021/1

SULZER Work - Intervals 1) ::...,

<...
Sheet (Service hours) tl
Vi

"-' RT Maintenance Schedule I

a
a
I
Vi
<1J
\.J
a a 4.1
....<1J ~ ala aa a c:
§-
-'- a aa Q;) C"lr
c:<1J

- -
<1J
Component Work to be carried out ....0
t:)
-e: o a lrJa I 10
V) Cl lrJ ~ \0 ~

Lubri cab ng oil Spot test J42

,
I
•
(engine)
Laboratory analysis 042 2
•
Cooling water Check inhibitor concentration

(according to supplier's instructions)

For the ~irst time af­

Check holding-down bolt tension ter 1500
Bedplate metal chocks 110 1 •
synthetics chocks
•
Main bearings

Check thrust bolt tension

(retension if necessary)
117 2
According to classifi­
•
Remove and inspect main bearings 117 ~,4 cation society
Remove and inspect lower bearing shells 117 5
•
Thrust bearing Check both axial and radial clearance 120 1
•
Check that bottom drain hole is clear
Remove and inspect thrust bearing segments
120
120
1
2 According to classifi­
•
cation society
I I I I I I I

..........
Tie ro ds Check tension, retension if necessary Initially after one
190
year, thereafter every
four years.
I I I I I I I
Cyli nder jacket Check the condition of the water guide ring 211 Always after removal
and the water spaces of acyl inder 1iner
I I
I I
Cyli nder 1i ner Determine the bore wear (in situ)
Remove cylinder liners
Remove wear ridge from bore
214
214
214
1 At each piston with-

2
drawal
I I I I I I
4 At each piston wi th-.
drawal
I.
Reworking the edges of the scavenging ports 214 4
•
Re-cut the lubrication grooves
Replace rubber rings
214
214
4
IIIII
3 Every time before re­
•
fitting

L.B. 1.89
 021-2

SULZER Work­ Intervals 1) ,

~

Sheet (Service hours) 0

Vl

Maintenance Schedule a
Vl
Q.l

RT a aa <:)
u
(\J
c:
..... a <:)

a a a~
'-a-
Q <:)

::J Q.l ~ a C) <:) c:

a a C) co I
- -
III ~ Q.l
0
.... .c::. a It) C") I It) I

~
CJ
Component Work to be carried out 0 V) It) \Q
LD
cY)

Lubricating quills Check for correct functioning a~d tightness 215 1 At each pi ston IIi th­
and accumul ator drallal
I I I I I
I I I I I I
Piston rod glands Clean rings and determine lIear (fit nell parts as 231 1 every time a piston is
necessary) lIithdralin
I I

Cylinder head Inspect combustion chamber 270 1 At each piston IIi· t h­

drallal
Clean sealing face for the fuel injectors in the
cylinder head, re-machine seat if necessary 271 4
•
Fue1 injector Check tightness of all external connections Before starting the
engine after an-exten-
Test spray (dependent on the fuel treatment)
Clean and overhaul injector nozzles
272
272
1 ded stop
2 • ••
Lap the contact faces of the nozzle ho1de r 272 3
Checking a circulating valves 272 4
•
Starti ng val ve Fuel the pipe before the valve IIhile the engine is rom time to time
running. If it is hot, the 'valve has to be dis­
mantled
Remove one starting valve and dismantle (random
ch eck). (Depending on its condition, determine the
273 1
•
time schedule for overhauling the remaining
valves)

Cylinder head
relief valve
Test, dismantle, reassemble and adjust 274 1
•
Exhaust outl et
va1ve
Overhaul and regri~g the valve seai and spindle
by machine if neiessary.-All overhi~l-\Iork must
275 2-4
•
be recorded on the sheet 'Exhaust Valve Record',
form 4-107.044.059 -1/-2. Checking the piston seal
ring in the air-cylinder casing and the rod seal
ri nQ in the Qui de bush. •
Crankshaft Measure crank deflections (in any case if vessel
has gone aground] 310 1
•
Viscous torsional
vibration damper
Remove a silicon fluid sample 313 2
•
• •
Axial damper Dismantling and assembling 314 1
checking the throttling nozzles

L. B. 10.85
 021-3
Work­ Intervals 1) ~
SULZER
Sheet (Service hours) ;;
Vi

RT Maintenance Schedule Vi
<lJ
lJ
ClJ
C
C
Q>

Component Work to be carried out ~

Turning gear Check oil level, top up oil if necessary. Check 320
Each time before use
oil condition and charge oil if necessary
• I·
Upper and lower
connecting rod
Check bearing clearances 330 1
•
330 14,~
bearings
Inspect bearings and replace if necessary
•
*Removal and fitting of a connecting rod 330 6
•
Guide shoes Check running clearances 332 1
•
*Remove crosshead when the piston has been remo­ 337 3
Crosshead pins
ved •
Working pi ston Withdraw, clean and measure grooves 340 1,3
•
Checking the piston top surface
Open up cooling spaces and clean (at least one
340
340
4
•
piston annually)
5
•
Check tightness after re-assembly 340 6 (on1 y when it has been
di smant1 ed)
Visually check through the scavenge ports
(Enter charge air receiver and turn crankshaft
with turning gear) •
(only after they have
Working piston Align the piston cooling telescopic pipes 342
been refitted)

