Motor Sulzer Manual

RTA84C
Maintenance Manual
Marine
(UG Version)
Vessel: Type: Engine No.: Book No.:
Wrtsil Switzerland Ltd PO Box 414 CH-8401 Winterthur Switzerland

E 2005 Wrtsil Switzerland Ltd, Printed in Switzerland
24hrs Support: +41 52 262 80 10 technicalsupport.chts@wartsila.com
This page is intentionally left blank
0 1 2 3 4 5 6 7 8
MM / RTA / Register
General Information
Bedplate and Tie Rod
Cylinder Liner and Cylinder Cover
Crankshaft, Connecting Rod and Piston
Camshaft and Control Elements
Governor, Injection Pump and Actuator Pump
Scavenge Air Receiver and Auxiliary Blower
Balancer
Piping
Tools
RTA96C
Betrieb
Group0
General Information
Group 0
For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000/1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001/1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002/1 Engine Numbering and Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008/1 o General Guidelines for Maintenance
Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011/1
Clearance Table
Main and Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/1 Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/2 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/3 Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/4 Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/4.2 Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/5 Piston Cooling and Crosshead Lubricating Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/6 Working Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/7 Working Piston and Piston Rings (Cylinder Liner with Antipolishing Ring) . . . . . . . . . . . . . . . . . 0330/7 Wheels for Camshaft Drive and Drive for PTO Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/8 PTO Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/9 Camshaft and Reversing Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/10 Gearing for Auxiliary Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/11 Intermediate Shaft for Auxiliary Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/12 Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/13 Roller Guides to Fuel Injection and Actuator Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/14 Gear Pump for Cylinder Lubricating Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/15 Balancer Drive Units 2nd Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/16 Integrated Balancer 2nd Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/17
Tightening Values of Important Screwed Connections

Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352/1 Tightening Instructions for Normal Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352/2 1
NSD Switzerland Wrtsil Switzerland Ltd Ltd
RTA84C / MM / 2001
Group0
Betrieb
RTA96C
Masses (Weights)
Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0360/1
Dimensions and Material Specification

O-rings and Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370/1 Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370/2
Maintenance Schedule
Inspection and Overhaul Intervals (Guidelines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0380/1
Engine Cross and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0803/1 Taking Oil Samples for Laboratory Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0900/1
2001 / MM / RTA84C
Wrtsil NSD Switzerland Ltd Wrtsil
RTA84C
Maintenance
0000/1.1
For Particular Attention
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.
Wrtsil Switzerland Ltd Winterthur Switzerland
Wrtsil Switzerland Ltd
1997
RTA84C Preface
Maintenance
0001/1.1
The instructions contained in this "Maintenance Manual" are intended to help to ensure that the maintenance which must be carried out at specific intervals is correctly carried out. It is a precondition that the personnel charged with such important work possesses the necessary training and expe rience. Information about the operation of the engine as well as descriptions of the function of the various systems are part of a separate book, the "Operating Manual". In this manual you can find also under sheet 0010/1 and 0040/1 ex planations to the layout and use of the Operating Instructions as well as of the Maintenance Manual. More detailed instructions on the operation and maintenance of components from subsuppliers can be gathered from the instruction leaflets of the respective manufacturers. Outside makes are, for example, such engine compo nents which are not manufactured in accordance with drawings of Wrtsil Switzerland Ltd. The Maintenance Manual is divided into the following main chapters: S General guidelines for maintenance S Clearance tables, tightening values of screwed connections, masses (weights), seal rings S Maintenance schedule S Design groups S Tool lists A few explanations to the above: 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 impor tant screwed connections, weights of individual engine components as well as the type and use of various sealing rings. The normal clearances given in the clearance tables sheet 0330/1 correspond to those resulting from manufacturing tolerances or clearances as adjusted on the new engine. The maximum clearances or max/min. dimensions represent values resulting from long periods of operation due to wear, which, however, must not be exceeded nor gone below, respectively. For parts where the clearance can be corrected by changing shim thickness, discs or spacers, the normal clearance should always be aimed at and ad justed. Where this is not possible, the worn parts must be replaced or reconditioned by buildingup (chromium plat ing, resurfacing by welding or by metal spray). If, during an overhaul, clearances or dimensions are found which nearly attain the permissible limits, then it must be left to the engineer responsible for the operation of the engine to decide whether the parts are replaced. This de pends, for example, on the duration of the next operating period till the next overhaul and what wear has to be ex pected based on experience made. The 'Maintenance Schedule' indicates nominal intervals in which various maintenance operations are to be carried out. Please note that maintenance intervals are based on experience and are subject to operation of the engine un der standard conditions. Detailed instructions are given in the 'Design Groups' on the procedure of maintenance work on certain engine parts. 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!
1997
RTA84C Table of Contents General information
Maintenance
0002/1.1
Group 0
For particular attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000/1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001/1 Engine numbering and designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008/1 General guidelines for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011/1 Safety measures and warnings Clearance tables Main and thrust bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crosshead guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rod gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top and bottom end bearings to connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston cooling and crosshead lubricating links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working piston and piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working piston and piston rings (cylinder liner with antipolishing ring) . . . . . . . . . . . . . . . . . . . . . . . . . Wheels for camshaft drive and drive for PTO gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft and reversing servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearing for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate shaft for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller guides to fuel injection and actuator pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump to cylinder lubricating pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancer drive units 2nd order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated balancer 2nd order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330/1 0330/2 0330/3 0330/4 0330/4.2 0330/5 0330/6 0330/7 0330/7 0330/8 0330/9 0330/10 0330/11 0330/12 0330/13 0330/14 0330/15 0330/16 0330/17
Tightening values of important screwed connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352/1 Tightening instructions for normal screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352/2 Masses (weights) of individual components per piece in kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0360/1 Dimensions and material specification of Orings and rubber rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370/1 Dimensions and material specification of the piston and rod seal rings . . . . . . . . . . . . . . . . . . . . . . . . . . 0370/2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0380/1 Inspection and overhaul intervals (guidelines) Engine cross section and longitudinal section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0803/1 Taking oil samples for laboratory analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0900/1
Bedplate and tie rod

Bedplate & thrust bearing Main bearing
Group 1
Checking the foundation bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112/1 Loosening and tensioning of bearing jack bolts . . . . . . . . . . . . . . . . . . . . 1132/1 Removal and fitting of a main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132/2
UG / 9.01
0002/1.2
Thrust bearing Tie rod
Maintenance
RTA84C
Checking the axial clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203/1 Removal and fitting of thrust bearing pads . . . . . . . . . . . . . . . . . . . . . . . . . 1224/1 Checking the tie rod pretension and tensioning the tie rod . . . . . . . . . . . 1903/1
Cylinder liner and cylinder cover

Cylinder liner
Group 2
Measuring bore wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124/1 Removal and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124/2 Removing wear ridges, redressing the lubricating grooves . . . . . . . . . . . . 2124/3 as well as the edges of the scavenge ports Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2136/1 Dismantling and assembling as well as measuring the wear . . . . . . . . . . . 2303/1 Removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic loosening and tensioning of cylinder cover studs . . . . . . . . . . . Mechanical loosening and tightening of cylinder cover studs . . . . . . . . . . Manual overhaul of sealing face for the fuel injection valve in the . . . . . . cylinder cover Checking, dismantling, assembling and setting (L 'ORANGE test stand) . Checking, dismantling, assembling and setting (O.M.T. test bench) . . . . . Cleaning and overhaul of injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . Lapping of nozzle holder contact surface . . . . . . . . . . . . . . . . . . . . . . . . . . 2708/1 2708/2 2708/3 2708/4 2722/1 2722/1 2722/2 2722/3
Lubricating quills and accumulators Piston rod gland Cylinder cover
Fuel injection valve
Starting valve Relief valve for cylinder cover Exhaust valve
Removing, fitting, dismantling, grindingin and assembling . . . . . . . . . . . 2728/1 Dismantling, assembling and testing (with L 'ORANGE test stand) . . . . . 2740/1 Dismantling, assembling and testing (with O.M.T. test bench) . . . . . . . . . 2740/1 Removal and fitting of the exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing and grinding the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grinding the seating surface on the valve head . . . . . . . . . . . . . . . . . . . . . 2751/1 2751/2 2751/3 2751/4
Crankshaft, connecting rod and working piston

Crankshaft
Group 3
Measuring crank deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103/1
Vibration damper Taking a silicone oil sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130/1 (on crankshaft and camshaft) Axial detuner Turning gear Crankcase Connecting rod Dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3146/1 Oil change and checking the worm wheels . . . . . . . . . . . . . . . . . . . . . . . . . 3206/1 Utilization of working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301/1 Loosening and tensioning the connecting rod studs and bolts . . . . . . . . . Inspection, removing and fitting of bottom end bearing . . . . . . . . . . . . . . Inspection, removing and fitting of top end bearing . . . . . . . . . . . . . . . . . . Removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303/1 3303/2 3303/3 3303/4
Connecting rod (1part)
Loosening and tensioning the connecting rod studs . . . . . . . . . . . . . . . . . . 3303/1 Inspection, removing and fitting of bottom end bearing . . . . . . . . . . . . . . 3303/2 Removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303/4
9.01 / UG
RTA84C
Crosshead Working piston
Maintenance
0002/1.3
Checking clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326/1 Removal and fitting a crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326/2 Removal and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the compression shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking piston top surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403/1 3403/2 3403/3 3403/4
Piston rings
Checking piston ring wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425/1 Checking piston ring wear (cylinder liner with antipolishing ring) . . . . . 3425/1
Camshaft and control elements

Camshaft driving wheels
Group 4
Checking the running and backlash clearances as well as . . . . . . . . . . . . . 4103/1 condition of the teeth Removal and fitting the intermediate gear wheel; . . . . . . . . . . . . . . . . . . . 4103/2 Replacing a gear rim Replacing the 2part gear wheel on the crankshaft . . . . . . . . . . . . . . . . . . . 4103/3 Removing and fitting a camshaft section . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and fitting of hydraulic locking elements . . . . . . . . . . . . . . . . . . Removing and Fitting of Hydraulic Locking Elements on the Camshaft . Removing and fitting of the camshaft coupling . . . . . . . . . . . . . . . . . . . . . . Removing and fitting of an SKF shaft coupling . . . . . . . . . . . . . . . . . . . . . Removing and fitting the gear wheel on the camshaft . . . . . . . . . . . . . . . . 4203/1 4203/2 4203/3 4203/4 4203/5 4203/6
Camshaft
Starting air distributor Starting air shutoff valve and valve for slow turning Rotation direction safe guard
Dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4303/1 Cleaning and function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325/1
Inspection and function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4506/1
Governor, fuel injection pump and actuator pump

WOODWARD governor PGA 200 Safety cutout device Fuel injection pump
Group 5
Installing, removing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5103/1 Maintenance and function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5307/1 Adjusting and checking the control with V.I.T. . . . . . . . . . . . . . . . . . . . . . . Lapping the sealing face for the covers of the suction, delivery . . . . . . . . and spill valves Checking and setting of the relief valve (with L 'ORANGE test stand) . . Checking and setting of the relief valve (with O.M.T. test bench) . . . . . . Tightening a nipple for the plunger guide . . . . . . . . . . . . . . . . . . . . . . . . . . 5512/1 5512/2 5512/3 5512/3 5512/4
Actuator pump
Determining the shim thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5513/1
Charge air receiver and auxiliary blower

Charge air receiver Auxiliary blower Charge air cooler Water separator
Group 6
Maintenance of the valve groups, air flaps and cleaning the . . . . . . . . . . . 6420/1 charge air receiver Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545/1 Cleaning (water side) with engine at standstill . . . . . . . . . . . . . . . . . . . . . . 6606/1 Removing and fitting a cooler element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606/2 Maintenance of water separator elements . . . . . . . . . . . . . . . . . . . . . . . . . . 6708/1
9.01 / UG
0002/1.4
Maintenance
RTA84C Group 7
Cylinder lubrication, PTO gear box and balancer

Cyl. lubricating pumps Driving shaft to the flow control valve of the cy linder lubrication PTO gearbox
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7203/1 Dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7212/1
Checking the tooth profile and tooth backlash, aligning the . . . . . . . . . . . 7403/1 gearbox housing, checking the running performance Removing and fitting gearbox components as well as the inter . . . . . . . . 7403/2 mediate gear wheel External inspection for oil leaks and constant venting . . . . . . . . . . . . . . . 7412/1 Fitting, removing, tensioning the roller chain . . . . . . . . . . . . . . . . . . . . . . . 7708/1 Fitting, removing the flexible coupling and a camshaft section Removal and fitting of balancer shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7722/1
GEISLINGER coupling Balancer 2nd order fitted at the free end Integrated balancer of 2nd order
Piping
Hydraulic piping for the exhaust valves drive Fuel pressure piping
Group 8
Removing and fitting the pipes and refacing the sealing faces . . . . . . . . . 8460/1 Fitting and dismantling, reconditioning the sealing faces . . . . . . . . . . . . . 8733/1
Tools
Tools Hydr. jacks and pumps Hydr. pretensioning jacks Tool list
Group 9
Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/1 Arrangement and application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/2 Storing, servicing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/3 General application instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/4 Standard tools, recommended tools, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/5 special tools obtainable on loan
9.01 / UG
RTA84C Engine Numbering and Designation
Maintenance
0008/1.1
Turbocharger 1
Auxiliary Blower
Turbocharger 2
Auxiliary Blower
Cylinder Numbering 1 2 3 4 5 6
Driving End 1 2 3 4 5 6 7 8
Free End
Thrust Bearing Pads

90.7034
Main Bearing Numbering
Fuel Pump Side
Exhaust Side
87.7056
Anticlockwise Rotation
Clockwise Rotation
1990
RTA84C General Guidelines for Maintenance Safety Measures and Warnings
Maintenance
0011/1.1
The maintenance work which is required to be carried out on the engine at regular intervals is described in the Maintenance Schedule sheet 0380/1 of this manual and is to be understood as a general guide. The maintenance intervals are dependent on the mode of operation, on the power as well as on the quality of the fuel used. 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. 1. General safety precautions It is the operator's 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 atten tion has to be given to the functioning, handling and dangers of cranes and lifting devices. The safety officer has to make sure that all precautions have been taken in order to avoid dangerous situa tions. The operator has to nominate a person responsible for assigning work tasks to every person who is partici pating on maintenance work. Make sure that fluids or gases draining or escaping cannot cause accidents, fires or explosions 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 get 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.
2.
Precautionary measures before beginning of maintenance work Before starting any maintenance work on the engine (particularly on the running gear), take the following precautionary measures: Close the shutoff valves on the starting air bottles. Close all the shutoff valves in the control air supply unit and open the drain cocks in the two air bottles. Open the drain valves placed in the pipes before and after the (automatic) shutoff valve for starting air and leave them in this position until maintenance work is completed. Open all indicator cocks on the cylinder covers and leave in this position until maintenance work is com pleted. Engage turning gear (gear pinion must be in engaged position) and lock the lever. Where the engine has been stopped due to overheated running gear or bearings, wait at least 20 minutes before opening the crankcase doors. The crankcase doors must always be locked with all the closing dogs whenever the engine is running 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. 7.04
0011/1.2
3. Special safety measures -
Maintenance
RTA84C
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 (dan ger 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. 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 sheet 0360/1) pay 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 wear safety goggles when working with hydraulic tools. For your own safety keep away from under hanging loads never undersling hanging parts with your fin gers or hands and never embrace lifting ropes with your hands. For reasons of safety, openings resulting from removed engine components must be closed. Removed parts must be secured in the engine room. For further notes regarding safety precautions and warnings (general remarks) see also Operating Manual sheet 0210/1.
Remark:
4.
Recommendations for performing work Carry out all work carefully, observing utmost cleanliness! For maintenance work on the engine use the tools and devices intended for the particular job, which, as a rule, are supplied with the engine (please refer to the tool list at the end of this manual). Tools and devices should be made ready prior to use, make sure they are in perfect condition. Calibrate gauge tools before using and at periodical intervals. Check hydraulic tools periodically for tightness and perfect functioning. Protect running faces and sealing faces of removed parts by suitable means to prevent damages. Close all openings which form when certain parts are removed e.g. pipes, oil holes any opening etc. 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 and wear table) have been reached or have even been exceeded, these parts must be replaced. Arrange to replace all parts taken from spares stock. When ordering new parts refer to Code Book, men tion code numbers and description. When tightening studs, nuts or screws, take the utmost care not to damage their thread. They must 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 sheets 0352/1 and 0352/2).
7.04
RTA84C
-
Maintenance
0011/1.3
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 on sheet 0370/1. 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.
9.99
RTA84C Clearance Table Main and Thrust Bearings
Maintenance
0330/1.1
Kurbelwellenlager
Zulssige Differenz a1a2 = max. 0,3 mm (mit gespannten Druckbolzen)
MAIN BEARING
a1 a2 ADMISSIBLE DIFFERENCE a1a2 = MAX. 0.3 mm (WITH JACK BOLTS TENSIONED) b1 B b
d1
d2
b1
i1
i2
01.7089
f1 f f
01.7090
Nominal dimension B = 870 b = 870 d = 415
Clearance max. due normal, new to wear
Nominal dimension
Clearance max. due normal, new to wear f 1 = 0.8 - 1.3 2.5
b1 = 0.48 - 0.68 d1 + d2 = 15
0.8
f = 150 -0.5 -0.6
i 1 +i 2 = 6
UG / 4.01
0330/2.1 Clearance Table Crosshead Guide
Maintenance
RTA84C
b1
c1 B A
95.7942
d Brennstoffseite FUEL SIDE
d1 e
Zum Messen der Spiele siehe Angaben in Blatt 3326/1. Das Spiel b1 gilt nur bei angezogenen Zugankern. FOR MEASURING CLEARANCES SEE INSTRUCTIONS ON SHEET 3326/1. CLEARANCE b1 IS ONLY VALID WITH TIE RODS TIGHTENED.
Nominal dimension A = 790 a = 790

0 - 0.10 0.25 - 0 - 0.2 - 0.25 + 0.03 0
Nominal dimension c = 400

- 0.03 - 0.06
Clearance max. due normal, new to wear c1 = 0.03-0.09 0.2
B = 990 + b = 990 C = 400
d = 1022.4-1023.0 b1 = 0.2-1.0 1.3
d1 = 0.6-2.0 e = 0.2-0.4
2.5
12.03
RTA84C Clearance Table Cylinder Liner
Maintenance
0330/3.1
A C 200 mm a1 (a2)
approx. 160
Nominal dimension 0.5 A = 1210 + + 0.7 0.5 B = 1216 + + 0.7 C = 840
Clearance max. due normal, new to wear a 1 +a 2 = 0.7 1.1 b 1 +b 2 = 0.7 1.1 845.90
b1 (b2) B G g1 (g2) h1 (h2) H

90.7035
Nominal dimension G = 1040 H = 1030
Clearance max. due normal, new to wear g1 +g 2 = 1.2 1.6 h1 +h 2 = 0.75 1.05
10.94
0330/4.1 Clearance Table Piston Rod Gland
Maintenance
RTA84C
a1 b1
b b
c1 d1
d1 c
d1
d1
d1
d1
Ring wear The differential value between nominal dimension and max. wear is equal for all rings, i.e. also for undersize rings.
011.376/03
Nominal dimension a = 31
Clearance max. due normal, new to wear min. = 25 a1 = 0.15-0.26 0.50 min. = 25 b1 = 0.15-0.26 0.50
Nominal dimension c = 24
Clearance max. due normal, new to wear min. = 22.20 c1 = 0.05-0.16 0.40 min. = 3.20 d1 = 0.10-0.17 0.40
b = 31
d=5
12.03
RTA84C Clearance Table Exhaust Valve Ventilspindel VALVE SPINDLE
Maintenance
0330/4.2
Luftzylinder AIR CYLINDER
A B e
Fhrungsbchse GUIDE BUSH
2/3 L max. due to wear 79.40 79.40 1/3 L
93.7092
Diameter Nominal dimension A B C D normal, new 280 +0.052 0 280 +0.052 0 80 +0.030 0 80 +0.030 0 max. due to wear 280.208 280.20 80.45 81.45 Nominal dimension e f
Diameter normal, new 80 -0.19 -0.23 80 -0.19 -0.23
1994
L=
Lnge LENGTH
0330/5.1
Maintenance
RTA84C
Clearance Table Top and Bottom End Bearings to Connecting Rod
f2
f1 B 10 mm b
d2
d1
10 mm
b1
h1
h2
m2
m1
10 mm
A n1 50 mm n2
a1
g1 Clearance Nominal dimension A = 870 0 a = 870-0.10 B = 790 0 b = 790-0.10 b1 = 0.46-0.72 d1+d2 = 0.42-0.62 12.03 0.90 normal, new max. due to wear Nominal dimension Clearance normal, new f1+f2 = 0.52-0.72 a1 = 0.45-0.70 1.00 g1+g2 = 15 h1+h2 = 0.40-0.80 m1+m2 = 0.45-0.70 n1+n2 = 1.10-1.50
g2
93.7072
max. due to wear
1.20
RTA84C
Maintenance
0330/6.1
Clearance Table Piston Cooling and Crosshead Lubricating Links
c1 a1
c2
95.7982
b1 a1
b2 Clearance max. due to wear 0.2
Nominal dimension a = 68 b = 151 c = 151
a normal, new a a1 = 0.03 0.09 b1+ b2 = 2.2 3.1 c 1+ c 2 = 1.3 1.9
a1
1989
0330/7.1 Clearance Table Working Piston and Piston Rings

a b c c
Maintenance
RTA84C
e1 n E
l k1 n d l K
g 40 40
The ring width at the positions A, B and C is the decisive criterion for re-fitting of used piston rings. Used piston rings may be re-fitted if they will keep within their min. ring width till the next overhaul (for judging and re-using the piston rings see also sheet 3425/1) [mm] 26 Piston ring width I 25 24 23 l 22 21 840 841 842 843 844 Cylinder liner bore a 845 846 [mm] min N lmin
Nominal dimension a = 840 b = 832.7 c = 836.7 d = 838.9 g = 310

- 0.056 - 0.108
Nominal dimension E = 16
+ 0.40 + 0.35 + 0.51 + 0.46 + 0.28 + 0.23
normal, new e1 = 0.42-0.50 j1 = 0.46-0.54 k1 = 0.30-0.38
7.30-7.73 3.30-3.73 1.10-1.53 dmin. = 836.8 dmin. = 309
J = 20 K = 16
l = 26.5 0.40 m = 20
0 - 0.03 0 0.03
H = 27.5 8.98
n = 15.93 -
H j1 m J l C B A Clearance max. due to wear 0.70 0.75 0.60 see diagram

Wrtsil NSD Switzerland Ltd
RTA84C Clearance Table Working Piston with Piston Rings

a b c c1
Maintenance
0330/7.1
Cylinder Liner with Antipolishing Ring

H e1 n E C l k1 n K 40 40 B A l The ring width at the positions A, B and C is the decisive criterion for re-fitting of used piston rings. Used piston rings may be re-fitted if they will keep within their min. ring width till the next overhaul (for judging and re-using the piston rings see also sheet 3425/1) lmin l min N
[mm] 26 25 24 23 22 21 840 841 842 843 844 845 846 [mm] Cylinder iner bore a Clearance max. due normal, new to wear Clearance Nominal dimension E = 20
+ 0.49 + 0.44
Pisto ring width I
Nominal dimension a = 840 b = 832.4 c = 834.6 c1 = 836.7 d = 838.9 g=

- 0.056 310 - 0.108
normal, new e1 = 0.44-0.52
max. due to wear 0.70
K = 20 1.10-1.53 dmin. = 836.8 dmin. = 309
+ 0.37 + 0.32
k1 = 0.32-0.40
0.60
l = 26.5 0.40
see diagram
H = 27.5
n = 20 -
0 0.03
Antip. Ring / UG / 2001
RTA84C
Maintenance
0330/8.1
Clearance Table Wheels for Camshaft Drive and Drive for P.T.O. Gear Box
Nominal dimension A = 300 a = 300 b = 290 C = 380 c = 380
Nominal dimension d = 290
Clearance max. due normal, new to wear d1+ d2 = 0.6 1.1 1.5
a1= 0.162 0.254 b1+ b2 =0.6 1.1
0.40 1.5
Backlash of teeth normal max. 1 = 0.36 0.60 2 = 0.48 0.72 0.80 0.90 0.90
c1= 0.262 0.358
0.50
3 = 0.48 0.73
1989
0330/9.1 Clearance Table P.T.O. Drive
Maintenance
RTA84C
Nominal dimension a = 380 b= 300 c = 240 d = 260
normal, new a1 =0.358 0.262 b1 =0.441 0.377 c1 =0.435 0.377 d1 =0.379 0.315 e =1.1 0.6
Clearance max. due to wear 0.50 0.82 0.81 0.69 1.5
Nominal dimension
normal, new 1.11 f = 0.60 g = 0.91 0,50
Clearance max. due to wear 1.7 1.5 max.* 0.62
normal 1 =0.48 0.73 2 =0.36 0.57
Backlash of teeth normal max.* 0.90 0.68 0.36 3 =0.52
1989
RTA84C Clearance Table Camshaft and Reversing Servomotor
Maintenance
0330/10.1
Nominal dimension A = 330 a = 330
Nominal dimension
Clearance max. due normal, new to wear c = 0.1 0.30 0.40 0.30 0.30
a1 = 0.17 0.256 b1 +b2 =0.14 0.45
0.35 0.60
d1=0.1 0.16 d2=0.1 0.16
1989
0330/11.1 Clearance Table Gearing for Auxiliary Drives
Maintenance
RTA84C
Siehe auch Blatt 0330/15.1 SEE ALSO SHEET 0330/15.1 Siehe auch Blatt 0330/12.1 SEE ALSO SHEET 0330/12.1
normal 1 =0.12 0.26 2 =0.14 0.26 3 =0.10 0.21
Backlash of teeth max.* normal 0.47 0.40 0.38 4 = 0.10 0.20
max.* 0.34
* = due to wear
1989
RTA84C Clearance Table Gearing for Auxiliary Drives
Maintenance
0330/11.2
Nominal dimension d = 50 m = 60
Clearance max. due normal, new to wear d1 = 0.175 0.110 m1 = 0.136 0.06 0.3 0.2
Nominal dimension
Clearance max. due normal, new to wear g = 1.0 0.5 h = 1.0 0.5 i = 0.2 0.15 k = 0.22 0.14 0.3 0.3 Backlash of teeth normal max.* 5 = 0.10 0.20 0.30
1989
0330/12.1 Clearance Table Intermediate Shaft for Auxiliary Drives
Maintenance
RTA84C
auch Blatt 0330/11.1 1 Siehe SEE ALSO SHEET 033/11.1
a1
95.7967
Clearance max. due normal, new to wear a1= 0.106 0.036 b = 0.8 0.3 0.2
Nominal dimension normal 1 =0.12 0.26
Clearance max. due* normal, new to wear max.* 0.47 normal 6 =0.12 0.26 max.* 0.50
1989
RTA84C Clearance Table Starting Air Distributor
Maintenance
0330/13.1
b1
90.7026
a1
Nominal dimension a = 50 b = 55
Clearance max. due normal, new to wear a1 =0.11 0.175 b1 =0.06 0.09 1 = 1.0 2 = 0.45 0.80 1.00 0.30 0.15
Nominal dimension
1989
RTA84C
Maintenance
0330/14.1
Clearance Table Roller Guides to Fuel Injection and Actuator Pumps
Nominal dimension a = 70 -0.03 -0.06
Clearance max. due normal, new to wear a1 =0.03 0.09 b1+b2 = 0.28 0.392 0.35 0.50
Nominal dimension
Clearance max. due normal, new to wear 0.12 0.09 1.3
d = 102 -0.036 -0.058 d1= 0.036 0.080 d2= 0.012 0.069 D = 102 +0.022 0 e= 140 -0.30 -0.60 e1+ e2 = 0.5 0.9
b = 300 -0.28 -0.34 B = 300 +0.052 0
c = 120 -0.036 -0.058 c 1 =0.069 0.115 +0.057 C = 120 +0.033
0.16
E= 140 +0.30 +0.20
1989
0330/15.1
Maintenance
RTA84C
Clearance Table Gear Pump for Cylinder Lubricating Pump Drive
Siehe auch Blatt 0330/11.1 SEE ALSO SHEET 0330/11.1
Clearance max. due normal, new to wear a1 = 0.050 0.009 0.15
Nominal dimension
Clearance max. due normal, new to wear 1 =min. 0.14 max. 0.26 2 =min. 0.06 max. 0.13 0.40 0.20
0.055 b = min. max. 0.130
max. 0.20
1989
0330/16.1 Clearance Table Balancer Drive Units 2nd Order
Maintenance
RTA84C
Clearance max. due normal, new to wear a1 = 0.19 0.32 b1+b = 0.6 1.4 2 0.45 2.0 0.75 1.5
Nominal dimension e = 425 f = 139.7 g = 330
Clearance max. due normal, new to wear e1 = 0.41 0.60 f 1= 0.3 0.7 g1= 0.23 0.30 0.75 1.5 0.45
c = 425 d = 139.7
c 1 = 0.41 0.60 d1 = 0.20 0.90
1989
RTA84C Clearance Table Integrated Balancer 2nd order
Maintenance
0330/17.1
Nominal dimension
Clearance max. due normal, new to wear 1.50 0.30
Nominal dimension
a = 310 -0.2 +a 2 = 0.60 1.10 -0.3 a1 b = 220 b1 = 0.121 0.20
Backlash of teeth normal 1 = 0.48 0.69 2 = 0.36 0.57
max.
0.90 0.75
1989
RTA84C
Maintenance
0352/1.1
Tightening Values of Important Screwed Connections
Tightening torque (Nm)
Tightening angle ( Elongation (mm)
With hydr. jacks pressure (bar)
Details on sheet No.
1
1112/1 Foundation bolts (metal and synthetic chocks) 1132/1 Main bearing, jack bolts 1132/2 Main bearing, nut for waisted stud 1903/1 Tie rod Cylinder jacket boltingup / bolts Cylinder jacket boltingup / fitted bolts M64x4 M125x6 M56 M160x6 600
1st step 350 bar
Thread
Description
600 600 35_
MOLYKOTE G
MOLYKOTE G MOLYKOTE G
M64 M64
Elongation 0.55 0.04 mm Elongation 0.45 0.03 mm
Oil Oil
2
2124/2 Waisted bolts for filling piece in cylinder liner 2708/2 Cylinder cover, nut for waisted stud 2722/1 Fuel injection valve, screwed connection with cylinder cover
(see instructions on sheet 2722/1)
M10 M100x6 M12
1st step 5 Nm 1st step to 2nd step
15_ (330_)
no additional lu bricant required Oil MOLYKOTE G
600
Tighten spring packet to solid block length, then loosen it by turn = 90_
1st step when S using a L'ORANGE test stand: pretighten with 20 bar or hammer blow S using a O.M.T. test bench: pretighten to 150 Nm 1st step to 2nd step
Fuel injection valve, cap nut to 2Pnozzle
M64x2
MOLYKOTE G
(loosen cap nut after initial assembly and then repeat tightening procedure) (see instructions on sheet 2722/1)
45_ 55_
MOLYKOTE G
2728/1 Starting valve spindle, nut

(spindle thread not to be lubricated in the region of locking ring)
M30x2
(800)
Starting valve, nut for waisted stud 2751/1 Exhaust valve cage, nut for waisted stud 2751/2 Exhaust valve, screw for grooved valve cone piece Exhaust valve, screws for cylinder Indicator valve, screws Flywheel, nuts for coupling bolts Crankshaft division, nuts for coupling bolts
D D
M27 M72x6 M16 M16 M20 M85x4 M85x4 600
(750)
90_ (150_)
MOLYKOTE G Oil MOLYKOTE G
180 170 80 35_ 50_
MOLYKOTE G MOLYKOTE G MOLYKOTE G MOLYKOTE G
The values in parentheses (...) are for information only, to be used for comparison. The screwed connections must be tightened in accordance with the values not in parentheses.
UG / 4.01
Lubricant
0352/1.2
Maintenance
RTA84C
2751/2 Crankshaft-vibration damper, nuts for cou pling bolts Crankshaft-counterweight, nuts for cou pling bolts Crankshaft-propeller shaft, nuts for cou pling bolts 3 3146/1 Fixing bolt for axial detuner with bedplate 3303/1 Connecting rod, stud for top end bearing
M85x4 M85x4 M85x4
Thread
Description
35_ 35_ 50_
MOLYKOTE G
MOLYKOTE G
MOLYKOTE G
M36 M76x6 600
(2270)
50_
MOLYKOTE G Oil
1st step 400 bar (gap = 0 mm) 2nd step 600 bar Check: 1st step to 2nd step
(23_) M90x6 600

1st step 350 bar (gap = 0 mm) 2nd step 600 bar Oil
Connecting rod, stud for bottom end bearing
Check: 1st step to 2nd step
(40_) M100x6 600

1st step 200 bar (gap = 0 mm) 2nd step 600 bar Oil
Connecting rod (1part), stud for bottom end bearing
Check: 1st step to 2nd step
(64_) M64 M42 M16 (1200)

