mm-rt-flex96c_wecs-9520_dynex_2014-04

RT-flex96C

Maintenance ManualMarine WECS9520 / Dynex Servo Oil Pumps

Vessel:

Type:

Engine No.:

Document ID: DBAC352038

Wrtsil Switzerland Ltd 24hrs Support: +41 52 262 80 10PO Box 414 [email protected] WinterthurSwitzerland

2014-04 Wrtsil Switzerland Ltd, Printed in Switzerland

Intentionally blank

Summary for Maintenance Manual

(MM)Page No. Title SubjectDate No.

new exch.

2008 Maintenance Manual, Issue 2008

Due to the major revision you receive a new complete

Maintenance Manuals Version with Dynex Servo Oil Pumps

x

Date of publication 2008-11-18

0352-1/A1 (2) 2008 Tightening Values of

Important Screwed

Connections

Number 15: Missing remark referring to retaining nut added x


0330-1/A1, B1

(26 and 27)

1.09 Clearance Table Former key No. 5, 6, 8 deleted: No. 2, 3 (max. clearance),

5 corrected

x

3303-2/A1

(1, 5 to 8)

7-67.364 Connecting Rod Tool 94323: design adapted; paragraph 1.3 with Fig. 'H' added;

figures and and texts concerning the new tool 94323a adapted

x

3303-3/A1, A2

1 to 5 (4)

7-67.364 Connecting Rod Tool 94323: design adapted; figures and texts concerning the

new tool 94323a adapted

x

3303-4/A1 x

3326-2/A1 (1) Crosshead x

3425-1/A1 (1) 7-65.977 Piston Rings Reversible ratchet 94338b deleted x

9403-5/A1

(21 and 26)

7-67.364 Tool List Tool 94323a with special fixation adapted; tool 94338b deleted x


Index Gr. 9 2.09 Tool list: Pages adapted correspondingly x

0002-1/A1 (5) Table of Contents x

9403-5/A1 (52) Tool List SW-download package 94930 as standard tool added x


Index 8 12.09 8135-1: Exhaust Waste Gate added x

0002-1/A1 Table of Contents x

0380-1/A1 (7) Maintenance Schedule 8135-1: Exhaust Waste Gate (LLT) added x

1132-2/A1 (2) Main Bearing (6-7

Cyl.)

Table (5th - 7th rows) with available bearing types corrected x

1132-2/A2 (2) Main Bearing (8-14

Cyl.)

Table (5th - 7th rows) with available bearing types corrected x

8135-1/A1 2009 Exhaust Waste Gate Low-Load Tuning x


0002-1/A1 2010-07 Table of Contents 0370-1 and 0370-2: Title Dimensions (and Material

Specification deleted); Tool List: Pages adapted

correspondingly

x

Index Gr. 0, 9 x

0330-1/A1 27 Clearance Table Key No. 3: altered to 0.12-0.24 mm (max. 0.3 mm) x

0352-1/A1 (1, 2,

5, 6, 8, 12, 13,

15, 16)

Tightening Values 2138-1: Description changed for 1-part lubricating quill; 2708-

2_13, 2751-1_18, 5564-1_63: lubricant altered to Never-Seez

NSBT-8; 5610_118: tightening torque changed to 270 Nm;

5612-1_86: Elastic bolt M22x282 added

x

0352-1/A1 (8) screw plug 94585 deleted therefore numbers sorted

accordingly

x

0352-2/A1 (1) 7-69.624 Tightening Values Columns specified with "Thread diameter" and "Fine thread" x

0370-1/A1 (2) 7-69.800

7-78.356

Dimension: O-rings 5556: O-ring 1.78x34.65 between flange - upper housing

added; 5612: O-ring between valve housing and lower cover

replaced with 2.62x59.99; Material specification deleted

x

0370-2/A1 (1) 7-77.791 Piston and Rod Seal

Rings

5556-1: former seal replaced with rod seal ring 70x3.53;

Material specification deleted

x

0380-1/A1 (2, 7) 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

x

1132-2/A1, A2

(13 or 16)

Main Bearing 6.2 Lifting the crankshaft: remark for further lifting (0.8 mm) in

case of difficulties during removing lower bearing shell

x

Modification ServiceEngine Documentation

RT-flex96C_WECS-9520_DynexModification Page or

Manual

1/6 31.3.2014



new exch.



Manual

2138-1/A2 7-73.638 Lubricating Quill on

Cylinder Liner

Multi-part quill replaced with one-part quill introduced x

2708-1/A1 (4) 2010-07 Cylinder Cover Sec. 4, 6th: lubr. for nuts (2) altered to Never-Seez NSBT-8 x

2708-2/A1 Cylinder Cover Protection cap (11) added and lubricant for nuts (2) altered to

Never-Seez NSBT-8

x

2722-1/A1

(1, 3, 6, 7)

Injection Valve (O.M.T.

Test Bench)

1.General: 4th sentence added; 3. Judging an injection valve:

revised; Remark concerning opening pressure of 375 bar and

reference dimension 'x1'= 49.5 mm in Fig. 'E' added

x

2722-1/A2

(1, 3, 5, 6)

Injection Valve (OBEL

Test Bench)

1.General: 4th sentence added; 3. Judging an injection valve:

revised; Remark concerning opening pressure of 375 bar and

reference dimension 'x1'= 49.5 mm in Fig. 'B' added

x

2751-1/A1

(4-6)

Exhaust Valve 3. Fitting: lubricant for studs (1) and nuts (2) altered to Never-

Seez NSBT-8; Sec. 4: Replacement of waisted studs revised

x

2751-2/A1 7-77.818 Exhaust Valve Rotation device 94290 deleted and therefore dismantling and

assembling procedure revised

x

2751-3/A1 Replacing and

Grinding the Valve

Seat

Rotation device 94290 deleted; new valve grinding device

94291 introduced and therefore grinding procedure revised

x

2751-4/A1 (1) Grinding the Seating

Surface on Valve

Head

New valve grinding device 94291 introduced x

3130-1/A1

(1, 4)

Vibration Damper 1st sentence on page 1, addresses and information about

labels updated

x

3130-2/A1 (1) Vibration Damper Attention concerning interrupted oil supply to the damper

added

x

3146-1/A1 (4) Axial Damper Remark concerning signs of wear of seal rings added x

3403-3/A1 (6) Piston Securing agent LOCTITE No. 0648 specified for spraying

nozzle

x

3425-1/A1 (1,

3)

Piston Rings Additional execution with 1xGTP1CC20 (GasTight) and

3xSCP2Cr20 piston rings added

x

4325-1/A1 (2) 7-72.925 Shut-off Valve for

Starting Air

Control valve modified x

5552-5/A1 Supply Unit Application of lubricating device 94844 specifically adapted x

5556-1/A3 (1, 2,

6-13, 15-17)