Remove, clean and determine wear. Fit new rings

.I 1 T. T J) I
At each plston wlth­
Pi ston rings
if necessary 342 dra lIa1
I I I

Pi ston cool i ng Remove stand pipes and check condition of the 1111 I I I
at each piston wfth­
guide bushes 360
drawa1
Dismantle telescopic pipe glands, clean and de­ I I I I I I I
termine wear 362 at each piston with­
dr.a\l~ 1
Piston underside Check the condition of the spaces and clean
•
021/4

SULZER Work- Intervals 1) ~

"-
Sheet (Service hours) tJ
V)

RT' Maintenance Schedule C)

C) 0
V)
C1l
u ",-./
C) 0 ClJ
C)
c:
g. .... ..:-
C) 0
C)
C) a C) 0 c:<1J
... ~ Clo-tJ
<1J ~ <;j
C) Co) C)

-
C1l <X:l r
0 a
-
I
~
C) lJ") I
Component Work to be carried out t:> lJ") ~ (Q
lJ") LD
(Y')

Camshaft driving
gearwheel s
Check condition of the teeth
Check backlash and bearing clearance of the in-
410 1
•
termediate wheel 410 1 •
*Remove intermediate wheel
*Replacement of the 2-piece gearwheel on the
410 2
•
crankshaft ,thrust bearing collar 410 3
•
Camshaft bearings Oetemine bearing clearance (see Table of
Clearances 012/10) •
Reversing servo­
mo tor
*Remove 420 2
•
Fuel cams Inspect running surfaces 421 1
•
Actuator cams Inspect running surfaces 421 1
•

Starting
..­ control
air distributor
Oi smantl e, cl ean and inspect
Check pilot valves for easy movement
430 1
•
Starti ng ai r shut­ Vent
._-.
off valve Oi smantl e, cl ean and inspect (seat" and spring in After each manoeuvring
particular)
Check performance
432
432
1 period
1
• •
Running direction
safeguard
~heck performance 453 1
•
Shut-down servo­
mo tor
Dismantle and clean 455 1
•
WOODWARD governor Check oil 1evel (top up if necessary}
~harge oil (flush out casing)
510
510
1
1 • •

L.B.

 021/5

SULZER Work­ Intervals 1) :::....

....
Sheet IService hours) 0
Vl

RT Maintenance Schedule C
C
Vl
~
u
C C
CIJ
..... C c:
g. ~ C c c c c:~
0
CIJ
~ 0- c c c co l'\iI
c lI") C I lI")
~ .... ~
0
lI") ....
~
Component Work to be carried out l:) Cl ~ <.0

Safety cut-out Ois~,antle,clean and inspect (replace round

device rubber rings if necessary) 530 1
•
Fuel injection
pumps
Clean, remove and inspect valves
Check timing and re-adjust if necessary
551
551 1
,4
•
•
Lubricate articulated joints of regulating
linkage
551 1
•
• •
*Lap sealing faces for the valve covers 551 2
Check and -adjust relief valves 551 3

Charge air recei­

ver
Observe outlet of the permanent drains
Inspect, clean and recondition non-return valves
(or replace them with either a new or cleaned
640 1 • •
set)

Clean receiver
Check and clean the water separator elements
640 1
640 2 • •
I
• u
-..- ~ I
E~haust gas turbo­ Wash the compressor during service >
L
L
-+-'
'"
e
650 1 •
charger (every 25 to 75 running hours) Q)
CI)
CI)
c: CI)
-.- c:: r-­
Q) 0 '"
Q) Q) or- ~
(./) U +-' c:

Exhaust gas turbo­ Wash the turbine during service

charger (every 250 to 1000 hours) Q)
u
.,....
CI)
c:
0
or­
650 1
•
Air filter Clean
( 6p max, : lQO mm WG)
>
L
Q)
CI)

Q)
Q)
-+-'
U
:::o~
L
-+-'
CI)
c:
'"c:
:::0
•
en .~
'"e

Auxiliary blower Clean impeller and casing

..
......
u
:::J
I
I
654 1
•
•
>
L
L
-+-'
'"
e
Charge air cooler Clean during service (air side) Q)
CI)
CI)
c: CI)
660 1 initially weekly
.,.... C r-­
Q) 0 '"
Q) <D .,.... ='
(.I) U +-' c::::