1st step 30 Nm 1st step to 2nd step
3403/1 Piston rod-crosshead, waisted screw 3403/3 Piston rod-piston crown, waisted screw Piston rod-spraying plate, waisted screw 4 4103/2 Intermediate gear bearing for camshaft drive, waisted screw Screwed connection, gear rim - hub of inter mediate wheel
(nut secured with LOCTITE No. 262)
30_ 50_ 30_
MOLYKOTE G MOLYKOTE G Oil
M48 M42x3
45_ 75_
MOLYKOTE G
no additional lu bricant required
4103/3 Gear wheel on crankshaft, waisted screw
M64x4
Elongation 1.050.05 mm
MOLYKOTE G
D D
The values in parentheses (...) are for information only, to be used for comparison. The screwed connections must be tightened in accordance with the values not in parentheses.
4.01 / UG
Lubricant
RTA84C
Maintenance
0352/1.3
4203/1 Reversing servomotor, fastening between shaft and wing Reversing servomotor, longitudinal fastening Balance disccamshaft, waisted screw for vibration damper (8-12 cylinder) Waisted stud for fuel pump housing Waisted screw for camshaft bearing in fuel pump housing 4203/6 Gear wheel in 2part on camshaft, screwed connection
(nut secured with LOCTITE No. 262)
M42 M24 M24 M64 M42 M42x3 (655)
Thread
Description
40_ 30_ 45_ 60_ 40_ 75_
no additional lu bricant required no additional lu bricant required no additional lu bricant required MOLYKOTE G MOLYKOTE G
no additional lu bricant required
5 5512/1 Fuel pump block, hexagon nut for waisted stud Fuel pump block, pressure nipple for valves
(loosen pressure bush after initial assembly and then repeat tightening procedure)
M45 M39x2 300
90_
MOLYKOTE G
MOLYKOTE G
Fuel pump block, screwed connection for valve cover 5512/4 Nipple for plunger bush
(loosen nipple after initial assembly and then repeat tightening procedure)
M12 M160x3
60 4 teeth
MOLYKOTE G
MOLYKOTE G
5513/1 Actuator pump, hexagon nut for waisted stud 8 8733/1 Cap nut for screwed connection of fuel pres sure piping, fuel distributor - fuel injection valve
(see instructions on sheet 8733/1)
M33
(620)
90_
MOLYKOTE G
M35x1.5
250
Oil
When using other jacks, the required pressure in bar must be calculated in relation to the effective jack piston surface! Conversion factor: 1 Nm = 0.102 mkp 1 bar = 1.02 kp/cm2 When using torque machine, please pay attention to the instructions of the respective manufacturers. D D The values in parentheses (...) are for information only, to be used for comparison. The screwed connections must be tightened in accordance with the values not in parentheses.
UG / 4.01
Lubricant
RTA84C
Maintenance
0352/2.1
Tightening Instructions for Normal Screws

This table is valid for all screws that are not considered on sheet 0352/1. Attention: These tightening instructions are valid only if: a) the screws are made of the 8.8 material. b) the threads have been lubricated with oil. Remark: It is recommended to lubricate the threads for screws which come into contact with 'hot parts' like ex haust pipings, expansion pieces, etc. with a heatresisting lubricant, e.g. THREAD GARD.
Screw thread M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 M42 M45 M48 M52 M56 M60
Tightening torque Nm 20 40 70 110 170 250 350 450 600 900 1200 1600 2100 2500 2900 3300 3700 4100 4600 5200
1999
0352/2.2
Maintenance
RTA84C
Waisted studs must be tightened according to the values in the following diagram: D D Before fitting a waisted stud clean and degrease the stud thread and the tap hole. Screw in the stud right to the bottom of the tap hole, and tighten. Always utilize a stud driver or two nuts. Tools like a pipe wrench etc. which would damage the stud shank must never be used.
Attention:
For the protection of the stud in the cylinder jacket and cylinder cover, fill the annular space above the thread with a nonhardening sealing compound (see sheet 2751/1).
Anzugsmomente fr Dehnbolzen TIGHTENING TORQUE FOR WAISTED STUDS
3500
Anzugsmomente fr Dehnbolzen TIGHTENING TORQUE FOR WAISTED STUDS
3000
400
Anzugsmoment in Nm TIGHTENING TORQUE Nm
2500 2000
Anzugsmoment in Nm TIGHTENING TORQUE Nm
97.8103
300
1500
200
1000
100
500
0
Gewindedurchmesser (mm) THREAD DIAMETER (mm)
0 10 20 30 40 50 60
Gewindedurchmesser (mm) THREAD DIAMETER (mm)
10 20 30 40 50 60 70 80 90 100 110 120
1999
RTA84C Masses (Weights) Individual Components per Piece in kg
Maintenance
0360/1.1
Group 1132 1132 1132 1132 1132 1132 1203 1903 1903 1903 1903
Component Main bearing cover (narrow) for 4 to 7 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing cover (narrow) for 8 to 12 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing cover (wide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing shell (narrow) per pair including shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing shell (wide) per pair including shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thrust bolt to main bearing complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kg 400 471 710 251 463 188
Thrust bearing pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Tie rod short complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1437 Tie rod long complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1887 Tie rod nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Intermediate ring to tie rod nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 End cylinder jacket (driving end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 400 End cylinder jacket (free end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 400 Cylinder jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 300 Cylinder jacket intermediate piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8800 End cylinder jacket complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 380 Cylinder jacket complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 280
2124 2124 2124 2303 2708 2708 2708 2708 2722 2728 2740 2751 2751 3103 3103 3103 3103 3103 3103 3103 3103 3103
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6100 Support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2610 Antipolishing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Gland to piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Cylinder cover: waisted stud with nut (8 pieces total = 960 kg) . . . . . . . . . . . . . . . . . . . . . . . 120 Water guide ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Cylinder cover without valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5010 Cylinder cover complete with valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7530 Fuel injection valve complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Starting valve complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Relief valve complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exhaust valve complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2205 Exhaust valve spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Crankshaft semibuilt 4 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . . 110 500 Crankshaft semibuilt 5 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . . 132 200 Crankshaft semibuilt 6 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . . 153 900 Crankshaft semibuilt 7 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . . 175 600 Crankshaft semibuilt 8 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . . 208 900 Crankshaft semibuilt 9 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . . 230 700 Crankshaft semibuilt 10 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . 252 500 Crankshaft semibuilt 11 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . 274 300 Crankshaft semibuilt 12 Cyl. including thrust bearing shaft . . . . . . . . . . . . . . . . . . . . . . . 296 100 UG / 4.01
0360/1.2
Group Component
Maintenance
RTA84C
kg
Flywheel (light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4400 - 10 420 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 800 - 22 200 3303 3303 3303 3303 3303 3303 3303 3303 Connecting rod complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6200 Connecting rod shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3580 Lower bearing half to bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640 Upper bearing half to bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 940 Bolt with nut to bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Upper bearing half to top end bearing complete with waisted studs . . . . . . . . . . . . . . . . . . . . 591 Bearing shell to top end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Linkage lever to piston cooling & crosshead lubrication complete . . . . . . . . . . . . . . . . . . . . . 184 1part connecting rod: Connecting rod complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6036 Connecting rod shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4200 Bearing cover with waisted studs to bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 981 Bearing shell to bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Bearing cover with waisted studs to top end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591 Crosshead pin without slippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3118 Guide shoe to crosshead pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565 Working piston complete with piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3912 Piston crown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1085 Piston skirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2374 Gear wheel on crankshaft complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate gear wheel of camshaft drive complete with journal pin . . . . . . . . . . . . . . . . . Gear wheel on camshaft 4-7 Cyl. complete with shaft and gear wheels . . . . . . . . . . . . . . . Gear wheel on camshaft 8-12 Cyl. complete with shaft and gear wheels . . . . . . . . . . . . . . 3278 2981 3934 3846
3303 3303 3303 3303 3303 3326 3326 3403 3403 3403 3403 4103 4103 4103 4103 4203 4203 4203 4203 4203 4203 4203 4203 4203 4203 4203 4220 5103 5512
Camshaft 4 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 12 970 Camshaft 5 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 15 878 Camshaft 6 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 17 278 Camshaft 7 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 20 440 Camshaft 8 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 21 907 Camshaft 9 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 24 457 Camshaft 10 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . 26 112 Camshaft 11 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . 29 374 Camshaft 12 Cyl. with cams, shaft coupling and gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . 30 317 Cam to fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Cam to exhaust valve actuator pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Bearing housing to camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2645 Woodward governor (PGA-200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Fuel pump body complete without plunger and guide bushes . . . . . . . . . . . . . . . . . . . . . . . . . 823 Turbocharger VTR 564 complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6300 Turbocharger VTR 714 complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 100
4.01 / UG
RTA84C
Group 6545 6545 6606 6606 Component
Maintenance
0360/1.3
kg
Auxiliary blower complete with electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920 - 1189 Suction space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 - 361 Charge air cooler GEA-K110 / Serck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge air cooler GEA-K220 / Serck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air duct before charge air cooler to VTR 564 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air duct before charge air cooler to VTR 714 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3200 4300 1116 1745
7708 7708 7708 7708 7708
Balancer weight (balancer 4-5 Cyl.) complete with pinion and pin . . . . . . . . . . . . . . . . . . . 2501 Balancer weight (balancer 6 Cyl.) complete with pinion and pin . . . . . . . . . . . . . . . . . . . . . . 2263 Flexible coupling to balancer 4-5 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3070 Flexible coupling to balancer 6 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2425 Roller chain to balancer 4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642 Exhaust manifold 4 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7500 Exhaust manifold 5 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8350 - 8650 Exhaust manifold 6 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9300 Exhaust manifold 7 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 700 Exhaust manifold 8 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 900 - 15 200 Exhaust manifold 9 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 600 - 15 750 Exhaust manifold 10 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 600 - 17 150 Exhaust manifold 11 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 900 Exhaust manifold 12 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 700 Compensator DN 350 after the exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Compensator DN 800 between the exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
UG / 4.01
RTA84C
Maintenance
0370/1.1
Dimensions and Material Specification of ORings and Rubber Rings

Group in CodeBook Thickness mm
191 211 214
Tie rod Relief valve to cylinder block type EVT224 Cylinder liner / guide portion in cylinder jacket of cylinder block respectively Cylinder liner / water guide jacket Lubricating quill Piston rod gland / housing Cylinder cover / water guide jacket Fuel injection valve / shoulder nut Starting valve Starting valve Starting valve Exhaust valve / valve drive housing, vent screw Exhaust valve / valve drive housing Exhaust valve / valve cage Exhaust valve / valve cage Exhaust valve / valve cage Exhaust valve / guide bush in valve cage Exhaust valve / piston to air cylinder Exhaust valve / bush, oil transition Relief valve to cylinder cover Working piston / oil pipe Working piston / oil pipe Working piston / spraying plate Working piston / spraying plate Camshaft / oil connections to slide ring Camshaft / oil connections to slide ring Camshaft / sleeve Gear box for auxiliary drive Gear box for auxiliary drive Solenoid valve Starting air distributor / valve block Starting air distributor / flange Starting air distributor / guide flange Starting air distributor / casing
6.99 8 9 9 3.53 7 9 3.53 6.99 1.78 1.78 2.62 6.99 6.99 6.99 6.99 5.33 5.33 3.53 5.33 6.99 5.33 9 9 5.33 5.33 6.99 2.62 2.62 1.78 3.53 5.33 5.33 7
151.77 NBR 70 Sh 210 990 1130 36.09 600 1130 36.09 Nitrile 70 Sh Silicon (MVQ) Silicon (MVQ) FPM 70 Sh Rubber (Si) seaml. Silicon (MVQ) FPM 70 Sh
214 231 270 272 274
132.72 NBR 70 Sh 14 NBR 70 Sh 10.82 FPM 70 Sh 13.94 367.67 532.26 380.37 291.47 110.49 78.74 32.92 43.82 135.89 215.27 550 490 FPM 70 Sh MVQ 50 Sh FPM 90 Sh FPM 90 Sh FPM 70 Sh FPM 70 Sh FPM 70 Sh MVQ 50 Sh NBR 90 Sh MVQ 50 Sh MVQ 50 Sh Rubber (Si) seaml. Rubber (Si) seaml.
275
277 340
421
37.47 NBR 70 Sh 43.82 NBR 70 Sh 608.08 NBR 70 Sh 12.37 15.54 14 28.17 40.64 88.27 177.17 NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh
428
434
UG
I.D. mm
Component where the Oring or the rubber ring is installed
Material
1994
0370/1.2
Maintenance
RTA84C
Group in CodeBook
436
Shutoff valve for starting air / casing Shutoff valve for starting air / cover Shutoff valve for starting air / valve for SLOW TURNING Control valve / cover Control valve / cover
6.99 6.99 5.33 3.53 2.62 5.33 5.33 5.33 5.33 3.53 2.62 3.53 5.33 1.78 3.53 2.62 5.33 2 2.62 3.53 4.42 3.53 5.33 3.53 3.53 12 3 3 3.53 3.53 7
202.57 177.17 62.87 44.04 13.94 78.74 59.69 69.22 43.82 63.09 13.94 44.04
I.D. mm
Thickness mm
Material
NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh
436-1 Valve for SLOW TURNING / bush Valve for SLOW TURNING / cover Valve for SLOW TURNING / casing Valve for SLOW TURNING / cover Valve for SLOW TURNING / bush Valve for SLOW TURNING / control valve Valve for SLOW TURNING / control valve 451 460 461 Reversing valve Control air supply Valve group for reversing blocking
110.49 NBR 70 Sh 9.25 20.22 4.42 50.17 10 4.42 72.62 2.62 18.64 NBR 90 Sh NBR 70 Sh Nitrile 70 Sh NBR 70 Sh Rubber 750 Nitrile 70 Sh NBR 70 Sh Nitrile 70 Sh NBR 70 Sh
461-1 Valve group for governor and air cylinder 466 469 Pickup Pneumatic logic unit Pneumatic logic unit Safety cutout device / casing Safety cutout device / valve plate
532
554-1 Fuel pump / locking pin of roller guide 554-2 Fuel and actuator pump / casing 558-1 Relief valve to fuel pump 581-3 Regulating linkage / air cylinder, cover and intermediate piece 646 725 Receiver connection Gear pump / casing Gear pump / inlet and discharge valve Cylinder lubricator control / flow regulating valve
196.22 NBR 70 Sh 66.27 72.62 720 150 50 26.57 FPM 90 Sh MVQ 50 Sh Viton 70 Sh Rubber 750 Rubber 750 NBR 70 Sh
726
770-3 Balancer / guide stud Cylinder cooling water air separator / throttle orifice
32.92 NBR 70 Sh 266.07 NBR 70 Sh
1994
UG
RTA84C
Maintenance
0370/1.3
Group in CodeBook
843
Prelubricating valve
2 5.33 5.33 5.33 6.99 1.78 3.53 2.62 3.53 2.62 1.78 3.53
10 100.97 113.67 123.19 148.59 9.25 21.82 18.72 17.04 12.37 9.25 21.82
I.D. mm
Thickness mm
Material
Rubber 750 NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh NBR 70 Sh Viton FPM 90 Sh NBR 70 Sh NBR 70 Sh
844-1 Hydraulic piping of exhaust valve Hydraulic piping / exhaust valve Hydraulic piping / exhaust valve Oil leakage return 870 Priming valve on the fuel distributor Priming valve on the fuel distributor Fuel pressure retaining valve
877
877-1 Fuel suction / spill piping shutoff valve Tool 94215 Tool 94277 Hydraulic tensioning device for cylinder cover Setting device for relief valve Setting device for relief valve
UG
1994
RTA84C
Maintenance
0370/2.1
Dimensions and Material Specification of the Piston and Rod Seal Rings
Seal Ring Turcon/Molybdaen PTF/MoS /Glass 2 Support Ring Viton FPM 705 Shore A Nitrile NBR 705 Shore A
of rod or of cylinder x width of seal ring
Component where the Piston Seal Ring (PSR) or the Rod Seal Ring (RSR) is installed Thrust bolt / crankshaft bearing Exhaust valve / piston to air cylinder Exhaust valve / valve guide bush Starting air distributor Starting air distributor Shutoff valve for starting air / valve
113 275 434 436
PSR PSR RSR PSR RSR PSR PSR PSR PSR RSR PSR RSR PSR RSR RSR PSR PSR
160x3.8 280x7.8 80x6.1 100x3.8 75x3.8 190x5.8 70x3.8 55x3.8 100x3.8 30x2.8 80x3.8 28x2.8 80x3.8 40x2.8 28x2.8 30x2.8 40x2.8 x x x x x x x x x x x x x x x x
PTF/Bronze
Group in Code Book
Sort
x x x
x x x x x x x x x x x x x x
436-1 Valve for slow turning / piston Valve for slow turning / piston 451 532 Reversing valve / valve Reversing valve / cover Safety cutout device / piston Safety cutout device / casing
581-3 Air cylinder to regulating linkage / piston Air cylinder to regulating linkage / cover Air cylinder to regulating linkage / intermediate piece 843 Valve to cylinder oil prelubrication Valve to cylinder oil lubrication
Piston Seal Ring (PSR) Cylinder
Rod Seal Ring (RSR) Bush Support ring Seal ring
Seal ring Support ring
Width
Width 4 Piston Rod
3.03
0370/2.2
Maintenance
Turcon/Molybdaen
RTA84C
PTF/MoS /Glass 2
Viton FPM 705 Shore A
Component where the Piston Seal Ring (PSR) or the Rod Seal Ring (RSR) is installed
94145 Foundation bolt jack / piston Foundation bolt jack / cylinder 94180 Tie rod pretension jack / piston Tie rod pretension jack / cylinder 94215 Cylinder cover pretension jack / piston Cylinder cover pretension jack / cylinder 94252 Valve cage pretension jack / piston Valve cage pretension jack / cylinder 94260 Valve seat withdrawing device / piston Valve seat withdrawing device / cylinder 94314 Bottom end stud pretension jack / piston Bottom end stud pretension jack / cylinder 94315 Top end stud pretension jack / piston Top end stud pretension jack / cylinder 94424 Mounting tool for pressseat components on camshaft 94706 Pretensioning jack for balancer / piston Pretensioning jack for balancer / cylinder 1part connecting rod: 94314 Pretensioning jack to bottom end bearing Supporting ring (piston) O 260 x O 247.8 Oring (piston) O 240.64 x 6.99 Supporting ring Oring (cylinder) (cylinder) O 130 x O 120.6 O 120.02 x 5.33
PSR RSR PSR RSR PSR RSR PSR RSR PSR RSR PSR RSR PSR RSR PSR PSR RSR
130x3.8 85x3.8 380x5.8 220x5.8 280x5.8 140x3.8 210x5.8 120x3.8 160x3.8 90x3.8 200x5.8 140x3.8 200x5.8 120x3.8 100x3.8 140x3.8 80x3.8
x x x x x x x x x x x x x x x x x
Turcon NBR 90 Sh Turcon NBR 90 Sh t
O-ring
Supporting ring
i o i
98.7510
4.01 / UG
Nitrile NBR 705 Shore A
of rod or of cylinder x width of seal ring
PTF/Bronze
Tool No.
Sort
x x x x x x x x x x x x x x x x x
RTA84C
Maintenance
0380/1.1
Maintenance Schedule Inspection and Overhaul Intervals (Guidelines)
Sheet 0 0900/1
Component
Work to be carried out
Intervals
Lubricating oil Cooling water
- Laboratory analysis - Check concentration of inhibitor (as per supplier's instructions)
3000 Op. h (operating hours)
1 1112/1 Bedplate Crankcase 1132/2 Main bearing - Check pretension of foundation bolts, first time after 1500 Op. h - Visual examination - Remove bearing upper half for inspection - Remove bottom bearing shell for inspection 1203/1 Thrust bearing - Check axial and radial clearances - Check bottom drain for free passage 1224/1 1903/1 2 2124/1 2124/2 Cylinder liner - Establish wear in bore (in fitted condition) - Remove cylinder liner - Replace Orings - Replace (soft iron) joint ring between cylinder liner and cylinder cover - Water guide jacket, replace Orings - Check condition of antipolishing ring (if fitted) 2124/3 - Grind off wear ridge in bore - Clean scavenge ports and refinish their edges - Refinish lubricating grooves 2136/1 Lubricating quill and accumulator - Check function and tightness - Check function of nonreturn valves - Replace Orings - Check diaphragm of accumulator 2303/1 2708/1 Piston rod gland Cylinder cover - Clean rings, establish wear - Check combustion space for damage at every piston removal as required at every removal at every piston removal at every piston removal at every piston removal at every piston removal as required as required at every piston removal at every liner removal at every liner removal at every piston removal at every piston removal at every piston removal UG / 2.05 Tie rod - Remove thrust bearing pads for inspection - Check pretension, first time after one year (if necessary retension) 12 000 Op. h 1500-3000 Op. h according to classification society acc. to class. society 6000-8000 Op. h 6000-8000 Op. h acc. to class. society 24 000-30 000 Op. h
0380/1.2
Maintenance
RTA84C
Sheet 2722/1
Component Injection valve
Work to be carried out - Check externally for tightness - Check spray pressure, tightness and condition of nozzle tip (life time about 6000 Op. h)
Intervals before starting engine after a longer standstill 3000 Op. h from time to time 6000-8000 Op. h
2728/1
Starting valve
- Check piping before valve during operation, if it is too hot: dismantle starting valve - Remove and dismantle one starting valve at random. From its condition determine time of overhaul for remaining valves
2740/1 2751/1 to 2751/4
Relief valve to cylinder cover Exhaust valve
- Check, dismantle, assemble and set - General inspection of valve housing, valve spindle and valve seat (without dismantling of exhaust valve) - Valve spindle, check condition and wear (if necessary regrind seat by machining) - Check piston seal ring / air spring & rod seal ring / guide bush - Valve seat, check condition and wear (if necessary regrind seat by machining)
18 000 Op. h at every piston removal
24 000-36 000 Op. h 24 000-36 000 Op. h 24 000-36 000 Op. h
3 3103/1 Crankshaft - Measure crank deflection (always in case of grounding of the ship as well as before and after every docking) 6000-8000 Op. h
3130/1
Torsional vibration - Take a silicon oil sample from viscous vibration damper damper (based on results of 1st sample, interval for taking further samples will be decided) Axial damper Turning gear - Dismantling and inspection - Inspection interval - Check bearing clearances - Inspect bottom end bearing (life time of shell to 1part connecing rod 60 000-72 000 Op. h) - Inspect top end bearing Guide shoe, Crosshead pin - Check clearances - Remove crosshead
first time after 15 000 18 000 Op. h 36 000-48 000 Op. h acc. to instructions of turn. gear manufacturer 6000-8000 Op. h 30 000-36 000 Op. h or acc. to class. society 30 000-36 000 Op. h or acc. to class. society 6000-8000 Op. h as required
3146/1
0330/5 3303/2
Connecting rod bearings
3303/3 3326/1 3326/2
2.05 / UG
RTA84C
Maintenance
0380/1.3
Sheet 3403/1
Component Piston
Work to be carried out - Remove, clean and measure ring grooves (cylinder liner with antipolishing ring and chromeceramic uppermost piston ring) - Remove, clean and measure ring grooves (cylinder liner without antipolishing ring) - Check tightness on piston in situ with running oil pump, visual check through scavenge ports
Intervals 18 000-20 000 Op. h
12 000-14 000 Op. h after refitting as required at every piston removal 1500-3000 Op. h
3403/3 3403/4
- Dismantling and assembling (open and clean cooling space, min. one piston every three years) - Check condition of piston top surface - Visual check through scavenge ports to piston, piston rings and cylinder liner (rotate crankshaft with turning gear) Piston underside - Check condition of space, clean it as required - Check drains for free passage
1500-3000 Op. h 1500-3000 Op. h at every piston removal 18 000-20 000 Op. h
3425/1
Piston rings
- Remove, clean and establish wear rate, if necessary fit new rings - Replace uppermost piston ring
4 4103/1 Camshaft driving wheels - Check condition of teeth - Check running clearance and backlash of teeth Camshaft bearing Fuel cam Actuator cam Roller to injection & actuator pumps 4303/1 4325/1 Starting air distributor Starting air shutoff valve and Valve for show turning 4506/1 5 5307/1 Safety cutout device - Dismantle, clean, inspect (if necessary replace sealing and Orings) - Functional check 5512/1 Injection pump - Clean, remove and inspect valves - Check controls, if necessary reset
6000-8000 Op. h 6000-8000 Op. h 1500-3000 Op. h 1500-3000 Op. h 1500-3000 Op. h 1500-3000 Op. h 24 000-36 000 Op. h after each manoeuvring period 24 000-36 000 Op. h 24 000-36 000 Op. h
- Visual examination of camshaft housing - Check running surface - Check running surface - Check running surface - Dismantle, clean and inspect pilot valves for ease of movement - Vent - Dismantle, clean and check (particularly seat, springs and seal rings) - Dismantle, clean and establish wear, functional check
Rotation direction safeguard
24 000-36 000 Op. h 6000-8000 Op. h 12 000-18 000 Op. h 12 000-18 000 Op. h UG / 2.05
0380/1.4
Maintenance
RTA84C
Sheet 5512/1
Component Injection pump
Work to be carried out - Apply MOLYKOTE paste G to spherical connections - Check spring link for free movement on eccentric shaft - Check wear of spherical bearings weekly
Intervals
monthly monthly as required 24 000-36 000 Op. h 1500 Op. h
5512/2 5512/3
- Lap sealing faces of valve covers - Check relief valves and set them - Check drain bore for relief valve in injection pump block for leakage during operation as well as for free passage and for indication of a possible discharge
5512/4
- Lap sealing face of guide bush and tighten it - Check at random plungers and bushes - Check sealing face between injection pump block and plunger bush (check bore) for leakage during operation
as required 24 000-36 000 Op. h 1500 Op. h
5513/1 6 6420/1
Actuator pump
- Dismantle and check one actuator pump
24 000-36 000 Op. h
Scavenge air receiver
- Check and clean air flaps - Clean receiver - Check water drain piping for free passage
4000-6000 Op. h 4000-6000 Op. h 1500-3000 Op. h (see Operating Manual) (see Operating Manual) (see Operating Manual) as required 24 000-36 000 Op. h 24 000-36 000 Op. h as required
Exhaust gas turbocharger
- Washcleaning of blower in service - Washcleaning of turbine in service - Dry cleaning of turbine in service - Air filter cleaning (np max. 10 mbar)
6545/1
Auxiliary blower
- Clean impeller and casing - Replace ball bearing
Scavenge air cooler - Cleaning of scavenge air cooler (air side) in service at the beginning weekly, later if np (pressure drop through SAC) reaches 50 mbar (for further instructions see Operating Manual) 6606/1 6606/2 - Cleaning (water side) on engine at standstill - Remove cooler for general overhaul - Check drains for free passage
as required as required 1500-3000 Op. h
2.05 / UG
RTA84C
Maintenance
0380/1.5
Sheet 6708/1
Component Water separator
Work to be carried out - Check permanent drainage (outlet either air or a mixture of air/water) - Check water separator elements (if necessary clean them), check drains for free passage daily
Intervals
1500-3000 Op. h
7 7203/1 Cylinder lubricating pump PTO gear box with GEISSLINGER coupling - Drain and wash out casing, first time after 1000 Op. h - Check condition of teeth 15 000-20 000 Op. h according to instruction of pump manufacturer 6000-8000 Op. h
7403/1
0330/9
- Establish backlash and bearing clearance - External check for oil leakage and clear vents
6000-8000 Op. h 1500 operating hours 18 000-24 000 Op. h 36 000-48 000 Op. h 3000 operating hours as required acc. to instruction of coupling manufacturer 6000-8000 Op. h
7412/1
- Dismantle and inspect coupling Clean and replace all seal rings - Overhaul, or replace spring stacks respectively
7708/1
Balancer drive elements
- Retension roller chain (after fitting new chain, first time after 500 Op. h) - Measure roller chain stretching - Inspection interval and dismantling of GEISLINGER coupling
7722/1
Integrated balancer (driving end)
- Check condition of teeth
0330/17
- Measure backlash of teeth and bearing clearance of balancer
6000-8000 Op. h
8 8460/1 Hydraulic piping to exhaust valve Starting air piping Pressure gauges and pyrometers Fuel and lubricating oil filters 8733/1 Fuel pressure piping - Recondition sealing faces - Drain (dewater) - Compare and calibrate according to master instruments - Clean or replace filter elements (depending on make, follow special mainte nance instructions by manufacturer) - Recondition sealing faces as required before and after every manoeuvring period 6000-8000 Op. h as required
as required
UG / 2.05
0380/1.6
Maintenance
RTA84C
The indicated maintenance intervals must be taken as guidance and may vary depending on the installation. The proper intervals are subject to the points mentioned below. Experience will show whether these intervals can be extended or must be shortened. Environmental and operating conditions Heavy fuel oil and lubricating oil qualities (see Operating Manual sheet 0710/1 and 0750/1) Engine load Fuel, lubricating oil and cooling water care (see Operating Manual sheet 0720/1 and 0760/1) Overhaul according to Maintenance Manual Genuine spare parts used Engine monitoring Engines according to specifications of Wrtsil Switzerland Ltd.
On the engine sectional drawings, sheet 0803/1, 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 Sheet numbers Lubricating quills and accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . 2136/1 Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2740/1 Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130/1 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301/1 Starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4303/1 Starting air shutoff valve and valve for slow turning . . . . . . . . . . . . . 4325/1 Rotation direction safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4506/1 Speed governor PGA 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5103/1 Safety cutout device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5307/1 Driving shaft to flow control valve of cylinder lubrication . . . . . . . . . 7212/1 GEISLINGER couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7412/1 Integrated balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7722/1
2.05 / UG
RTA84C
Maintenance
0803/1.1
8460/1 2751/1-/4 8733/1 2728/1 2708/1-/4 3425/1 3403/1-/4
6420/1
2303/1

6606/1-/2 6708/1 6545/1
5512/1-/4
4203/2-/5
4203/1 3326/1-/2
3303/1-/4

89.7264
7403/1-/2
3206/1
3103/1
1112/1
5.92
0803/1.2
Maintenance
RTA84C
4 - 7 Zylinder-Motoren 2722/1-/3
2751/1
2124/1-/3
7203/1
6545/1
6545/1
2303/1 1903/1 3326/1
4203/6
3303/1
7708/1 1132/1 3146/1 4103/1-/2 1132/2
4103/3
1203/1 1224/1 1903/1

89.7271
1994
UG
RTA84C
Maintenance
0900/1.1
Taking Oil Samples for Laboratory Analysis

At intervals of approx. 3000 operating hours, a sample should be taken of the engine oil and sent to a laboratory for an analysis. With the oil pump running and the engine oil at operating temperature drain a small quantity of oil from a cock in the lubricating system to flush out any dirt accumulated in this cock. Following this take an oil sample in a clean glass for the test. The receptacle with the sample of oil must be marked with the following information for the laboratory: Ship's name or name of plant Engine type Engine serial number Date of sampling Operating hours of oil and of engine Oil brand and quality
Oil inspection The condition of the lubricating oil charge or its alteration during operation can be assessed on the basis of some analysis data. With regular checks a deterioration can be detected at an early stage and remedial measures taken. The indications for limiting values are to be taken as guiding ones, which should not be exceeded in service, and in the case of the flash point not fall below (see also sheet 0750/1 of the Operating Manual).
Parameter Kin. Viscosity at 40 _C Flash point (COC) Total insolubles Base Number (BN) Water Recommended test method is IP 316/88.
Unit mm2/s [cSt] _C m/m [%] mgKOH/g m/m [%]
Limit max. min. max. max. max 160 180 2.0 30 0.5
If one of the limits is reached appropriate remedial action should be considered to correct the situation. Such action may be intensified purification (reduction of throughput, adjustment of temperatures), treating in a renovating tank or partial exchange of the oil charge. These limits are set out as a guidance. The quality condition of the oil in circulation, however, cannot be fully judged by a single parameter. Other oil parameters as well must be used in context to be able to find the cause of the prob lem and the appropriate remedy for correction. Experience shows that with correctly designed installations and carefully performed oil care measures, generally a sufficient safety margin to the above values can be maintained.
3.03
RTA96C
Betrieb
Group1
Bedplate and Tie Rod
Group 1
Bedplate and Thrust Bearing

Checking the Foundation Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112/1
Main Bearing
Loosening and Tensioning of Bearing Jack Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132/1 Removing and Fitting of a Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132/2
Thrust Bearing
Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203/1
Thrust Bearing
Removal and Fitting of Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224/1
Tie Rod
Checking the Tie Rod Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . . . . . . . . . . . . 1903/1
RTA84C / MM / 2001
RTA84C Bedplate and Thrust Bearing Checking the Foundation Bolts

Tools: 1 1 1 1 Feeler gauge Pretensioning jack HP oil pump HP hose 94122 94145 94931 94935
Maintenance
1112/1.1
Key to Illustration: 1 2 3 4 5 6 7 8 9 10 Relief valve Vent screw Tensioning nut Piston Spacer sleeve Nut Bedplate Foundation bolt Chock Ship's foundation plate 11 Nut 12 Angel 13 Bush K M P R V Y Checking gap Pressure gauge HP oil pump Round bar Relief valve Measuring place
M V P(94931) 2 1
The foundation bolts shall be checked at longer intervals e.g. during overhauls, for their tightening condition (see sheet 0380/1). The 'General Application Instructions' for the utilization of hydraulic pretensioning jacks and screw fasteners are appli cable (see sheet 9403/4). Working sequence
3 4 Y 5 6 R K 7 8
Tension the foundation bolt with 600 bar and keep pressure constant. Check with feeler gauge through the gap 'K' if there is any clearance between the nut 6 and its seating. If there is no clearance, this means that the tightening condi tion of the foundation bolt has remained unchanged since the last check. The pressure can be released to zero and the pretensioning jack removed. Should however a clearance be found, the nut 6 must be tightened down onto its seating with round bar 'R' while the pressure is kept at 600 bar (then check again with the feeler gauge for clearance). Lower the pressure to zero and re move the pretensioning jack. Remark:
9 10
11
95.7994
Gezeichnet fr RT58 DRAWN FOR RT58
Should clearance exist at 600 bar between nut 6 and seating surface and the nut can not be tightened down with the round bar, this means that the nut is jammed on the founda tion bolt and the thread has first to be eased and the bolt thread smeared with MOLYKOTE paste. Then the respective foundation bolt has to be tensioned with 600 bar, the nut tightened onto its seating and checked for clearance.
Loosening of foundation bolts Attention! For loosening, the pretensioning jack must be so fitted on the bolt, that a clearance of about 2 mm remains between spacer sleeve and tensioning nut i.e. at 'Y', before beginning to tension the founda tion bolt (otherwise the hydr. pretensioning jack can later not be removed). Then the foundation bolt has to be tensioned with about 620 bar and the nut 6 turned loose by one turn. After releasing the pres sure to zero, the pretensioning jack and later the nut 6 can be removed.
9.99
1112/1.2
Maintenance
RTA84C
Drucklagerhalterung THRUST HOLDER
M 2 1
3 4 Y 5 6 R
P(94931)
K 13
12
9 10
11
95.7995
1989
RTA84C
Maintenance
1132/1.1
Main Bearing Loosening and Tensioning of Bearing Jack Bolts