7-69.800

7-77.791

7-77.818

Fuel Pump Fitting & dismantling device 94592 introduced instead of

rotation device 94290; tool 94550 and description concerned

added; dismantling and assembling procedures revised

x

5556-2/A1 7-72.876 Fuel Pump Removal of a jammed pump plunger revised x

5564-1/A1 (3) 7-69.624 Injection Control Unit Lubricant of screw (10) altered to Never-Seez NSBT-8 x

5612-1/A1 7-78.356 Exhaust Valve Drive Fitting instruction adapted and completed with new torques x

8733-1/A1

(1, 2)

7-77.538 Fuel Pressure Piping Fixation of fuel pressure piping reinforced with an additional

holder (12)

x

8750-1/A2 Intermediate Fuel

Accumulator

Checking procedure revised, table with physical characteristics

for test & calibration fluid added

x

8752-1/A1

(1, 4-6)

7-78.121 Fuel Pressure Piping Regrinding device 94870 consisting of 94870i,j, k, l

implemented for fuel pressure pipe (with left-hand thread

M36x2 LH) between FP and intermediate fuel accumulator

x

9403-5/A1 7-77.818

7-75.992

Tool List Tool 94290, 94290b, 94278, 94278c, former 94291 and 94585

deleted

x

9403-5/A1

(1-5, 31, 38, 39,

40, 47, 49, 56)

7-77.818

7-78.121

EAAD082065

tool numbers for all general tools introduced (94000 - 94017,

94022, 94025, 94026, 94032, 94045, 94046, 94050); tool

94550, 94592 consisting of 94592a, b, c, d, e added; covers

94653, 94653a, b, c, d, e, 94655a, b, c specified for TPL85-B,

MET83MA, A190 and A185 TCs; tool box with No. 94720

specified for CLU4 only; new valve grinding device 94291

designed; regrinding device 94870 consisting of 94870i,j, k, l

added; tools newly sorted on 60 pages

x


0002-1/A1 2010-11 Table of Contents x

Index Gr. 7 x

New group 7218-1/A2 added

2/6 31.3.2014



new exch.



Manual

0380-1/A1

(7, 8)

Maintenance Schedule 7218-1: Procedure specified for checking gas (nitrogen) pre-

charge pressure

8750-2 Fuel pressure control valve: Replace filter (control oil)

added and therefore on page 5 deleted

x

7218-1/A1 2010 Lubricating Pump

CLU4

Procedure specified for checking gas (nitrogen) pre-charge

pressure and refilling the accumulator

x


0380-1/A1 (8) 2011-02 Maintenance Schedule 8744: Check of supply unit fuel drain pipings added:

8750: Check of non-return valves in IFA deleted

x

2138-1/A2

(1, 4)

Lubricating Quill on

Cylinder Liner

Test procedure of non-return valve modified (test medium

altered to oil) and required tools added

x

5556-1/A3

(1, 20)

Fuel Pump Section 5: Oil flow check added x

8750-2/A1 (3) Fuel Pressure Control

Valve

To prevent any clogging, new filter (35) is not secured with

LOCTITE, however fitted with oil and tightened with 10 Nm

x


Index 8 2011-03 8733-1/A2: Fuel pressure piping with spherical sealing

surfaces added

x

0002-1/A1 Table of Contents x

2722-1/A1 (6) 7-77.630 Injection Valve (O.M.T.

Test Bench)

Fig. 'E': detail with spherical insert bush added x

2722-1/A2

(5)

Injection Valve (OBEL

Test Bench)

Fig. 'B': detail with spherical insert bush added x

8135-1/A1 EAAD082110 Exhaust Waste Gate

(Low-Load Tuning)

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

x

8733-1/A1 (1) 7-77.538 Fuel Pressure Piping Attention concerning fuel leakage pipe added; reinforced

holder adapted

x

8733-1/A2 2011 7-77.630 Fuel Pressure Piping with spherical sealing surfaces added x

9403-5/A1 (49) 2011-03 7-57.949 Tool List Regrinding device 94872 for spherical sealing surfaces added x


2751-2/A1 2011-05 EAAD077748 Exhaust Valve A new valve stroke sensor 30 adapted. Former items 33, 34

deleted and therefore following items renumbered

x

3403-1/A1

(1,4-8)

EAAD082346 Piston Pages 1, 4: Protection 17, paragraph 4.2 and Fig. 'D' added.

Page 6: Remark concerning main lubricating pipe added

x

6420-1/A1 (5) Scavenge Air Receiver Opening pressure of relief valve (15) specified for TIER I and II x

9403-5/A1 (28) EAAD082346 Tool List Quantity of device 94350 reduced to 1 piece and 'X' adapted to

1174 mm

x


0352-1/A1 (1) 2011-05 Tightening Values 2138-1: Description (passage for LQ and screw-in union)

changed for redesigned pulse feed lubricating quill

x

2124-1/A1 Cylinder Liner Measuring bore wear adapted with regard to setting screw (ST)

and compression shims

x

2124-3/A1 EAAD082901 Cylinder Liner Collection / pressure reduction grooves (SN1) introduced x

2138-1/A2 EAAD082645 Lubricating Quill on

Cylinder Liner

Arrangement of LEE non-return valve redesigned, i.e. placed

into screw-in union (7)

x

2751-2/A1 EAAD077748 Exhaust Valve A new valve stroke sensor 30 adapted. Former items 33, 34

deleted and therefore following items renumbered

x

3403-1/A1

(1,4-8)

EAAD082346 Piston Pages 1, 4: Protection 17, paragraph 4.2 and Fig. 'D' added.

Page 6: Remark concerning main lubricating pipe added

x

6420-1/A1 (5) Scavenge Air Receiver Opening pressure of relief valve (15) specified for TIER I and II x

9403-5/A1 (28) EAAD082346 Tool List Quantity of device 94350 reduced to 1 piece and 'X' adapted to

1174 mm

x


0380-1/A1(7) 2011-07 Maintenance Schedule 7218-1: Interval of checking gas pre-charge pressure adapted x

3/6 31.3.2014



new exch.



