
1 Lifting tool
with head screws M12x70
for removal and fitting of a fuel pump
X = 120 mm
012.280/04
31/ 62
2010-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Lifting support
for removal and fitting of covers and
bearing covers to supply unit,
including: 3 Head screws M16x30
X = 2087 mm
X
012.281/04
012.282/04
94553c
2008
32/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
1
014.386/06
94554
94554a
94554b
94554c
94554d
94554e
1 Fork lever
for lifting camshaft
consisting of:
94554b
94554d
94554e
Face plate
Rocker arm
Nut
Bolt with circlip
Web with screw
X = 329 mm
94554a
94554c
X
012.283/04
94555
Spacers
for cutting out of individual fuel pumps,
depending on number of cylinders:
4 pieces for 67 cylinder engines
6 pieces for 810 cylinder engines
8 pieces for 1114 cylinder engines
X =
95 mm
008.764/01
33/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
X
94556
2 Pre-tensioning jacks
for waisted bolts to intermediate wheel
bearing of supply unit,
including a metal box
X = 195 mm
00.7014
X
94557
2 Pre-tensioning jacks
for gear wheel and waisted bolts to
camshaft bearing,
including a metal box
X = 155 mm
012.284/04
94558
2 Sleeves
X = 166 mm
X
012.285/04
94559
1 Socket wrench
X = 206 mm
012.286/04
94560
2 Round bars 6 mm
X = 100 mm
X
012.287/04
2008
34/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94561
1 Device
for removal and fitting of pinion to
supply unit
X = 1376 mm
014.387/06
X
1 Cam adjusting gear
X = 194 mm
consisting of:
94562
94562e
94562f
94562a
94563
1 Distance holder
for setting fuel cam No. 1
X = 365 mm
94562f
014.495/06
014.496/06
X
014.497/06
35/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94566
2 Supports
for removal and fitting of camshaft
X = 1097 mm
012.296/04
94567
94569a
2008
1 Assembly template
for removal and fitting of bearing
shells to supply unit
X = 100 mm
including:
94567a 1 Pipe
X =
94569
012.302/04
012.297/04
200 mm
Blank flange
to fuel pump
2 pieces for 6 & 7 cylinder engines
4 pieces for 810 cylinder engines
5 pieces for 11 & 14 cylinder
engines
with screws M12x55 mm
X =
110 mm
Blank flange
to intermediate fuel accumulator
2 pieces for 6 & 7 cylinder engines
4 pieces for 810 cylinder engines
5 pieces for 11 & 14 cylinder
engines
with screws M12x50 mm
X =
110 mm
36/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94571
1 Rail
for removal and fitting of intermediate
wheel to supply unit,
including: 2 Shackles
(Lifting capacity 1500 kg)
4 Screws M30x130
X = 2565 mm
WCH01168
94571b
94571a 2 Screws M20x200
94571a
94571b 2 Washers
012.299/04
94571c 1 Carriage
to rail 94571
X = 280 mm
94571d
94571c
X
012.300/04
94571f
94571e
94571f
WCH01168
94581
1 Assembly tool
for removal and fitting of fuel pump
X = 905 mm
(max. lifting capacity 450 kg)
including:
94581a
37/ 62
2013-05
94035/A1
Maintenance
RT-flex96C
Standard Tools
94583
1 Pipe
for pressure built-up in fuel rail
during commissioning
X = 687.5 mm
012.303/04
94584
1 Lifting plate
for removal and fitting of injection
control unit,
including 2 screws M12x30
X = 300 mm
(max. lifting capacity 330 kg)
X
012.304/04
94586
94587
94589
4 Shut-off plugs
for servo oil rail and servo oil return
X = 144.5 mm
011.955/04
4 Conical plugs
for servo oil return
X =
20 mm
011.976/04
2 Withdrawing tools
for removing lip seal from injection
control unit
X = 310 mm & 638 mm
X
012.308/04
2010-07
38/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94593
94592c
94592b
94592e
X
94592d
94592a
016.787/08
1 Assembling device
for assembling fuel pump
consisting of:
94592
94593d
94593c
94593a
94593b
014.390/06
94593e
1 Mandrel
for fitting seal into lower spring carrier
and lower housing of fuel pump
X =
70 mm
014.494/06
94597a 1 Mandrel
for fitting seal into lower spring carrier
X =
40 mm
1 Impact wrench
for loosening and tightening fuel
pump on supply unit
X = 256 mm
94598
94598
94598a 2 Extension 1
X = 330 mm
X
94598b
94598a
39/ 62
014.389/0
2010-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
94651
1 Dismantling device
for auxiliary blower
consisting of:
009.995/02
94651c 1 Trolley
94652
2 Centring studs
for removal and fitting of electric
motor
on auxiliary blower
X = 615 mm
000.427/93
2 to 4