Tools: 1 1 1 3 2 Special feeler gauge Depth gauge HP oil pump Pressure gauges (1000 bar) Connecters HP hoses 1 Open end spanner to item 9 94123 94126 94931 94932 94933 94935 AF110 Key to Illustrations: 1 2 3 4 5 6 7 8 9 Jack bolt Column center part Bearing cover Vent valve Locking wire Set screw Cylinder Nut Milled facing for open end spanner 10 Piston seal ring 11 Locking wire 12 Shims
D R S T V
Pressure space Eye bolt Round bar Rope Relief valve
2 94933
A
T 94933
D 10
5 94932 6 7 S 94935 8
2 R
11
9 1 94932
a1
94931
12
12
93.7151
a2
10.94
1132/1.2
Attention!
Maintenance
RTA84C
Loosening and tensioning the jack bolts may only be undertaken when the engine tie rods are fully tightened to specification (see sheet 1903/1). The jack bolts are so designed that they must be loosened or tensioned hydraulically, and for which the tools sup plied with the engine are to be used. Before detensioning the bearing jack bolts secure these with rope 'T' and eye bolt 'R against falling outward. L o o s e n i n g the jack bolts Working sequence: (see Fig. 'A') - Remove locking wire 11. Unscrew threaded plugs for oil input to cylinders 7, and in their place screw in connect ers 94933 firmly. Connect these to HP oil pump 94931. - Tension jack bolts with abt. 620 bar and keep this pressure constant until both nuts 8 have been screwed back by abt. 1 to 2 turns. Release pressure to zero, by opening relief valve 'V' on the pump and unscrew the connecters 94933. - Thread back both nuts 8 until the jack bolts can be removed. - Close oil input holes again with the threaded plugs to prevent the entry of foreign matter (dirt). T e n s i o n i n g the jack bolts Working sequence: - Compare the three pressure gauges 94932 with a calibrated pressure gauge for correct indications. - Clean seat faces for spherical thrust bolt ends on bearing cover and in column center part. - Fit the jack bolts turning their cylinders 7 to such a position that the connecters with pressure gauge can be fitted, tighten nuts 8 with the round bar 'S' (without any extension). - Screw in both connecters 94933 firmly and connect them to the HP oil pump 94931 by HP hoses 94935. - Establish distances 'a1' and 'a2' with depth gauge 94126. The difference between the two distances may not ex ceed 0.30 mm. If necessary bring the bearing cover 3 to the right position by slightly loosening the nut 8 of the thrust bolt on which side distance 'a' is less, and tighten the nut of the other thrust bolt with round bar 'S' while holding thrust bolt firm with an open end spanner. - When the difference between distances 'a1' and 'a2' is within 0.30 mm tighten both nuts with the round bar until fully seated. - Remove locking wire 5 and slightly loosen vent valve 4 while actuating the HP oil pump until the air has escaped from the pressure space 'D'. Then tighten vent valve 4 again and lock it with locking wire 5. - Actuate pump and build up a pressure of 600 bar (check whether all three pressure gauges show the same pres sure). Hold this pressure constant until both nuts 8 have been tightened with the round bar 'S' till fully seated on the cylinders 7 (check seating with feeler gauge). - Release the pressure on the pump and measure the distances 'a1' and 'a2'. Should the difference exceed 0.30 mm, loosen the jack bolts, adjust the bearing cover correspondingly and repeat the tensioning procedure. - Finally lock the nuts with locking wire 11, remove the two connecters and close the oil input holes with the threaded plugs. For safeties sake check with the special feeler gauge 94123 whether sufficient bearing clearance is available (see Clearance Table sheet 0330/1). Remark: In case of new jack bolts or such ones which had been dismantled consideration must be given to the fact that for filling the pressure space the oil level in the pump will drop considerably. In case of utiliz ing a motor driven oil pump the oil level must therefore be carefully watched to avoid a dryrunning.
10.94
RTA84C Main Bearing Removal and Fitting of a Main Bearing

Tools 1 1 1 2 1 1 1 3 2 1 Suspension device Roller support Removal device for bearing shell Steel ropes Girder HP oil pump Distributor piece HP hoses Hydr. jacks Dial gauge with magnetic base Lifting tackle 1 Impact ring spanner AF 85
Maintenance
1132/2.1
Key to illustrations 94111 94117 94118 94119 94141 94931 94934a 94935 94936 1 2 3 4 5 6 7 Main bearing cover Upper bearing shell Crankshaft Holding strap Lower bearing shell Bearing girder Thrust bearing flange
R Eye bolt
Removal of a main bearing cover 1 and of the upper bearing shell 2 Remark: On eight to twelve cylinder engines, first the thrust bearing casing on the driving end must be removed, prior to the dismantling of No. 1 main bearing cover and shell. Depending on number of cylinders and engine design execution the main bearing cover of the outer most main bearing one is fastened by two screws instead of with the jack bolts.
- Turn crankshaft 3 (Fig. 'B') to bring the crank web of the respective bearing to approximately horizontal position. Loosen bearing pressure bolts as described in sheet 1132/1 and remove them, as well as possibly fitted retaining screws to the main bearing cover one. - Mount roller support 94117, as well as suspension device 94111 as shown in Fig. 'A'. - Using one rope and lifting tackle lift main bearing cover 1 by only a few millimeters. Should the upper bearing shell 2 be lifted with the cover, knock the same with a piece of wood or a lead hammer on the bearing collar to separate the shell from the cover. - Lift now bearing cover (without bearing shell) high enough to permit pulling it with a second rope in the engine axis (Fig. 'B'). - Using a second lifting tackle and another rope lift the bearing cover out of the engine. For engines with camshaft drive at the driving end of the engine the instruction for removal of main bearing cover one and two are the same as described above, however in addition the following points have to be observed: D To remove the main bearing cover 1 (Fig. 'D') in the thrust bearing region, holding straps 4 for the thrust pads must not be removed. D Remove piping to thrust bearing lubrication. D The broader main bearing cover can be removed through the opening of cylinder one. D The narrow main bearing cover one has to be removed on exhaust side as shown in Fig. 'D'. For this, the end cover of the gear train has to be removed. The removal of the two types of upper bearing shell 2 are effected the same way as the bearing covers. In order to lift the shell a eye bolt 'R' have to be driven into the threaded hole on the shell crown (Fig. 'C'). Using a rope, a lifting tackle and roller support 94117 lift upper bearing shell 2 and remove it from the engine crankcase. Removal of a lower bearing shell 5 Remarks: Girder 94141 is used specially for the removal of the broader lower bearing shell 5. It has however also to be used for removing the narrow lower bearing shell in the thrust bearing region. For this an addi tional jack can be used outside the engine under the crankshaft flange. When removing lower bearing shell never remove at the same time two neighbouring lower bearing shells.
- For the removal of a lower bearing shell 5 turn the crankshaft to such a position that the lower side of the respec tive crank is parallel to the bedplate, which corresponds to about 106_ before or after T. D.C. (Fig. 'E'). - Place a dial gauge above a crank web near the bearing shell to be removed (if possible dial gauge with magnetic base) and set it to zero.
9.99
1132/2.2
Maintenance
RTA84C
- Mount removal device 94118 on one separating face of the lower bearing shell and screw fasten it with the special Allen wrench in the tool set. - Attach a steel rope to the short hook on removal device 94118 and lead the same outside along the shell collar to the other side and on to roller support 94117. (If necessary two steel ropes on either side of the bearing shell can be applied). - Place girder 94141 on bearing girders 6 of the respective cylinder as shown in Fig. 'E'. - Place hydraulic jacks 94936 on girder 94141 as per Fig. 'E'. Connect jacks to HP oil pump 94931 and build up pressure to lift the crankshaft by the bearing to be removed. Lift the crankshaft max. to the point where the neighbouring main bearings show no vertical clearance any more between main bearing cover and crankshaft. This process is to be checked by means of the dial gauge fitted over the crank web. Keep the pressure at the jacks constant! - By pulling on the steel rope turn bearing shell 5 out. - When the bearing shell lies on the crankshaft journal, remove the steel rope and screw eye bolt 'R' into the threaded holes on the crown of the shell rear surface. Then lift bearing shell 5 and remove it out of the engine by lifting tackle. Fitting a lower bearing shell 5 Before fitting a lower bearing shell 5 smear its rear surface lightly with MOLYKOTE G paste. Smear crankshaft journal and running surface of bearing shell lavishly with clean bearing oil. Check to verify that bearing girder 6 is clean in the bore and undamaged. - Place lower bearing shell with help of eye bolt 'R' and roller support 94117 carefully on the crankshaft journal, i.e. analogous to the removal but in reverse sequence. Make sure that the bearing numbering corresponds with the number on the bearing girder. - Remove eye bolt and lift the crankshaft again as described for the removal, in case it has meanwhile been low ered. - Turn in the bearing shell till the separating faces are equidistant from the upper edge of bedplate (measure this with a depth gauge). - Release pressure on oil pump 94931 and remove all tools out of the engine. Attention! Should a crank web deflection check be made before upper bearing shell and bearing cover 1 are fitted, then care must be taken to prevent the lower shell 5 from turning. Locate the shell temporarily by a wooden piece.
Fitting of upper bearing shell 2 and of bearing cover 1 Fitting of upper bearing shell 2 and of bearing cover 1 is effected in reverse sequence to their removal. Great care must be taken that no dirt is on crankshaft journal and running surface as well as on the rear surface of the bearing shell and bore of bearing cover. Before placing the bearing shell in position smear the crankshaft journal lavishly with bearing oil. The rear surface of the bearing shell and the bore of the bearing cover must be clean and dry and free from oil. For lining up the main bearing cover and for tensioning the bearing bolt, the instructions on sheet 1132/1 must be followed. On engines, the main bearing covers of which are held by two screws at the DRIVING END, these have to be tight ened to an tightening angle of 35 _ and to be locked with a locking plate. Check: After fitting of a main bearing shell the following points must be checked: D Crank deflection (see sheet 3103/1). D Vertical bearing clearance (see Clearance Table 0330/1). D Lubricating oil supplied to the main bearing with the oil pump in operation!
9.99
RTA84C
Maintenance
1132/2.3
94117
94117 94111 1
94111 2 1 2 5 3
94117
94111 1 R 2
96.7000
1989
1132/2.4
Maintenance
RTA84C
96.7001
94111
1989
2
Antriebsseite DRIVING END
RTA84C
94119
94117
94117
94119 94935 94118 94931 5 94935 5 6 3 94934a

96.7002
94118
Maintenance
6 94936 94141 94141 94936
1132/2.5
1989
RTA84C Thrust Bearing Checking the Axial Clearance

Tools: 1 Inside micrometer 1 Feeler gauge 1 Dial gauge with magnetic base 94101 94238
Maintenance
1203/1.1
Key to Illustration: 1 Coupling flange for flywheel 2 Oil catcher 3 End cladding (driving end) 4,4a Holding stirrups AHEAD 5 Thrust flange 6 Crankshaft 7 Thrust bearing pads for ASTERN 7a Thrust bearing pads for f1 Axial clearance X Checking measure
Should the classification society demand measuring of axial clearance of the thrust bearing flange in the thrust bear ing, or should other reasons call for it, this can be done in various ways: Method 1 The total displacement which results from pushing the crankshaft axially both ways until it contacts the thrust bear ing pads AHEAD and ASTERN, is measured with a clock gauge. This is then checked against the figure marked on the sheet 'Checking Dimensions' in the engine documents supplied. A possible increase against the nominal figure signifies wear of the thrust bearing pads. Axial clearances f1 = 0.8 - 1.3 (see clearance table 0330/1) Method 2 The crankshaft is displaced axially until it rests on the engine side thrust bearing pads (AHEAD) and is then fixed in this position. The distance between the flywheel coupling flange and the upper part of the oil catcher is measured with an inside micrometer at the position indicated (see Fig. 'B'). The amount by which the distance 'X' is smaller than that given on the sheet 'Checking Dimensions' corresponds to the wear of the engine side thrust bearing pads (AHEAD). By displacing the crankshaft axially until it rests on the thrust bearing pads for 'Astern', the inside micrometer can be used to determine the total axial clearance as well.
1989
1203/1.2
Maintenance
RTA84C
3 2 5 4a 4 1
Schub THRUST
7a
f1
89.7126
Alle 6000 - 8000 Betriebsstunden ist die Bohrung auf freien Durchgang zu kontrollieren EVERY 6000 - 8000 OPERATING HOURS THE HOLE IS TO BE CHECKED FOR FREE PASSAGE
1989
RTA84C
Maintenance
1203/1.3
B
1 2 3 5 6
96.7003
94101
1989
RTA84C
Maintenance
1224/1.1
Thrust Bearing Removal and Fitting of Thrust Bearing Pads

Tools: 1 Carrier bolt with nut 1 Turningout device 1 Eye bolt M16 94155 for 4-7 cylinders Key to Illustration: 1 Thrust bearing flange 2,2a Thrust bearing pads 3 Split gear wheel on thrust bearing flange 4 Screws 5 Screws with spacer sleeves 6 7 8 9 Casings Retaining clamp Oil pipe Screws
94155a for 8-12 cylinders
S Nut for 94155
Removal Should it become necessary to remove thrust bearing pads, the retaining clamps 7 of the respective row of thrust bearing pads must be removed. To reach these, remove the oil pipes 8 and additionally the two casings 6 for the 4-7 cylinder engines, then the retaining clamps 7 can be removed on the required side (see Fig. 'A' and 'B'). The access to the thrust bearing pads being now freed by the removal of the above mentioned parts, insert the car rier bolt 94155 into the respective drilling of the split gear wheel 3 on the thrust bearing flange and fasten it with the nut 'S' (by only light tightening) in its position (Fig. 'C'). Refer also to the removal alternative according to Fig. 'D' for engines with 8-12 cylinders, in which gear wheel 3 is not fitted to the thrust bearing flange but instead on the crankshaft coupling (midengine). For this removal alterna tive of the thrust pads turningout device 94155a has to be used. It has to be fastened on the circumference of the thrust bearing flange with two screws 9. Therefore, threaded holes are provided. The crankshaft is then to be turned with the turning gear until an eye bolt M16 can be screwed into a pad which can then be lifted up and taken away. Remark: When only a few thrust bearing pads are removed the crankshaft is located in its axial position by the re maining pads. Should however the necessity arise that all thrust bearing pads must be removed then the crankshaft must be prevented from sliding axially from its specific position. This might happen for exam ple if the ship is heavily stern trimmed. (To avoid such shifting, insert a piece of hardwood of the same thickness as the pads in the place of the thrust bearing pads). Fitting Make absolutely sure that all the thrust bearing pads are meticulously clean and smeared with fresh engine oil; the thrust bearing pads must all be replaced in their original position. Note the numbering of the individual pads. Please also refer to the following sheets for the arrangement of thrust bearing pads on engines with fixed pitch propellers (F.P.P.) and controllable pitch propellers (C.P.P.) respectively. Fitting the thrust bearing pads for AHEAD operation should pose no problems, as the crankshaft in a stern trimmed ship rests against the ASTERN thrust bearing pads. For fitting the thrust bearing pads tools 94155 or 94155a respectively can also be utilized. Please note in this 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 end ones on the fuel pump side and on the exhaust side must stand back by the same distance over the upper edge of the bedplate; the retaining clamps 7 can now be refitted. When fitting the thrust bearing pads for ASTERN operation it may possibly be necessary to shift the crankshaft slightly in an axial direction towards the free end. After fitting the thrust bearing pads immediately remove tool 94155 or 94155a respectively. Attention! When fitting new or remetalled thrust bearing pads, care must be taken that their thickness (final dimension) corre sponds exactly with the neighbouring pads. When replacing a complete row of new or remetalled thrust bearing pads the clearance must be adjusted to the original values (as shown in the Clearance Tables 0330/1) by using the inside micrometer tool 94101 as shown on sheet 1203/1.
1989
1224/1.2
Maintenance
Gezeichnet fr 47 Zyl. DRAWN FOR 47 CYL.
RTA84C
3mm
6 4
3mm
2/2a
Gezeichnet fr 812 Zyl. DRAWN FOR 812 Cyl. 8
3mm
3mm 4
89.7066
2/2a
1989
EXHAUST SIDE
Abgasseite
RTA84C
Maintenance
1224/1.3
C
I
II - II
I-I
II
II
2a S 94155 3
I
2
2 94155
D
I
II - II
Gezeichnet fr 812 Zyl. DRAWN FOR 812 Cyl.
I-I
II
II
94155a
2a
I
2
96.7004
94155a
1989
1224/1.4
Maintenance
RTA84C
Anordnung der Drucklagerkltze fr Motoren mit Festpropeller ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH FIXED PITCH PROPELLER
Rechtsdrehender Motor CLOCKWISE ROTATING ENGINE
zurck ASTERN
voraus AHEAD
Auflageflche SUPPORT SURFACE
Antriebseite DRIVING END
Motorseite ENGINE END
96.7005
Propellerschub S PROPELLER THRUST S
von Antriebsseite gesehen Kltze auf Antriebsseite VIEW FROM DRIVING END PADS AT DRIVING END
S voraus S AHEAD
von Antriebsseite gesehen Kltze auf Motorseite VIEW FROM DRIVING END PADS ON ENGINE SIDE
S zurck S ASTERN
Kltze fr Zurck PADS FOR ASTERN
Kltze fr Voraus PADS FOR AHEAD
zurck ASTERN
Linksdrehender Motor COUNTER-CLOCKWISE ROTATING ENGINE
voraus AHEAD
Auflageflche SUPPORT SURFACE 96.7005
1989
RTA84C
Maintenance
1224/1.5
Anordnung der Drucklagerkltze fr Motoren mit Verstellpropeller ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH CONTROLLABLE PITCH PROPELLER
zurck ASTERN
voraus AHEAD
96.7006
S voraus S AHEAD
S zurck S ASTERN
zurck ASTERN
voraus AHEAD
1989
1224/1.6
Maintenance
RTA84C
Anordnung der Drucklagerkltze fr Motoren mit Festpropeller ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH FIXED PITCH PROPELLER
zurck ASTERN
voraus AHEAD
96.7007
S voraus S AHEAD
S zurck S ASTERN
zurck ASTERN
voraus AHEAD
1989
RTA84C
Maintenance
1224/1.7
Anordnung der Drucklagerkltze fr Motoren mit Verstellpropeller ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH CONTROLLABLE PITCH PROPELLER
zurck ASTERN
voraus AHEAD
S voraus S AHEAD
S zurck S ASTERN
zurck ASTERN
voraus AHEAD
1989
RTA84C
Maintenance
1903/1.1
Tie Rods Checking the Tie Rod Pretension and Tensioning the Tie Rods
Tools: 2 1 3 2 1 1 2 1 Pretensioning jacks HP oil pump Pressure gauges Connecting piece Oil branch piece Distributing piece HP hoses HP hose 94180 94931 94932 94933 94934 94934a 94935 94935a 1 2 3 4 5 6 7 8 9 10 11 12 13,13a 14 15 Key to Illustration: Cylinder jacket Intermediate ring Upper tie rod nut Allen screw Jack cylinder base Jack cylinder Jack piston Flange ring Belleville spring stack Screw Vent screw Round bar Tie rod Screw Protection cap 16 17 18 19 20 21 22 23 AN L K S V Y Z Opening for solvent Clamp screw Column Bed plate Oring Lower backing ring Lower tie rod nut Bush Drain slot Thread protrusion Checking slot Measuring place Relief valve Measuring place Checking place
A
94933 11
9 10 8 Z 7 6 94932 94933 94180 94932 5 4 94934a 94931 V 94934 94935a 12 K Gezeichnet fr RT58 DRAWN FOR RT58 S 13 94935 94932
Y 2 1
96.7033
We recommend that about one year after commissioning the engine all the tie rod are checked for their correct pretensioning and if necessary to tension them to the specified value. Later it is sufficient to make random checks during major overhauls. For such checks it is n o t required to loosen the thrust bolts of the crankshaft main bearings nor the clamp screws of the tie rods.
1989
1903/1.2
Checking the pretension of tie rods Procedure:
Maintenance
RTA84C
Remove the threadprotecting hoods 15 from all tie rods and clean the contact face of the intermediate ring 2. Screw both pretensioning jacks onto two tie rods lying opposite each other until the lower part of the cylinder 5 rests on the intermediate ring 2. If necessary, turn the whole pretensioning jack back a little so that the holes in the tie rod nuts are easily accessible. Slightly slacken vent screws 11. Connect both pretensioning jacks with hoses to the highpressure oil pump and operate pump until any air present in the pretensioning jacks has escaped; then retighten vent screws. Operate pump up to 600 bar and maintain this pressure. Using a feeler gauge inserted through the checking slot 'K', check at 'S' if there is any clearance between the tie rod nut 3 and the intermediate ring 2. If any clearance does exist, tighten the tie rod nut with tommy bar 12 until it rests firmly on the intermediate ring (check with feeler gauge) and then release the pressure. If no clearance exists, the pressure can immediately be released and the pretensioning jacks removed. All the tie rods have to be checked in this manner and, wherever necessary, the tie rod nut has to be tightened. After checking has been completed, the tie rod threads have to be protected against corrosion by coating them with nonacidic grease. Afterwards, the protecting hoods must be screwed on tightly. Remark: If it is impossible to tighten the tie rod nut with the round bar although there is clearance at 'S', this means that the thread is blocked/seized. In this case remove screw plug in bore 16 and press in some releasing agent or lubricant. Insert a strong brass or copper bar into a hole in the tie rod nut through the slotted orifice in the lower part of the cylinder 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 pretensioning jack. Seal off the bore 16 again with the screw plug.
After completion of the checks, the pretensioning tools have to be preserved and the connections blanked off. Thereafter they are to be stored in a safe place. Loosening and tightening the tie rods Should, for some reason or other, tie rods have to be removed, the following points have to be carefully observed: Tie rods may only be loosened or tensioned when the thrust bolts of the main bearing have been previously loosened (see sheet 1132/1). The clamping screws 17 must also be removed. Loosening and tensioning has to be carried out in two steps. The order in which the tie rods are to be loosened or tensioned is shown in schematic illustration (Fig. 'D'), i.e. in pairs, first tie rods a/a, then b/b, etc. Loosening The procedure for loosening the tie rods is the same as the one described above for checking pretension, except that after being screwed down onto the intermediate ring (2) the pretensioning jacks must be released again by 3/4 turns so that a measurable clearance of 4.5 mm is achieved at 'Y'. At this starting point connect the jacks to the highpres sure pump with the hoses and operate the pump until a pressure of 600-620 bar is reached. The tie rod nuts are now loose and can be unscrewed with the round bar 12 until they touch the pretensioning jack cylinders. Before releasing the hydraulic pressure to zero, it is of great advantage to place a hardwood wedge under the lower tie rod nut in the bed plate, whereby the wedge will take the full weight of the tie rod. The pretensioning jacks can now be removed.
1989
RTA84C
Tensioning Preliminary work: Clamping screws 17 must not be tightened up. The lower nut 22 of the tie rod is screwed on.
Maintenance
1903/1.3
Clean the seating surface for backing ring 2 and the upper nut 3 and smear with MOLYKOTE paste G. Smear the tie rod thread for the upper nut 3 lavishly with MOLYKOTE paste G and screw the nut on (check for easy threading). Screw ring screw into the tie rod and lift carefully till the lower tie rod nut rests snugly against the bearing girder. (The safest way is to use a lifting tackle hooked onto the crane, with which the tie rod can be lifted till the lower nut is snug on its seating, as with the crane the landing of the nut cannot easily be felt and the rope might break.). In this position tighten the upper tie rod nut with the round bar 12 till firmly seated on the backing ring, separate lifting tackle from tie rod and remove ring screw. (Between bearing girder and lower tie rod nut there must now be no clearance and the lower tie rod nut must e flush with the tie rod end). Working sequence for tensioning All points of the preliminaries completed, measure on all tie rods the distance 'L ' and record them (see Fig. 'C'). Set pretensioning jacks on the two tie rods a/a, so that the jackcylinder base 5 comes to rest on the backing ring 2 (arrange base 5 for easy access to tightening window for nut!) Join pretensioning jacks by hphoses to hpoil pump. Loosen vent screw 11 on pretensioning jacks a little and actuate oil pump till oil flows out bubblefree, then tighten vent screw. Verify that no play or only very little play remains at 'Z' (Fig. 'A'). If necessary open relief valve 'V' on the pump to drain the oil back into the pump, then screw the jack piston 7 sufficiently down onto the tie rod until the clearance at 'Z' is eliminated. This is very important, as otherwise the required pretensioning pressure will not be attained. Actuate the hppump and raise a pressure of 350 bar (lst stage), keep pressure constant till the two upper tie rod nuts 3 have been tightened down with the round bar 12 firmly. Then open relief valve 'V' on the pump to lower the pressure to zero and no clearance remains at 'Z'. In this manner tension all the tie rods in the sequence described before and measure on all the distance 'L ' and re cord them as 'L1' (reference value 'L1' - 'L ' = about 6.0 mm for the short tie rods = about 7.5 mm for the long tie rods) Repeat the same procedure, but raise the pressure to 600 bar (2nd stage). Finally measure again the distance 'L ' and record them as 'L2'. The tie rods are correctly tensioned when on a pres sure of 600 bar a total elongation of n L = 10.0 mm on the short tie rods n L = 12.5 mm on the long tie rods is attained ('L2' - 'L '). After completing the tensioning, smear the protruding thread portion of all the tie rods lavishly with acid free grease and fit the protection caps 15. All the clamp screws 17 must be firmly tightened! Follow the Remark at the end of 'Checking the pretension of tie rods'!
1989
1903/1.4
Maintenance
RTA84C
IV
14
III - III IV
1 17
15
16 3
23 2
II
18 18
13 1
13
13a
II
III III
19 AN 13 23 1 17
19 20 21 22
96.7034
96.7034
Hier bndig FLUSH
1989
RTA84C
Maintenance
1903/1.5
13
13a
Antriebsseite DRIVING END
1989
RTA96C
Betrieb
Group2
Cylinder Liner and Cylinder Cover
Group 2
Cylinder Liner
Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124/1 Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124/2 Removing Wear Ridge, Re-dressing Lubricating Grooves, and Edges . . . . . . . . . . . . . . . . . . . 2124/3 of the Scavenge Ports
Lubricating Quills and Accumulators (Multi-level Lubrication)

Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2136/1
Piston Rod Gland

Dismantling and Assembling as well as Measuring the Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 2303/1
Cylinder Cover
Removing and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708/1 Hydraulic Loosening and Tensioning of Cylinder Cover Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708/2 Mechanical Loosening and Tightening of Cylinder Cover Studs . . . . . . . . . . . . . . . . . . . . . . . . . 2708/3 Manual Overhaul of Sealing Face for the Injection Valve in the Cylinder Cover . . . . . . . . . . . . 2708/4
Fuel Injection Valve

Checking, Dismantling, Assembling and Setting (with LORANGE Test Stand) . . . . . . . . . . . . 2722/1 Checking, Dismantling, Assembling and Setting (with O.M.T. Test Bench) . . . . . . . . . . . . . . . . 2722/1 Cleaning and Overhauling of Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722/2 Lapping of Nozzle Holder Contact Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722/3
Starting Valve
Removing, Fitting and Dismantling, Grinding-in and Assembling . . . . . . . . . . . . . . . . . . . . . . . . 2728/1
Relief Valve for Cylinder Cover

Dismantling, Assembling and Testing (with LORANGE Test Stand) . . . . . . . . . . . . . . . . . . . . . . 2740/1 Dismantling, Assembling and Testing (with O.M.T. Test Bench) . . . . . . . . . . . . . . . . . . . . . . . . . . 2740/1
Exhaust Valve
Removal and Fitting of the Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751/1 Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751/2 Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751/3 Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751/4
RTA84C / MM / 2001
RTA84C Cylinder Liner Measuring Bore Wear

Tools: 1 Inside micrometer 1 Ladder 1 Measuring gauge 94101 94224 94225
Maintenance
2124/1.1
Key to Illustrations: 1 Cylinder liner S Setting screws 'S'
Whenever a working piston is removed for overhaul, the cylin der liner bore has also to be measured. The figures found are to be recorded so that they can serve as comparison with earlier or later measurements. In this way, normal wear can be determined and followed. Comparisons with other mea surements can, however, only be made if the measurements are always taken at the same place. For this reason, use the measur ing gauge 94225 which is part of the tool kit. The measurements have to be taken in both longitudinal and transversal directions to the en gine axis by putting the inside micrometer 94101 into the holes especially provided for this pur pose in the measuring gauge. The ridge formed during the course of operation at the top of the cylinder bore has to be re moved carefully without dam aging the running surface for the piston rings. Should the thickness of the com pression shims be altered after putting the engine into opera tion, then on measuring gauge 94225 the length of the setting screw 'S' has to be adjusted accordingly. By this the measur ing bores of the gauge 94225 are again brought to the original setting relative to the position of the piston.
94225 1
94101
94.7275
10.94
RTA84C Cylinder Liner Removal and Fitting

Tools: 1 1 2 2 4 1 1 1 1 2 2 Suspension bridge beam Supporting beam Suspension straps Screws to 94206 Suspension straps HP oil pump Pressure gauge Connection piece HP hose HP hoses Hydr. jacks 94202 94203 94206 94207 94208 94931 94932 94934a 94935 94935a 94936
Maintenance
2124/2.1
Key to Illustration: 1 2 3 4 5 5a 6 7 8 9 10 Clamp Holder Centring pin Centring pin Cylinder cover waisted stud Nut Allen screw Cylinder cover Water guide jacket Cylinder jacket Cylinder liner 11 12 13 14 15 16 17 Supporting ring Round rubber ring Round rubber ring Antipolishing ring Screw Filling piece Waisted bolt
AF Seating surface H Wooden underlay
Preparations for the removal of a cylinder liner Drain cylinder cooling water from the respective cylinder, and remove cylinder cover (see sheet 2708/1). Remove piston together with piston rod gland (see sheets 3403/1 and 2303/1). Remove the two screws 15 which locates cylinder liner 10 on support ring 11 (see Fig. 'C').
If a SIPWA transmitter is provided remove it from the cylinder liner. Separate all cylinder lubricating oil connections from the lubricating quills. Remove all passages for lubricat ing quills as well as their protecting bushes (see sheet 2136/1) before pulling out any cylinder liner.
If cylinder liner 10 has to be pulled out together with support ring 11 then Allen screws 6 must be loosened and removed instead of screws 15. The passages for lubricating quills and their protection sleeves do not have to be re moved for this work provided the support ring does not have to be separated from the cylinder liner. Removal (Fig. 'B') Working procedure: Lower supporting beam 94203 of the dismantling device, suspended on the crane, through the bore of the cyl inder liner and place it on the piston rod gland seating of the cylinder jacket in longitudinal direction of the engine. Put both hydr. jacks 94936 onto the supporting beam 94203 and position these below the cylinder liner. Connect hydr. jacks by HP hoses 94935 and 94935a as well as connection piece 94934a to the HP oil pump 94931. Jack cylinder liner 10 out of its guide portion. Mount suspension bridge beam 94202 and screw fasten it together with the suspension straps 94206 and screws 94207. Pull cylinder liner fully out by the crane. Remove hydr. jacks and supporting beam 94203.
Preparations for the fitting Clean all guide areas and sealing surfaces on cylinder liner 10, cylinder jacket 9 and supporting ring 11. Place round rubber rings 12 of the specified quality and dimension, into the grooves on the cylinder liner. Smear round rubber rings and guide areas of cylinder liner and of cylinder jacket with lubricating oil. Clean seating surfaces 'AF' of supporting ring 11 and of cylinder liner 10 carefully. UG / 4.01
2124/2.2
Fitting -
Maintenance
RTA84C
Fit suspension bridge beam 94202 to the cylinder liner, as used for the removal (see Fig. 'B'). Move the cylinder liner hanging on the crane over the supporting ring 11. Apply a nonhardening sealing compound (e.g. silicone) to the seating surface 'AF' on supporting ring 11 and to the collar of the cylinder liner 10. Lower cylinder liner while guiding centring pin 3 (Fig. 'C') into the centring hole in supporting ring 11. Place a cylinder cover 7 on cylinder liner 10, and fit four nuts 5a of cylinder cover waisted studs 5 equally spaced. Tighten nuts alternately to press the cylinder liner firmly onto the supporting ring (Fig. 'D'). After removing the cylinder cover refit and firmly tighten screws 15 for locking the cylinder liner on the support ring (Fig. 'C'). The waisted bolts 17 for the filling piece 16 (Fig. 'C') must be pretightened to 5 Nm, and subsequently tightened with an angle of 15_.
Remark:
Removal and fitting of the antipolishing ring Depending on design of the cylinder liner an antipolishing ring 18 (Fig. 'E') may be provided at the top of the collar. Four suspension straps 94208 are fitted for removing and fitting the antipolishing ring as shown in Fig. 'A'. The latter can be lifted with the aid of wire ropes which are attached to the suspension straps and connected to the crane. Before fitting, clean the seating surfaces on the antipolishing ring as well as the cylinder liner, and smear the antipol ishing ring lightly with oil. Further pay attention that one of the holes for fastening the suspension straps lies on fuel side.
94208
14
10
00.7364
4.01 / UG
RTA84C
Maintenance
2124/2.3
B
94202
94206
94207
10
I
94935
I
94936
94203
00.7684
I-I
94935a 94932
94936 94203
94935
94931
94934a 94935a 94936
UG / 4.01
2124/2.4
Maintenance
RTA84C
I-I III
8 3 2 10 11 2 11 10 7 8 13 3
15
II I II
III
II - II IV
8 15 1 10 11 1 11 10 AF 11 11 6 10 7 8 15 15 Abgasseite EXHAUST SIDE 6
IV
4 9 9
Befestigung des Aufsatzringes FASTENING OF SUPPORTING RING
12
17
16
90.7039
4.01 / UG
RTA84C
Maintenance
2124/2.5
Putting upright or laying down a cylinder liner (Fig. 'E') The suspension bridge beam 94202 is fitted to the cylinder liner and suspended to the crane hook according to Fig. 'E'. The cylinder liner can now be put upright or laid down with the aid of the crane. Attention! Putting upright or laying down must only be carried out in longitudinal direction of the suspension bridge beam as shown in Fig. 'E'! The supporting ring 11 (Fig. 'E') is fastened with three Allen screws 6 to the cylinder jacket 9 and lo cated on the fuel side by centring pin 4. For the removal of the supporting ring the three Allen screws 6 can be used as jacking screws. Prior to refitting the supporting ring, the sealing surfaces on the sup porting ring and on the cylinder jacket must be carefully cleaned. For refitting the sealing surfaces are to be smeared with a nonhardening sealing compound (e.g. silicone).
Remark:
D
5a 7
E
94202 94206 94207 10 AF 5
H 5a 7 9
87.7040
90.7043
UG / 4.01
RTA84C
Maintenance
2124/3.1
Cylinder Liner Removing the Wear Ridge, Redressing the Lubricating Grooves, as well as the Edges of the Scavenge Ports
Tools: 1 Wear ridge grinding device Emery cloth Assorted files Fine grain carborundum 94299 Key to Illustrations: 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
G Lubricating grooves K Check bore P Scavenge port
Due to wear by the piston movement in the cylinder liner running surface ridges are formed on top and bottom to where the piston does not reach. Due to the wear the lubricating grooves in the cylinder liner lose their depth, fur thermore the corner radii of the scavenge port edges become smaller and thereby sharper. It also happens that the edges get damaged. When a piston is removed the opportunity should be taken to measure the bore of the cylinder liner (see sheet 2124/1) and to remedy any irregularities which occurred. The following points are of particular importance: Protect the space below the cylinder liner from falling particles with suitable material. After completing the reconditioning clean the bore of the cylinder liner thoroughly and remove any trace of metal dust (particularly from the lubricating grooves). Carefully remove waste particles which may have passed into the scavenge space through the ports. Actuate the cylinder lubrication until oil flows from all the lubricating points, thereby flushing any metal dust which accumulated there. Removing the wear ridge When grinding away the wear ridge take greatest care not to damage the running surface within the area covered by the piston and piston ring stroke from T.D.C. to B.D.C. The machining of the wear ridge has to be carried out as shown in Fig. 'B'. We therefore recommend using a wear ridge grinding device (Fig. 'B') for carrying out this work. It is listed in the tools list under 'Recommended Special Tools'. Redressing the lubricating grooves If the depth of the lubricating grooves has worn to less than 1.5 mm (new depth 2.5 mm) redress them to their origi nal depth and slightly chamfer their edges with an oil stone or similar. The execution type of the cylinder liner is either equipped with one or two rows of lubricating grooves. Redressing the edges on the scavenge ports The shape of the scavenge ports shown in Fig. 'A' corresponds to new cylinder liners. If the condition of the edges requires reconditioning (depending on the degree of wear or damage) aim at matching these shapes. Take great care not to damage the running surface in the cylinder liner bore. Polish the passages into the running surface with emery cloth.
10.94
2124/3.2
Maintenance
RTA84C
Brennstoffpumpenseite
Kanten gebrochen FUEL PUMP SIDE SHARP EDGES REMOVED
II
I-I
II
94.7068
10.94
RTA84C
Maintenance
2124/3.3
94299
10
11
3 2
TDC 2-3mm 6 1mm
12 4
11
93.7460
10.94
RTA84C
Maintenance
2136/1.1
Lubricating Quills and Accumulators (Multilevel Lubrication) Function Check