Manual

7218-1/A1 Lubricating Pump

CLU4

Procedure of checking / refilling the gas pre-charge pressure

adapted according to TB RT-110 (Issue 1, 31.05.2011)

x

9403-5/A1(47) Tool List Case 94720 changed to 94720c as new standard x



Index Gr. 5, 9

0330-1/A1 (26) Clearance Table Fuel pump with connection pin and addidional O-ring updated x

0352-1/A1

(1, 4, 9, 10)

Tightening Values 2124-2_8: Filling piece in cylinder liner deleted and following

items up to (12) renumbered; clamping part (12) deleted;

5562_54: tightening value changed to 150 Nm

x

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

x

1903-1/A1 Tie Rod Tensioning procedure altered to one step: 100 bar -> 1000 bar

with a tie rod elongation of 15.5 17.5 mm

x

2124-2/A1

(1, 5, 6, 7)

Cylinder Liner Filling piece with waisted bolts deleted. Key of illustration and

numbering adapted

x

2138-1/A1

(1, 2, 3)

EAAD083591 Lubricating Quill

(Pulse Jet)

New lubricating quill with housing (11) and LEE non-return

valve introduced, tools 94720c, 94931, 94934h, 94934i and

94935 added

x

2138-1/A2

(1, 2, 3)

Lubricating Quill

(Pulse Feed)

Section3: Non-return valve revised;

tools 94720c, 94931, 94934h, 94934i and 94935 added

x

2722-1/A1

(1, 2)

Injection Valve with

O.M.T Test Bench

1. General: Test & Calibration fluid specified, therefore line

shifted to page 2

x

2722-1/A2

(1, 2)

EAAD083679 Injection Valve with

OBEL Test Bench

1. General: Test & Calibration fluid specified, therefore line

shifted to page 2; tool 94272b and view I replaced with 94272g

x

2751-1/A1

(1, 5)

Exhaust Valve Dismantling tool 94008a-M100 introduced. Figure 'G' added. x

2751-2/A1

(1, 2)

Exhaust Valve Bore 'BO' in damper (33) and corresponding detail in Fig. 'B'

added.

x

2751-4/A1 (2) Grinding the Seating

Surface on Valve

Head

Recon. conditions due to corrosion at the valve plate newly

defined. Case when reconditioning is not possible added

x

5556-1/A3 (7) EAAD082996 Fuel Pump Fig. 'O' designed with a 2nd O-ring on lower housing; spring

dowel removed from guide piston / thrust piece

x

5610-1/A1 2012 EAAD082961 Pressure Reducing

Valve 8.11-1

Pressure reducing valve with hydraulic accumulator (1) and

procedure for checking gas pre-charge pressure introduced

x

6420-1/A1

(1, 2, 3)

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

x

6545-1/A1 Auxiliary Blower All figures and items concerning execution 'Schmid' deleted. x

7218-1/A1 EAAD082961 Lubricating Pump

CLU4

Figure 'E' changed (8.11-1 with hydraulic accumulator) x

8750-2/A1 EAAD082683 Fuel Pressure Control

Valve (PCV)

New maintenance concept for the PCV introduced according to

Technical Bulletin RT-125 (03.04.2012)

x

9223-1/A1 Crank Angle Sensor

Unit

CAS modified according to Technical Bulletin RT-127, i.e. item

'MB' and paragraphs 3.2 & 3.7 added

x

(20, 21, 22) 2012 New paragraphs 9.3, 4, 5, 6 and section 10 added x

9403-5/A1

(3, 17, 28, 52)

2012-05 Tool List Tool 94272b deleted;

94008a-M100, 94272g, 94934h and 94934i added;

dimentions of 94272a, 94272c changed and 94350 redesigned

x


New group 5610-1/A1 added; Tool list specified with new page

numbers

4/6 31.3.2014



new exch.



Manual

0380-1/A1 (5) 2012-05 Maintenance Schedule x

5610-1/A1

(1, 2)

2012 Pressure Reducing

Valve 8.11-1

x


2722-1/A1, A2

(1)

2012-11 Injection Valve Cross reference to Operating Manual 2722-1 (Pressure release

and drainage of injection valve) added.

x

5564-1/A1 (1) Injection Control Unit Further information regarding replacement of ICU added x



Index Gr. 9

1132-2/A1

(2, 19, 20)

Removal and Fitting of

a Main Bearing

Arrangement and characteristics of main bearings updated

according Service Bulletin RT-141

x

1132-2/A2 (1,

2,3,17,24,25)

Removal and Fitting of

a Main Bearing

x

5552-5/A1 EAAD084033 Supply Unit Instruction for the lubrication of SU during maintenance works

updated due to changes on the lubricating device

x

9403-3/A1 (6) Hydr. Pre-tens. Jacks 94180: Allen screw M10x 97 (item 11) added x

9403-5/A1 51,

(48, 49)

(50)

EAAD082083

EAAD084033

Standard Tools SW-download P. 94930: 2 USB-keys (blue colour) deleted;

Tools 94844, a, b, c, d and e for lubrication of SU added;

Regrinding device 94872 adapted to a radius of 25 mm

x


5552-4/A1 2013-05 EAAD083955 Supply Unit Instruction for the removal of the intermediate gear wheel

updated and extended by an additional tool (94571e and

94571f)

x

5552-5/A1 EAAD082818 Supply Unit Instruction for the lubrication of SU during maintenance works

updated due to changes on the lubricating device

x

9403-5/A1 (16,

37, 50)

EAAD082818 Standard Tools Retrofitted support tool 94266a for cradle added; support tools

94571e and 94571f added for the removing of the intermediate

gear wheel; tool 94844f for lubrication of SU added

x


0002-1/A1 x

Index 3 x

0011-1/A1 (1) Safety Measures and

Warnings

Attention concerning clean areas (no water or cleaning fluids)

added

x

0330-1/A1

(20, 21)

Clearance Table Key No. 6 and 7: points A and B added x

0370-2/A1 (5) Piston and Rod Seal

Rings

94215b with dimensions added x

0380-1/A1

(2, 3)

Maintenance Schedule 2728-1: Monthly check of nut on solenoid added according to

Technical Bulletin RT-143 (05.02.2013);

3103-1: Interval changed "according to classification society"

3403-1: Intervals changed to 18 000-36 000 operating hours

x

(3, 8) 3403-4: Intervals changed to 500-1000 operating hours

3425-1: Work to be carried out and intervals changed;

WECS electronic components: ALM-20 added

x

2722-1/A1

(1, 3, 5, 6, 9)

Injection Valve

(O.M.T. Test Bench)

Sec. 11 added; system oil as test media mentioned; Sec. 3:

keeping opening pressure changed from 10 to 30 seconds;

Remark concerning IMO technical file and detail of nozzle type

added; detail to Fig. 'E' added

x

2722-1/A2

(1, 3, 4, 8)

Injection Valve

(OBEL Test Bench)

Sec. 11 added; system oil as test media mentioned; Sec. 3:

keeping opening pressure changed from 10 to 30 seconds;

Sec. 4: => 4th sent, Sec. 5: => 3rd, 4th and 5th sent. added;

x

(5, 6) Detail to Fig. 'E' added; Remark concerning IMO technical file

and detail of nozzle type added

2728-1/A1

(1, 3)

Starting Valve CHECK: Periodical venting of starting air manifold (OM 0320-

1) and monthly check of nut (18) on solenoid added

x

2013-08 Table of Contents 3425-1/A1, A2: checking wear of ring grooves added

Tool list specified with new page numbers

Amendment: 5610-1 Checking gas (nitogen) pre-charge

pressure (min. 20 bar / max. 25 bar) adapted to same values

as specified for 7218-1

5/6 31.3.2014



new exch.