C~ean
(6
at standstill (air side)
P max. : 300 mm WG)
660 1
•
Clean the inside of the water tubes 660 2
•
Remove cooler for general cleaning 660 3
•

I . R_
1. 89
 021/5
Work Interval s 1)
SULZER
Sheet (Servi ce ho urs)
Maintenance Schedule >0­
L
RT <U
</l
</l
a a c
a
a
00 '"u
a. -<-' >0­
-
co
00
-a -a '"c
'" 00 c
'"'" '"
~

0 0 00 I I """""I
Component '"
.~

Work to be carried out =

L --'= <U
= '-"
0 '-" 0 '-" '-" --'=
en ~ ('V") u:J ~ C"Y)
=
Cyl inder 1ubri ca­
to rs
Drain casings and wash out 721 1 •
P.T.O.-gear trans­
mission
Check conditions of teeth; establish back-lash
and bearing clearances (compare with clearance
740 n , i •
table 012/9a) external checking for oil leakage
•
{

with and cl ear vents

Gei sl inger
coupl i ng
Di smantel coupl ing, inspect, clean and replace
all seal rings
740 3
•
Overhaul, or replace spring stacks respecti vel y
•
Efficiency-Booster Check oil 1evel in hydro coupling (if necessary

refill with oill.

Check rubber pads of flex. pad coupling

750 1
• I

(replace if condition demands it).

750 1
•
Analyse the oil of the hydro coupl i ng (renew if

condition demands it).

750 1 •
Turbine part of power turbine, check every 8'000

hours in acc. with manufacturer instructions.

•
Planetary gearbox of power turbine, have it over~;

hauled at manufacturer works as instructed by the

•
them every 16'000 hours.

Check function of shut-off flap (in case of bad

operating condo every 3'000 hours).

750 2
•
Gneck function of angle valve (in case of bad

operating conditions every 3'000 hours).

750 2
•
Wash power turbine during operation (Depending on

operating conditions every 250 till 1'ODD

751
•
operating hours).

Balancer
ori vee1em ent s
Re-tension roller chain
(After fi Hi ng a new chain first time at 500 op.
770 1
•
hours) •
with Measure roller chain stretching (if req. replac­
ing roller chainl.
•

Geislinger coupl i ng (See group 740).

L. B. 12.89

021/7

SULZER
Work­ Intervals 1)
...:....
Sheet (Service hours) C)
VI

RT
Maintenance Schedule C)
C)
til
<lI
lJ
C) QJ
C)
C) c
g. ~ :..,
OJ:::: C)
C)
C)
C)
C)
C)
co
C)
C'\j C
<lI

Component Work to be carried out ...a

(:)
-C. a C) Ie) C)
l.I) Cl Ie) " ­ C'1
I
<0 ~
I

Exhaust pipe Check the condition of the exhaust pipe mounting

bolted connections
811 'I •
Cl~an the sliding surfaces and inspect for wear
•
Check pre-tension of tie rods on RT76 and 84 en­
gines (see sheet 013/2)
•

Hydraulic Conduits
t 0.'£ xhaus t val ve
Reconditioning the sealing surfaces 846 1 •

Before 'and after

Starting air pipes Drain (water)
every manoeuvring
peri od

Pressure gauges Compare with master instrument and adjust •

•

and pyrometers

Fuel and 1ubricat­

ing oil filters
Clean or exchange filter inserts. (Depending on
the make observe the supplier1s special instruc­ •

ti ons)

The indicated intervals 1) must be taken as guide only. Exoerience must show ~hether these intervals can
be extended or must be shortened, as operating modes, quality of fuel and lubricating oils used as well
as iJany other fadors infl uence the condi bon of engine components.
On the engine sedional drawings, sheet 004/1 and -2, those parts are r.larked with group numbers, under
which so-called 'work-sheets ' are found in the corresponding book section.
Of the following engine components 'work sheets' exist, although these parts are not marked on the sec­
tional drawings:
Enaine CO~Donent Work sheet
Lubricating quills and accumulators 215/1
Vibration damper 313/2
Axial damper 314/1
Turning gear / 320/1
Starting control air distributor 430/1
Rotation di redion safeguard 453/1
Shut-do~n servomotor 455/1
Speed governor 510/1
Safety cut-out device 530/1
P.T.O. Gearbox 740/1;3
Efficiency-Booster 750/1 +2

Remark!
The maintenance work r.larked in the column "work to be carried out" with* must not be carried out periodi
cally, but only when required. The respective work sheet' serves as information only.

11.86
L. B.
 Table of Contents
-""-"---------------------------------­

Ma.intenance Instructions

Clearance Tables

Tightening Values for Bolt Connections

Weights

Maintenance Schedule

WorkSheets

ToolUsts