Key to Illustrations: 1 2 3 4 5 6 7 8 9 10 11 Accumulator cylinder Spring Accumulator piston Cap nut Diaphragm Accumulator casing Cap nut Backing screw Copper sealing rings Cylinder liner Lubricating quill 12 13 14 15 16 17 18 19 20 21 22 'DF' Passage for lubricating quill Filling pin Steel ball Nonreturn valve housing Flange ring Screw Support ring Flange Joint Protecting bush Oring Sealing face
When pulling a working piston, the cylinder lubrication system should also be checked for correct functioning. The function check must also be carried out in case of malfunctioning of the cylinder lubrication. Turn the crank of the respective cylinder lubricating pump until oil emerges from all the lubricating points in the bore of the cylinder liner. Note that on cylinder liners with two rows of lubricating grooves (multilevel lubrication) the oil delivery for upper and lower row of lubricating grooves may be differently set on the lubricator (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 quantity outflow is equal Should deliveries differ, check on the cylinder lubricating pump the setting screw pertaining to the respective lubri cating point, in relation to the others setting screws of the respective row. Use the occasion to check at random several accumulators. Open them to inspect the diaphragm 5. If oil is found in the inner space of the accumulator piston 3 or in cylinder 1, the diaphragm is leaking or brittle and must be replaced by a new one. New diaphragms are supplied in special plastic boxes, ready for fitting. Fit the diaphragm with greatest care so as not to damage it. If a nonreturn valve has to be replaced, remove first the backing screw 8 after which the valve can be pulled out together with the filling pin 12 which is joined to it. Nonreturn valves are only supplied complete with filling pin as replacement parts. After fitting the new valve tighten the backing screw 8 moderately and lock it with a centre punch. Before removing a cylinder liner 10, the passages for lubricating quills 12 and the protecting bushes 21 must be first disconnected. If only the passage for lubricating quill 12 has to be removed, with cylinder liner 10 fitted, then the protecting bush 21 can remain in place. When refitting the passage for lubricating quill make sure that the sealing surface 'DF' between cylinder liner 10 and passage for lubricating quill 12 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.
1990
2136/1.2
Maintenance
RTA84C
10
18

90.7016
20 19 16 5

12
1 2 3 4
DF
22
21
13
17 11 15 9 14
1990
RTA84C
Maintenance
2303/1.1
Piston Rod Gland Dismantling and Assembling as well as Measuring the Wear
Tools: 1 1 1 2 2 4 1 Distance pipe (2part) Taper ring (2part) Clamp ring (2part) Templates Fitting tools Distance pieces Piston supporting device 94345 94345a 94345b 94345c 94345e 94345f 94350 Key to Illustrations: 1 2 3 4 4a 5 6 7 8 9 10 11 Housing, 2part Upper housing Scraper ring Sealing ring Sealing ring Sealing ring Oil scraper ring Scraper ring Screws Sealing segment Piston rod Screw 12 13 14 15 16 17 18 19 20 21 22 Tension spring Tension spring Screw Cover Cylinder jacket (block) Oring Locating pin Locating pin Sealing ring Fixing plate Locating pin
To remove the gland box, screw the distance pipe (2part) 94345 onto the foot of piston rod 10 (Fig. 'A'). Loosen the four screws 11 (Fig. 'B') after which the gland box can be removed, including the piston (refer also to sheet 3403/1, Removal of a Working Piston). At every piston overhaul, the piston rod gland must also be dismantled and inspected. Excessively worn or damaged parts are to be replaced. It is important that a piston rod gland is in perfect condition when it is assembled, as an earlier than planned inspec tion also necessitates the removal of cylinder head and working piston. The gland is dismantled after the working piston has been pulled out and placed into its supporting device 94350 arranged on the upper platform.
1 94345
10
98.7262
Dismantling a gland Fix working piston in the piston supporting device 94350. For this the split housing 1 of the gland must rest on the two covers 15 of the device. Loosen screws 8 (two fitted screws and two standard screws each), and remove the upper housing 2 (Fig. 'B' and 'C'). Remove tension spring 12 to the scraper rings 3 and the sealing rings 4, 4a by means of fitting tool 94345e (see Tool List 9405/1). Remove the four screws 14 (two fitted screws and two standard screws each) with their locking plates to the 2part housing 1. Push the two gland housing halves 1 away from the piston rod. 9.99
2303/1.2
-
Maintenance
RTA84C
Remove tension springs 13 as well as the sealing rings 5 with the sealing segments 9, and the scraper rings 6, 7. Determine the wear on the following parts: Upper gland group . . . . . . . . . . . . . . . . . . . . . . Scraper rings 3 Sealing ring 4, 4a (4part) (4part)
Lower gland group . . . . . . . . . . . . . . . . . . . . . . Sealing rings 5 (3part) Oil scraper rings 6 (3part) Scraper ring 7 (3part) The admissible wear on the wear parts is indicated in clearance table sheet 0330/4. Such parts which are beyond the admissible tolerance must be replaced. Wear parts approaching the tolerance limit should be replaced in doubtful cases, as they cannot be checked again before the next piston overhaul. The tension spring 12 and 13 as well as the Orings 17 must be replaced as well when they are no longer in perfect condition.
Assembling a gland (see Fig. 'D' and 'E') Fix working piston in the piston supporting device 94350. 2piece clamp ring 94345b and taper ring 94345a can be used for better fitting of tension springs 13 to the lower gland group. Place oil scraper ring 6 between clamp ring and taper ring. Fit tension spring 13 onto taper ring 94345a. The tension spring can now easily be pushed over the taper part of the device into the groove in the oil scraper ring. In the same way fit all oil scraper rings 6. Pay attention that their designations TOP point upwards, and the locating pin 18 of a segment fits into the corresponding upper segment. For fitting of the two sealing rings 5 proceed as mentioned above, whereby sealing segments 9 must be addi tionally fitted. Remove clamp ring 94345b and taper ring 94345a from the piston rod. Fit scraper ring 7 with spring 13. Place the two templates 94345c on the covers 15 of the piston supporting device and use them to adjust the scraper ring as well as the oil scraper rings and the sealing ring pair, so that each group is in place at the height of its allotted ring groove in the 2part housing 1. Smear piston rod as well as all rings with bearing oil. Then push both housing halves on the covers 15 over the ring packs against the piston rod, then screw them together with screws 14 (two fitted screws and two standard screws each) and lock these. Place two distance pieces 94345f (8 mm thick) on the 2part housing 1 as shown in Fig. 'C'. Place the sealing rings 4 and 4a with their designations TOP pointing upwards on the distance pieces. Pay attention to the radial locating pins 19! Fit scraper rings 3. Pay attention to the locating pins 18 and designation TOP. Fit tension spring 12 by means of fitting tool 94345e (see Tool List 9403/5). Fit two distance pieces 94345f (9 mm thick) as shown in Fig. 'C' and install the two uppermost scraper ring pairs 3 in the same way as mentioned above. After fitting of the tension spring remove all distance pieces 94345f required for positioning. Smear piston rod and rings lavishly with bearing oil. Screw up the upper housing 2 using the four screws 2 (two fitted screws and two standard screws each). Check the upper housing 2 for free moveability. Just before the gland is fitted with the working piston, smear the respective centering portions in the cylinder jacket as well as on the gland casing in the Oring 17 region with lubricating oil. When fitting the gland into the cylinder jacket the spacer tube 94345 must be mounted on the foot of the piston rod as shown on Fig. 'A'. The locating pin 22 (Fig. 'B') must mate with the corresponding bore in the twopart casing 1. Fit upper scraper ring 2 with tension spring 7. Tighten and lock screws 11. 9.99
After assembling of the lower gland group, the upper gland housing has to be assembled as follows: -
RTA84C
Maintenance
2303/1.3
B
2
obere Hlfte UPPER HALF
I-I
II
12 3 4 4a 5 1 11 20 16
II
17
untere Hlfte LOWER HALF
6 7
21 22
10
13
II - II
11
Brennstoffpumpenseite FUEL PUMP SIDE
14
98.7453
8
8.98
2303/1.4
Maintenance
RTA84C
C
94345f 3
9 mm
18 3 19 3 18 4 4a 9 5 2
12 1 94345f 11
18
6 18
6 18
6 18 7
8 mm
20
98.7449
13
21
9.99
RTA84C
Maintenance
2303/1.5
D
94350 94345a 13 15
94345b
10
94345c 15
10 94345
93.7012
8.98
RTA84C Cylinder Cover Removing and Fitting

Tools: 1 1 2 3 Hydr. pretensioning jack Suspension device Spec. eye screws Protection caps 94215 94265 94265a 94265b 1 2 2a 3 4 5 5a 6
Maintenance
2708/1.1
Key to Illustration: Cylinder cover Nut Cylinder cover stud Cyl. cooling water outlet Leak oil outlet Exhaust valve cage Stud of exhaust valve cage Connection for valve shank lubrication 10 S 6 12 7 8 9 10 11 12 13 Fuel injection valve Starting valve Connection for hydr. oil Indicator valve Relief valve Air inlet for valve spring Water guide jacket
R Eye bolt S Lifting screw
2a
8 Brennstoffpumpenseite FUEL PUMP SIDE Abgasseite EXHAUST SIDE
1 3
7 4
94.7293
9 Removal
11
Drain the cylinder cooling water from the affected cylinder, i.e. first shut the two valves for cylinder cooling water inlet and outlet and then open the drain valve which is located directly behind the cooling water inlet valve at the bottom of the cylinder jacket on the fuel pump side. The cooling water outlet valve is on the top above the exhaust valve cage. Then open the vent valve in the cylinder cooling water outlet pipe of the respective cylinder! - Disconnect all the pipes to the cylinder cover and to the exhaust valve. - Clean all the thread protrusions on the cylinder cover studs. - Loosen and remove the nuts of the cylinder cover studs in accordance with the instructions on sheet 2708/2. - Screw the spec. eye screws 94265a to suspension device 94265 onto the studs 5a of the exhaust valve cage. Insert the two hooks of the suspension device into the spec. eye screws. - Lift the cylinder cover 1 and water guide jacket 13 together with the crane (see Fig 'C'). Attention! For dismantling and fitting, as well as for transportation of the cylinder cover, with installed valve cage, the eye bolts 'R' may not be used. For this purpose, tools, as shown in Fig 'C' must be utilized.
Alternative: (see Fig 'B') Removing and transporting the cylinder cover is the same after the exhaust valve cage 5 has already been removed. For the transport of a cylinder cover the three suspension screw 'S' on Fig 'A' should be used. They are fitted with LOCTITE in the cylinder cover and therefore locked.
UG
1994
2708/1.2
Maintenance
RTA84C
Fitting Before placing the cylinder cover in position the following points must be taken care of: The compression space must be absolutely free of foreign particles or dirt. The seating surfaces on cylinder cover and cylinder liner must be clean and undamaged. A new soft iron joint ring 2 mm thick must be placed on the cylinder liner in such a way that it lies flat all over. The inner surface of the water guide jacket 13, screwed onto the cylinder cover, as well as the corresponding guide portion on the collar of the cylinder liner must be clean and smeared with clean bearing oil. The grooves in the cylinder liner must be equipped with new rubber rings of specified size and quality, they have also to be oil smeared. The threads of the cylinder cover studs must be clean and smeared with MOLYKOTE paste. Place three protection caps 94265b on cylinder cover waisted studs 2a (see Fig 'C'). When these conditions are all met, lower the cylinder cover, attached to the suspension device 94265, slowly over the cylinder cover studs, the correct position being provided by the guide pin (see sheet 2124/2). After the removal of the suspension device screw all the nuts by hand onto the cylinder cover studs, pay attention to easy turning. If necessary the stud thread may have to be reconditioned, so that the nuts can be screwed on by hand without spanner. Pretension the studs with the hydraulic pretensioning device 94215 in accordance with sheet 2708/2 then fit all pipes to cylinder cover and exhaust valve. Finally shut drain and vent cock, and open the cocks for cooling water inlet and outlet.
B
94265
94265a
94265a 5a
5a 5
1 13 94265b 2a
96.7037
1989
RTA84C
Maintenance
2708/2.1
Cylinder Cover Hydraulic Loosening and Tensioning of Cylinder Cover Studs

Tools: 1 Hydr. tensioning device consisting of: 2 Device halves each with four pretensioning jacks HP hoses Compr. air hose Suspension device 1 Air hydraulic oil pump 94215 Key to Illustrations: 1 Cylinder cover stud 2 Stud nut 3 Vent screw 4 Piston 5 Round nut 6 Flow control valve 7 Pressure limiting valve 8 Pressure gauge 9 Cylinder 10 Distributor 11a, b Support and Oring 12a, b Support and Oring 13 Connecting piece to HP hose 14 Connecting piece 15 Ball 16 17 18 19 20 21 22 Sleeve Coupling Screw Lower spring pack Screw Cover Connecting halve
94215a 94215c 94215d 94215e 94941
R Round bar W Emplacement for round nuts 5 when not in use S Emplacement for round bars 'R' when not in use X Distance about 7 mm
Remark:
The instructions on sheet 9403/4 concerning the application of the hydraulic pretensioning jacks for screwed fastenings must be followed. Should a cylinder cover stud have to be replaced, please observe the indication on sheet 2751/1.
1) Preparations for loosening or tensioning D Clean the threads of all cylinder cover studs 1 (Fig. 'C') as well as the area around stud nuts 2. D Mount two device halves of the hydraulic pretensioning device 94215 over the cylinder cover studs and rest them on the cylinder cover (arrangement according to Fig. 'A'). D Open the air vent screw 3 of each tensioning jack so that their pistons 4 can automatically take up their starting positions and that the air can escape when starting to pump. D Screw the round nuts 5, one nut to each pretensioning jack (which hang on hooks 'W' when not in use) onto the cylinder cover studs till seated on the piston 4. The round nuts 5 must only be slackened afterwards by about 1 turn for loosening. D Check that the dimension 'X' at each tensioning jack is about 7 mm, i.e. they are in the correct initial position. D Connect the two device halves by HP hoses to the airhydraulic pump (called pump for short) as shown in Fig. 'A'. D Verify the oil level in the pump. The pump may not be startedup when insufficient or no oil is present in the container. D Connect pump by compressed air hose 94215d to compressed air system (7bar). For operating the air motor only clean slightly oily air must be used. 2) Hydraulic loosening After completing all preparations as per section 1) proceed as follows: - Move hand lever of flow control valve 6 to position open for oil supply to the jacks. - Turn knob of pressure limiting valve 7 till the stop in direction of arrow '-' (minus). - Open air supply, which starts the pump. - Close vent screws 3 on the jacks as soon as oil flows bubblefree. - Slowly turn pressure limiting valve 7 in direction of arrow '+' (plus) until a pressure of 620 bar is indicated on the pressure gauge 8. - Turn all the cylinder cover nuts upwards till they contact the cylinder 9, using round bar 'R'. Store round bar 'R' at 'S' while not in use (see Fig. 'A'). - Release pressure to zero by moving hand lever of flow control valve 6. Assist lowering of pistons 4 by lightly moving round nuts 5 with the round bar.
9.99
2708/2.2
- Stop air supply; Pump stops.
Maintenance
RTA84C
- Disconnect all HP hoses between pretensioning jacks and pump. - Unscrew round nuts 5 from cylinder cover studs and deposit them on hook 'W' (see Fig. 'A'). 3) Hydraulic tensioning Preparations: In addition to the steps described in section 1) arrange for the following: D Smear threads and seating surface of stud nuts 2 with MOLYKOTE paste G. D Prior to mounting the tensioning device, tighten all stud nuts down with the round bar till fully seated (check with feeler gauge). D Mark position of all stud nuts, with a line on nuts and cylinder cover with a felttip pen (this will serve for a later check).
Tensioning - Move hand lever of flow control valve 6 to position open for oil supply to the jacks. Turn knob of pressure limit ing valve 7 till the stop in direction of arrow '-' (minus). - Open air supply, which starts the pump. - Shut vent screws 3 on the jacks as soon as oil flows bubble free. - Slowly turn pressure limiting valve 7 in direction of arrow '+' (plus), until a pressure of 600 bar is indicated on pressure gauge 8. - While keeping this pressure constant tighten all stud nuts with round bar 'R' till fully seated on the cylinder cover (check seating with feeler gauge), verify while tightening that all stud nuts can be turned by about the same angle i.e. about 330_. - Where it is found that a stud nut can only be turned considerably less than the others, it must be assumed that the respective cylinder cover stud has become insufficiently tensioned. This can occur if support and Orings 11a, b and 12a, b (Fig. 'B') of a hydr. jack are defective or if a piston 4 has been jammed. A further possibility is an incorrect connection between connecting piece 13 of HP hose and connecting piece 14 (Fig. 'C'). In this case the non return valves 15 (balls) do not open or open only partly, in which case the oil supply to the respective jack is restricted. For this reason the sleeves 16 of the connecting piece 14 must always be fully tightened. If necessary the whole tensioning procedure must be repeated after the cylinder cover studs have again been loosened. - When all stud nuts have been tightened by practically the same angle, release the oil pressure to zero by turning the hand lever of the flow control valve 6. Assist lowering of pistons 4 by lightly moving round nuts 5 with the round bar. - Stop air supply; Pump stops. - Unscrew round nuts 5 from the cylinder cover studs and deposit them on hook 'W' (see Fig. 'A'). - Verify by the previously applied marks that all stud nuts have been turned equally by an angle of about 330_. - When this is confirmed loosen hose connections between pump and tensioning device and remove them. Close open hose couplings with dust caps. Lift device by crane and store away. 4) Overhauling the hydraulic pretensioning jacks In the event of the support and Orings 11a, b or 12a, b having to be replaced, proceed as follows: - Slacken off bolts 18 and remove them together with the lower spring packs 19. - Slacken off and remove screws 20. Slacken off vent screw 3. - Lift the cover 21 off the piston 4. - Pull the piston 4 out of the cylinder using two eye bolts. Assembly of a pretensioning jack is carried out in reverse order from dismantling it. All the parts have to be coated with clean oil before assembly. When fitting the support and Orings 11a, b and 12a, b resp., care has to be taken to ensure that their support rings are not over stressed (deformed). It is recommended to soak the support ring in boiling water before fitting so that it is considerably more pliable. 9.99
RTA84C
Maintenance
2708/2.3
A
94215e
R 94215c
22
94215a 94215d 94941 94215c
S 20
10
Brennstoffseite FUEL SIDE
99.7486
9.99
2708/2.4
Maintenance
RTA84C
21
12a,b
11a,b 9
18
19
13
93.7170
15
I-I
2 16 15 14 17
93.7171
9.99
RTA84C
Maintenance
2708/3.1
Cylinder Cover Mechanical Loosening and Tightening of Cylinder Cover Studs (Exceptional Case)
Tools: 1 Pneumatic impact wrench with socket spanner insert 1 Closed impact wrench Attention! Never loosen all adjacent nuts simply one after another, or tighten either in this way, but always only diagonally across and in small steps as described hereafter. Nonobservance of this strict requirement can lead to the cylinder cover being damaged. Whenever possible loosen or tighten cylinder cover stud nuts always by pretensioning the studs with the hydraulic pretensioning device, so that any possible inequality in the stress of each stud is prevented, as such can bring about warping of the cylinder cover. Only in cases where the hydr. pretensioning device cannot be used may the cylinder cover stud nuts be loosened/ tightened by mechanical means, strictly then, in accordance with the following procedure. Loosening Loosen all nuts with the pneumatic impact wrench by a preliminary 150_ (1st step) in the exact sequence shown on Fig. 'A'. Follow again the same sequence to loosen evenly in several steps all nuts fully. Tightening Smear the thread of studs and nuts as well as the landing surfaces of nuts and areas on the cylinder cover with MO LYKOTE paste G and screw all nuts on by hand till fully seated. Tighten with a spanner by a smart jerk (by hand) all nuts equally (check with feeler gauge for full seating). Mark with felttip pen the '0' position on a corner of each nut and on the cylinder cover. Further mark on the cylinder cover the tightening positions at the end of tightening step 1, 2 and 3 as shown on Fig. 'B', with the felttip pen. Set the socket spanner with its '0' mark (on its circumference) at the same corner as the mark on nut and cylinder cover. Tighten all nuts in the sequence shown on Fig. 'A' by 60_ (1st step). Then tighten all nuts in the same sequence by further 120_ (2nd step) and finally by the last 150_ (3rd step). The total tightening angle of 330_ must be once more checked on all nuts at the end of the tightening process. A 5 2 8 B 3rd step 150 _ 94264
Total 330 _ '0' Marks 2nd step 120 _ 1st step 60 _
7 1
10.94
RTA84C
Maintenance
2708/4.1
Cylinder Cover Manual Overhaul of Sealing Face for the Fuel Injection Valve in the Cylinder Cover
Tools: 1 Overhauling device 1 Ring spanner AF 36 94270 Key to Illustration: 1 2 3 4 5 6 Cylinder cover Milling cutter holder Guide flange Setscrews Profiling cutter Centring mandril
S Screw * Threaded holes to take the screws 'S' when the tool is not in use
SW36
RT52 84C
When fitting the fuel injection valve, the seat sealing face in the cylinder cover must be clean and undam aged as the sealing is metallic.
2 * S 3
Should any blowby of combustion gases have been noticed during engine operation, the spring packets with their screws of the fuel injection valve are not, under any circumstances, to be tightened further as a counter measure as this might lead to deformation of the fuel injection valve. Dirty or slightly damaged sealing faces can be re conditioned on the spot by using the overhauling de vice 94270 which forms part of the tool kit. This is done by carefully inserting the profiling cutter, bolted to the milling cutter holder, into the hole in the cylinder cover with the guide flange. This flange is clamped down with two screws 'S' which are kept screwed into the threaded holes marked * when not in use. 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 sta bility and direction. Cutting is done by pressing down lightly with the hand on the milling cutter holder at the same time as turning the hex. head evenly with the other hand using the AF 36 ring spanner. Try to remove as little material as possible but suffi cient, however, to obtain the desired standard for the seating area.
6
Putting some sticky grease on the profiling cutter will prevent any foreign matter entering the combus tion chamber during overhaul.
96.7041
1989
RTA84C
Maintenance
2722/1.1
Fuel Injection Valve Checking, Dismantling, Assembling and Setting

Tools: 1 Hydr. tightening device 1 Protective cap 1 L ' ORANGE valve test stand 1 Holding angle 1 Connection piece 1 Hose pipe (1500 bar)
with L ' ORANGE Test Stand

Key to Illustration:
94269 94271 94272 94273 94274 94275
A
1 2 3 23 4 4 7
5 6 24
1 2 3 4 5 6 7 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 EV FL H MA SN
13 14 16 17
Allen screw Spring plate Cup spring (packet) Nozzle holder Spring tensioner Collar nut Oring Compression spring Spring plate Guide bush Spindle Stop/guide bush Cap nut Nozzle body with needle seat Nozzle needle Locating pin Locating pin Nipple Pressure sleeve Nozzle tip Locating pin Locating pin Relief valve Filter Pump lever Pressure gauge Lubricating nipple
Arrangement of the cup springs (spring packet)
1 2 3 5.5 mm
22
18 19 20 21 25 28 26
94.7069
27
UG/L' ORANGE
1994
2722/1.2
Maintenance
RTA84C
C
EV 94269b 20 19
94269c
94269a
33806
809
1994
UG/L' ORANGE
RTA84C
Maintenance
2722/1.3
For testing, dismantling, assembling and setting the fuel injection valve utilize the L ' ORANGE valve test stand 94272 belonging to the engine tool set. Pay attention to the following points: Keep the valve test stand clean and always fill only clean diesel fuel (gas oil) into its tank. Do not pour the once used fuel oil back into the test stand. (For filling remove the cover, which is secured by two spring latches). From time to time the pressure gauges have to be calibrated or compared with a testpressure gauge and reset if necessary. When working with the fuel injection valve the connection at top left is to be used, to which the left hand pumping lever and the upper pressure gauge (0-600 bar) belong. The connection at top right the lower pressure gauge (0-1600 bar) and the pumping lever at the right are used for testing the relief valves of the fuel injection pumps.
Judgeing a fuel injection valve (called f.i. valve for short) A f.i. valve atomizes correctly when at specified opening pressure fuel oil is sprayed from all the nozzle holes in equally atomized condition. This should be accompanied by a loud 'chatter', and after the end of the pumping stroke no fuel should 'dribble' from the injection nozzle. To check whether the atomizing is equal, hold a clean sheet of paper in front of the spray holes of the injection nozzle, and bring the f.i. valve to spray by single short pump jerk. On the 'spray pattern' thus obtained it is easy to establish whether individual spray holes are partly or fully blocked. Attention! Never actuate pump when a finger or a hand is held directly against the injection nozzle! (danger of accident)
Injection nozzles which do not spray properly must be taken apart and reconditioned or replaced (see sheet 2722/2 and /3).
Testing a f.i. valve (see Figs. 'A' and 'B') Working sequence: Place f.i. valve (injection nozzle downwards) into the holding angle of the valve test stand and fasten with the two nuts. Clean injection nozzle outwardly with a brass wire brush (removing combustion residue). Fit screwin connection piece (tool No. 94274) onto nipple 24 and join it to hose pipe 94275. Check first with a few short pump lever jerks the atomization of the fuel, then with slow equal pump strokes observe at what pressure the f.i. valve opens (see pressure gauge 'MA'). The specified opening pressure is given in the test and timing records of the engine. Finally remove hose pipe 94275 and screwin connection piece 94274. For inspection tighten nipple 8.
Dismantling a f.i. valve (see Figs. 'A', 'C' and 'D') The following basic rules must always be observed: 1. The cap nut 19 to the f.i. valve may never be loosened, before the spring tensioner 5 is not unscrewed sufficiently to detension the spring 13 completely (Fig. 'A'). 2. Never interchange nozzle needle 21 and nozzle body 20! Each nozzle needle belongs to it mated nozzle body into which it has been individually fitted with greatest precision.
UG/L' ORANGE
1994
2722/1.4
Working sequence:
Maintenance
RTA84C
Bring holding angle 94273 with f.i. valve into horizontal position (Fig. 'C'). Place spanner 94269a on cap nut 19 and loosen the cap nut with the aid of hydraulic jack 94269b and pump 94269c (Fig. 'C') then remove the injection nozzle. Attention! The spanner 94269a must always be set back before the piston of the jack is fully pushed out. At the start of pumping the spanner must stand as close as possible to the jack while its piston is fully pushed in. The relief valve 'EV' at the pump to be slightly opened.
Remove spring tensioner 5, spindle 17, spring plate 14 and spring 13 and inspect their condition. If necessary lap the sealing face of the nozzle holder 4 (please refer to 2722/3).
Assembling a f.i. valve Always observe the following basic rules: 1. Fit only completely clean nozzles, which were washed in kerosene and blown out with compressed air. 2. Assemble nozzle tip 26, pressure sleeve 25 and nozzle body 20, taking care that locating pins 27 and 28 fit into the respective holes. During the assembly of these above parts ensure meticulous cleanliness and absolutely perfect sealing surfaces. 3. If the spindle 17, the spring plate 14, the spring 13 and the spring tensioner 5 are already fitted, the spring ten sioner may only be screwed in by about one turn, so that the spring 13 is absolutely not under tension. Should this rule be neglected then the nozzle body 20 does not lie flat on the nozzle holder 4, for the assembling.
Working sequence: Adjust the holding angle 94273 with nozzle holder 4 so that the sealing face is on top (Fig. 'D'). Wipe sealing face on nozzle body 20 and nozzle holder 4 with the clean hand and place the nozzle body with needle on top. Take care that the needle does not fall out and that the cylindrical locating pins 22 of the nozzle holder fit into the corresponding holes in the nozzle body (Fig. 'D'). Tighten cap nut 19 by hand till seated firmly. Swing mounting angle 94273 with fuel valve to the horizontal position. Apply spanner 94269a and hydr. jack 94269b and raise with pump 94269c a pressure of 20 bar (or with a hammer blow on the spanner) to pretighten cap nut 19. Thus pretightened mark the position of cap nut 19 against nozzle holder 4 with a felt scribe ('0' mark). From this '0'mark the cap nut has to be tightened by further ( 45_. If a new nozzle tip 26 has been fitted, release the cap nut 19 again after tightening as above mentioned and repeat the tightening procedure as before to ascertain that any clearance or deformations have been cancelled out. Attention! Always set spanner 94269a back before the jack piston is fully extended. Before starting to pump, set the spanner as closely as possible to the jack, the piston being pushed right in, after slightly opening vent valve 'EV' at the pump.
Remove hydraulic tool and spanner and swing the holding angle 94273 with f.i. valve to a vertical position (injection nozzle pointing downwards). Fit the lightly oil smeared parts 17, 14 and 13 and screw in the spring tensioner 5. Do not tighten the collar nut 6 before the opening pressure is set and checked.
10.94
L'ORANGE
RTA84C
Setting the opening pressure
Maintenance
2722/1.5
Adjust the f.i. valve in the test stand as described under "testing a f.i. valve" (Fig. 'B'). Move pump lever 'H' slowly up and down, while simultaneously tightening the spring tensioner 5 until the specified pressure (refer to the test and timing records of the engine) is attained. Check then with a few short fast pump jerks whether the injection nozzle atomizes equally and thereby 'chatters'. When this condition is reached, tighten the collar nut, thereby locking the spring tensioner. Maintenance of the L' ORANGE valve test stand Depending on how frequently the test stand is used, grease must be pumped into the lubricating nipples 'SN' from time to time. Likewise, the two filters 'FL ' must be removed and cleaned periodically or replaced by new ones. When cleaning the fuel oil container, do not use any fibrous cloth materials or cotton waste. Use only brushes and compressed air instead. Do not reuse fuel collected in the transparent plastic drip tray. It is necessary to subject the test stand occasionally to a highpressure test. For this, close the connecting nipple with the steel ball and cap nut supplied. When pumping strongly up to approx. 600 bar (lefthand pump) and 1200 bar (righthand pump) , the pointer of the pressure gauge in question should remain in the same position. Rapid pres sure drop shown on the pressure gauge indicates leakage. Fitting a fuel injection valve into the cylinder cover Before fitting a fuel injection valve into the cylinder cover, make sure that the seat in the cover is clean. If necessary, recondition this seat with the tool supplied with the tool kit (see sheet 2708/4). The sealing must be metallic, i.e. no joint whatsoever may be fitted. For storing and transporting the nozzles together with the nozzle holder, protect the nozzle tip with a protective cap tool 94271 on tools list, to prevent its being damaged. Carefully fit the fuel injection valve into the cylinder cover. Press down the fuel injection valve evenly onto its seat with the two Allen screws. The correct pretension is reached, when the cup springs 3 (Fig. 'A') are first fully compressed by the two Allen screws 1, to their block length, after which the Allen screws are again loosened by an angle of 90_. The socalled block length is then reached, when a noticeable increase of tightening torque is felt while tightening the Allen screws.
SN
FL
338016
L'ORANGE
10.94
RTA84C
Maintenance
2722/1.1
Fuel Injection Valve Checking, Dismantling, Assembling and Setting