Manual

3103-1/A1 Measuring Crank

Deflection

1. General aspects; 2. Condition of measuring and 4. Crank

deflection limits revised

x

3206-1/A1 (2) Turning Gear Address of Lubrication Engineers Inc. changed x

3425-1/A1 Piston Rings

(Four Piston Rings)

Determination of wear rate of chrome-ceramic piston rings and

measuring piston ring grooves introduced

x

9403-5/A1

(55, 56)

Tool List Tools 94291a, 94356 (only figure modified) and 94357 added x


9403-5/A1 (59) 2014-04 Tool List Tools: 94211, 94212 deleted x


6/6 31.3.2014

01

2

3

4

5

6

7

8

9

MM

/ R

Tf

lex

/ Reg

iste

r

Driving Wheels and Shut-off Valve for Starting Air

Crankshaft, Connecting Rod and Piston

Cylinder Liner and Cylinder Cover

Bedplate and Tie Rod

General Information

Supply Unit, Injection and Exhaust Valve Control

Scavenge Air Receiver and Auxiliary Blower

Cylinder Lubrication

Piping

Crank Angle Sensor Unit, Tools

This page is intentionally left blank

Maintenance Group0RT-flex96C

Wrtsil Switzerland Ltd 1/ 1

For Particular Attention 00001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preface 00011/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table of Contents 00021/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Numbering and Designations 00081/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Guidelines

for Maintenance: Safety Measures and Warnings 00111/A1. . . . . . . . . . . . . . . . . . . . . . . .

for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts, etc. 00121/A1. . . . . . . . . . . . .

Clearance Table 03301/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Thrust Bearing (6 and 7 Cylinder Engines) 2, 3. . . . . . . . . . . . . . . . . . . . . . Crankshaft and Thrust Bearing (8 14 Cylinder Engines) 4, 5. . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Main Bearing 6, 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crosshead Guide 8, 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Liner 10, 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rod Gland 12, 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Valve 14, 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top and Bottom End Bearings to Connecting Rod 16, 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Cooling and Crosshead Lubricating Link 18, 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Piston Rings 20, 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driving Wheels for Supply Unit 22, 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supply Unit with Dynex Servo Oil Pumps 24, 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump 26, 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information Group 0

Wrtsil Switzerland Ltd RTflex96C / MM / 201007

Maintenance 00001/A1RT-flex96C


This manual is put at the disposal of the recipient solely for use in connection withthe 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, par-ticularly the copyright, remains with Wrtsil Switzerland Ltd. This documentand parts thereof must not be reproduced or copied without their written permis-sion, and the contents thereof must not be imparted to a third party nor be used forany unauthorized purpose.

Before the operator intends to use the engine or before maintenance work is un-dertaken, the Operating Instructions or the Maintenance Manual respectively is tobe read carefully.

To ensure the best efficiency, reliability and lifetime of the engine and its compo-nents, only original spare parts should be used.It is to be ensured as well that all equipment and tools for maintenance are in goodcondition.

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

The data, instructions and graphical illustrations etc. in this manual are based ondrawings made by Wrtsil Switzerland Ltd and correspond to the actual stan-dard at the time of printing (year of printing is indicated on title page).Those specifications and recommendations of the classification societies whichare essential for the design have been considered therein. It must be recognizedthat such data, instructions and graphical illustrations may be subject to changesdue to further development, widened experience or any other reason.

This manual is primarily intended for use by the engine operating and maintenancepersonnel. It must be ensured that it will always be at the disposal of such person-nel for the operation of the engines and/or for the required maintenance work.

This manual has been prepared on the assumption that operation and mainte-nance of the engines concerned will always be carried out by qualified personnelhaving the special knowledge, training and qualifications needed to handle in aworkman-like manner diesel engines of the corresponding size, the associatedauxiliary equipment, as well as fuel and other operating media.

Therefore, generally applicable rules, which may also concern such items asprotection against danger, are specified in this manual in exceptional cases only.It must be made sure that the operating and maintenance personnel are familiarwith the rules concerned.

This manual has been prepared to the best knowledge and ability of its au-thors. However, neither Wrtsil Switzerland Ltd nor their employees as-sume any liability under any legal aspect whatsoever, including possiblenegligence in connection with this manual, its contents, or modificationsto 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 othersare expressly excluded.

Wrtsil Switzerland Ltd

Winterthur

Switzerland

For Particular Attention

2008



The instructions contained in this Maintenance Manual are intended to help toensure that the maintenance which must be carried out at specific intervals is cor-rectly carried out.

It is a precondition that the personnel charged with such important work possessesthe necessary training and experience.

Information about the operation of the engine as well as descriptions of the func-tion of the various systems are part of a separate book, the Operating Manualcontaining also under 00101 explanations of the layout and structure of the Oper-ating and Maintenance Manuals as well as of the used symbols, signs and specialcharacters.

More detailed instructions on the operation and maintenance of components fromsub-suppliers can be gathered from the instruction leaflets of the respectivemanufacturers. Outside makes are, for example, such engine components, toolsor devices which are not manufactured in accordance with production drawingsfrom Wrtsil Switzerland Ltd.

The Maintenance Manual is divided into the following main chapters:

General guidelines for maintenance

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

Maintenance schedule

Design groups

Tool lists

A few explanations to the above:

The General Guidelines for Maintenance contain, in addition to recommen-dations on precautionary measures to be taken, also suggestions for carryingout the work.

The above mentioned tables inform about normal and maximum acceptableclearances, the tightening of important screwed connections, weights of indi-vidual engine components as well as the type and use of various sealing rings.

The Maintenance Schedule indicates nominal intervals in which variousmaintenance operations are to be carried out. Please note that the mainte-nance intervals are based on experience and are subject to operation of theengine under standard conditions.

Detailed instructions are given in the Design Groups on the procedure ofmaintenance work on certain engine parts.

Tools and devices necessary to carry out maintenance are described in theTool Lists, and are generally supplied with the engine.

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

Preface

2008

Maintenance 00021/A1

Table of Contents

RT-flex96C

Wrtsil Switzerland Ltd 1/ 5 2013 -08

General Information Group 0For Particular Attention 00001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preface 00011/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Numbering and Designations 00081/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Guidelines

for Maintenance: Safety Measures and Warnings 00111/A1. . . . . . . . . . . . . . . . . . . . . . . .

for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts, etc. 00121/A1. . . . . . . . . . . . .

Clearance Table 03301/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Thrust Bearing (6 and 7 Cylinder Engines) 2, 3. . . . . . . . . . . . . . . . . . . . . . Crankshaft and Thrust Bearing (8 14 Cylinder Engines) 4, 5. . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Main Bearing 6, 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crosshead Guide 8, 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Liner 10, 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rod Gland 12, 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Valve 14, 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top and Bottom End Bearings to Connecting Rod 16, 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Cooling and Crosshead Lubricating Link 18, 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Piston Rings 20, 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driving Wheels for Supply Unit 22, 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supply Unit with Dynex Servo Oil Pumps 24, 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump 26, 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

Maintenance00021/A1

Table of Contents

RT-flex96C

2/ 5 Wrtsil Switzerland Ltd2013-08

Bedplate and Tie Rod Group 1Bedplate and Thrust Bearing: Checking the Foundation Bolts 11121/A1. . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . .

Cylinder Liner and Cylinder Cover 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. . . . . . . . . . . . . . . . .


Table of Contents

RT-flex96C


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. . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft, Connecting Rod and Piston Group 3Crankshaft: Measuring Crank Deflection 31031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . .

Maintenance00021/A1

Table of Contents

RT-flex96C

4/ 5 Wrtsil Switzerland Ltd2013-08

Driving Wheels and Shut-off Valve for Starting Air 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. . . . . . . . . . . . . . . . .

Supply Unit, Injection and Exhaust Valve Control 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air Receiver and Auxiliary Blower Group 6Checking the Air Flaps and Cleaning the Scavenge Air Receiver 64201/A1. . . . . . . . . . . . . .Auxiliary Blower: Maintenance 65451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air Cooler

Removal, Fitting of Cooler Element & Cooler Pre-stage 66061/A1. . . . . . . . . . . . . . . . . . . Removal, Fitting of Cooler Element & Cooler Pre-stage (Engine with Rail) 66061/A2. . .

Water Separator: Removal and Fitting 67081/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scavenge Air Waste Gate: Dismantling and Assembling 67351/A1. . . . . . . . . . . . . . . . . . . . .

Cylinder Lubrication Group 7Lubrication Pump CLU4: Checking the Gas Pre-charge Pressure 72181/A1. . . . . . . . . . . . .


Table of Contents

RT-flex96C


Piping Group 8Exhaust 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. . . .

Fuel Pressure Piping

Removing, Fitting and Regrinding of Conical Sealing Faces 87331/A1. . . . . . . . . . . . . . . Removing, Fitting and Regrinding of Spherical Sealing Faces 87331/A2. . . . . . . . . . . . .

Intermediate Fuel Accumulator

Checking and Setting of Relief Valve with O.M.T. Test Bench 87501/A1. . . . . . . . . . . . . . Checking and Setting of Relief Valve with OBEL Test Bench 87501/A2. . . . . . . . . . . . . . .

Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling 87502/A1. . . .Fuel Pressure Piping: Removing, Fitting and Regrinding 87521/A1. . . . . . . . . . . . . . . . . . . . .

Crank Angle Sensor Unit, Tools Group 9Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 92231/A1. . . . . . . . . . . . .Tools: Explanation 94031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Jacks and Pumps: Arrangement and Application 94032/A1. . . . . . . . . . . . . . . . . . .

Hydraulic Pre-tensioning Jacks

Storing, Servicing and Maintenance 94033/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Application Instructions 94034/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tool List 94035/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Tools Pages 01 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Special Tools Pages 54 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools Obtainable on Loan Pages 59 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



General:

65432

1 2 3 4 5 6

871

7 8

9 10 11

Turbocharger1

Turbocharger 2

DRIVINGEND

FREE END

CylinderNumbering

Thrust Bearing Pads

011.945/04

013.059/05

FUEL SIDE EXHAUST SIDE

Rail Unit

ClockwiseRotation

Supply Unit

Main Bearing Numbering

GeneralEngine Numbering and Designations

2008

Maintenance00081/A1 RT-flex96C


flex Parts:

FREE END

FUEL SIDE

Crank Angle Sensors

Sensor 2(GT5127C)

Sensor 1(GT5126C)

DRIVINGEND

FUEL SIDE

Control Oil Pumps

Pump 2 Pump 1

DRIVING END

Pump B4Pump B3Pump B2Pump B1

Pump A4Pump A3Pump A2Pump A1

Supply Unit

Actuator A2Actuator A1

Pump 3Pump 2Pump 1

Actuator B1Actuator B2

Pump 4Pump 5Pump 6

Counting DirectionFuel Pumps

Counting DirectionServo Oil Pumps

Fuel Pump RowBank B

Fuel Pump RowBank A

013.061/05

Engine Numbering and Designations

2008



Overview1. General 1/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. General safety precautions 1/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. Precautionary measures before beginning of

maintenance work 2/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. Special safety measures 3/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. Recommendations for performing work 4/4. . . . . . . . . . . . . . . . .

1. General

The maintenance work which is required to be carried out on the engine at regularintervals is described in the Maintenance Schedule 03801 of this manual and is tobe understood as a general guide. The maintenance intervals are dependent onthe mode of operation, on the power as well as on the quality of the fuel used. Fur-ther details are set out in the maintenance schedule.Experience will show whether the intervals may be extended or need to be short-ened.Strict compliance with the below mentioned recommendations regardingsafety measures and maintenance work is mandatory; the recommenda-tions are not exhaustive.

2. General safety precautions

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 andmaintaining a diesel engine plant. In particular greatest attention has to be giv-en to the functioning, handling and dangers of cranes and lifting devices.

The safety officer has to make sure that all precautions have been taken inorder to avoid dangerous situations.

The operator has to nominate a person responsible for assigning work tasksto 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 sur-roundings clean. Cleanliness increases the quality of the work and helps toprevent accidents.Before beginning maintenance work on the diesel engine the correspondingsystems which are influenced by the maintenance work must be relieved ofpressure and/or drained if necessary. A protocol must be established evi-dencing these activities.

Certain media, i.e. fuels etc., are highly inflammable, therefore all precaution-ary 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 canbe released into the engine room while people are still inside. Emergency es-capes are to be marked and personnel is to be instructed of what to do in caseof fire.

Oils and other media can cause slippery surfaces. In order to avoid injury allsurfaces which can be stepped on must be kept clean and dry.

Attention! Do not use water or any cleaning fluid to clean the WECS electroniccomponents and control boxes on the engine as well as on the rail unit. Damagecan occur if water goes into these electronic components or control boxes.

General Guidelines for MaintenanceSafety Measures and Warnings

2013-08



3. Precautionary measures before beginning of maintenance work

Before starting any maintenance work on the engine (particularly on the runninggear), take the following precautionary measures:

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

Close all the shut-off valves in the control air supply unit, and open the drainson both air bottles until it is depressurized.

Close by hand the (automatic) shut-off valve for starting air and open the ventand drain valve to the main starting air piping on the engine as well as the ventvalves on the shut-off valve for starting air, and leave them in this position untilmaintenance work is completed.

Open all indicator cocks on the cylinder covers and leave them in this positionuntil maintenance work is completed.

Engage turning gear (gear pinion must be in engaged position) and lock thelever (see also 32061 and 07501 in the Operating Manual).

Where the engine has been stopped due to overheated running gear orbearings, wait at least 20 minutes before opening the crankcase doors.

The crankcase doors must always be locked with all the clamps when-ever the engine is running, even if this is only for a short time in order tomake 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 outwithin them.

Attention! When performing electric welding near or on the engine, electromag-netic fields or peak voltage may occur, which may damage the electronic compo-nents of the WECS (Wrtsil Engine Control System).