94653a 1 to 2
94653c 1 to 2
94653e 1 to 2
2010-07
40/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
1 Lifting device
for removal and fitting of cooler
element and cooler pre-stage
X = 910 mm
(max. lifting capacity 6000 kg)
014.396/06
X
94660a 1 Lifting device
for removal and fitting of cooler
element and cooler pre-stage
X = 1780 mm
(max. lifting capacity 6000 kg)
014.397/06
94660b 1 Extension
to lifting device 94660
with screws M20x60 and nuts
X = 1780 mm
014.398/06
94660c 1 Extension
to lifting device 94660
with screws M20x60 and nuts
X = 1780 mm
014.399/06
41/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94662
1 Roller plate
for removal and fitting of
scavenge air cooler
including: 8 Screws M12x80
10 Screws M20x40
X = 2346 mm
012.312/04
94663
94664
1 Support
for fitting scavenge air cooler,
including 4 screws M24x45
X = 385 mm
(WLL=10 000 N)
012.313/04
1 Beam
for removal and fitting of
scavenge air cooler
X = 1738 mm
X
012.314/04
94665
4 Swivel lugs
for removal and fitting of
cooler pre-stage
X = 1000 mm
(max. lifting capacity 4000 kg)
X
012.315/04
2008
42/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94666
012.316/04
012.317/04
012.318/04
43/ 62
012.319/04
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
X
014.400/06
1 Extension
for removal and fitting of
scavenge air cooler
with 8 screws M20x45
X = 1740 mm
94661
014.401/06
94662
1 Roller plate
for removal and fitting of
scavenge air cooler
including: 8 Screws M12x80
10 Screws M20x40
X = 2346 mm
012.312/04
94663a 1 Support
for removal and fitting of main cooler
with 4 screws M12x35
X = 187 mm
X
014.402/06
2008
44/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94663d 1 Support
for removal and fitting of
scavenge air cooler
with 4 screws M24x45
(for 6, 8, 10, 12, 14 Cyl. engines)
X = 1027 mm
014.403/06
94663e 1 Support
for fitting scavenge air cooler
including: 4 Screws M24x45
X = 1653.5 mm (7 cylinder engines)
X = 1146.0 mm (9 cylinder engines)
014.405/06
94663f
2 Supports
for removal and fitting of
cooler pre-stage
including: 2 Screws M20x40
X = 1181 mm
014.406/06
94664a 1 Beam
for removal and fitting of
scavenge air cooler
X = 1758 mm
X
012.314/04
94665c 4 Discs
014.407/06
45/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94667
94666f
012.319/04
012.318/04
1 Carriage
for removal of water separator,
including: 4 Screws M12x180
1 Eye bolt M30
1 Shackle (LC 1000 kg)
X = 641 mm
012.321/04
94668
1 Pulley device
for removal and fitting of water
separator,
including: 2 Screws M30x55
X = 230 mm
X
012.322/04
2008
46/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94669
94672
1 Support
for removal and fitting of water
separator,
including: 2 Screws M16x30
1 Screw M16x80 with nut
X = 440 mm
012.323/04
1 Lifting device
for removal and fitting of water
separator,
including 4 screws M12x50
X = 2386 mm
X
012.324/04
94673
012.325/04
94720c 1 Case
consisting of:
94811
018.472/09
2 Lifting lugs
(incl. 2 shackles) for removal and fitting
expansion piece to exhaust valve cage
X = 636 mm
(max. lifting capacity 150 kg)
000.471/93
47/ 62
2011-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
X
94831
1 Blank flange
for blanking off starting air pipe
during emergency operation
X = 320 mm
004.017/96
94835
94843
X1
015.817/07
Y
94844
1 Lubricating device
to supply unit
X = 600 mm
Y = 200 mm
X
WCH01042
2013-02
48/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
Ii
Y
94844a 1 Filling device
to lubrication device
X = 482 mm
Y = 225 mm
X
WCH01042
Y
94844b 1 Filling device
to lubrication device
X = 203 mm
Y = 165 mm
X
WCH01042
Y
94844c 1 Filling device
to lubrication device
X = 312 mm
Y = 140 mm
X
WCH01042
WCH01042
X
WCH01042
49/ 62
2013-02
94035/A1
Maintenance
RT-flex96C
Standard Tools
94844f
1 Holder
to lubrication device
WCH01042
94870
1 Regrinding device
for conical sealing surfaces on fuel
pressure piping (87331)
X = 106 mm
consisting of:
94870c
94870d
1 Template
X =
50 mm
94872
1 Regrinding device
for spherical sealing surfaces on fuel
pressure piping (87331)
X = 60 mm (radius of 25 mm)
94870
a
c
94870g
94870h
2013-05
016.740/08
016.776/08
1 Regrinding device
for sealing surfaces on fuel pressure