Tools: 1 Protective cap 1 O.M.T. test bench
with O.M.T. Test Bench

Key to Illustration:
94271 94272
A
5 6 1 2 3 17 4 4 7 18
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
8 9 10 11
Allen screw Spring plate Cop spring (packet) Nozzle holder Spring tensioner Collar nut Oring Compression spring Spring plate Guide bush Spindle Stop/guide bush Cap nut Nozzle body with needle seat Nozzle needle Locating pin Locating pin Nipple Pressure sleeve Nozzle tip Locating pin Locating pin Holding angle HP hose Torque beam
Arrangement of the cup springs (spring packet)
1 2 3 5.5 mm
16
12 13 14 15 19 22 20
94.7069
21
UG/O.M.T.
1995
2722/1.2
Maintenance
RTA84C
24
17 23
B
94272
C
94272
25
24
23
95.7534
1995
UG/O.M.T.
RTA84C
Maintenance
2722/1.3
Use test bench 94272 (Fig. 'B' and 'C') part of standardtools for testing, dismantling, assembling and setting of the fuel injection valve. Pay attention to the manufacturer's detailed instructions and working specifications of the test bench, in particular prior to commissioning as well as for the various operations of the test bench. Keep test bench always clean and fill only clean Diesel oil (Gas oil) into the fuel tank. Check and compare the pressure gauges of the test bench from time to time with a control pressure gauge; If neces sary reset them. Testing of a fuel injection valve (called injection valve in the following text) - Clean injection nozzle externally with a brass wire brush to remove combustion residues. - Fit injection valve, nozzle pointing downwards, into holding angle 23 of test bench 94272 and fasten it by both screws 1 (Fig. 'C'), thereby pay attention to the correct position given through locating pin 17. - Connect high pressure hose 24 of the test bench with fuel inlet of injection valve. - Start test bench, following the instructions of the test bench maker's. - Check atomization of fuel spray by a few smart pump strokes, then with slow pump strokes observe opening of injection valve on the pressure gauge. Attention! Never hold finger or hands directly before the spray holes of the injection nozzle. Risk of bad accident.
For correct functioning and for a reuse of an injection valve observe the following points: D The injection valve sprays correctly, when the fuel at the prescribed opening pressure (see setting table), sprays from all spray holes of the injection nozzle, equally well atomized. The spraying should be accompanied by a 'Chatter' and after the end of pumping the injection nozzle must not drip. D In order to test tightness between nozzle needle 15 (see Fig. 'A') and needle seat, keep the pressure constant in the test bench over a period of 10 seconds at 20 bar below the opening pressure. During this period of time no dripping should occur at the nozzle tip. D The internal tightness within the injection valve, i.e. tightness of sealing surfaces as well as leakage between nozzle needle 15 and nozzle body 14 (see Fig. 'A') must be checked in such a way, that a pressure set at the test bench at 100 bar may not drop below 70 bar within minimum 10 seconds. D The spray holes of nozzle tip 20 may not be unduly flushed out (see sheet 2722/2). - Injection valves which do not spray efficiently must be dismantled as described under 'Dismantling an injection valve'. Often, a through cleaning suffices to make them fully functional. - Nozzle tip 20 with flushed out spray holes must be replaced by new ones. - Injection nozzle which leaks or drips must be dismantled and reconditioned or replaced (see sheet 2722/2 and -/3). Therefore we recommend reconditioning of such injection nozzles by the nozzle manufacturer or by a specialized firm. Dismantling an injection valve For dismantling, the injection valve has to be held in holding angle 23 of test bench 94272, as already mentioned. Prior to dismantling an injection valve unscrew collar nut 6, then loosen spring tensioner 5 till compression spring 8 is fully relaxed. To remove the following items, turn holding angle 23 with injection valve fitted, so that the injection nozzle points upwards (Fig. 'B'). - Lower torque beam 25 with the socket spanner of test bench 94272 over the injection valve. Note test bench manufacturer's application instruction. - Actuate hydraulic loosening (or tightening) device of the test bench to loosen retaining nut 13, then remove them. - Dismantle pressure sleeve 19, nozzle tip 20 as well as nozzle body 14 with nozzle needle 15. - For removing spring tensioner 5, spindle 11, spring plate 9 and compression spring 8, the holding angle 23 of the test bench 94272 must be turned so that nozzle holder 4 comes to horizontal position. Attention! Never interchange nozzle needle 15 and nozzle body 14! Each nozzle needle is adjusted individually with its nozzle body; they form a unit together.
UG/O.M.T.
1995
2722/1.4
Assembling an injection valve
Maintenance
RTA84C
To assemble an injection valve, follow generally the reverse sequence to the dismantling process, but note also the following points: D To clean injection valve parts, use only clean Diesel oil (gas oil) or fresh kerosene, and dry compressed air. D Turn holding angle 23 with nozzle holder 4 to vertical position so that its sealing surface points upwards (Fig. 'B'). D Assemble nozzle tip 20, pressure sleeve 19 and nozzle body 14, taking care that locating pins 21 and 22 fit into the respective holes. During the assembly of these above parts ensure meticulous cleanliness and absolutely perfect and dry sealing surfaces. D Wipe sealing face on nozzle body 14 and nozzle holder 4 with the clean hand and place the nozzle body with needle on top. Take care that the needle does not fall out. D If the spindle 11, the spring plate 9, the compression spring 8 and the spring tensioner 5 are already fitted, the spring tensioner may only be screwed in by about one turn, so that the compression spring is absolutely not under tension. Should this rule be neglected by the assembly, then the nozzle body 14 does not lie flat on the nozzle holder 4. D Firmly tighten by hand cap nut 13 till solid metallic seating is obtained. With the aid of hydraulic tightening (or loosening) device of the test bench 94272 (Fig. 'B'), pretighten cap nut to 150 Nm. Starting from this position, tighten it by a further angle of ( 45_. D If a new nozzle tip 20 has been fitted, release the cap nut 13 again after tightening as above mentioned and repeat the tightening procedure as before to ascertain that any clearance or deformations have been eliminated. D If parts 8, 9 and 11 still have to be fitted, lightly smear them with oil and fit spring tensioner 5. Do not tighten the collar nut 6 before the opening pressure is set and checked. Setting the opening pressure Adjust the f.i. valve in the test bench as described under 'Testing of a fuel injection valve' (Fig. 'C'). Check atomization of fuel spray by a few smart pump strokes and simultaneously tighten the spring tensioner 5 until the specified pressure (refer to the setting table of the engine) is attained. Check then with a few short fast pump jerks whether the injection nozzle atomizes equally and thereby 'chatters'. When this condition is reached, tighten the collar nut, thereby locking the spring tensioner. Fitting a fuel injection valve into the cylinder cover Before fitting a fuel injection valve into the cylinder cover, make sure that the seat in the cover is clean. If necessary, recondition this seat with the tool supplied with the tool kit (see sheet 2708/4). The sealing must be metallic, i.e. no joint whatsoever may be fitted. For storing and transporting the nozzles together with the nozzle holder, protect the nozzle tip with a protective cap tool 94271 on tools list, to prevent its being damaged. Carefully fit the fuel injection valve into the cylinder cover. Attention! When fitting the injection valve take care in any case, that the nozzle tip 20 is not striking anywhere and thereby damaged.
Press down the fuel injection valve evenly onto its seat with the two Allen screws. The correct pretension is reached, when the cup springs 3 (Fig. 'A') are first fully compressed by the two Allen screws 1, to their block length, after which the Allen screws are again loosened by an angle of 90_. The socalled block length is then reached, when a noticeable increase of tightening torque is felt while tightening the Allen screws.
1995
UG/O.M.T.
RTA84C
Maintenance
2722/2.1
Fuel Injection Valve Cleaning and Overhaul of Injection Nozzle

Tools: 1 Case consisting of special tools 1 Face plate 94280 94281-94287 94288 1 2 3 4 5 Key to Illustration: Nozzle body Nozzle needle Nozzle tip Pressure sleeve Cap nut a b c f = positioning holes = bores for fuel = channel for circulating fuel = sealing face
Nadelhub NEEDLE STROKE N
Dichtflche JOINT FACE f
Injection nozzles which no longer atomize perfectly may not be used again. It is often sufficient to clean them thor oughly to fully restore them. If this proves insufficient, the nozzle has to be repaired. Unskilled handling renders a nozzle useless. We recom mend, therefore, that such nozzles be sent to a specialist firm or to the manufactures. Cleaning injection nozzles
5 1 2
Remove carbon deposits from the outside of the nozzle with the wire brush 94284. Carefully clean carbonedup spray holes by hand, using a drill 94285 which should be 0.025 mm smaller than the nominal diameter of the spray holes. Once all spray holes have been cleaned in this way, tap the nozzle - with its sealing face pointing downwards against a piece of wood or lead so that the deposits fall out. Thoroughly wash the nozzle with paraffin, gas oil, perch lor or similar and blow out with compressed air. If further cleaning is necessary in the interior of the nozzle, a metal object may never be used. A wooden dowel rod covered with a piece of cloth is the most suitable thing to use for this purpose. With a clean nozzle, the nozzle needle (after having been dipped in clean paraffin or gas oil) should slide onto its seat under its own weight. Checking spray holes Check with the pin gauge 94286 supplied that the spray holes have not been scoured out excessively. If the pin gauge can be inserted into one of the spray holes, the nozzle is to be replaced. Reconditioning of injection nozzles Should careful cleaning of the nozzle not suffice to re store its serviceability, although nozzle needle, needle seat as well as spray hole diameters are in order, or should the needle lift 'N' (the measure engraved on the nozzle body) have increased by more than 0.1 mm, the nozzle must be reconditioned by a specialist firm. Should any damage show on the sealing face 'f' this must be lapped at right angles to the bore of the needle guide, on the face plate 94288.
4 3
Spritzlcher SPRAY HOLES
a b c
96.7867
1989
RTA84C
Maintenance
2722/3.1
Fuel Injection Valve Lapping of Nozzle Holder Contact Surface

Tools: 1 Lapping disc 1 Copper mandrel 1 Face plate Lapping powder 1 Lapping plate 94281 94282 94283 94287 94288 Key to Illustration: 23 Nozzle holder 30 Hardened bush
Tools only delivered under separate order.
Rough or slightly deformed nozzle holder sealing surfaces have to be reconditioned. If the surface is only slightly worn, reconditioning by lapping in is sufficient. In more severe cases, however, it is necessary to grind the contact surface by machine and then lap it, making sure that the seat is at right angles to the axis of the nozzle holder. After the contact surface has been machined, the hardened bush in the center of the nozzle holder must be approx. 0.02 mm below the face edge. This is obtained by grinding the bush - with only very little of a fine grinding paste - using a drilling machine and the copper mandrel 94282. A disc punched out of fine emery cloth may be used in place of the grinding paste (see Fig. 'A' overleaf). Before starting to lap the contact surfaces, check the faces of the lapping disc 94281 for flatness. Where necessary, lap them in on the cast iron lapping plate 94288 with lapping powder/paraffin (kerosene) mixture until flat. After having been a long time in service the contact surface of a nozzle holder will be slightly convex (arched out wards). The center area must, therefore, be lapped in first with the small lapping disc (Fig. 'B'). For checking the contact surface to be lapped in, use the dry, special bronze check disc 94283. From time to time this disc has to be checked for flatness on a dressing plate. Since the check disc is made of bronze, the contact spots appear slightly yellow (Fig. 'C'). The lapping disc works more effectively where it is pressed by the thumb. Rotating should therefore be done over the whole surface during lapping. As soon as yellow spots are visible on the whole contact surface when checking with the check disc, the reverse side of the lapping disc, which has a greater diameter, should be used to finish lapping the face (Fig. 'D'). Care should be taken not to rotate too far over the edge of the face in order to prevent it from becoming convex. The final face must be clean, smooth and flat or slightly concave (arched inwards), but never convex! During the last check, contact spots should be visible everywhere on the contact face with the exception of the hard ened bush. After lapping, the nozzle holder must be washed with paraffin or similar and blown out.
Diameter of lapping tools in mm a 15 b 8 c 46 d 40 e 54
1989
2722/3.2
Maintenance
RTA84C
A B
a
94281
min. 0.02 mm
23
c d
30
94283
94281
C
e
D
d c
E
4 mm 0.03 mm
94288
~300 mm
98.7837
Falls die Abrichtplatte uneben geworden ist, muss sie wieder plangehobelt werden, wobei die Oberflche ein Profil erhalten soll, das der Abb. 'E' entspricht. SHOULD THE DRESSING PLATE HAVE BECOME UNEVEN, IT MUST BE PLANED FLAT AGAIN AND GIVEN A SURFACE PROFILE AS SHOWN IN FIG. 'E'.
1989
RTA84C
Maintenance
2728/1.1
Starting Valve Removing, Fitting and Dismantling, Grindingin and Assembling

Tools: l Depth gauge 2 Jacking screws 94124 1 2 3 4 5 6 7 8 9 10 11 Key to Illustrations: Nut Cover Intermediate ring Casing Oring to casing Cylinder cover Selflocking nut Piston Valve spindle Allen screws Compression spring 12 13 14 15 16 H Joint ring Control valve Transfer sleeve Oring Piston ring Control air pipe (from starting air distributor) J Control air pipe (from starting air pipe) R Eye bolt S Air cap
Should functional difficulties occur with the starting valves when starting or during manoeuvring, or should a start ing air pipe near to where it joins the cylinder cover become noticeably hotter in operation than on the 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. Removal from the cylinder cover Loosen control air connections and push control air pipes 'H' and 'J' aside. Loosen and remove all four nuts 1. Loosen and remove allen screws 10. Screw jacking screws into the threaded holes in the casing 4 and by tightening them jack the complete starting valve from the bore in the cylinder cover 6. To remove the complete valve insert both screws 10 again. The valve can then, suspended by the two eye bolts 'R', be lifted by crane from the cylinder cover. When the removal is carried out with the cylinder cover fitted on the engine, the vacated opening must be immedi ately covered by suitable means to prevent the possibility of foreign particles entering the combustion space. Dismantling a starting valve Lift cover 2 with mounted control valve 13 of casing 4. Take care that during lifting, the cover does not get jammed, whereby transfer pipe 14 risks being damaged. Remove intermediate ring 3 from casing 4. For further dismantling clamp the valve on the milled faces below the spindle head (spanner purchase) in a vice. Loosen selflocking nut 7 with a socket spanner, and remove it. Pull piston 8 and compression spring 11 from the casing. Lift casing 4 up over valve spindle 9. Grindingin Should the valve seat require regrinding, apply some grinding paste to the spindle seat and grind it in on the valve seating. Badly worn seat faces must first be machined (angle 60_) and only then ground in (lapped) manually.
1989
2728/1.2
Assembling Clean all parts and smear them lightly with oil.
Maintenance
RTA84C
Assemble the valve (excluding the cover 2) in reverse sequence to the dismantling. Apply MOLYKOTE paste G to the thread of spindle 9 and tighten the selflocking nut 7 with 800 Nm or by a tight ening angle of 55_. The spindle thread in the region of the synthetic material, locking ring of the selflocking nut 7 must not be lubricated. Place new Orings 5 and 15 in the groove in the valve casing, and transfer sleeve respectively and oil lightly. After completing the assembly (without cover 2) check the easy movement of the spindle by moderately tapping the spindle top several times with a lead block in an axial direction; the spindle must jump every time back on the seat. Should the valve seat have been ground / machined several time, check the air gap 'S', as it diminishes with every reconditioning of spindle or seat, in the extreme case the valve will no longer shut. The air gap 'S' (see Fig.) must be minimum 1 mm: The gap can be measured with depth gauge (tool 94124) from the upper edge of intermediate ring 3 onto the piston 8. Fit cover 2 and tighten it with allen screws 10. Take care that when assembling the cover 2, the transfer sleeve 14 does not interfere. Fitting in the cylinder cover Place a new joint ring 12 on the shoulder of the bore in the cylinder cover. Smear bore in cylinder cover lightly with oil and fit the assembled starting valve. Screw in the nuts 1 and tighten them crosswise through an angle of 90_.
1989
RTA84C
Maintenance
2728/1.3
I-I II
13 1 2 S 3 7 16 4 5 16 6 8 4 H J
III - III
10 2
IV - IV
2 15 14 15 4
II
R 10 1 13 H J
9 11
III IV
12
IV III
89.7127
1989
RTA84C Relief Valve for Cylinder Cover Dismantling, Assembling and Testing
Tools: 1 1 1 1 1 2 Valve test stand L ' ORANGE Mounting angle bracket Flexible hose (1500 bar) Testing head Copper joint (for 94276) Jacking screws M12 94272 94273 94275 94276
Maintenance
2740/1.1
with L 'ORANGE Test Stand

Key to Illustrations: 1 2 3 4 5 6 7 8 9 10 11 Spring tensioner Distance ring Nut Studs Round rubber ring Housing Compression spring Spring plate Valve body Valve seat Cylinder cover 11a 12 13 14 15 16 16a 17 18 19 Copper joint Nut Tie rod Testing head Connecting union Closing union with protective cap TREDO seal Pump lever High pressure hose Stop lever
A
1 2 3 4 5
6 7 8 9 10
All relief valves are to be removed from the cylinder covers at intervals of approx. 6000-8000 running hours earlier, if necessary - with the two jacking screws M12 and checked for absolute tightness and correct opening pressure, with the aid of the valve test stand. Even if the opening pressures are still correct, it is advisable to check a few relief valves at random. Depending on the condition found, possibly check the remaining ones too. The correct opening pressure is marked on the rectangular flange of the valve housing and given in the set ting records of the engine.
1 mm
11a 11
98.7838
LORANGE
1989
2740/1.2
Maintenance
RTA84C
B
12 1 2
13
6 9 10 11a 14 (94276) 16
18 (94275)
15 16a
94273
Gezeichnet fr RT58 DRAWN FOR RT58
98.7839
1989
LORANGE
RTA84C
Dismantling and assembling
Maintenance
2740/1.3
C
1 2 12 94273 18 (94275) 19 17
14 (94276) 16 15
Procedure for dismantling The relief valve, clamped in the test stand according to Fig. 'B' and 'C', is moved into horizontal position. Unscrew spring tensioner 1 and remove spring 7 and spring plate 8. Clamp valve housing at the rectangular upper part in the vice and unscrew valve seat 10. After that, the valve body 9 can also be removed. All components should be thoroughly cleaned and checked.
10 a
10 45 + 0
43 b Schutz PROTECTION
98.7660
LORANGE / 3.03
2740/1.4
Procedure for grindingin
Maintenance
RTA84C
Valve seats of which the contact surfaces are in bad condition are best reground by machine, aiming at the following angles: Seat of valve body 9 = 43_ Seat of valve seat 10 = 45_
+ 10' 0
Valve seats which are only slightly damaged, however, can be reconditioned by grindingin by hand, following the procedure below (Fig. 'E'): Clamp valve body 9 into a bench vice. Using a small pointed stick, place a few dots of grinding paste onto the seat of the valve body, towards the greater diameter (Fig. 'E'/a). Put valve seat 10 onto valve body 9 and turn valve seat backwards and forwards. Clean the faces several times and repeat the grinding process until a relatively narrow, shiny band towards the smaller diameter indicates the con tact area (Fig. 'E'/b). Finally thoroughly clean valve seat and body. Procedure for assembling Thoroughly clean all components and lightly oil them. Coat valve body 9, the landing faces of spring 7 and the threads of spring tensioner 1 with MOLYKOTE paste G. Use a high temperature resistant lubricant, such as THREAD GARD or LOCTITE ANTI SEIZE COMPOUND, for coating the threads of valve seat 10. (These lubricants can of course also be used for the parts mentioned above). Clamp the relief valve at the rectangular upper part in the vice and screw the valve seat 10 with valve body 9 fitted into the housing 6 and tighten firmly. Place relief valve vertically into the test head 14 already screwed into the mounting angle bracket of the test stand and firmly tighten with nuts 12. Attention! First insert copper joint 11a into test head.
Fit spring plate 8 and spring 7 and screw in the spring tensioner 1 (at first without distance ring 2) until the distance to the valve housing corresponds approximately to the thickness of the distance ring. Procedure for testing Connect high pressure hose 18 to connecting union 15 of the test head (see Fig. 'C') and operate pump lever 17 until the relief valve opens (check the opening pressure on pressure gauge). Depending on the opening pressure found, further tighten or loosen spring tensioner 1 until the correct opening pressure has been established. Now measure the distance between the spring tensioner 1 and the valve housing and prepare a distance ring 2 of corresponding thickness. Unscrew the spring tensioner and insert distance ring. Test relief valve once again. Fitting the relief valve into the cylinder cover (see Fig. 'A') Before fitting the relief valve, thoroughly clean the bore and contact surface in the cylinder cover. Make sure that no foreign matter enters the combustion chamber when carrying out the work with the cylinder cover fitted. Fit the relief valve with a rubber ring in perfect condition and place a new copper joint onto the contact surface in the cylinder cover. Coat the outside of the valve housing with a little grease or oil to protect it against rust. Coat the threads of the studs 4 with MOLYKOTE paste G and, after fitting the valve very firmly tighten the nuts crosswise and in even stages.
3.03 / LORANGE
RTA84C Relief Valve in the Cylinder Cover Dismantling, Assembling and Testing
Tools: 1 O.M.T. test bench 2 Jacking screws M12 94272
Maintenance
2740/1.1

Key to Illustrations: 1 2 3 4 5 6 7 8 Spring tensioner Distance ring Nut Studs Oring Housing Compression spring Spring plate 9 10 11 11a 12 13 14 Valve body Valve seat Cylinder cover Copper joint Nut Tie rod Adapter (testing head)
1 2 3 4 5
All relief valves are to be removed from the cylinder covers at intervals of approx. 6000-8000 running hours - earlier, if necessary - with the two jacking screws M12 and checked for absolute tightness and correct opening pressure, with the aid of the test bench 94272 (Fig. 'B'). Even if the opening pressures are still cor rect, it is advisable to check a few relief valves at random. Depending on the condition found, possibly check the re maining relief valves too. The correct opening pressure is marked on the rectangular flange of the valve housing and given in the setting records of the engine. Dismantling (Fig. 'A') For dismantling clamp the relief valve at the rectangular upper part in the vise. Unscrew spring tensioner 1 and remove compression spring 7 with spring plate 8. Then loosen valve seat 10 and after that valve body 9 can also be removed. All components should be thoroughly cleaned and checked.
8 9 10
11
11a
93.7179
O.M.T.
1995
2740/1.2
Procedure for grindingin
Maintenance
RTA84C
Valve seats of which the contact surfaces are in bad condition are best reground by machine, aiming at the following angels: Seat of valve body 9 = 43_ Seat of valve seat 10 = 45_
+ 10' 0
Valve seats which are only slightly damaged, however, can be reconditioned by grindingin by hand. In this case follow the procedure below (Fig. 'C'): Clamp valve body 9 into a bench vice. Using a small pointed stick, place a few dots of grinding paste onto the seat of the valve body, towards the greater diameter (Fig. 'C'/a). Put valve seat 10 onto valve body 9 and turn valve seat backwards and forwards. Clean the faces several times and repeat the grinding process until a relatively narrow, shiny band towards the smaller diameter indicates the con tact area (Fig. 'C'/b). Finally thoroughly clean valve seat and body. Assembly - Thoroughly clean all components and lightly oil them. - Apply MOLYKOTE paste G to valve body 9, the landing faces of compression spring 7 and the threads of spring tensioner 1. - Use a high temperature resistant lubricant, such as THREAD GARD or LOCTITE ANTI SEIZE COM POUND, for coating the threads of valve seat 10. (These lubricants can o course also be used for the parts men tioned above). - Clamp the relief valve at the rectangular upper part in the vice and screw valve seat 10 (with valve body 9 fitted) into housing 6 and tighten firmly. - Place relief valve vertically into adapter 14 already screwed into test bench 94272 (Fig. 'B') and tighten with nuts 12 (first insert copper joint 11a into the adapter). - Fit spring plate 8 and compression spring 7 and screw in spring tensioner 1 (at first without distance ring 2) until the distance to the valve housing corresponds approximately to the height of the distance ring. Testing the relief valve Pay attention to the manufacturer's detailed instructions and working specifications of the test bench, in particular prior to commissioning as well as for the various operations of the test bench. - Depending on the opening pressure found, further tighten or loosen spring tensioner 1 until the correct opening pressure has been established. - Now measure the distance between spring tensioner 1 and valve housing and prepare a distance ring 2 of the corresponding height. - Unscrew spring tensioner and insert distance ring. - Tighten spring tensioner 1 once again and recheck the relief valve. Fitting the relief valve into the cylinder cover (see Fig. 'A') Before fitting the relief valve, thoroughly clean the bore and contact surface in the cylinder cover. Make sure that no foreign matter enters the combustion chamber when carrying out the work with the cylinder cover fitted. Fit the relief valve with a rubber ring in perfect condition and place a new copper joint onto the contact surface in the cylinder cover. Coat the outside of the valve housing with a little grease or oil to protect it against rust. Apply MOLYKOTE paste G to the threads of studs 4 and after fitting the valve, firmly tighten the nuts crosswise and in even stages.
3.03 / G.M.T.
RTA84C
Maintenance
2740/1.3 I
B
12
12
13
I
14 13
94272
14
11a
94.7252
C
10 a
10 45 + 0
43 b Schutz PROTECTION
98.7660
G.M.T. / 3.03
RTA84C
Maintenance
2751/1.1
Exhaust Valve Removal and Fitting of the Exhaust Valve

Tools: 1 1 1 1 2 1 1 1 2 1 1 Hydr. tensioning device Valve protector Impact tightener with socket spanner Suspension device Jack screw HP oil pump Distribution piece HP hoses HP hoses Air hydr. pump Impact wrench AF 105 94252 94262 94264 94265 94267 94931 94934a 94935 94935a 94941 Key to Illustration: 1 2 3 4 5 6 7 8 9 10 11 Waisted stud Stud nut Valve seat Steel ball Connecting piece Connecting piece to HP hose Sleeve to connecting piece Cylinder cover Soft iron gasket Valve spindle Valve cage
AF Seating surface R Round bar
After loosening the four nuts which fasten the exhaust valve to the cylinder cover and after disconnecting the piping, the complete exhaust valve can be pulled by the crane with suspension device 94265 (Fig. `E`) out of the cylinder cover. Should the valve cage be jamming in the cylinder cover (due carbon formation), two jack screws 94267 have been provided. Insert these in the threaded holes EX on the valve cage (see sheet 2751/2, Fig. 'A') and jack the valve cage out of the cylinder cover. Remark: It is essential that the instructions on sheet 9403/4 referring to the application of hydraulic pretension ing jacks to screwed fastenings be strictly followed. The loosening or tightening of the waisted studs, holding the valve cage to the cylinder cover, with the impact tightener is only permitted in exceptional cases. Regarding draining cylinder cooling water please refer to sheet 2708/1.
Working sequence for removal Clean the threads of waisted studs 1 of the valve cage as well as the area around the stud nuts 2 (Fig. `B`). Mount tensioning device 94252 consisting of four pretensioning jacks with straps on the four waisted studs 1 (Fig. 'B'), afterwards turn them back by turn. Connect jacks up to the HP oil pump with HP hoses 94935, 94935a and oil distributor 94934a (see Fig. 'C'). Start up HP pump, at the same time open the vent screws of the pump till oil flows out bubblefree. Raise a pressure of 600 - 620 bar with the pump and keep this constant till the four stud nuts 2 have been loosened. Loosen all stud nuts with a round bar by one turn. Open valve on HP pump to release pressure to zero, remove hydr. pretensioning device 94252. Hang the hooks of suspension device 94265 (Fig. `E`) into the eye screws of the valve cage 11, then lift complete exhaust valve, with the crane. If the exhaust valve is not to be dismantled at site immediately, mount the valve protector 94262 (Fig. `D`).
1989
2751/1.2
Working sequence for fitting
Maintenance
RTA84C
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 9 of 2 mm thickness lies flat in its recess in the cylinder cover. Replace all Orings by new ones of specified dimensions and quality, oil Orings slightly before fitting. Fit the complete exhaust valve with the help of the suspension device 94265, taking greatest care not to damage the thread of the waisted studs. The correct position of the exhaust valve cage is determined by the cylindrical dowel pin set in the cylinder cover. Smear thread of waisted stud lightly with MOLYKOTE paste G. Fit stud nuts 2 and tighten them firmly with a spanner till fully seated before mounting the hydr. tensioning device 94252 (check seating with feeler gauge). Mark position of stud nuts on a corner and their position on the valve cage 11 with a felttipped pen (for later checks). Mount the four jacks of the hydr. tensioning device 94252 as described under paragraph 'Working sequence for the removal' and vent the same, whereby the jacks are to be screwed on completely. Slowly raise a pressure of 600 bar at the HP oil pump. Keep this pressure constant and tighten the four stud nuts 2 with a round bar till firmly seated on exhaust valve cage 11 (check seating with feeler gauge). After tightening the stud nuts ascertain that the nuts have been turned by about the same angle i.e. about 150_. Remark: When couplingup and connecting HP hoses, always tighten sleeve 7 of connecting piece 5 (Fig. 'A') fully. This assures that non return valves 4 (balls) are open and the oil supply to the respective jack is not restricted.
1989
RTA84C
Maintenance
2751/1.3
A
94935a
R 6 4 7 4 5 1
AF
I-I
98.7738
98.7738
R 94252
94941 (94931)
94935 94934a
94935a AF
94935a
98.7841
1989
2751/1.4
Maintenance
RTA84C
I-I
11
E
94265
10
94262
11
98.7842
10
1989
RTA84C
Maintenance
2751/1.5
Mechanical loosening and fastening of the valve cage on the cylinder cover Whenever possible the waisted studs of the valve cage must always be loosened or tightened with the hydraulic pretensioning device, which prevents any unequal stresses in the studs which could lead to deformations of the valve cage. Only in emergencies e.g. when the hydr. pretensioning device cannot be utilized, may the nuts of the valve cage waisted studs be loosened or tightened with the pneumatic impact tightener 94264, when the procedure described below must be followed. Loosening Use pneumatic impact wrench to loosen by 60_ two diagonally opposed nuts 2 (Fig. 'F'). Loosen the other two nuts 2 completely and remove them. Loosen, in several equal steps, the first two nuts, which had been loosened by 60_, till fully loose and remove them. Tightening Smear threads of studs as well as nut seating surface on the valve cage well with MOLYKOTE paste and threadon the nuts by hand till fully seated. Tighten with spanner by hand with a smart jerk all nuts equally (check seating with feeler gauge). Mark, with felt tipped pen a corner on each nut and corresponding point on the valve cage, the position '0'. Further also mark on the valve cage by each nut in accordance with Fig. 'G' the positions for the 1st, 2nd and 3rd step with a short line. Apply the socket spanner in such a way that its '0' mark (on its circumference) corresponds with the '0'mark on nut and valve cage. Tighten the four nut Fig. 'F' crosswise by an angle of 30_ (1st step). Then tighten four nuts by further 60_ (2nd step), then by 60_ (3rd step). Finally check the complete tightening angle, it should be 150_ (Fig. 'G') on four nuts equal.
11
G
0 Marke MARK
Total 150 _
60 _
98.7843
2. Stufe / STEP
1989
2751/1.6
Replacement of waisted studs
Maintenance
RTA84C
Should waisted studs 1 (in the following text called stud for short) of the valve drive, cylinder cover, relief valve or starting valve have to be replaced, then their annular spaces must be filled with a sealing compound! Moreover the following points must be observed: D Before fitting a stud clean its thread and corresponding tap hole. The sealing faces must be degreased (use white spirit) and subsequently primed. D Screw in the stud without lubricant on the thread, right to the bottom, and tighten it according to the instruc tions on sheet 0352/1. Always utilize a stud driver or two nuts. Tools like a pipe wrench etc. which would damage the stud shank must never be used. D For the protection of the stud in the cylinder cover, fill the ring space above the thread with a well adhering, water and oil proof sealing compound. The sealing compound must remain plastic at normal operating tem peratures. Recommended jointing compound and adhesive primers Jointing compound RTVME 622A No. of compounds 2 Hardener ME 622B Adhesive primer G 790 Manufacturer Wacker Chemie (Switzerland) Ltd. Lautengartenstr. 23 PO Box 4002 Basel CH4052 Basel BS Wachendorf Ltd. Auf dem Wolf 17 PO Box 4002 Basel CH4052 Basel BS
Silcosed 6/105
A or D
without type designation or OP
Equivalent products of other manufacturers may also be used.
1
Dichtmittel SEALING COMPOUND
Ringraum ANNULAR SPACE
Dichtflche SEALING FACE
93.7194
9.99
RTA84C Exhaust Valve Dismantling and Assembling

Tools: 1 1 2 1 Feeler gauge Depth gauge Jack screws Rotation device for valve cage 94122 94124 94263 94290
Maintenance
2751/2.1
Key to Illustrations: 1 2 3 4 5 5a 6 6a 7 8 8a 9 Valve cage Valve drive housing Damper Piston (hydraulic) Bush Retaining ring Pressure flange Screw Ridged valve cone piece Piston Piston seal ring Air cylinder housing 10 11 12 13 14 15 16 17 18 19 B R EX Guide bush Rod seal ring Valve spindle Rotation wing Valve seat Cylinder cover Oring Vent screw Spacer ring Locating dowel Shim Eye bolt Threaded hole for jack screw
Remarks: For inspection or dismantling, tool 94290 has to be used, onto which the complete exhaust valve is mounted to per mit locating it in any desired position (Fig. 'D'). Dismantling an exhaust valve Valve cage is located vertically in rotation device 94290. Loosen all four screws fastening the valve drive housing 2 to the valve cage. Attach eye bolt 'R' to the lifting tackle and lift damper 3, together with valve drive housing 2, hydr. piston 4 and bush 5 off the valve cage 1. The hydr. piston 4 remaining in bush 5 is thereby pulled up and held by retaining ring 5a. Bring valve cage to the horizontal position with the help of the rotation device 94290. Loosen and remove screw 6a in pressure flange 6 from the connection piston 8 / valve spindle 12. The piston 8 can now be pushed down in the air cylinder 9 and the two ridged valve cones 7 can be pushed from the groove in the shank of the valve spindle 12. Actuate inverting drive on the inverting support and bring the valve cage with the still fitted valve spindle (for spindle removal upwards) into the vertical position. Should the height for spindle removal be restricted, the re moval is also possible in a horizontal position (see Fig. 'B'). Remove valve spindle. If the guide bush 10 has to be removed, press it out with the two jack screws 94263 (Fig. 'B1').
1989
2751/2.2
Maintenance
RTA84C
2 16
17
R 3 2 4
5 17 2 6a 8 9 11 1 10
Leckl LEAK OIL
5a 6 8a 7 18
EX 13 12 15 19
14
98.7846
1989
RTA84C
Maintenance
2751/2.3
B
Gezeichnet fr RTA76 DRAWN FOR RTA76
Ausbau DISMANTLING
B1
94263
Einbau ASSEMBLING
10
10 1
98.7847
1989
2751/2.4
Assembling the exhaust valve
Maintenance
RTA84C
The assembly is carried out along the same lines as the dismantling but in reverse sequence. Note that rod seal ring 11 and spacer ring 18 must always be fitted after fitting the valve spindle, otherwise the rod seal ring might be dam aged when the valve spindle is inserted. For attention D The condition of the piston seal ring 8a has to be checked at every opportunity, at the latest however during an exhaust valve overhaul according to the maintenance schedule. A defective piston seal ring as well as rod seal ring 11 must be replaced without fail. For the admissibles dimensions of the exhaust valves please consult Clearance Table sheet 0330/4. When an exhaust valve is equipped with a new valve seat or valve spindle, in every case without exception the valve seat must be reconditioned in the fitted condition with the valve seat grinding machine (see instructions on sheet 2751/3). Smear threads of screws 6a to pressure flange 6 lightly with MOLYKOTE G paste, then screw them in. Tighten the screws equally to a final tightening torque of 180 Nm. After tightening all screws 6a, check them repeatedly for correct tightening, as the valve cone pieces 7 embed themselves during the tightening proce dure. The screws which have already been fully tightened can thereby lose their pretension, and must there fore be checked again for correct pretension. Apply a bit of MOLYKOTE paste to the screws for the bush 5 and the retaining ring 5a. Subsequently the screws must be tightened to 170 Nm and secured with a locking wire. In the course of every overhaul of the exhaust valve seat/spindle the damper 3 must be removed. Establish with depth gauge 94124 the measure 'H' from the upper edge of housing head 2 to the bottom of the damper bore in piston 4 (see Fig. 'C'); for this the exhaust valve must be closed (check with feeler gauge whether the valve plate lies against the valve seat without clearance). Establish the thickness 'h' for the new shims 'B' to be fitted with the help of formula below: h = 207 - H 0.50 mm Fit damper with newly adjusted shim stack. Single shim rings to 1 mm thickness are available. D After each overhaul the vent screw 17 (Fig. 'A') must be checked and cleaned.
D D
C
3
94124 20
88.7023
9.99
RTA84C
Maintenance
2751/2.5
94290
98.7848
1989
RTA84C Exhaust Valve Replacing and Grinding the Valve Seat