Therefore, prior to performing electric welding in the vicinity of the mentioned com-ponents, the following precautions must be taken:

Stop the engine if it is in operation.

Power off the electronic system and wait one minute.

If the welding point is within a radius of two metres from an electronic moduleand/or a sensor, disconnect the modules and/or sensors.

Close the covers of all electric boxes and protect cables, sensors, etc. againstsparking and heat.

Shield the check and control units with a conductive material and connectthem to earth.

Run the welding cable from the welding apparatus directly to the welding pointwithout any unnecessary loops; also, avoid leading the welding cable parallelto cables of the electronic control unit.

Safety Measures and Warnings

20088



4. Special safety measures

Prior to turning the crankshaft with the turning gear, make sure and take no-tice:

that no person is inside the engine and no loose parts, tools or devicescan get jammed.

bear in mind that the coupled propeller turns too (danger in surround-ings).

that lubricating device 94844 has been installed to prevent bearingbushes of the servo oil pump drive in the supply unit from being damaged(dry running) due to turning the engine during overhaul works.

Prior to turning the crankshaft with the turning gear, make sure that no personis inside the engine and no loose parts, tools or devices can get jammed. Alsobear in mind that the coupled propeller turns too (danger in surroundings).

At all times when somebody is inside the engine casing another person muststand by in order that he can give the necessary aid if something unexpectedhappens to the person inside the engine. The person who is inside the enginecasing must be equipped with all safety gears which are required to preventsuffocation within the limited space and atmospheric conditions. Moreover anantifall guard must be carried at dangerous places!

The allowed load capacity of the engine room crane, the lifting tools, ropesand chains must be sufficient for the parts to be lifted (see 00121 and03601).Pay also attention to the weight distribution and attachment of the lifting tacklein 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 wood-en pieces, leather or special edge guards which are placed between the partand the rope or chain.

Always use gloves, a face shield and wear safety goggles when working withhydraulic tools.

For your own safety keep away from under hanging loads, never underslinghanging parts with your fingers or hands and never embrace lifting ropes withyour hands.

Removed parts must be secured in the engine room.

For reasons of safety, openings resulting from removed engine componentsmust be closed!

Remark: For further instructions see also Safety Precautions and Warnings (Gen-eral Information) 02101 in the Operating Manual.


2008



5. Recommendations for performing work

Pay attention to Utilization of Working Platform and Ladder 33011.

Carry out all work carefully, observing utmost cleanliness!

For maintenance work on the engine use the tools and devices intended forthe particular job, which, as a rule, are supplied with the engine (see tool list atthe end of this manual).

Tools and devices must be made ready prior to use, make sure they are inperfect 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 meansto prevent damages.

Close all openings which form when certain parts are removed e.g. pipes, oilholes etc. to prevent dirt from entering the engine. (This includes also thepipes which are removed).

Check all repaired, overhauled or replaced parts for perfect functioning beforestarting 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 maxi-mum permissible values (see Clearance Table 03301) have been reached oreven exceeded, these parts must be replaced.

Arrange to replace all parts taken from spares stock. When ordering newparts refer to the Code Book, mention code numbers and description.

When tightening studs, nuts or screws, take the utmost care not to damagetheir thread. They must be screwed in by hand until metal to metal contact isachieved. Always use the specified lubricants on the threads.

Adhere to tightening values wherever they are indicated. Use the specifiedlubricant on the threads (see 03521 and 03522).

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

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

Used rubber rings must always be replaced by new ones when an overhaul ofany engine component takes place; they must conform in dimension andquality to the specifications in the 03701.The fitting of piston seal rings and rod seal rings requires the greatest of careto prevent damage, over expansion or deformation. Before fitting the ringsheat them first in boiling water.


2008



1. General

The permissible capacities of the engine crane, lifting tools, ropes, chains, liftingeye 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 theWLL = Working Load Limit.

For fitting and removal of engine components or their transportation, only the toolswhich are in perfect condition and intended for this purpose may be used. Ropeswhich have begun tearing or otherwise are defective and tools which are damagedhave to be exchanged.

For safe and proper handling of crane, suspension tools or transport of loads werecommend to proceed as follows for safety reasons:

Determination of the weight of load

Determination of the suspension centres and weight distribution

Choice of attachment elements

Attaching and disconnecting

2. Attachment elements

2.1 Wire rope slings

The lifting capacity of the wire rope slings is listed under their tool number in ToolsList 94035.

2.2 Span-sets

Span-sets have the advantage of easy and simple handling. The code and thecolour normally indicate the maximum admissible total load. Loops and knots inthe span-sets reduce their lifting capacity by one third.

2.3 Eye bolts and eye nuts

Only those eye bolts and eye nuts may be used which are in accordance with DIN580 & 582:200308 or which fulfil or exceed these values, including the safetyfactor.

All calculations for components and tools where eye bolts and eye nuts are usedare laid out accordingly and based on the mentioned standards.

General Guidelines for Lifting ToolsWire Rope Slings, Span-sets, Eye Bolts, etc.

2008



Lifting capacity (for information purposes only):

Eye bolts &

eye nuts,

thread size

Lifting capacity [kg]

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:

is completely turned in or screwed down;

lies flat and fully on the seating surface;

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 theeye bolts or eye nuts must be brought to the right position, if necessary by us-ing distance rings.

If there are through holes, a washer should be placed from the opposite sideunder the nut or screw head.

Whenever possible, do not apply an angle of inclination bigger than 45 (in alldirections 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 withthread diameters one size higher should be used.

2.4 RUD-eye bolts and RUD-swivel lugs

Only those RUD-eye bolts & RUD-swivel lugs may be used with a safety factor 4.

Manufacturer:

RUD KettenRieger & Dietz GmbH u. CoFriedensinselD73432 AalenGermanyhttp://www.rud.com

General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc.

2008



2.4.1 Remarks on the use of RUD-eye bolts

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 anyextension).

In order that after tightening the ring of the RUD-eye bolt is freely rotatable, thestar-profile wrench must be removed from the inner hexagon of the screw asshown in Fig. A.

Prior to loading the RUD-eye bolt adjust it in force direction (RUD-eye boltsare not suitable to be turned under load).

Lateral loading is permitted in no circumstances! (Fig. B)

A

FORCEDIRECTION

Ring

Star-profilewrench

Screw

FO

RC

ED

IRE

CT

ION

B

013.444/05

FO

RC

ED

IRE

CT

ION


2008



2.4.2 Remarks on the use of RUD-swivel lugs

they must be completely screwed down, lying fully on the seating surfaces.

they are hand-screwed with an open end wrench.

Prior to loading the RUD-swivel lug adjust it in force direction (Fig. C and D).

Loading as shown in Fig. E should be be avoided if possible!

C D E

013.445/05

FORCEDIRECTION

FO

RC

ED

IRE

CT

ION

FO

RC

ED

IRE

CT

ION

2.5 Shackles

Only those shackles may be used which are in accordance with American Stan-dard 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 ac-cordingly and based on the mentioned standards.