piping (87521)
X = 158.5 mm
consisting of:
94870e
94870f
94870a
94870b
e
g
f
X
X
016.741/08
1 Template
X =
80 mm
50/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
Ii
94870
1 Regrinding device
for sealing surfaces on fuel pressure
piping (87521)
(intermediate fuel accumulator FP)
X = 158.5 mm
consisting of:
94870i
94870j
94870k
94870l
94873
X
016.741/08
1 Template
X =
80 mm
1 Turnbuckle
for removing and fitting of fuel pressure
piping
X =
70 mm
X
012.329/04
94874
1 Tightening device
for loosening and tightening connection
piece on injection control unit,
including 4 screws M12x30
X =
95 mm
014.408/06
94924
1 Hook spanner
for crank angle sensor
X = 205 mm
94925
1 Hook spanner
for crank angle sensor
X = 242 mm
94930
008.771/00
1 SW-download package
to WECS9520 for flexView operator
consisting of:
1
1
1
1
1
USBmemory stick
CAN cable (ca. 10 m)
UBS to CAN adapter
Connection diagram
Requirements
018.127/09
ca. 1000
51/ 62
80
2013-02
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 HP oil pump
working pressure max. 2500 bar
94932
1 Pressure gauge
100 mm
working pressure 02500 bar
connecting branch G
94936
94935a
94932a
94934a
94934e
94934d
012.335/04
94935
94942
015.220/07
3 HP hoses
working pressure max. 2500 bar
length approx. 1800 mm
94935
94935a 2 HP hoses
working pressure max. 1800 bar
length approx. 1800 mm
94935b 4 HP hoses
working pressure max. 1800 bar
length approx. 700 mm
94931
001.547/97
94932
94942
1 Hydraulic unit
94934c
94935b
94935c
012.336/04
2008
52/ 62
RT-flex96C
Maintenance
94035/A1
Standard Tools
94934i
WCH00724
53/ 62
2012-05
94035/A1
Maintenance
RT-flex96C
94016
2 Manual rachets
(max. lifting capacity 750 kg)
94017
012.232/04
94203
2 Wedges
for hydr. jacks 94936 as support
X = 130 mm
001.610/97
2008
54/ 62
RT-flex96C
94035/A1
Maintenance
94291
94291a
2 Grinding discs
(C-M No. 11373-04-05)
016.774/08
1 Tool cupboard
X = 1120 mm
X
94300
016.773/08
001.412/96
1 Connecting flange
for pre-lubrication of top and bottom
end bearings
X = 130 mm
94336
001.411/96
94344
1 Dismantling device
for removal of piston rod gland
downwards
X = 1300 mm
008.550/01
55/ 62
2013-08
94035/A1
Maintenance
RT-flex96C
X
94349
000.461/93
94356
1 Equipment case
with instruments
for measuring thickness of chromeceramic-layer on piston rings
WCH01216
94357
1 Calliper gauge
for measuring piston ring grooves
94424
94481
014.409/06
1 Metal box
for storage of spare filter cartridges
Remark: Dimensions are
depending on size of parts to
be accommodated inside.
012.235/04
2013-08
56/ 62
RT-flex96C
94035/A1
Maintenance
1 Jack
for removal of a jammed fuel pump
plunger (with 12-hole pump cover)
X = 270 mm
94595
014.499/06
014.500/06
014.501/06
X
94595e 2 Screws M30
with nuts
X = 400 mm
X
014.502/06
57/ 62
2008
94035/A1
Maintenance
RT-flex96C
94650
000.460/93
94655
94655a
94655b
94655c
94655c
1 to 3
2010-07
58/ 62
000.487/93
RT-flex96C
94035/A1
Maintenance
1 Measuring apparatus
for leveling bedplate
consisting of:
4 Supports
4 Weights with wire
1 Measuring underlay
X = 1400 mm
94105
000.459/93
4 Thread protectors
to upper threads of tie rods, when fitting
a cylinder jacket
X = 225 mm
M36
94174
001.410/96
94177
M24
X
1 Thread protector
to lower thread of tie rod
X = 158 mm
000.458/93
59/ 62
012.333/04
2014-04
94035/A1
Maintenance
RT-flex96C
94574
012.334/04
94574a 1 Holder
with head screws M20x180
X = 176 mm
94574b 3 Holders
with head screws M20x130
X = 125 mm
2008
X
94574a
60/ 62
X
94574b
RT-flex96C
94035/A1
Maintenance
94690
1 Transport tool
for 3 Cyl. rail unit module
(max. lifting capacity 24 000 kg)
X = 3500 mm
consisting of:
x2
94690b
x1
94690a
014.410/06
94691
1 Transport tool
for 4 or 6 Cyl. rail unit modules
(max. lifting capacity 24 000 kg)
X = 5040 mm
consisting of:
94690b
94690c
94690a
X1
014.411/06
61/ 62
2008
94035/A1
Maintenance
RT-flex96C
94692
1 Transport tool
for 5 or 7 Cyl. rail unit modules
(max. lifting capacity 24 000 kg)
X = 6860 mm
consisting of:
94690b
X
94690a 1 Lifting element
94690b 1 Lifting element
94690d 1 Bracket
incl. 48 screws M24x80 and nuts
X1 = 3360 mm
94690d
94690a
X1
014.412/06
94922
1 Alignment tool
for crank angle sensor
X = 172 mm
008.773/00
2008
62/ 62