Tools: 1 1 1 1 1 1 1 1 Feeler gauge Valve seat fitting and dismantling device Valve seat grinding machine Pilot Holding strap Milling cutter Gauge Rotation device for valve cage
Maintenance
2751/3.1
Key to Illustrations: 94122 94261 94278 94278a 94278b 94278c 94279 94290 1 Valve cage 2 Valve seat 3 Oring AF H R T Z Seating face Hammer Eye bolt Tensioning screws Centring
On valve seats where 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 to the vertical (see Fig. 'C'). This is also the position required for grinding with the valve seat grinding machine. The guide bush (spindle guide) does not have to be removed. Grinding as well as any repair work on the valve seat must be recorded on the sheet 'Exhaust Valve Record', Form 4-107.044.059-1/-2.
Removing the valve seat (Fig. 'A') Fit both pairs of ring halves of the valve seat fitting and dismantling device 94261 into the groove on the circumfer ence of the valve cage 1 and valve seat 2 respectively. With the aid of the three jack screws of the valve seat fitting and dismantling device, the valve seat can be pressed out of its seating in the valve cage. Should a used valve seat be reused, then it must be marked together with the valve cage before removing. When refitting the valve seat the previously applied markings must again be brought in line.
2 3 94261
99.7487
9.99
2751/3.2
Fitting the valve seat (Fig. 'B') -
Maintenance
RTA84C
Place valve cage - as for the seat removal - vertically (Fig. 'C'). Clean bore as well as seating shoulder at 'AF' meticulously and with greatest care. Unevenness or damage to seating face 'AF' would lead to leaks. Smear the bore into which the valve seat has to fit with oil, or lubricants such as e.g. THREAD GARD, LOC TITE, ANTISEIZE COMPOUND etc. Smear with the same lubricant and place new Oring 3 of original specification into the groove in the valve cage. Push valve seat as far as possible into the bore, then mount valve seat fitting and dismantling device 94261 (Fig. 'B') and by even tightening of the jack screws press the valve seat down till fully seated. Through the control openings in the valve seat fitting and dismantling device check with the feeler gauge 94122 all around the cir cumference that no clearance remains at 'AF'. For this check the fitting device has still to be fitted fast as re quired for the subsequent grinding of the valve seat.
2 94261
94122
94261
99.7488
AF
9.99
RTA84C
Grinding the valve seats
Maintenance
2751/3.3
Valve seats must be ground only with the valve seat grinding machine. Grinding in valve seats using valve spindle with grinding paste must be avoided as a matter of principle! When should valve seats be ground in the valve cage? Always when new valve seats are fitted to the valve cage. When new or reconditioned valve spindles are fitted. An exception can be made if the seating surface is neither worn nor damaged by corrosion. When the seat surface on the valve seat is badly damaged through operation with heavy fuel oil (Impacts, corrosion scars). Chamfer Angle Width h 15_ h1 15_ 10 mm 30 mm i i1
94278b
Z T 94261
30 _ + 2 0
94278a
98.7856
h1
i1
1989
2751/3.4
Maintenance
RTA84C
The machines from the makers HUNGER and CHRIS MARINE are well proven for valve grinding. When grinding the valve seat, take care that as little grinding dust as possible falls into the valve cage or even stays there. A thorough cleaning after completion is absolutely essential. Regarding the operation of the grinding machine please refer to the operating instructions supplied with it. The grinding must produce an even and smooth surface. It is particularly important that the grinding machine is mounted in such a way that it is correctly centred in the valve guide bush. The chamfers in the valve guide bush provide fixed setting surfaces for the cones on the 'Pilot' (see de tails in Fig. 'C'). Before inserting the grinding machine remove carbon deposits from the chamfers with tool 94278c. With the help of centring aid 'Z' fitted to the 'Pilot' fasten the grinding machine optimally. Furthermore remove rod seal ring 11 (see Fig. 'A' on sheet 2751/2) to save it from being damaged. For grinding fit spacer ring 18 (without rod seal ring), as its chamfer serves as a guide. Experience has shown that when grinding valve seat surfaces 'chatter' marks are generated if vibrations are set up by motors or other machines in the vicinity. To prevent with certainty such 'chatter' marks always mount the valve cage for grinding the valve seat, in the mounting trestle tool 94290, which is seated for this reason in spring elements. To prevent counterrotation of the grinding machine during the grinding fix the holding strap 94278b as shown in Fig. 'C' to the ring of valve seat fitting device 94261. The forked end of the holding strap grasps the hand grip and thus keeps the machine head in position. . We recommend however always to grind from inside In principle grinding can be carried out in both directions to outside. Finishing however must be done from inside out, as only this method achieves the required angle preci sion. Valve seat angle = 30_
+ 2 0
The grinding allowance on the valve seat is maximum 3 mm. The wear condition can be checked efficiently with gauge 94279 in combination with feeler gauge 94122 (see Fig. 'D'). Possible burn scars at the inside of the valve seat must not exceed 13 mm. The depth of the burn scars can also be verified with the gauge 94279 as shown in Fig. `D'. Valve seats which exceed the above mentioned values must be replaced.
D
max. 13mm
E
R 94279 H
97.7079
8.98
RTA84C
Maintenance
2751/3.5
After grinding it is necessary to check whether the new or reground valve makes correct contact with the valve seat. For this the spindle head seat face is stained with a thin coating of blueing paste, then inserted vertically into the valve guide bush. The angle difference is chosen such that in the hot operating condition the valve makes contact by 50% - 100% from the outer edge. The blueing check should show that the cold valve makes contact only from inside around the whole circumference. The angle difference can be checked at the gap 'S' on the outer edge with a feeler gauge (Fig. 'G'). For careful attention: The "Remarks" in sheet 2751/2 concerning the fitting of reground valves or valve seats must be considered.
The blueing on the valve seat must be checked by tapping the valve head three or four times with a hammer on a wooden block! (Fig. 'E'). Do not rotate the valve spindle on the valve seat face, as this risks seizure of the seating.
F
30 _ + 2 0
50100%
S = 0.130.16 mm
93.7199
1989
2751/3.6
Maintenance
RTA84C
1989
RTA84C
Maintenance
2751/3.7
1989
RTA84C
Maintenance
2751/4.1
Exhaust Valve Grinding the Seating Surface on the Valve Head

Tools: 1 Feeler gauge 1 Valve grinding machine 1 Gauge 94122 94291 94292 Information concerning the grinding of valve seats in valve cages is given in sheet 2751/3. All grinding and repair work carried out on the valve spindle must be recorded on the Sheet "Exhaust Valve Record", Form umber 4-107.044.059 -1/-2. Form samples are attached as sheets 6/7 at the end of group 2751/3.
Grinding in a valve together with its valve seat with grinding paste is not permitted. Valves which have had the seating surfaces badly damaged by pitting or corrosion have to be reground by machine. It is strongly recommended that a suitable grinding machine such as tool 94291 be made available. The machines from the makers HUNGER and CHRISMARINE are well proven for valve grinding and can also be ordered direct from Wrtsil Ltd, Winterthur.
94291
Seating face angle on valve a = 30_ +18' +20'

98.7857
Only as little material as necessary should be ground off the valve seating face to provide a clean and smooth fin ished surface. Only grind with cooling (wet). In order to avoid the appearance of chatter marks on the seating surface, the grinding machine should be placed in an area which is free of vibration from running machinery or engines, etc. If necessary the grinding machine should be stood on a rubber mat. For the operation of the grinding machine, please refer to the operating instructions of the respective makers. Good results have been obtained by using the following recommended grinding wheels: Cut Supplier HUNGER CHRISMARINE Stone quality 64A46H15 VP 01/1373 Coarse approx. 0.025 mm Fine approx. 0.010 mm
Feed rate with automatic oscillation system
10.94
2751/4.2
Maintenance
RTA84C
A maximum of 3 mm may be ground off the valve seating face.
The wear condition can be checked at any time with the gauge (tool 94292) and feeler gauge (Fig. 'B').

max. 3mm
On engines with heavy operation duty, corrosion may form at the bottom of the valve plate, after a longer operating time. Valve plates, on which the corrosion layer is deeper than 12 mm or where the seat surface has been ground back by more than 3 mm (Fig. 'B'), can be reconditioned by buildup welding.
Such a repair process may, however, only be carried out by a Wrtsil Switzerland Ltd authorized repair workshop.
C
Where the precise angle required has been obtained during grinding, a check with marking blue with the valve on the re ground valve seat in the valve cage will show only a line con tact or a very narrow band (extent of contact) starting from the smaller diameter (Fig. 'C'). See also remarks on sheet 2751/3 regarding the valve beha viour at running temperature. Please note:
95.7977a
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.
8.98
max. 12 mm

94292
RTA96C
Betrieb
Group3
Crankshaft, Connecting Rod and Working Piston

o
Group 3
Crankshaft
Measuring Crank Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103/1
Vibration Damper
Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper) . . . . . . . . . . . . . . 3130/1
Axial Detuner
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3146/1
Turning Gear
Oil Change and Checking the Worm Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3206/1
Crankcase
Utilization of the Working Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301/1
Connecting Rod
Loosening and Tensioning the Connecting Rod Studs and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . 3303/1 Inspection, Removing and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303/2 Inspection, Removing and Fitting of Top End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303/3 Removing and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303/4
Connecting Rod (1-part)

Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303/1 Inspection, Removing and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303/2 Removing and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303/4
Crosshead
Checking Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326/1 Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326/2
Working Piston
Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403/1 Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403/2 Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403/3 Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403/4
Piston Rings
Checking Piston Ring Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425/1 Checking Piston Ring Wear (Cylinder Liner with Antipolishing Ring) . . . . . . . . . . . . . . . . . . . . . 3425/1
RTA84C / MM / 2001
RTA84C Crankshaft Measuring Crank Deflections

Tools: 1 Dial gauge 94305
Maintenance
3103/1.1
Key to Illustration: 1 Flywheel 2 Pinion
In order to ascertain whether the axes of the crank journals deviate from the theoretical shaft axis, the crank deflec tions must be measured. When doing so the ship must be floating freely. Under normal circumstances, it is sufficient to measure the crank deflections once a year. They must, however, be measured as soon as possible in case the ship has grounded or after replacing the main bearing shells. The deflec tions have to be measured again approx. 100 service hours after replacing the bearing shells. Should signs of damage of the main bearings be found during inspection of the crankcase, the crank deflections should also be measured. Measuring is carried out using a crankshaft dial gauge (tool 94305) which, for this purpose, is inserted between the crank webs of the crank to be measured. When turning the crankshaft, the change in distance between the crank webs can be read from the dial gauge as this indicates any opening or closing up. The smaller the variations the better the position of the shaft. Rotation direction of crankshaft: To measure the crank deflection the crankshaft must always be turned in such a manner - despite the ordinary rotation direction of the engine - that flywheel 1 and pinion 2 of the turning gear are rotating as indicated by the arrow (see Fig. 'A').
A
1
99.7009
9.99
3103/1.2
Maintenance
RTA84C
Measuring procedure (indicator valves must be open) With the running gear in place, the crank to be measured has to be turned towards (before or after) B.D.C. until the dial gauge can be fitted next to the connecting rod at the position indicated. Pretension the dial gauge slightly and set it to "0" (see Fig. 'B'). Turn the crankshaft with the turning gear, reading the dial gauge in the crank positions which are indicated in Fig. 'B' and noting down the values. The last value is for checking; if everything has been carried out correctly it should be nearly "0".
Measuring points
Kurbel im O.T.P. CRANK AT T.D.C.
Dial gauge 94305
93.7167
Noting down the values: The values which have been read are to be noted down in a table containing the following data: At what positions of the crankpin the values have been read, in terms of B.D.C. fuel side - exhaust side T.D.C. Rotation direction of the crankshaft when measuring the crank deflection.
9.99
RTA84C
Maintenance
3103/1.3
The difference (Da) between the indicated values at B.D.C. and T.D.C. shows the amount of crank deflection dur ing one revolution (see Fig. 'C'). All influences which cause a temporary deformation of the hull and/or the engine affect the crank deflection. These are for example: loaded condition of the ship engine cold or at service temperature differing air/water temperatures strong sunshine
The values of Da given below are valid for all conditions independent of outside influences. Where values are measured which lie over the maximum permissible limits, the cause has to be found and the neces sary remedial measures taken (defective main bearing, engine support altered due to hull deformation, loose hold ingdown bolts, defective shaftline bearings, etc.). When measuring the crank deflection, ensure that the crank journals are fully seated in their bearings.
Dial gauge 94305
Stroke s
a B.D.C.
a T.D.C.
Difference Good values Values still admissible
n a = a T.D.C. a B.D.C. n a = 0 0.30 mm n a = 0.30 0.60 mm
9.99
RTA84C
Maintenance
3130/1.1
Vibration Damper Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper)
Tools: 1 1 1 1 Large screw driver Flat caulker Medium hammer Center punch assorted spanners 1 1a 2/2a 3/3a 4 5 6 6a/b 7 7a Key to Illustrations: Cladding Hood Casing bottom Casing cover Rubber ring Intermediate shaft Crankshaft end Coupling bolts Camshaft Coupling 8/8a 9 9a 10 11 12 C D K Spacer ring Balance mass Counter weight Rubber ring Sealing ring Screw plug Sample container Cover Lock by center punching *Alternative execution
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 contribute to a reduction in the damper's effective ness. By periodic examination of the silicone oil the makers of the vibration damper can draw conclusions on its condition. It is therefore recommended to have the siliconoil examined periodically the first time after about 15-18'000 op erating hours. Future intervals for examinations depend on the result of these first findings. Special sample containers can be obtained from the damper makers (see Fig. 'C'). Remark on the drawing of a silicone oil sample: In the casing bottom 2/2a or in the casing cover 3/3a, two oil drawing holes are carefully closed and sealed with screw plugs 12. Vibration dampers of very recent manufacture will be equipped with two each withdrawing points on ei ther side, so that the samples can be taken on the side of best accessibility. Vibration damper on the free end (crankshaft)
5.92
3130/1.2
Maintenance
RTA84C
Vibration dampers on the free end (camshaft)
Preparations Remove the hood 1a or cover 'D' respectively. Rotate the crankshaft or the camshaft until one of the screw plugs 12 on the sample drawing side chosen, is in the best accessible position (Fig. 'B'). Pay attention to the vibration damper make concerned! Using a flat caulker, hammer back the squeezed material in the slot, which serves as locking means. Loosen the screw plug, but do not unscrew it yet, it must still seal the oil in. Rotate the crankshaft or camshaft respectively until the chosen and prepared oil drawing opening reaches the bot tom most point. Leave the damper in this position for at least two hours. (If the oil sample is to be withdrawn from a removed vibra tion damper the same conditions apply as regards the positions and the waiting time). In both cases the vibration damper must have cooled down to about room temperature. Prepare the sample container, i.e. remove the cap nut and examine the bore which must be meticulously clean. Attention! The threads on the two ends are different on the Holset damper (see Fig. 'C').
1989
RTA84C
Drawing a sample -
Maintenance
3130/1.3
Unscrew the screw plug 12 and in its place screw in the prepared sample container. Wait till the silicone oil flows out of the open sample container end. Depending on the viscosity of the silicone oil this may take some time. As soon as the silicone oil begins to flow out, close the sample container with the first cap nut. Unscrew the sample container from the damper casing (hold vertically) and fit immediately the screw plug 12 with a new sealing ring11. (Avoid unnecessary leakage of silicone oil)! Fit the second cap nut on the sample container and finally tighten both moderately.
- Tighten the screw plug 12 with about 25 Nm and lock it by caulking metal into the slot. If a sample is not obtained by the method described, proceed as follows: 1. 2. 3. 4. 5. 6. 7. Leave sample container in position. Remove the opposite screw plug, connect a compressed air supply and apply about 3.5 bar pressure. 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 to the sampling container. Disconnect compressed air supply. Remove sample container and fit the other cap nut. Refit the corresponding screw plugs to all withdrawal openings. Tighten and lock the screw plugs as already mentioned under 'Drawing a sample'. The special sample container permits drawing a specific quantity of silicone fluid from the damper. The total numbers of samples should be limited to ten times. The filled sample container has to be labelled and sent to the following address for examination:
Attention:
Hasse & Wrede Carl Hasse & Wrede GmbH Mohriner Allee 30-42 D-12347 Berlin Germany Telefon: 0049 30 70 1810 Telefax: 0049 30 700 90 811 or
Holset Simpson International Ltd (UK) 131 Parkinson Lane GBHalifax HX1 3RD United Kingdom Telefon: 0044 1422 357 234 Telefax: 0044 1422 354 432
The label must contain the following information: Engine type, Engine No., Number of operating hours of the vibration damper, also its manufacturing serial number (this number is stamped into the cover in the vicinity of the warning plate).
9.99
3130/1.4
Maintenance
RTA84C
1989
RTA84C Axial Detuner Dismantling and Assembling

Tools: 1 Wire rope with two shackles 1 Roller support 2 Eye bolts M30 94119 94310
Maintenance
3146/1.1
Key to Illustrations: 1 2 3 4 5 6 7 8 9 Upper part of cylinder Lower part of cylinder Screw Screw Screw Large seal ring Small seal ring Selflocking nut Allen screw 10 11 12 13 14 15 16 17 R Throttling valve Spindle Locking screw Diaphragms Oil inlet pipe Main bearing cover Crankshaft Main bearing shell Eye bolt
Prior to any overhaul work being started on an axial detuner, switch off the bearing oil pump. Then remove the upper half of the twopiece crankshaft cladding at the free end. Dismantling Remove oil inlet pipe 14. Pull both taper pins locating the upper and lower part of cylinder 2 and 1 respectively. For this purpose 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. Screw in the two eye bolts 'R' (Fig.'B') into the upper part of cylinder and join the two eye bolts by wire rope 94119 and the two shackles. Fasten roller support 94310 to the face of the free end of the engine as shown in Fig. 'B'. Using lifting tackle carefully raise upper part of cylinder . Make absolutely sure that the upper part of cylinder slides out of the seal rings 6 and 7 without jamming, as otherwise the seal rings risk being damaged. Should seal rings 6 and 7 (in two parts) have to be replaced, loosen first selflocking nut 8 and remove Allen screw 9. The sealing rings can then be turned out of their grooves in the lower part of cylinder 2 without prob lems.
Checking the throttling valve When overhauling the axial detuner check also the condition of throttling valve 10. The spindle position has been locked by locking screw 12 and a locking plate. This has been done because changing this position is forbidden. The throttling valve is turned back by about four turns starting from the closed position. No further adjustment is normally necessary after setting the proper position. Should it become necessary to replace a spindle for any reason, at a time where no instrument is available for mea suring the axial vibrations of the crankshaft, then the spindle must be adjusted in the following manner: Turn the spindle clockwise till the stop, then turn it back by the distance marked on the nameplate. Should this mark not have been made on the nameplate, then measure the distance from the spindle face to the casing of throttling valve. A new spindle has to be adjusted to the same distance. When the above check brings to light any defect of throttling valve 10 (Fig. 'A') then diaphragms 13 screwed into the throttling valve must also be checked for possible damage and replaced if necessary. Attention The spindle must not be turned back by more than 16 turns, that corresponds to a stroke of 48 mm. The engine must not be operated with the spindle removed or with the oil supply to the axial detuner interrupted.
4.01
3146/1.2
Assembling
Maintenance
RTA84C
Badly worn or damaged seal rings 6 and 7 must be replaced. The seal rings are fastened by two Allen screws 9 and selflocking nuts 8. Immediately before fitting them smear the seal rings with clean engine oil. Newly fitted seal rings must allow radial movement when fitted The assembling of the axial detuner is done analogous to dismantling but in reverse sequence. Pay the utmost atten tion when lowering upper part of cylinder 1 into place that seal rings 6 and 7 are not being damaged. Before tightening screws 3 as well as 4 and 5 fit the taper pins for the upper part and lower part of the cylinder. Tighten screw 4 between axial damper and bedplate with a tightening angle of 50 _(.
9.99
RTA84C
Maintenance
3146/1.3
12 10 11
13
15 1 5 4 3 6 15
17
I
2
16
99.7489
89.7070
9.99
3146/1.4
Maintenance
RTA84C
I B
94310
94119
1 16
94310
94119
15
16
89.7067
1989
RTA84C
Maintenance
3206/1.1
Turning Gear Oil Change and Checking the Worm Wheels

Key to Illustrations: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Housing Spacer ring Bearing flange Bolt with locking plate Oil drain screw Worm wheel Cover Backing plate Bolt with locking plate Oil level indicator Spacer sleeve Tapered roller bearing Horizontal worm shaft Bearing flange Bolt with locking plate Intermediate flange Spring pack Closing cover Bolt with locking plate Bolt with locking plate 22 23 24 25 26 27 27a 28/28a 29 30 31 32 33 34 35 36 37 38 39 Electric motor Handwheel Large worm wheel Oil filling screw Engaging / disengaging lever Pinion shaft Protective tube over pinion shaft Turning pinion/Turning wheel Flexible coupling Bolt with locking plate Bearing flange Connecting piece Tapered roller bearing Vertical worm shaft Intermediate flange Spacer ring Spring pack Bolt with locking plate Bearing flange
1989
3206/1.2
Maintenance
RTA84C
Before putting the turning gear into operation, always first check the oil level in the housing by removing the dipstick from the oil level indicator 10. The oil level must lie between the two marks on the dipstick. Top up the oil if necessary, using a Hypoid gear oil of viscosity 220-270 cSt at 40_C (16.5-19.7_ E at 50_C)
The pinion shaft 27 must always be coated liberally with MOLYKOTE grease whereas it is sufficient for the teeth of the turning pinion 28 to be greased lightly. Once a year, drain off some oil from the turning gear and visually examine it for wear particles (firmly retighten oil drain screw 5 afterwards). If this examination clearly shows contamination, the oil has to be drained off completely and the condition of the worm wheels has to be checked. This can be done after removing the cover 7 and the oil filling screw 25. This check must in any case be carried out at least every four years. The oil capacity is approx. 60 liters for 4 - 7 Cyl. engines, approx. 148 liters for 8 - 12 Cyl. engines. The housing has to be thoroughly flushed out with flushing oil before filling up with oil. Replacing the tapered roller bearings Should it become necessary to replace the tapered roller bearings of either the horizontal or vertical worm shafts, the procedure is as follows: a) Horizontal worm shaft (see Fig. 'A'): Drain off all the oil and remove cover 7. Slacken off and remove the four bolts 9 which secure the backing ring 8 of the worm wheel 6 on the worm shaft. Using two of the removed bolts, now bolt the backing ring onto the side face of the worm wheel 6; two threaded holes are available. With the aid of a jacking screw M 24 screwed into the threaded hole in the center of the backing ring 8, jack off the worm wheel from the shaft. Remove the mounting bolts of both the bearing flanges 3 and 14 and pull off the latter using jacking screws. The worm shaft can then be removed. When fitting new tapered roller bearings, the same procedure as for removal is followed in the reverse order. When doing so, ensure that the spacer sleeve 11 is replaced between the tapered roller bearing 12 and worm wheel 6 as well as the spacer ring 2 under bearing ring 3. b) Vertical worm shaft (see Fig. 'B'): Drain off all the oil and remove cover 7. After removing the mounting bolts, lift off the electric motor with the crane. Remove the mounting bolts of both the bearing flanges 31 and 39 and pull off the latter using jacking screws. The worm shaft can then be removed. When fitting new tapered roller bearings, the same procedure as for removal is followed in the reverse order. When doing so, ensure that the spacer sleeve 36 is placed under bearing flange 31.
1989
RTA84C
Maintenance
3206/1.3
1989
3206/1.4
Maintenance
RTA84C
1989
RTA84C Crankcase Utilization of the Working Platform

Tools: 2 Working platforms, consisting of 3 grids each 3 Working supports 94142 94143
Maintenance
3301/1.1
Key to Illustrations: 1 2 3 4 Engine longitudinal beam Crank web Step Strap
To avoid accidents, the grids of working platform 94142 and working supports 94143 should be used for inspections or work in the crankcase. The grids must always be fitted in such a way that their Uprofiles come to lie between engine longitudinal beam 1 and that the opposite end rests on crank web 2. Working support 94143 can be fitted between the columns at the desired height, on steps 3. These are safeguarded against falling down by shoving straps 4 against the steps. Attention! Never rotate the crankshaft while the grids or working supports are in position.
A
I-I I
3 94143
94143
94143 4
94142 1 2
94142 1
010.858/03 010.859/03
3.03
RTA84C
Maintenance
3303/1.1
Connecting Rod Loosening and Tensioning the Connecting Rod Studs and Bolts
Tools: 2 1 2 2 1 3 2 1 1 1 Pretensioning jacks HP oil pump Pressure gauge Connecting branchs Distributing piece HP hoses Impact ring spanner AF 85/115 Feeler gauge Depth gauge Sledge hammer * 94314/315 94931 94932 94933 94934a 94935/a 94122 94124 Key to Illustrations: 1 2 3 4 5 6 7 8 Connecting rod stud / bolt Nut Cylinder Rod seal ring Piston seal ring Piston Vent screw Screws 8a Cover with grip 9 Cup springs
K R V X
Checking slot Round bar Relief valve Check point
* To be used only in emergency when the hy draulic pretensioning device is out of order.
A
Attention! Never rotate the engine (with the turning gear) when the hydraulic pretensioning jacks are mounted on the connecting rod (waisted) studs or bolts!
94932
94933
8
Important Remarks!
8a 9 6 5 4 3 94314 94315
93.7200
To loosen or tension the connecting rod studs / bolts always use the hydraulic pretensioning de vice. Only in emergency in case the hydr. preten sioning device is not serviceable, may spanner and sledge hammer be used for tightening. For loosening and for tensioning the connecting rod studs / bolts always follow the sequence shown in Fig. 'B' i.e. a + a and b + b. Before screwing the nuts onto the studs clean their threads and the seating surface for the nut carefully: corrosion protecting oil may remain in the thread. Furthermore check that the nuts turn freely on the stud thread.
1990
3303/1.2
Maintenance
RTA84C
1989
RTA84C
Maintenance
3303/1.3
For loosening and for tightening the studs of connecting rod top end bearing as well as the bolts of connecting rod bottom end bearing the crank of the respective cylinder should be turned to B.D.C. or T.D.C. position. The pretensioning jacks are autoresetting, i.e. when the oil pressure is released, by opening the release valve on the oil pump, their pistons are again returned to their neutral position by the force of the cup springs (spring packet). This entails that the release valve at the pump remains open l minute, allowing the oil to flow back to the pump. For information on the removal and fitting as well as inspection of bottom end and top end bearings refer to sheets 3303/2 and 3303/3. Under no circumstance the separating faces of the upper connecting rod bearing shells must be reduced by filing etc. as otherwise the essential prestress for the bearing assembly would be lost. Loosening the connecting rod studs and bolts of top and bottom end bearing shells 1) Hydraulically: For this, follow the general instructions for the application of hydraulic pretensioning jacks in sheet 9403/4. 2) Mechanically (only in case of emergency): Should it be impossible to use the hydraulic device, then the nuts must be loosened in pairs across and in equal small steps using impact ring spanner and sledge hammer. Tensioning the connecting rod studs and bolts 1) Hydraulically: The previously mentioned 'Important Remarks' must be considered. Tighten the nuts first with the spanner by hand with a smart jerk. Distribute the clearance equally between the bearing cover and connecting rod shank (bearing projection) of the top end bearing by using feeler gauge 94122. Check whether the nuts rest flush. Screw both pretensioning jacks 94314 or 94315 respectively onto the connecting rod studs or bolts of the corre sponding bearing (see Fig. 'B', a + a and b + b) until they rest against the connecting rod shank. If necessary turn jacks back a little to allow access of nuts 2 with the round bar, so that it can later be turned. Connect the jacks to the pump and set pressure to 400 bar for the connecting rod top end bearing, and 350 bar for the bottom end bearing (1st step) and hold these constant. Tighten the nuts with the round bar and check with the feeler gauge that no clearance 'X' remains between nut and connecting rod shank. Proceed in the same manner for the second pair of connecting rod studs or bolts. Check with the feeler gauge that no clearance remains between bearing cover and connecting rod shank (for top end bearing). Should clearance remain, loosen the fastening and compare the bearing projection with the nominal value as indicated in sheet 3303/3. Mark the position of the nuts against shank as shown in Fig. 'a', with felt marker or similar. Raise the pressure to 600 bar and hold it constant (2nd step). Tighten nuts down and check correct seating with feeler gauge. Check from the markings applied by how much the nuts were turned after pretightening (1st step). Tightening angle (1st to 2nd step) to be = about 23_ on the studs of top end bearing (Fig. 'b') Tightening angle (1st to 2nd step) to be = about 40_ on the bolts of bottom end bearing (Fig. 'b') For an additional check, the elongation can be measured with depth gauge 94124 by unscrewing the jacks after pre tensioning (1st step), and measuring the lengths 'L ' on all the connecting rod studs or bolts and recording them indi vidually (Fig. 'c'). Mount the pretensioning jacks again as described before, then raise the pressure to 600 bar and hold it constant (2nd step). Tighten nuts down, check correct seating with feeler gauge.
11.98
3303/1.4
Maintenance
RTA84C
When all connecting rod studs / bolts are fully pretensioned, remove jacks and measure the lengths 'L ' a second time with the depth gauge 94124 and record these readings as 'L1' (Fig. 'c'): L1 - L = DL = 0.39 mm for studs of top end bearing (1st to 2nd step) DL = 0.70 mm for bolts of bottom end bearing (1st to 2nd step)
Should considerable differences to these nominal values be encountered then repeat the tensioning process. Finally check the vertical bearing clearance (compare with Clearance Table 0330/5) and lock the nuts 2.
2) Mechanically (only in case of emergency): The previously mentioned 'Important Remarks' must be considered. Tighten the nuts with the spanner by hand with a smart jerk. Distribute the clearance equally between the bearing cover and connecting rod (bearing projection) on the top end bearing by using feeler gauge 94122. Check to ascertain that the nuts are fully seated on the connecting rod and that the two bearing halves of the con necting rod bottom end bearing are seated without clearance in the dividing faces. Tighten all nuts of the top end bearing in small steps with impact ring spanner and sledge hammer until the clear ance on either side of the bearing between cover and connecting rod shank measures 0.04 mm. Mark the position of nuts against the shank Fig. 'a' with felt marker . Measure the lengths 'L ' on all the connecting rod studs or bolts with the depth gauge 94124 and record the readings (Fig. 'c'). Tighten all nuts of respective bearing alternately and in small steps with impact ring spanner and sledge hammer to the following tightening angles (Fig. 'b') 45_ for studs of top end bearing 90_ for bolts of bottom end bearing Measure the lengths 'L ' a second time with the depth gauge and record the readings as 'L1': L1 - L = DL = 0.75 mm for studs of top end bearing DL = 1.50 mm for bolts of bottom end bearing
In case of considerable deviations from these nominal values, repeat the tightening process. Finally check the vertical bearing clearance (compare with Clearance Table 0330/5) and lock the nuts 2. Fig.'a' Fig. 'b' fully tensioned DL pre-tensioned Stud thread L L1 Fig. 'c'
y y x Tightening angle

Nut Connecting rod
x = Mark with felt marker on connecting rod shank y = Mark with felt marker on the nut
11.98
RTA84C
Maintenance
3303/2.1
Connecting Rod Inspection and Removal of Bottom End Bearing