Normally, the permissible lifting capacity of the shackles is specified for one singlestrand.

Attention! If tools are combined (e.g. beams with shackles, RUD-eye bolts orRUD-swivel lugs and ropes, etc.), it is always the weakest element which deter-mines the maximum lifting capacity (see details in Tools List 94035).


2008



3. Attaching and disconnecting

The following must be observed:

Distribution of load:

one strand carries the total of load weight

two strands carry each one half of the load weight

four strands carry each one quarter of the load weight if the load is distrib-uted 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 theropes tend to slide on smooth surfaces (e.g. tubes, shafts).

Protect the ropes against damages by providing a wooden pallet or a rag.Sharp edges may even cut steel cables!

If possible always tie down the load. (danger of fall)

Wrapping the rope twice increases friction and adhesion in such a mannerthat even a smooth, oily shaft is sliding less.

Hemp rope strands, wrapped around the hook, prevent sliding. Do not wrapsteel 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. Neverseize the load at the bottom, but always lead it laterally. Always put down the loadson a perfect ground, and use sufficiently sized bases.


2008



Overview 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. General

The clearances listed in the column Nominal dimension of the following table cor-respond to design and manufacturing values or to the settings on the new engine.

The values listed in the column Maximum clearance, dimension are such valuesas may be reached after a lengthy operating period, which however may not beallowed to be exceeded or fall below. On components where the clearance is ad-justable by modifying the thickness of shims, discs, spacers etc. the value given asNormal Clearance should always be arrived at, or striven to attain. Where this isnot possible, worn parts must be replaced by standard new ones or reconditionedby suitable material buildup.

If, during an overhaul, clearances are measured which have almost reached thepermissible limit, it must be left to individual judgement to decide whether a compo-nent part should be replaced or remain fitted till the next overhaul. This depends forexample on the duration of the next operation period till the next overhaul and whatwear has to be expected based on experience gained.

Clearance Table

2008



3

2

1

001.404/96

001.404/96

001.404/96

2008

Clearance TableCrankshaft and Thrust Bearing 6 and 7 Cylinder Engines



Gro

up

Key

No

.

Description Measuring

direction

(method ofmeasuring)

Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

1132 Main bearing

Bearing shell width 425

1 Lateral clearance per side 15.5

1203

1224

Thrust bearing

Thrust bearing pad thickness 120 0.5 0.6

2 Thrust bearing clearance axial (total) 0.81.3 2.5

3 Thrust bearing pad, lateral clearance total 6

2008

Clearance TableCrankshaft and Thrust Bearing 6 and 7 Cylinder Engines



3

2

1

001.404/96

011.332/03

20086

Clearance TableCrankshaft and Thrust Bearing 8 14 Cylinder Engines



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

1132 Main bearing

Bearing shell width 425

1 Lateral clearance per side 15.5

1203

1224

Thrust bearing

Thrust bearing pad thickness 120 0.5 0.6

2 Thrust bearing clearance axial (total) 0.81.3 2.5

3 Thrust bearing pad, lateral clearance total 6

2008

Clearance TableCrankshaft and Thrust Bearing 8 14 Cylinder Engines



30 m

m50

mm

30 m

m

2

3

6

7

6

7

5

8

2

3

1

4

008.298/01 008.298/01

48

50 m

m

001.404/96

MAIN BEARINGSNo. 2 ...

MAIN BEARINGNo. 1

2008

Clearance TableCrankshaft and Main Bearing



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

1132 Main bearing No. 1

Crankshaft outer 990 0 0.10

Main bearing inner 990

1 Bearing clearance vertical 0.30.6 0.75

*2 Lateral clearance total 0.91.2


**4 Positional tolerance (bearing cover) vertical max. 0.3

1132 Main bearing No. 2 and following


Main bearing inner 990




**8 Positional tolerance (bearing cover) vertical max. 0.3

All main bearing clearances are only valid with tie rods and main bearing studstightened.

* Pay attention to measuring point!

** The difference between the two values (positional tolerance) must not begreather than 0.3 mm when the studs are tightened!

2008

Clearance TableCrankshaft and Main Bearing



6

1 2

453

8

7

014.087/06

EXHAUST SIDE

2008

Clearance TableCrosshead Guide



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

3326 Crosshead guide

1 Guide way (column) transverse 1430

2 Guide shoe transverse 1430 0.20 0.35

*3 Guide shoe clearance 0.201.10 1.4

Cylinder No. 1

4 Guide rail longitudinal 977.5978.5

5 Guide rail, lateral clearance Driving End T.D.C. 1.11.7

B.D.C. 1.11.3

Guide rail, lateral clearance Free End 0.30.9

Cylinder No. 214

4 Guide rail longitudinal 978.30979.30

5 Guide rail, lateral clearance total 0.601.80 2.2

6 Guide shoe, lateral clearance longitudinal 0.200.40

7 Guide shoe, bearing pin outer 550 0.05 0.10

Guide shoe, bearing bore inner 550 + 0.070

8 Bearing clearance radial 0.050.17 0.30

For measuring of clearances see instructions in 33261.

* Clearance 3 is only valid with tie rods tightened.

2008

Clearance TableCrosshead Guide



7

app

rox.

2202

40 m

m

5

6

1

2

3

4

014.090/06

2008

Clearance TableCylinder Liner



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

2124 Water guide jacket on cylindercover

Water guide jacket 1425 + 0.70+ 0.50

1 Clearance total 0.801.20

Water guide jacket 1290+ 0.70+ 0.50






2124 Supporting ring for cylinder liner

Supporting ring 1181.5+ 0.200


2124 Cylinder jacket

Cylinder jacket 1150+ 0.200


2124 Cylinder liner

*7 Cylinder liner bore radial 960 966.7


2008

Clearance TableCylinder Liner



7

7

7

6

5

4

2

3

1

1

99.7406

011.333/03

1

2008

Clearance TablePiston Rod Gland



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

2303 Piston rod gland

*1 Ring width radial 31 min. 25

*2 Ring width radial 24 min. 22.20

*3 Ring width radial 5 min. 3.20

4 Ring clearance axial 0.100.26 0.50




* Ring wear

The differential value between nominal dimension and max. wear is equal for allrings, i.e. also for undersize rings.