Tools: 4 Holding pins Hydr. tools as per sheet 3303/1 Lifting tackle 2 Eye bolts Assorted steel ropes 94323 1 2 3 4 5 6 7 8 Key to Illustrations: Connecting rod bolts Nut Locking element Locking plate Locking screw Lower bearing cover Top end bearing cover Guide rail 9 Threaded holes for eye bolts 10 Connecting rod 11 Allen screw 12 Cylindrical dowel 13 Cylindrical dowel 14 Crankshaft 15 Strap 16 Holder
Inspection and removing For removing the lower cover to the bottom end connecting rod bearing loosen nuts 2 of connecting rod bolts 1 hydraulically as described in sheet 3303/1, which operation must be carried out with the crank in T.D.C. Prior to that remove locking plates 4, locking screws 5 and locking elements 3. Fit a eye bolt on either side of lower bearing cover 6 in the threaded hole 9 provided on its crown. Further secure lower bearing cover 6 by two steel ropes attached to straps 15 (Fig. 'A') and two suitable lifting tackle. Remove all four nuts 2. The connecting rod bolts are secured by holders 16 from falling out. Gradually and carefully lower lower bearing cover with the four connecting rod bolts 1 using two lifting tackles. Take great care that the two cylindrical dowels 13 slide out of their bores without jamming and that the threads of the connecting rod bolts are not damaged. Remove the lower bearing cover together with the four connecting rod bolts from the crankcase. Should the case occur that after the removal of the lower bearing cover the top end bearing cover 7 has to be in spected or removed then proceed as follows: Insert all four holding pins 94323 into the guide rails (Fig. 'A'). Secure connecting rod with a rope and lifting tackle on the fuel pump side. Turn crankshaft carefully towards fuel pump side till the slippers come to rest on the holding pins 94323. If neces sary turn the holding pins somewhat till the slippers rest snugly against the excenters of the holding pins. Attention: Do not yet unscrew ALLEN screws 11 (Fig. 'B'). Turn crankshaft further downwards while at the same time correcting with the lifting tackle on the fuel pump side so that during this operation the upper bearing cover 7 stays always free off the crank pin. In the position shown in Fig. 'A' the upper bearing cover can be inspected. Should an upper bearing cover have to be removed then the lifting tackle has to be slackened until connecting rod 10 hangs vertically down. Screw two eye bolts into the threaded holes 9 in the upper bearing cover. Secure the upper bearing cover with two ropes attached to straps 15 and hold the upper bearing cover with two lifting tackles in its position. Remove both 'Allen' screws 11. With the aid of the two lifting tackles slowly lower the upper bearing cover taking care that the two cylindrical dow els 12 can slide out of their bores without jamming. Remove the upper bearing cover. Fitting The fitting of the upper as well as the lower bearing cover to the connecting rod has to be carried out in reverse sequence to the removal. Smear bearing running surfaces lavishly with clean engine oil. The tensioning of the connecting rod bolts in de scribed on sheet 3303/1. Attention! Never turn the crankshaft as long as the hydraulic jacks are screwed onto the connecting rod bolts. After completing the work, never forget to remove holding pins 94323 from the slide rails.
1989
3303/2.2
Maintenance
RTA84C
1989
RTA84C
Maintenance
3303/3.1
Connecting Rod Inspection, Removing and Fitting of Top End Bearing

Tools: 4 Retaining pins 1 Connecting flange Hydr. tools according to sheet 3303/1 2 Eye bolts Grip screws 94323 94336 1 2 3 4 5 6 7 8 Key to Illustrations: Crankshaft Toggle lever Connecting rod Locking plate Locking screw Locking device Nuts Studs 9 10 11 12 13 14 Threaded holes for ring screws Cylindrical pins Bearing shell Hexagon socket head screw Bearing cover Guide segments
L Oil pressure pipe P Lubricating pump R Eye bolt
Inspection and removal When a top end bearing has to inspected or removed, proceed as follows: Turn crank of the corresponding cylinder to B.D.C. Loosen the five screws fastening the toggle lever 2 of the crosshead lubrication and piston cooling, and separate the toggle lever from the connecting rod 3. Remove the locking screws 5, locking plates 4 and locking device 6. Loosen all four nuts 7 of studs 8 of top end bearing with the hydraulic device as instructed on sheet 3303/1 and re move the nuts. Turn crank upwards till the holding pins 94323 can be inserted into the slide rails. Finally turn the holding pins so that the excenters prop up the slippers. Fit two eye bolt 'R' on both sides of the top connecting rod head into the threaded holes 9. Secure the connecting rod with the two eye bolt 'R', the lifting tackle and a holding rope. Turn the crank down carefully and guide the connecting rod down with the holding ropes (Fig. 'B'). Take care that the cylindrical pins 10 and the four studs 8 slide out through the bores without jamming (Fig. 'C'). Before removing the bearing shell 11 loosen the two hexagon socket head screws 12 and remove them. Use the grip screws (M 8) to lift the bearing shell out. Attention: Should the case occur that after the removal of the piston an inspection or a removal of the top end bearing is carried out then the suspension device 94324 for the crosshead (see sheet 3326/2) must with out fail be fitted. This is to prevent the bearing cover 13 from turning and falling down when the connect ing rod is being lowered. Fitting The fitting of bearing shell 11 and of bearing cover 13 is carried out analogously but in the reverse sequence to the removal. When fitting the bearing shell 11 take care that, the two recesses (for hexagon socket head screw 12) which are milled into the front face of the bearing shell, coincide with the corresponding recesses in the connecting rod. Before fitting smear the running surfaces lavishly with clean bearing oil. The tensioning of the bearing studs must be carried out as instructed in sheet 3303/1. Remarks: When fitting the bearing shell as well as the crosshead pin, pay careful attention not to damage the two guide segments 14. The two white metal lined guide segments are fitted to the front sides of the bearing saddle (Fig. 'C'). Always fit toggle lever 2 in such a way that its curvature (knee) stands upwards. After completing the work the retaining pins 94323 must be removed without fail.
5.92
3303/3.2
Remarks to the fitting of a bearing shell:
Maintenance
RTA84C
Should it become necessary to replace a bearing shell to the top end bearing then care must be taken, that the run ning surface of the journals are in perfect condition. While fitting a bearing shell the utmost attention must be given to prevent dirt or foreign particles entering 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 at both ends of the separating face by the same distance. This protrusion is a must and under no circumstances may the separating face of the bearing shell be filed to reduce it! (Fig. 'A'). On a new bearing shell of the top end bearing the protrusion should be: x1 + x2 = 0.58 - 0.66 mm. Above measuring checks must be carried out without fail when fitting new bearing shells. For this the bearing shells are placed in position the bearing covers fitted and tightened down by hand with a spanner and a slight jerk. Prior to final assembly smear the running surfaces lavishly with clean bearing oil. Should, however, the engine have to be frequently turned after the fitting of the bearing, or should a restart of the engine not be immediately planed, then instead of bearing oil a mixture of 2/3 steamengine cylinder oil and 1/3 normal bearing oil should be used. Special oils suited to this purpose are also available from reliable suppliers. In order to further reduce the risk of dry running on newly fitted bearing shells, a connecting flange 94336 can be fitted (see Fig. A1), after removing oil pressure pipe 'L ' to the crosshead bearing. The connecting flange has to be connected via an oil pressure hose to a lubricating pump 'P'. The pump has to be filled with the above mentioned oil mixture or special oil. The lubricating pump 'P' has to be operated from time to time, until oil is pouring out from the bearing side faces. Before the engine is put back into operation, the oil pressure pipe 'L ' must be mounted back again. The remainder of the above mentioned special oil or oil mixture may remain in the engine oil system.
5.92
RTA84C
Maintenance
3303/3.3
1989
RTA84C Connecting Rod Removing and Fitting

Tools: 1 Working platform 4 Retaining pins 1 Girder Various ropes and lifting tackle Hydr. tools according to sheet 3303/1 1 Eye bolts 94142 94323 94335
Maintenance
3303/4.1
Key to Illustrations: 1 Crankshaft 2 Toggle lever 3 Stud to top end bearing 4 Guide rail 5 Connecting rod shank 6 Crosshead pin 7 Cover 8 Bearing cover to top end bearing 9 Upper bearing cover to bottom end bearing 10 Straps 11 Support R Eye bolts
As an aid for the removal or fitting of the connecting rod as well as of other heavy engine components, the girder 94335 can be used. As shown in Fig. 'A' it can be fitted between two supports 11 of the cylinder platform. Thereto place four pins of girder 94335 into the respective holes of the supports 11. Following secure the pins with retaining springs belonging to it.
11
94335
11
94.7070
Brennstoffpumpenseite FUEL PUMP SIDE
10.94
3303/4.2
Maintenance
RTA84C
A connecting rod can be removed and fitted without removing working piston and crosshead pin. The procedure has been shown in Fig. 'A' and 'B' as well as described in the following instructions. Should it become necessary to remove a connecting rod after pulling a working piston, it is absolutely essential to mount suspension device 94324 for crosshead pin 6 (please refer to sheet 3326/2). This prevents that bearing cover 8 can turn and fall down when the connecting rod is lowered. Remark: To protect the crankpin being damaged it is recommended to fit the crankpin with a protective ban dage (e.g. thick leather) and remove this protection only immediately before the connecting rod with the bearing has been placed on the crankpin.
Regarding loosening and tensioning the connecting rod studs or bolts as well as regarding removal and fitting of bearings, see sheets 3303/1 to /3.
Removal - Turn crankshaft 1 of respective cylinder to B.D.C. - Install working platform (see sheet 3301/1). - Separate toggle lever 2 of crosshead lubrication and piston cooling from connecting rod 5. - Remove locking elements to studs 3 of top connecting rod bearing. - Loosen nuts of studs as described in sheet 3303/1 and remove them. - Remove working platform 94142 from crankcase. - Turn crankshaft to T.D.C. - Remove lower half of bottom end connecting rod bearing as described in sheet 3303/2. - Insert four retaining pins 94323 into guide rail 4 then turn crankshaft 1 carefully towards exhaust side, until the slippers rest on the retaining pins. If necessary adjust the retaining pins by turning them till the slippers rest on all the eccentrics of the retaining pins. - Screw eye bolts 'R' into the threaded hole meant for it in connecting rod 5 and secure the same, as shown in Fig. 'B', on the exhaust side by a steel rope and lifting tackle. Depending on the design execution of the column a cover 7 may be screw fastened on the exhaust side. Remove this cover and connect an additional steel rope with lifting tackle with the connecting rod through the freed open ing. Should it not be possible to remove this cover 7, fix a steel rope with lifting tackle to strap 10 and connect it with the connecting rod. - Now carefully rotate the crankshaft towards exhaust side and take care that the waisted bolts and the cylindrical pins of bearing cover 8 slide out of their bores without jamming. Guide the connecting rod with the lifting tackle on the exhaust side in such a way that when lowering it, crosshead pin 6 is in no danger of being damaged. - Continue turning crankshaft 1 further downwards with care till 105_ after T.D.C. - Use the lifting tackle and lower the connecting rod on the exhaust side further until it rests on the column on the fuel pump side, the resting surface being covered by a protective underlay as shown in Fig. 'B'. - Now pull connecting rod fully from the crankcase with lifting tackle and crane.
Fitting - For fitting connecting rod 5 proceed analogously to the removal but in the reverse sequence. - Immediately before assembling top end and bottom end connecting rod bearings (sheet 3303/1 and /3) clean run ning surfaces of the bearing carefully and smear them lavishly with fresh engine oil. - As soon as the retaining pins 94323 are no longer required for assembling the top end connecting rod bearing remove them immediately. - Always fit toggle lever 2 for the crosshead lubrication and piston cooling in such a way that its buckling (knee) stands upwards.
10.94
RTA84C
Maintenance
3303/4.3
10.94
RTA84C
Maintenance
3303/1.1
Connecting Rod Loosening and Tensioning the Connecting Rod Studs

Tools: 1 1 2 2 1 3 2 1 1 2 Feeler gauge Depth gauge Pretensioning jacks Pretensioning jacks HP oil pump Pressure gauges Connecters Connection piece HP hose HP hoses 94122 94124 94314 94315 94931 94932 94933 94934a 94935 94935a Key to Illustrations: 1 2 3 4 5 6 7 8 9 10 11 Connecting rod stud Round nut Cylinder Rod seal ring Piston seal ring Piston Vent screw Screw Cover with grip Cup spring Top end bearing
1part Connecting Rod
12 Bearing shell 13 Bearing cover to top end bearing 14 Sealing ring 15 Tension nut 16 Bottom end bearing 17 Bearing cover to bottom end bearing
R Round bar
Loosening and tensioning the connecting rod studs of the top end bearing (Fig. 'A' and 'B') The pretensioning jacks 94315 are selfresetting. When the oil pressure is released to zero by opening the relief valve on the HP oil pump, piston 6 slides back to its initial position by the force of the cup springs (spring packet). This entails that the relief valve at the HP oil pump remains open to one minute, allowing the oil to flow back to the HP oil pump.
94932
A
Remark: For loosening and tensioning the connecting rod studs of the top end bearing the crank of the respective cylinder must be turned to B.D.C. position. Clean the threads of the connecting rod studs 1 and the area around the nuts. Apply oil to the threads of the connecting rod studs be fore screwing on the nuts and furthermore check that the latter turn freely on the stud threads. For information on the removal and fitting as well as inspection of the top end bearing see sheet 3303/3. R Under no circumstance the separating faces of the bearing shells 12 must be reduced by filing as otherwise the essential prestress for the bearing assembly would be lost. Attention! Never turn the crankshaft as long as the pre tensioning jacks are mounted on the connect ing rod studs!
94933
9 10 6 5 4 3 94315
93.7200
1-part Connecting Rod / UG / 2001
3303/1.2
Maintenance
RTA84C
Loosening the connecting rod studs of the top end bearing The previously mentioned 'Remarks' and the 'General Application Instructions' for hydraulic pretensioning jacks on sheet 9403/4 must be considered. Remark: For loosening the four studs always follow the sequence shown in Fig. 'B' i.e. a+a and b+b.
Place pretensioning jacks 94315 diagonally onto the connecting rod studs (Fig. 'B') which have to be loosened and completely screw them on with opened vent screws 7. Connect pretensioning jacks by HP hoses 94935 and 94935a as well as connection piece 94934a to the HP oil pump 94931. Verify oil level in the HP oil pump. Actuate HP oil pump and close vent screws 7 on the pretensioning jacks as soon as oil flows bubblefree. Raise pressure to 620 bar and keep it constant. Turn back round nuts 2 by one turn, using round bar 'R'. Release pressure to zero at the HP oil pump and remove pretensioning jacks. Proceed in the same manner for the second pair of connecting rod studs.
94935a a 94315 94932
I
11 94931 94935 94934a
13 1
12
94935a 94315
00.7754
94932
2001 / UG / 1-part Connecting Rod
RTA84C
Maintenance
3303/1.3
Tensioning the connecting rod studs of the top end bearing Tighten the round nuts 2 first with the a round bar 'R' by hand with a smart jerk. Check whether the round nuts rest flush on the connecting rod. Equally distribute the bearing shell protrusion. Screw both pretensioning jacks 94315 onto the connecting rod studs (a+a, see Fig. 'B') until they rest against the connecting rod. If necessary turn pretensioning jacks back a little to allow access of the nuts with the round bar. Connect the pretensioning jacks to the HP oil pump and set pressure to 400 bar (1st step) and keep pressure constant. Tighten the round nuts with the round bar and check with the feeler gauge that no clearance remains between round nut and connecting rod. Proceed in the same manner for the second pair of connecting rod studs (b+b). Check with the feeler gauge that no clearance remains between bearing cover and connecting rod. Should clearance remain, loosen the fastening and compare the bearing protrusion with the nominal value as indi cated on sheet 3303/3. Mark the position of the round nuts 2 against connecting rod as shown in Fig. 'a', with felt marker. Raise pressure to 600 bar (2nd step) and keep it constant. Tighten nuts down and check correct seating with the feeler gauge. Check from the markings applied by how much the round nuts were turned after pretightening (1st step). Tightening angle (1st to 2nd step) to be about 23_ (Fig. 'b'). Screw pretensioning jacks onto the other pair of connecting rod studs and raise pressure to 600 bar (2nd step) and keep it constant. Tighten nuts down and check correct seating with the feeler gauge. Check tightening angle. Release pressure to zero at the HP oil pump and remove pretensioning jacks. Fig. a Fig. b
y y x
Check elongation with depth gauge For an additional check the elongation of the connecting rod studs can be measured with the depth gauge as follows: After tensioning to 400 bar (1st step) mea sure and record length 'L ' with depth gauge 94124 (Fig. 'c'). After tensioning to 600 bar (2nd step) mea sure and record length 'L1' and calculate elongation nL (to be about 0.39 mm). Should considerable differences to this nominal value be encountered then repeat the tensioning process. Fig. c Tensioning 2nd step Tensioning 1st step Stud thread DL L1 L 23_ Tightening angle
98.7700
Nut

Connecting rod
3303/1.4
Maintenance
RTA84C
Loosening and tensioning the connecting rod studs of the bottom end bearing (Fig. 'C' and 'D') The pretensioning jacks 94314 are not selfresetting. When screwing the tension nut 15 onto the connecting rod studs 1 the relief valve at the HP oil pump must be open so that piston 6 of the pretensioning jack can slide back to its initial position.
94932
94933
15
94314 x max. stroke x = 11 mm 14 6 3 R

00.7751
Remark:
For loosening and tensioning the connecting rod studs of the top end bearing the crank of the respec tive cylinder must be turned to T.D.C. position. Clean the threads of the connecting rod studs 1 and the area around the nuts. Apply oil to the threads of the connecting rod studs before screwing on the nuts and furthermore check that the latter turn freely on the stud threads. For information on the removal and fitting as well as inspection of the bottom end bearing see sheet 3303/2. Under no circumstance the separating faces of the bearing shells 12 must be reduced by filing as other wise the essential prestress for the bearing assembly would be lost.
Attention!
Never turn the crankshaft as long as the pretensioning jacks are mounted on the connecting rod studs!
RTA84C
Maintenance
3303/1.5
Loosening the connecting rod studs of the bottom end bearing The previously mentioned 'Remarks' and the 'General Application Instructions' for hydraulic pretensioning jacks on sheet 9403/4 must be considered. Place pretensioning jacks 94314 onto the connecting rod studs (Fig. 'D') which have to be loosened and fasten them with tension nuts 15. Connect pretensioning jacks by HP hoses 94935 and 94935a as well as connection piece 94934a to the HP oil pump 94931. Open relief valve on the HP oil pump, and press piston 6 down by means of tension nut 15 until there is no or very little clearance at 'x' (Fig. 'C'). Subsequently turn tension nut back by one turn. Verify oil level in the HP oil pump and close relief valve. Actuate HP oil pump and raise pressure to 620 bar and keep it constant. Turn round nuts 2 back by one turn, using round bar 'R'. Release pressure to zero at the HP oil pump and remove pretensioning jacks.
D
94932 94314 94314 94932
12
16 1 94935a
94932
94931
94935
94934a
17
94935a
00.7753
3303/1.6
Maintenance
RTA84C
Tensioning the connecting rod studs of the bottom end bearing Tighten the round nuts 2 first with the a round bar 'R' by hand with a smart jerk. Check whether the round nuts rest flush on the connecting rod. Equally distribute the bearing shell protrusion. Place pretensioning jacks 94314 onto the connecting rod studs (Fig. 'D') and fasten them with tension nuts 15. Connect pretensioning jacks by HP hoses 94935 and 94935a as well as connection piece 94934a to the HP oil pump 94931. Open relief valve on the HP oil pump, and press piston 6 down by means of tension nut 15 until there is no or very little clearance at 'x' (Fig. 'C'). Close relief valve on the HP oil pump and set pressure to 200 bar (1st step) and keep pressure constant. Tighten the round nuts with the round bar and check with the feeler gauge that no clearance remains between round nut and connecting rod. Check with the feeler gauge that no clearance remains between bearing cover and connecting rod. Should clearance remain, loosen the fastening and compare the bearing protrusion with the nominal value as indi cated on sheet 3303/2. Mark the position of the round nuts 2 against connecting rod as shown in Fig. 'd', with felt marker. Raise pressure to 600 bar (2nd step) and keep it constant. Tighten nuts down and check correct seating with the feeler gauge. Check from the markings applied by how much the round nuts were turned after pretightening (1st step). Tightening angle (1st to 2nd step) to be about 64_ (Fig. 'e'). Release pressure to zero at the HP oil pump and remove pretensioning jacks.
Fig. d
Fig. e
y y x
23_ Tightening angle
98.7700
Check elongation with depth gauge For an additional check the elongation of the connecting rod studs can be measured with the depth gauge as follows: After tensioning to 200 bar (1st step) mea sure and record length 'L ' with depth gauge 94124 (Fig. 'f'). After tensioning to 600 bar (2nd step) mea sure and record length 'L1' and calculate elongation nL (to be about 1.1 mm). Should considerable differences to this nominal value be encountered then repeat the tensioning process. Fig. f Tensioning 2nd step Tensioning 1st step Stud thread DL L1 L
Nut

Connecting rod
RTA84C
Maintenance
3303/2.1
Connecting Rod Inspection, Removing and Fitting of Bottom End Bearing

Tools: 2 Working platforms 4 Retaining pins 1 Device 94142 94323 94326 Key to Illustrations: 1 2 3 4 5 6 Connecting rod stud Round nut Crank Bearing cover Connecting rod Guide way
7 8 9 10 11 12
Tap hole for eye bolt Bearing shell Securing (Allen) screw Cylindrical pin Guide shoe Lifting tackle
A
Inspection and removing 5 2 6 Lowering the bearing cover: Turn crank of the cylinder concerned to T.D.C. Loosen the round nuts 2 to the connecting rod studs of the bottom end bearing according to in structions on sheet 3303/1. Screw two eye bolts into the bearing cover 4, each on either side directly below the bearing separation. Attach lifting tackle as shown in Fig. 'A', and connect ropes 'a' and 'b' with lifting tackle and eye bolts. Tighten the ropes.
4 3
00.7768
B
5 1 2
7 10 4
00.7764
3303/2.2
Maintenance
RTA84C
Remove round nuts 2 and carefully loosen the bearing cover from the connecting rod. Take care that the cylindrical pins 10 slide out of their bores without jamming. Evenly lower the bearing cover onto the oil trough while taking care not to damage the threads of the connecting rod studs nor the sur face of the crankpin. If only the bearings are to be inspected the bearing cover may remain on the oil trough.
Remark:
4 Removing the bearing cover from the crankcase: 00.7769
Lifting tackle and rope 'a' remain attached to the bearing cover 4 (Fig. 'C'). Loosen ropes 'b' and suspend lifting tackle at the top in the crankcase as shown in Fig. 'C'. Pull up the bearing cover towards the fuel side. Slacken rope 'a' and remove it together with the lifting tackle from the crankcase. Turn the crankshaft by approximately 30 to wards the exhaust side (Fig. 'D'). Attach rope 'c' to the eye bolt and connect the bearing cover with it to the lifting tackle 12 in or der to pull it out of the crankcase using rope 'b'. Lay down the bearing cover on the floor plates and secure it.
D
12
c c
Abgasseite EXHAUST SIDE
4
00.7770
RTA84C
Maintenance
3303/2.3
E
Brennstoffseite FUEL SIDE 94323 11 Inspection of the bearing shell: Turn the crankshaft to T.D.C. Insert four retaining pins 94323 in the guide ways 6, taking care to turn the pins with their eccentrics in such a manner that they touch the guide shoes. Secure the connecting rod with a rope 'd' and the lifting tackle on the fuel side (Fig. 'E'). Carefully turn down the crankshaft to the fuel side, following with the connecting rod bottom by pulling it with the lifting tackle and rope 'd' just as far as to keep always a safety distance between the connecting rod bearing and the crank 3. For inspection of the bearing shell turn the crankshaft to the position shown in Fig. 'F' and install the working platform 94142 according to the instructions on sheet 3301/1.
00.7773
Removal of the bearing shell: b
Attach the device 94326 to the bearing shell 8 using four screws (belonging to the device). Fasten rope 'b' to the device and tighten it. Remove the securing screws 9 Fig. 'B' and 'G') from the bearing shell. Lower down the device 94326 together with the bearing shell with rope 'b'. Connect rope 'e' to the device 94326, and re move it together with the bearing shell from the crankcase.
8 94326
G
5
94142
00.7775
9 8
00.7771
3303/2.4
Fitting
Maintenance
RTA84C
The fitting of the bearing shell 8 and the bearing cover 4 is carried out analogous to removing but in reverse se quence. The running surfaces have to be lavishly smeared with clean bearing oil. The tensioning of the connecting rod studs must be carried out according to the instructions on sheet 3303/1. Attention! Remark: Never turn the crankshaft as long as the pretensioning jacks are mounted on the connecting rod studs! After completing the work the retaining pins 94323 must be removed without fail.
Remarks on the fitting of a bearing shell: Should it become necessary to replace a bearing shell to the bottom end bearing then care must be taken that the surface of the crankpin is in perfect condition. While fitting a bearing shell the utmost attention must be given 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. This protrusion is a must and under no circumstances may the separating face of the bearing shell be filed to reduce it! New bearing shell Bottom end bearing Fig. H Protrusion x1 + x2 0.400.66 mm
x1
00.7889
Remark:
Above measuring checks must be carried out without fail when fitting a new bearing shell. For this the bearing shell is 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 restart of the engine not be immediately planned, then instead of bearing oil a mixture of 2/3 steamengine cylinder oil and 1/3 normal bearing oil should be used. Spe cial oils suited to this purpose are also available from reliable suppliers.
x2
RTA84C Connecting Rod Removing and Fitting

Tools: 1 4 1 3 Working platform Retaining pins Support Eye bolts 94142 94323 94335
Maintenance
3303/4.1

Key to Illustrations: 1 2 3 4 Connecting rod Crankshaft Guide way Bearing cover to top end bearing 5 Pin 6 Support 7 Crosshead pin R Eye bolt
As an aid for the removal or fitting of the connecting rod and other heavy engine components, the support 94335 can be used. It can be fitted between two supports 6 of the cylinder platform at the required position as shown in Fig. 'A'. Thereto place four pins of support 94335 into the corresponding holes of the supports 6, and secure the pins with their retaining springs. A connecting rod can be removed and fitted with the working piston and crosshead pin in situ. The procedure has been shown and described in the following figures and instructions. Attention! Should it become necessary to remove a connecting rod after pulling a working piston, it is absolutely essential to mount suspension device 94324 for crosshead pin (see sheet 3326/2). This prevents that bearing cover 4 can turn and fall down when the connecting rod is lowered. To protect the crankpin from damage, it must be wrapped for best effect with a bandage (e.g. thick leather) which is only removed just before the connecting rod with the bearing shell is replaced on the crankpin. 6 5 94335 6
Remark:
00.7890
3303/4.2
Removal
Maintenance
RTA84C
As regards the loosening and tensioning of the connecting rod bearing studs, as well as removing and fitting of the bearing, see sheets 3303/1 to 3303/3 for directions. - Turn crankshaft 2 of the respective cylinder to B.D.C. - Install working platform (see sheet 3301/1). - Separate toggle lever for the crosshead lubrication and piston cooling from connecting rod 1. - Loosen round nuts to the connecting rod studs of the top end bearing according to instructions on sheet 3303/1. - Remove working platform 94142 from the crankcase. - Turn crankshaft to T.D.C. - Remove the bearing cover to the bottom end bearing, see sheets 3303/1 and 3303/2. - Insert four retaining pins 94323 into the guide ways 3 and turn crankshaft 2 carefully towards exhaust side until the guide shoes rest on the retaining pins. If necessary adjust the retaining pins by turning them till the guide shoes rest on all the eccentrics of the retaining pins. - Screw eye bolt 'R' into the corresponding tap hole in the connecting rod 1, connect it with rope 'a' and lifting tackle as shown in Fig. 'B', and then tighten the rope. - Carefully turn the crankshaft towards exhaust side, taking care that the connecting rod studs to the top end bear ing and the cylindrical pins of the bearing cover 4 slide out of their bores without jamming. Guide the connecting rod with the lifting tackle in such a way that when lowering it, the crosshead pin 7 is in no danger of being dam aged. - Continue turning the crankshaft until about 105_ after T.D.C. - Lower the connecting rod towards fuel side until it rests on the column (apply protection) by loosening rope 'a'. - Sling rope 'b' around the upper connecting rod head and tighten rope by means of the lifting tackle. - Attach rope 'a' to the eye bolt screwed into the lower connecting rod head (Fig. 'B'). - Turn crankshaft slowly after T.D.C. until the connecting rod head protrudes from the crankcase, while adjusting ropes 'a' and 'b' correspondingly. - Attach lifting tackle to the support 94335, rope 'c' to the eye bolt 'R' screwed into the upper connecting rod head and tighten it (Fig. 'B'). - Sling rope 'b' around the lower connecting rod head and tighten rope by means of the lifting tackle. - Continue turning crankshaft beyond the T.D.C. while adjusting ropes 'a', 'b' and 'c' correspondingly. - Connect engine crane with upper connecting rod head by rope 'd'. - Sling rope 'c' around the lower connecting rod head as shown in Fig. 'C'. - Remove ropes 'a' and 'b'. - Remove the connecting rod from the crankcase. Fitting the connecting rod Fitting the connecting rod 1 is carried out analogously to the removal but in reverse sequence. - Before assembling the top end and bottom end bearings (see sheets 3303/1 and 3303/3) clean the running sur faces of the bearings carefully and smear them lavishly with fresh engine oil. - Immediately remove the retaining pins 94323 as soon as they are no longer required for assembling the top end bearing. - Always fit toggle lever for the crosshead lubrication and piston cooling in such a way that its curvature (knee) stands upwards.
RTA84C
Maintenance
3303/4.3
94335
7
c
4 3
a b
94323 2
R 1
01.7012
3303/4.4
Maintenance
RTA84C
94335
01.7013
RTA84C Crosshead Checking Clearances

Tools: 1 Feeler gauge 94238 1 2 3 4
Maintenance
3326/1.1
Key to Illustrations: Crosshead pin Guide shoe Retaining cover Guide rail in engine column 5 Top end bearing 6 Piston rod 7 Guide rail
On the occasion of an overhaul or when a crosshead has been removed measure the various running clearances and compare them with the values found in the clearance table 0330/2.
12.03
3326/1.2
Checking the clearances Clearance b1
Maintenance
RTA84C
Clearance between guide shoes and guide ways: The corresponding crankpin must stand in such a position that guide shoes 2 lie on guide ways 4 on fuel or exhaust side. Clearance b1 is valid for the whole guide way length and is measured according to the positions as shown in Fig. 'B'.
Clearance c1
Radial clearance between crosshead pin and guide shoe: This clearance is very difficult to establish inside the engine. It is therefore best to measure and calculate this clearance on the removed crosshead. For this the pin diameter and the bore in the guide shoe have to be measured with micrometers.
Clearance d1
Lateral clearance of crosshead between the columns: The clearance is measured in every position of the crosshead. The complete crosshead must be pressed axially to a side with suitable hardwood wedges or similar aids. The pressure must be exerted onto the guide shoe and not onto the crosshead pin 1.
Clearance e
Lateral clearance between guide shoe and crosshead pin: Push the corresponding guide shoe to the stop of the retaining cover 3 in the above mentioned position of the crosshead.
2 4 10 BEFORE / AFTER T.D.C.
b1
90 BEFORE / AFTER T.D.C.
10 AFTER / BEFORE B.D.C.
009.229/01
12.03
RTA84C
Maintenance
3326/2.1
Crosshead Removal and Fitting of a Crosshead Pin

Tools:: 1 Suspension device Various lifting tackle, ropes and eye bolts 94324 Key to Illustrations: 1 2 3 4 5 6 7 Crank Connecting rod Crosshead pin Guide shoe Adjacent cylinder (neighbouring) Guide rails Cover of connecting rod top end bearing
If a crosshead pin has to be removed, the working piston must first be pulled out. As the case may be for reasons of working space the toggle lever to the crosshead lubrication and piston cooling should also be removed from the crankcase. Removal Loosen and remove all four main bearing jack bolts of the respective cylinder as described on sheet 1132/1. Turn the crank 1 of the affected cylinder to T.D.C. Loosen and remove all four nuts of the connecting rod top end bearing studs as described on sheet 3303/1. Turn the crank to B.D.C. and carefully lift the bearing cover 7 with the crane. Take particular care that the bearing cover with its studs slides out of their bores without jamming. Mount the suspension device 94324 on the crosshead pin 3. Screw two eye bolts into the top connecting rod head 2 and secure the connecting rod with ropes and lifting tackle (see also sheet 3303/3). Raise the crosshead pin 3 with the crane until it is fully clear of the connecting rod top end bearing. Now turn the crank to the socalled 'ideal position' i.e. the crank of the cylinder where the crosshead pin has to be removed must stand between 140 and 230_ after T.D.C. The crank of one of the adjacent cylinder 5 must stand according to the cylinder 100_ or 260_ after T.D.C. (ideal position). In a special position the crank of the adjacent cylinder has to be turned to 95_ or 110_ after T.D.C. The correct position of a neighbouring cylinder 5 can be found in the table on sheet 3326/2.4. The connecting rod can now be rested on the crank case towards the exhaust side and must be secured with ropes depending on the crank position (Fig. 'A'). Protect the connecting rod surface with a wooden underlay. Lower the crosshead pin as far as possible on the crane (Fig. 'B'). Loosen and remove guide rail 6 and the retaining cover to the guide shoes 4 (see sheet 3326/1 items 7 and 3) on the side of the neighbouring cylinder (crank position see table). Using rope and lifting tackle pull the crosshead pin 3 as far as possible in axial direction towards the neighbouring cylinder 5 (Fig. 'C') so that the retaining cover of the guide shoe 4 on the end opposed to the neighbouring cylinder can be removed. On this guide shoe the guide rail 6 must not be removed. One guide shoe can now be placed on the crank web of the neighbouring cylinder and the other guide shoe on the main bearing cover (Fig. 'D'). For safeties and space sake it is, however, advisable to remove both guide shoes out of the crankcase. Push the crosshead pin alone without guide shoes to its initial position (cylinder axis) then rotate it horizontally by 90_ (Fig. 'D'). The crosshead pin can now be removed through the column door (Fig. 'E').
12.03
3326/2.2
Maintenance
RTA84C
1989
RTA84C
Maintenance
3326/2.3
1989
3326/2.4
Fitting
Maintenance
RTA84C
Fitting procedure is analogous to the removal only in reverse sequence. 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. Fit toggle lever to crosshead lubrication and piston cooling in such a way that its curvature (knee) always stands upwards. 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. Furthermore check, with lub. oil pump running, that crosshead, connecting rod bottom end bearing as well as main bearings are supplied lavishly with oil.
4 Zyl. Cyl. 1 2 3 4 5 Zyl. Cyl. 1 2 3 4 5 Zyl . 6 Cyl. 1 2 3 4 5 6 7 Zyl. Cyl. 1 2 3 4 5 6 7 8 Zyl. Cyl. 1 2 3 4 5 6 7 8
Nachbarzylinder NEIGHBOURING CYL 2 3 2 3
( nach OTP ( AFTER TDC * 260 _ 100 _ *
9 Zyl. Cyl. 1 2 3 4 5 6 7 8 9 10 Zyl. Cyl. 1 2 3 4 5 6 7 8 9 10 . 12 Zyl Cyl. 1 2 3 4 5 6 7 8 9 10 11 12
Nachbarzylinder ( nach OTP NEIGHBOURING CYL ( AFTER TDC 2 3 2 3 6 5 8 9 8 100 _ 100 _ 260 _ 100 _ 260 _ 100 _ 100 _ 100 _ 260 _
2 1 2 3 4
* * 100 _ 100 _ *
2 1 2 5 4 5 2 1 4 5 4 7 6 ** 2 3 4 3 6 5 8 7 *** 2 1 4 3 6 5 6 7
260 _ 100 _ 100 _ 260 _ 100 _ 100 _ 260 _ 100 _ 100 _ 100 _ 260 _ 260 _ 100 _ ** 95 _ 95 _ 260 _ 100 _ 260 _ 100 _ 95 _ * *** * 95 _ 100 _ 260 _ 100 _ 260 _ 95 _ 95 _
2 1 4 3 4 7 6 7 10 9
260 _ 100 _ 110 _ 260 _ 100 _ 100 _ 260 _ 100 _ 100 _ 260 _
2 1 2 5 4 5 8 7 8 11 10 11
260 _ 100 _ 100 _ 260 _ 100 _ 100 _ 260 _ 100 _ 100 _ 260 _ 100 _ 100 _
* Connecting rod of the neighbouring cylinder must be removed ** 8 cylinder engine with firing order 1-6-5-2-7-4-3-8 *** 8 cylinder engine with firing order 1-8-3-4-7-2-5-6
9.99
RTA84C Working Piston Removal and Fitting