2008

Clearance TablePiston Rod Gland



VALVE SPINDLE

GUIDE BUSH

L =

LE

NG

TH

3

21

~ 1/

3 L

~ 2/

3 L

001.400/97

011.334/03

2008

Clearance TableExhaust Valve



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

2751 Valve spindle

1 Spindle outer 95 0.35 0.40 94.50

2751 Guide bush

*2 Bore inner 95 + 0.0350 95.50

*3 Bore inner 95 + 0.0350 96.50


2008

Clearance TableExhaust Valve



10 m

m

10 m

m50

mm

10 m

m

2

3

6

7

2

3

6

7

1

4

8

4

8

5

001.399/97

001.399/97

2008

Clearance TableTop and Bottom End Bearings to Connecting Rod



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

3303

3326

Top end bearing

Crosshead pin outer 900 0 0.10

Bearing inner 900




4 Axial clearance total 0.40.8 1.2

3303 Bottom end bearing


Bearing inner 990




8 Axial clearance total 34


2008

Clearance TableTop and Bottom End Bearings to Connecting Rod



4

1

1

3

1

3 3

2

3

2

003.314/00

4

003.314/00

2

2008

Clearance TablePiston Cooling and Crosshead Lubricating Link



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

Piston cooling and crossheadlubricating link

Pin outer 72

1 Bearing clearance radial 0.030.09 0.20

2 Bearing width 173

3 Lateral clearance total min. 1.0

4 Lateral clearance total 2.0

2008

Clearance TablePiston Cooling and Crosshead Lubricating Link



7

3

8

8

11

10

6

4

1

2

5

9

BA

BA

2013-08

Clearance TablePiston and Piston Rings



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

3403 Piston crown

1 Crown outer 951.7

2 Crown outer 956.7

3403

3425

Piston ring grooves

3 Height of the two uppermost grooves vertical 20 + 0.50+ 0.45

4 Height of the two lower grooves vertical 20 + 0.40+ 0.35

5 Groove depth radial 31

3425 Piston rings

Ring height vertical 20 0 0.03

Point A Point B

6 Ring clearance vertical 0.440.52 0.75 0.95

7 Ring clearance vertical 0.350.43 0.65 0.80

8 Ring width radial 30 0.45

3403 Piston skirt

9 Skirt outer 958.9 0 0.2 min. 957

10 Rubbing ring outer 959.3 0 0.1

3403 Piston rod

11 Rod outer 370 0.062 0.119 min. 368.80

Used piston rings may be refitted if they will keep within their min. ring width untilthe next overhaul (for judging and reusing piston rings see also 34251).

For evaluating and reusing piston heads see 34251).

2013-08

Clearance TablePiston and Piston Rings



2 3 3 2

011.501/04

15

4

6

2008

Clearance TableDriving Wheels for Supply Unit



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

4103 Intermediate wheel

1 Shaft outer 340


*3 Axial clearance total 0.61.5 1.9

4 Tooth backlash 0.400.62 0.85



* Clearance 3 is only valid with tie rods tightened.

2008

Clearance TableDriving Wheels for Supply Unit



9

10

4

5

6

5

7

1 3 2

014.096/06

8

2008

Clearance TableSupply Unit with Dynex Servo Oil Pumps



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

5552 Supply unit

1 Pinion outer 120 0 0.022

Bearing (fitted) inner 120 + 0.23+ 0.14

2 Bearing clearance radial 0.140.252


5552 Camshaft unit

4 Cam shaft outer 300 0 0.032



7 Tooth backlash 0.160.29

*8 Minimum clearance 3

5552 Intermediate wheel



* Minimum clearance between cam and roller with fuel pump cut out.

2008

Clearance TableSupply Unit with Dynex Servo Oil Pumps



4

3

6

5

1

2

WCH00832

149

29

A

B

C

73 m

m

D

PLUNGER & CYLINDER

42

1

145

33

A

B

C

73 m

m

D

PLUNGER & CYLINDER

46

1

014.104/06

2012-05 / V4

Clearance TableFuel Pump



Gro

up

Key

No

.


direction


Nominal

dimension

(normal, new)

[mm]

Maximum clearance,

dimension

(due to wear)

[mm]

5556 Fuel pump

Plunger (42 mm)

1 Clearance (plunger / cylinder) AB radial 0.0350.038 0.045

Clearance (plunger / cylinder) BC radial 0.0250.028 0.035

Plunger (46 mm)

1 Clearance (plunger / cylinder) AB radial 0.0350.038 0.045

Clearance (plunger / cylinder) BC radial 0.0250.028 0.035

* Clearance (plunger / cylinder) D radial 0.0400.043 0.5

Guide piston outer 185

Lower housing inner 185

2 Clearance radial 0.220.68 0.8

3 Piston / lower spring carrier axial 0.120.24 0.3

4 Regulating sleeve / upper springcarrier

axial 0 .50.7 0.8

5556 Roller guide

Pin outer 80 0 0.013

Guide piston (bore) inner 80 + 0.04+ 0.01

5 Clearance radial 0.0100.053 0.08

6 Total clearance between guide pistonand roller with pressure discs

axial 0.260.54 0.7

* Plunger conically machined in range CD; i.e. clearance increases in diam-eter of 0.015 mm.

V4 / 2010-07

Clearance TableFuel Pump



Group Description Thread Tightening values Lubricant

1[bar]

2[Nm]

3[; mm]

1

1106 * Bedplate parting faces, screw1 M36 2090 Oil

* Bedplate parting faces, screw2 M56 4970 Oil

11121 Foundation bolts (metal andsynthetic chocks)

3 M64 10001st step 600 bar

MOLYKOTE G

11321 Main bearing, nut for waisted stud4 M64x6 1000 (130) Oil

17151 Engine stays (friction type)5 M64 200 MOLYKOTE G

19031 Tie rod(see instructions in 19031)

6 M140x6 10001st step 100 bar

2nd step 1000 bar

MOLYKOTE G

2

2106 *

*Cylinder jacket bolting-up / bolt

Cylinder jacket bolting-up / fitted bolt

7

7

M64

M64

Elongation 0.550.04 mm Oil

Elongation 0.45 0.04 mm Oil

21242 Lifting gear (tool 94202(a), screw(see instructions in 21242)

8 M24 30 no additionallubricant required

Special screw (tool 94207)(see instructions in 21242)

9 M48 30 no additionallubricant required

Supporting ring, screw10 M24 400 see details in21242

21361 Lubricating quill, set screw11 M16x20 50 see details in21361

21381 Lubricating quill (Pulse Jet), screw12 M8x150 10 see details in21381/A1

21381 Passage for lubricating quill andscrew-in union (Pulse Feed)

12 M22x1.5 30 see details in21381/A2

27082 Cylinder cover, nut for waisted stud13 M110x6 1000 (390) Never-SeezNSBT-8

1 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/cm2

2 Tightening torque3 Tightening angle or elongation

Numbers in 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.

Tightening Values of Important Screwed Connections

2012-05



Group Description Thread Tightening values Lubricant

1[bar]

2[Nm]

3[; mm]

27221 Injection valve, screwed connectionwith cylinder cover(see instructions in 27221)

14 M12 Equally tighten Allenscrews until spring guidesare flush with spring cages

Never-SeezNSBT-8

Injection valve, retaining nut, nozzlebody nozzle holder

15 M65x1.5 1st step 100 Nm1st step to 2nd step 30

Never-SeezNSBT-8

(see instructions in 27221)

mm-rt-flex96c_wecs-9520_dynex_2014-04

Documents