Tools: 1 1 1 1 1 1 1 Piston ring expander Suspension device Insertion funnel (2part) Distance pipe (2part) Cover plate Tap Device for piston supporting 94338 94341 94342(a) 94345 94345d 94348 94350
Maintenance
3403/1.1
Key to Illustrations: 1 2 3 3a 3b 4 5 Piston rod Crosshead Waisted screw Locking element Screw Platform support Upper slide plates 6 7 8 9 10 11 12 Lower slide plates Gland box housing Straps Locking screw Waisted screw Centring pin Cylinder liner
Working sequence for the removal Remark: 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.
- Drain the water from the respective cylinder, remove cylinder cover (see sheet 2708/1). - Turn crank to B.D.C. - If the cylinder liner at the top of the collar is provided with an antipolishing ring, it must be removed as described on sheet 2124/1. - Remove wear ridge in the cylinder liner (see sheet 2124/3). - Loosen screwed connection piston rod 1 / crosshead 2 and remove screws 3 with locking elements 3a (Fig. 'E'). - Screw fasten the distance pipes 94345 to the piston rod foot (Fig. 'B'); utilize screws 3b and screw locking ele ments. - Loosen and remove all screws of the connection gland box housing with cylinder jacket (see sheet 2303/1). - Turn crank to T.D.C. whereby the gland box is pushed out of its seating in the cylinder jacket by the distance pipes 94345 (Fig. 'C'). - Use tap 94348 to clean threaded holes of combustion residue in the piston crown. - Mount suspension device 94341 to piston crown. - Fasten device for piston supporting 94350 to the platform supports 4 designed for this on the cylinder cover plat form (Fig. 'C' and 'F'). - Pull piston by crane out of cylinder liner (Fig. 'C'). - Push the two upper and lower slide plate halves 5 and 6 of the piston supporting device 94350 apart (Fig. 'F'). - Lower piston on crane into the supporting device until the piston rod foot protrudes below the supporting device. - Push the two upper and lower slide plate halves 5 and 6 together and screw fasten them. - Lower piston further till the piston rod head rests on the upper slide plates 5. With this the gland box housing 7 comes to rest on the lower slide plates 6. - Secure the piston in the supporting device by the two straps 8 of the upper slide plates and two locking screws 9 to the waisted screws 10. Remark: Attention! The piston may not be transported with builton gland box (risk of accident, possible damage to piston rod), but it must be dismantled firstly from the piston rod. For reasons of safety and preventing accidents, the gland box bore in the cylinder jacket must be cov ered with cover plate 94345d immediately after pulling the working piston out as shown in Fig. 'G'.
UG / 4.01
3403/1.2
Fitting preliminaries
Maintenance
RTA84C
- Remove piston rings with ring expander 94338 and clean piston exterior thoroughly. (Use no tool which could scratch or otherwise damage the surface!). - Establish the height of the piston ring grooves (see clearance table 0330/7). - Clean piston rings and measure them (see sheet 3425/1). Remark: When refitting used piston rings be sure to fit them in the same grooves as before. For refitting of used and new piston rings, follow strictly the instructions on sheet 3425/1.
- Fit the piston rings in such a manner that their marking TOP is on top. - Check the piston top surface (see sheet 3403/4). - Measure bore of cylinder liner (see sheet 2124/1) and carry out any needed reconditioning to scavenge ports and lubricating grooves (see sheet 2124/3). - Turn crank of the respective cylinder lubricating pump until oil flows from all the lubricating points. - Piston rod gland and both distance pipes 94345 must be mounted on the piston rod (see sheet 2303/1). - Place insertion funnel 94342 for piston rings on the cylinder liner as shown in Fig. 'D'. If the cylinder liner 12 is provided with an antipolishing ring, the insertion funnel 94342a must be fitted to the cylinder liner as shown in Fig. 'A'. - The suspension device 94341 must be fastened to the top of the piston crown. - Smear piston rings, piston skirt, piston rod and running surface in cylinder liner lavishly with bearing oil. - Remove the locking screws 9 which were perhaps used to secure the piston in the piston supporting device, and screw them again into the piston rod for locking of the waisted screws 10.
94342a
12
00.7367
4.01 / UG
RTA84C
Working sequence for the fitting -
Maintenance
3403/1.3
Lift piston by crane until the gland box with distance tubes 94345 is just clear off slide plates 6 in supporting device 94350. Push upper and lower slide plates 5 and 6 apart. Lift piston out of supporting device and bring it over the cylinder liner, lower it slowly into it. When the piston is lowered into the cylinder liner until the lowest piston ring is at the upper level of the inser tion funnel, arrange the piston rings so that their gaps alternate by 180_ to each other. 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 11 in the crosshead pin. Slacken crane rope and remove suspension device. Turn crank to B.D.C. and direct the insertion of the piston rod gland into its seating bore in the cylinder jacket. Pay attention that centering pin in the fixing plate of cylinder jacket fits into the centering hole in the gland box housing 7.
Attention! -
Remove both distance tubes from the piston rod foot. Smear thread and seating of the waisted screws to piston rod / crosshead pin connection with MOLYKOTE paste G. Fit and hand tighten the screws. Mark the screw head positions with felt marker against piston rod foot (initial position). With ring spanner and hammer tighten screws alternately in small steps until the tightening angle has reached 30_. Apply locking elements. Tighten all screws fastening the gland box housing firmly. If the cylinder liner at the top of the collar is provided with an antipolishing ring, it must be fitted as described on sheet 2124/2.
Remark:
Leak test After every fitting of a piston in the cylinder a leak test must be carried out. 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. Remark: Any increase in the dirty oil level in the scavenge air space may be caused by a faulty Oring in the pis ton.
UG / 4.01
3403/1.4
Maintenance
RTA84C
94341
94342
94350
94345
4.01 / UG
94345
94345
RTA84C
Maintenance
3403/1.5
UG / 4.01
3403/1.6
Maintenance
RTA84C
4.01 / UG
RTA84C
Maintenance
3403/1.7
94345 d
94345 d
UG / 4.01
RTA84C Working Piston Changing the Compression Shims

Tools: 1 Propping device (for changing shim) 2 Eye bolts 1 Spanner 94347
Maintenance
3403/2.1
Key to Illustration: 1 2 3 4 5 6 Gland housing (2 parts) Piston rod Piston rod foot Crosshead pin Piston Compression shim
Working sequence for fitting and removing compression shims Loosen locking devices and screw fastenings of the piston rod foot 3 and crosshead pin 4, as described on the sheet 3403/1. Mount the two supporting sheets, of propping device 94347 for changing the compression shim, between the gland housing 1 and the upper flange of piston rod 2 (see Fig. 'A') Turn crank of respective piston 5 carefully downwards and take care that the two centring pins in the crosshead pin 4 do not jam in the piston rod foot. Loosen the two screws fastening the compression shim 6 and remove them. Remove the compression shim with the aid of the two eye bolts. For fitting the new compression shim proceed in reverse sequence to the removal. Remark: If the new compression shim is thicker that the old one, it must absolutely be remembered to grind away the wear ridge at the top of the cylinder liner (see sheet 2124/3).
1989
3403/2.2
Maintenance
RTA84C
1989
RTA84C Working Piston Dismantling and Assembling

Tools: 1 Suspension device 1 Piston supporting device 2 Jacking screws 2 Jacking screws 1 Ring spanner AF 65 H Wooden underlays R Eye bolt 94341 94350 94363 94364 1 2 2a 3/3a 4 5 6 7 8
Maintenance
3403/3.1
Key to Illustrations: Piston crown Spraying plate Nozzle to spraying plate Screws for locking plate Dowel pin Piston skirt Piston rod Oil pipe Oring 9 10 10a 11 12 13 14 15 16 Oring Oring Oring Screw Waisted screw Locking element Screw with locking plate Centring pin Strap
A) Dismantling (take also note of alternative paragraph 'd') Should the dismantling of a working piston become necessary (cleaning the cooling space, reconditioning the ring grooves, etc.), this should be done on the upended piston placed with the top resting on a solid wooden underlay (see illustration 'E'). Fig. a) Piston in dismantling position Fig. b) Removal of piston rod with piston skirt from piston crown. Fig. c) Piston skirt in position for separation from piston rod. Fig. d) Removal of piston rod out of piston skirt. Working sequence for dismantling of a piston Place the upended piston on an even wooden underlay as per Fig. 'a' of illustration 'E'. a) Separation of piston rod 6 from piston crown 1: Remove locking elements 13 with screw and locking plate 14 from all waisted screws 12 (illustration 'A'). Loosen and remove all waisted screws 12. Lift piston on crane slightly off the ground. Insert both jacking screws 94363 into the two holes for locking screws 14 in the piston rod head Fig. 'A' view II, and drive them in till they press against piston crown 1 (illustration 'B'). Equally tighten the two jack screws in small steps, till the piston crown is separated from the piston rod. Take particular care not to damage the nozzles 2a of the spraying plate 2. Turn the two jacking screws back, but leave in piston rod head, they will be required for further dismantling. b) Separation of piston rod 6 from piston skirt 5: Lift piston rod 6 with piston skirt 5 and fit the two jacking screws 94364 into the two threaded jacking holes opposite the jacking screws 94363 (illustration 'C'). Loosen with a spanner but do not remove the screws 11 (illustration 'A') which fasten piston rod to piston skirt. Rest piston rod with piston skirt on the wooden underlay 'H' (see illustration 'E', Fig. 'c'). Attention, do not damage nozzles 2a to spraying plate 2! Unscrew the previously loosened screws 11 by hand and lift piston rod with piston skirt about 3 to 4 cm off the wooden underlay. Tighten both jacking screws 94363 (still inserted in the piston rod head) equally, whereby the piston skirt is jacked off the piston rod. The piston rod can now be lifted off and placed on another wooden underlay. Remove jack screws 94363 and locking screws 14. c) Removing the spraying plate 2 and the oil pipe 7: Bend locking plates up under screws 3 and 3a, loosen screws and remove. Spraying plate and oil pipe can individu ally be removed. Attention! Do not damage nozzles 2a to spraying plate 2!
1989
3403/3.2
Maintenance
RTA84C
d) Dismantling (alternative): A working piston can also be dismantled without upending it first (see illustration 'D'). For this alternate manner place the piston into the supporting device 94350, which must be fastened on the platform support designed for this purpose. The only difference to the dismantling alternative under A) consists in the piston rod remaining in the supporting device whereas piston crown 1 and piston skirt 5 are lifted off with the crane. The application of tools is the same. Remark: When fitting and removing the waisted screws 12 the piston rod must be steadied against rotation with the two straps 16 of the supporting device and two locking screws 14. When dismantling or assembling a piston take particular care that the spray nozzles 2a to the spray ing plate 2 are not damaged.
B) Assembling Preliminaries: For assembling the piston the following points must be observed: D D D D Any damaged nozzle 2a to spraying plate 2 may under no circumstances be refitted. Whenever possible always use new Orings, they must conform in dimensions and quality to our specifications (refer also to sheet 0370/1). All cylindrical guide portions as well as Orings, screw head seatings and screw threads must be smeared with MOLYKOTE paste before fitting. The screws 3a to the spraying plate are to be pretightened with 30 Nm using a torque wrench, then tighten to an angle of 30_ and finally secured with a locking plate. Use only lube oil on all threads of screws 3a before fitting.
a) Assembling piston rod with piston skirt: Place piston skirt 5 on wooden blocks of sufficient height that the threaded holes for screws 11 are accessible from below (see Fig. 'd' in illustration 'E'). Carefully insert piston rod 6 into the piston skirt, while paying attention that the dowel pin 4 enters the corre sponding hole in the piston skirt. Drive in screws 11 and tighten them firmly.
b) Assembling piston rod to piston crown and tightening the waisted screws: Place piston crown on an even wooden underlay (see Fig. 'b' illustration 'E'). Place Oring 10a into its groove (observe points 1 to 3 of preliminaries). Insert piston rod with piston skirt into piston crown paying attention that the two centring pins 15, which also serve as guides, fit into the respective bores in the piston skirt. Screw in all waisted screws 12 into the well cleaned threaded holes till fully seated; tighten these carefully cross wise in small steps with ring spanner. Mark position of screw heads against piston rod flange with felt marker (= initial position). Using ring spanner and hammer tighten the screws in small steps diagonally across till the screw head have described a tightening angle of 50_ (refer to sheet 0352/1). Lock all the screws 12 with its locking element 13. For fitting a locking element a screw may under no circum stance be turned back; it must instead be tightened further (by max. 5_).
9.99
RTA84C
Maintenance
3403/3.3
I-I
1 2a 10 10a 9 3 3a 2 4 5
III - III
12 13 Brennstoffpumpenseite FUEL PUMP SIDE 6 14
IV - IV
7 8
15
89.7245
II
II III
14
I III I IV V
14 13 12 11
V-V
IV
V 1989
3403/3.4
Maintenance
RTA84C
Abdrcken des Kolbenoberteils SEPARATING THE PISTON CROWN 1 2a 2 94364 Abdrcken des Kolbenunterteils SEPARATING THE PISTON SKIRT

94363 6
94363
6 94341 1
16 14
12
94350 6
89.7243
1989
RTA84C
Maintenance
3403/3.5
1989
RTA84C Working Piston Checking Piston Top Surface

Tools: 1 Feeler gauge 1 Template 1 Template 94122 94366 94366a
Maintenance
3403/4.1
Every time a piston is pulled the piston top surface contour must be checked with the checking template 94366 con tained in the tool set and with feeler gauge 94122. The template is placed on the topmost piston ring and rotated around the piston axis (see Fig. 'A'). Where burn scars are only slight it is sufficient to grind over them 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 restarting the engine, the reason for such heavy burns should be established. These causes must be reme died. Causes of heavy burn scars may be: Poor combustion, worn nozzles, heavy local carbon deposits on top of the piston crown etc.
A
94366
Kolbenring PISTON RING
94366a
99.7490
The template 94366a should be used if a check has to be carried out on the shape of the top of the piston crown of a working piston in situ. As shown in Fig. 'B', the template is to be pushed across through one of the scavenge ports of the cylinder liner and placed on top of the piston crown.
9.99
RTA84C Piston Rings Checking Piston Ring Wear

Tools: 1 1 1 1 1 1 Inside micrometer Feeler gauge Piston ring expander Insertion funnel Micrometer (0 - 25 mm) Wire brush Various cleaning liquids 94101 94122 94338 94342
Maintenance
3425/1.1
94338
00.7573
In the course of a piston overhaul the following work has to be done depending on the requirement. Removing piston rings Always use piston ring expander 94338 to remove rings from piston ring grooves. Expand the rings only sufficiently to allow removal over the piston crown. Avoid unnecessary strain (overstrain, while fitting or removing). Thoroughly clean piston, piston rings and piston ring grooves. Use a steel wire brush to remove carbon and lacquer residue, then wipe clean all the parts with a cloth and suitable cleaning agent. Measuring piston rings and piston Check all dimensions with the clearance table (sheet 0330/7) and record them. 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. Piston rings Measure the piston rings at points A, B and C (see sheet 0330/7) with a micrometer and record the values. These measurements are important for the judgement of the piston ring wear. Such a check measurement is also required on piston rings to be newly fitted. To establish the ring gap (clearance) of a topmost piston ring proceed as follows: D D D Measure with an inside micrometer 94101 the inside IC of insertion funnel 94342, as well as inside LB of the cylinder liner above the scavenge ports. Place the topmost piston ring in the insertion funnel and measure its ring gap SIC. Based on these two values the difference of the ring gap nS in the insertion funnel and fitted in the cylinder liner can be calculated by the following formula: nS = ( IC LB) x p D The ring gap SLB of the fitted topmost piston ring at the scavenge port height is determined by the formula: SLB = SIC nS Record the calculated ring gap SLB. Example: IC = 845 mm LB = 840.20 mm nS SLB = = (845 - 840.20) x p 21 mm - 15.07 mm
SIC
= = =
21 mm 15.07 mm 5.93 mm (to be recorded)
8.98
3425/1.2
Maintenance
RTA84C
Later regular optical checking of the piston rings through the scavenge ports provide a reliable judgement of piston ring condition. Depending on the position of the topmost piston ring, its ring gap can be measured through the ports. The ring gap measured during such an inspection also permits a determination of the next piston overhaul. Should the gap of the topmost piston ring be in an inconvenient position, do not try turning it by using any sort of tool. In such cases it is recommended to measure the ring gap at a later opportunity. Piston ring grooves Measure the vertical clearances n1, j1 and k1 with fitted piston rings and feeler gauge 94122. At the measuring point press the piston ring right into the groove (see Fig. 'A'). Reuse of piston rings It is recommended to pull one piston after about 2000 operating hours, to establish the wear rate of cylinder liner and of the piston rings. With the aid of the diagram on sheet 0330/7 the approximate service life of a piston ring can be estimated. At the same time the replacement date for the piston ring can be estimated. Examples (see also the diagram) Case one New cylinder liner, new piston rings: Piston pulled after 2000 operating hours. Wear was established as: Cylinder liner . . . . . . . . . . . . . . . . . . . . . 0.14 mm = 0.07 mm / 1000hrs. point 1 Piston ring . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm = 0.50 mm / 1000hrs. point 1 If all piston rings are otherwise in good condition they can be refitted. One must, however, take into consideration that refitted piston rings may only be used till the limiting line I min. Case two First piston overhaul after total 7000 operating hours: Total wear of cylinder liner . . . . . . . . . . 0.49 mm = 0.07 mm / 1000 hrs. point 2 Total wear of piston ring . . . . . . . . . . . . 3.50 mm = 0.50 mm / 1000 hrs. point 2 Point 2 lies above the line I min. It is not recommended to refit the piston ring its service life is limited by line I min. Case three Second piston overhaul after total 13 000 operating hours of the engine: Wear of cylinder liner 0.42 mm since the first overhaul = 0.07 mm / 1000hrs. point 4 Wear of piston ring . . 3.00 mm since the first overhaul = 0.50 mm / 1000hrs. point 4 Point 4 lies above the line I min. It is not worth while to refit the piston ring.
Remark
1. 2. 3.
Line I min Line I min N
= for old reused piston rings = for new piston rings
When fitting piston rings, note whether they are new ones or used ones. To ensure good sealing of the whole piston ring set, the diagram must be followed without fail. When piston rings are worn too much, an optimum seal of the piston ring set is no longer ensured. Experience has shown that used and refitted piston rings seal rather less well in operation than newly fitted ones. For this reason the limit for total wear of old reused piston rings (I min) has been set somewhat higher than for new piston rings (I min N).
8.98
RTA84C
Fitting of used piston rings
Maintenance
3425/1.3
When reusing old piston rings, only such rings may be fitted which are in undamaged, good condition. The piston rings must be fitted with the marking TOP upwards. Reused old piston rings with sharp edges must be rounded off with radii according to Fig. 'B' (with the exception of SCP1CC piston ring). The edges of the ring gap must be rounded off with a radius of 0.50 mm (with the exception of SCP1CC piston ring). Reused piston rings must be fitted again in the same ring grooves and in the same position (TOP) as removed. Be fore fitting used piston rings, measure them in view of a later judgement, as mentioned. Fitting of new piston rings The marking TOP stamped into the piston ring must, without fail, be facing upwards. Before fitting new piston rings, measure them in view of a later judgement, as mentioned. Newly fitted piston rings have to be runin according to the relevant indications in the Operating Manual. The following piston ring equipment is to be used (Fig. 'B'): Ring type Uppermost piston ring 'a' 1 x SCP1CC 20* or 1 x SCP1RC 20* 1 x SCP1RC 16 Piston rings 'b' - 'e' 4 x SCP1RC 16 Coating / material Application
chromeceramic with runningin coating
for new and used cylinder liners for new and used cylinder liners as an alternative
with runningin coating
for new and used cylinder liners
* For uppermost ring groove with a height of 20 mm Reconditioning of worn piston ring grooves If an inspection reveals much wear of the chrome Cr layers (Fig. 'A'), then a new chrome plating is indicated (new condition 0.40-0.45 mm). Instructions for reconditioning work of piston ring grooves can be requested from the engine maker. Remark: For piston crown designed with an increased hight of the uppermost piston ring groove 'a', the same piston ring equipment is to be used as described above, however, with the exception of the correspond ing piston ring hight of the uppermost piston ring 'a'.
11.02
3425/1.4
Maintenance
Ring arrangement with uppermost piston ring of increased hight
RTA84C
A
Cr j1
TOP r 2.0 a
Cr
r 2.0 Ring arrangement with piston rings of equal hight TOP
CR
e1
r 2.0 a
CR
TOP
CR e1
r 2.0
b
CR
r 2.0
k1
c
CR k1
d
CR k1
e
CR
98.7460
CR (Chromium plating) = 0.400.45 mm
Original ring width = 26.5 mm l [mm] 26 1 25 24 4 23 22 21 840 841 842 843 844 Max. liner wear = 845.88 mm 845 846 [mm] 2 l min N lmin 3
0 1 2 3 4 5
Radial ring wear [mm]
9.99
RTA84C Piston Rings Checking Piston Ring Wear

Tools: 1 1 1 1 1 1 Inside micrometer Feeler gauge Piston ring expander Insertion funnel Micrometer (0-25 mm) Wire brush 94101 94122 94338 94342a
Maintenance
3425/1.1
Cylinder Liner with Antipolishing Ring
94338
00.7573
In the course of a piston overhaul the following work has to be done depending on the requirement. Removing piston rings Always use piston ring expander 94338 to remove rings from piston ring grooves. Expand the rings only sufficiently to allow removal over the piston crown. Avoid unnecessary strain (overstrain, while fitting or removing). Thoroughly clean piston, piston rings and piston ring grooves. Use a steel wire brush to remove residues of combustion, then wipe clean all the parts with a cloth and suitable cleaning agent. Measuring piston rings and piston Check all dimensions with the clearance table (sheet 0330/7) and record them. 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. Piston rings Measure the piston rings at points A, B and C (see sheet 0330/7) with a micrometer and record the values. These measurements are important for the judgement of the piston ring wear. Such a check measurement is also required on piston rings to be newly fitted. To establish the ring gap (clearance) of a topmost piston ring proceed as follows: Measure with an inside micrometer 94101 the inside IC of insertion funnel 94342a, and inside LB of the cylinder liner above the scavenge ports. Place the uppermost piston ring in the insertion funnel and measure its ring gap SIC. Based on these two values the difference of the ring gap nS in the insertion funnel and fitted in the cylinder liner can be calculated by the following formula: nS = ( IC LB) x p The ring gap SLB of the fitted uppermost piston ring at the scavenge port height is determined by the formula: SLB = SIC nS Record the calculated ring gap SLB Example: IC nS SLB = = = 845 mm 840.20 mm (845 - 840.20) x p 21 mm - 15.07 mm = = 15.07 mm 5.93 mm (to be recorded) Antip. Ring / UG / 2001 SIC = 21 mm LB =
3425/1.2
Maintenance
RTA84C
Later regular optical checking of the piston rings through the scavenge ports provides a reliable judgement of the piston ring condition. Depending on the position of the topmost piston ring, its ring gap can be measured through the ports. The ring gap measured during such an inspection also permits a determination of the next piston overhaul. Remark: Should the gap of the topmost piston ring be in an inconvenient position, do not try turning it by using any sort of tool. In such cases it is recommended to measure the ring gap at a later opportunity.
Piston ring grooves Measure the vertical clearances e1 and k1 with feeler gauge 94122. For that the piston ring must be fitted and pressed right into the groove at the measuring point (see Fig. 'A' and clearance table). Reuse of piston rings It is recommended to pull one piston after about 2000 operating hours, to establish the wear rate of the cylinder liner and the piston rings. With the aid of the diagram on sheet 0330/7 the approximate service life of a piston ring can be estimated. At the same time the replacement date for the piston ring can be estimated. Examples (see also the diagram) Case one New cylinder liner, new piston rings: Piston pulled after 2000 operating hours. Wear was established as: Cylinder liner . . . . . . . . . . . . . . . . . . . . . 0.14 mm 0.07 mm / 1000 h point 1 Piston ring . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm 0.50 mm / 1000 h point 1 If all piston rings are otherwise in good condition they can be refitted. One must, however, take into consideration that refitted piston rings may only be used till the limiting line I min. Case two First piston overhaul after total 7000 operating hours: Total wear of cylinder liner . . . . . . . . . . 0.49 mm 0.07 mm / 1000 h point 2 Total wear of piston ring . . . . . . . . . . . . 3.50 mm 0.50 mm / 1000 h point 2 Point 2 lies above the line I min. It is not recommended to refit the piston ring its service life is limited by line I min. Case three Second piston overhaul after total 13 000 operating hours of the engine: Wear of cylinder liner 0.42 mm since the first overhaul 0.07 mm / 1000 h point 4 Wear of piston ring 3.00 mm since the first overhaul 0.50 mm / 1000 h point 4 Point 4 lies above the line I min. It is not worth while to refit the piston ring. Remark: Line I min Line I min N 1. 2. 3. for old reused piston rings for new piston rings
When fitting piston rings, note down whether they are new ones or used ones. To ensure good sealing of the whole piston ring set, the diagram must be followed without fail. When piston rings are worn too much, an optimum seal of the piston ring set is no longer ensured. Experience has shown that used and refitted piston rings seal rather less well in operation than newly fitted ones. For this reason the limit for total wear of old reused piston rings (I min) has been set somewhat higher than for new piston rings (I min N).
2001 / UG / Antip. Ring
RTA84C
Fitting of used piston rings
Maintenance
3425/1.3
When reusing old piston rings, only such rings may be fitted which are in undamaged, good condition. The piston rings must be fitted with the marking TOP upwards. Reused old piston rings with sharp edges must be rounded off with radii according to Fig. 'B' (with the exception of SCOBFC 20 ring). The edges of the ring gap must be rounded off with a radius of 0.5 mm (with the exception of SCOBFC 20 ring). Reused piston rings must be refitted in the same ring grooves and in the same position (TOP) as removed. Before fitting used piston rings, measure them in view of a later judgement, as mentioned. Fitting of new piston rings The marking TOP stamped into the piston ring must, without fail, be facing upwards. Before fitting new piston rings, measure them in view of a later judgement, as mentioned. Newly fitted piston rings have to be runin according to the relevant indications in the Operating Manual. The following piston ring equipment is to be used (Fig. 'A'): Ring type Uppermost piston ring 'a' 1 x SCP1CC 20 Piston rings 'b' - 'd' 3 x SCP1RC 20 Coating / material Application
chromeceramic
with runningin coating
Reconditioning of worn piston ring grooves If an inspection reveals much wear of the chrome Cr layers (Fig. 'A'), then a new chrome plating is indicated. Instructions for reconditioning work of piston ring grooves can be requested from the engine maker.
Antip. Ring / UG / 11.02
3425/1.4
Maintenance
RTA84C
e1 a
TOP
r 2.0
e1 b
TOP
r 2.0 r 2.0
r 2.0 k1 c
k1
d
96.7141
Chromium plating
Original ring width = 26.5 mm l [mm] 26 1 25 24 4 23 22 21 840 841 842 843 844 845 846 [mm] Max. cylinder liner wear = 845.88 mm 2 l min N lmin 3
0
Radial ring wear [mm]
1 2 3 4 5
2001 / UG / Antip. Ring
RTA96C
Betrieb
Group4
Camshaft and Control Elements
Group 4
Camshaft Driving Wheels

Checking the Running and Backlash Clearances as well as Condition of the Teeth . . . . . . . . 4103/1 Removal and Fitting the Intermediate Gear Wheel, Replacing a Gear Rim . . . . . . . . . . . . . . . . 4103/2 Replacing the 2-part Gear Wheel on the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103/3
Camshaft
Removing and Fitting a Camshaft Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203/1 Removing and Fitting of Hydraulic Locking Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203/2 Removing and Fitting of Hydraulic Locking Elements on the Camshaft . . . . . . . . . . . . . . . . . . . 4203/3 Removing and Fitting of the Camshaft Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203/4 Removing and Fitting of an SKF Shaft Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203/5 Removing and Fitting the Gear Wheel on the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203/6
Starting Air Distributor

Starting Air Shut-off Valve and Valve for Sow Turning

Cleaning and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325/1
Rotating Direction Safeguard

Inspection and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4506/1
RTA84C / MM / 2001
RTA84C
Maintenance
4103/1.1
Camshaft Driving Wheels Checking the Running and Backlash Clearances as well as Condition of the Teeth
Tools: 1 Feeler gauge 1 Dial gauge 1 Lead wire 94122
Gear wheels of new engines have to be checked visually during the runningin period after about 1-2 operating hours. The same applies to old engines which have been equipped with new gear wheels. For this the respective casings have to be removed. Rotate crankshaft with the turning gear until all the teeth have been inspected. Follow ing this, check with running lubricating oil pump, whether all the spray nozzles are delivering oil freely. Further, check whether all the screws are correctly locked, and whether any irregularities can be detected. After the running in period we recommend checking the gear wheels periodically every 3 months in the manner described above. Should in this time any faults appear, then these can in certain cases be remedied by an experienced engineer. Should noises be heard in the region of the gear train, these should be investigated and remedied as quickly as pos sible. 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 6000-8000 hours the abovementioned inspec tion may be carried out annually. Checking the gear tooth backlash The information concerning the correct gear tooth backlash values can be found in the table of clearances. (See Sheet 0330/8). The backlash can be determined in several ways. Depending on the possibilities, the following meth ods of measurement can be used: With feeler gauge 94122 The gap between the teeth flanks can be measured by using the different thickness of feelers in the feeler gauge. Repeat the measurement at a minimum of four points on the circumference of the gear wheel. With dial gauge Mount the dial gauge in such a way that the turning movement can be read off in mm. The gear wheel is then turned in such a way that the tooth profile of one tooth moves from one side to the other. When using this method of mea suring great care must be taken since the drive wheel must not be allowed to turn. With lead wire (see also example in sheet 7403/1) A lead wire of diameter 1-2 mm is laid on the drive wheel. Using the turning gear so that the wire is fed through the gear wheels. The gear tooth backlash can now be measured using a slide gauge to determine the thinnest part of the wire. Should large deviations from the desired value be measured, it will also be necessary to check the bearings of the intermediate wheels.
1989
RTA84C Camshaft Driving Wheels
Maintenance
4103/2.1
Removal and Fitting the Intermediate Gear Wheel Replacing a Gear Rim
Tools: 2 Adjusting devices various lifting tackle and steel ropes 1 Feeler gauge 94410
Key to Illustrations: 1 Split gear wheel on crankshaft 2 Intermediate gear wheel 4 Gear wheel on camshaft 5 Bearing journal 6/6a Bearing pair 7 Locking strap with screws 8 Waisted screw 9 Oil space cover 10 Taper dowels 11 Locking wire 12 Oil spray nozzles 13 Inspection cover 14 15 16 18 19 20 21 22 A M U W X Y Z Casing cover Casing cover Casing cover Gear train double column Wheel hub Gear rim Waisted bolt Spec. crown nut Marking DRIVING END Marking lines Vertical outer edge Key position for split gear wheel Suspension point for lifting tackle Axial distance according to Clearance Table 0330/8
94122
1989
4103/2.2
Maintenance
RTA84C
1989
RTA84C
Maintenance
4103/2.3
The removal or fitting of the intermediate gear wheel is effected from the exhaust side of the engine. Before remov ing an intermediate gear wheel consider the following important points: 1. If the engine is equipped with a PTO gear box, this has to be removed with the intermediate gear wheel proper to it. Relevant instructions are found on sheet 7403/2. 2. If the engine is equipped with an 'Integrated Balancer' on the driving end (4-6 Cyl. engines) then the upper compensating wheel of the balancer must be removed, for which, instructions are found on sheet 7722/1. 3. For engines with 4-6 cylinders equipped additionally to the integrated balancer with a balancer at the free end (chain driven) the instructions on sheet 7708/1 are applicable. Attention! The compensating masses of the balancer must be brought without fail to the bottom most position before removing intermediate gear wheel 2, risk of accidents.
Removal Engage turning gear. Remove electrical fuses, so that it is impossible to start the turning gear while work on removal is in progress. Remove casing covers 14 and 15 (one each on fuel pump side and on exhaust side) as well as inspection cover 13. Attach one each lifting tackle with steel ropes 'a' and 'b' at points 'X' and 'Y' respectively (Fig. 'A'). The steel ropes are pulled through the holes provided in the disc of the gear wheel 2 for this purpose and hooked into the lifting tackle (as e.g. shown in Fig. 'A'). Tauten steel ropes a little. Loosen the bearing from its fastenings towards the free end, from the crank space side. Remove locking wires 11 from all the waisted screws 8. Loosen all waisted screws and remove together with oil space cover 9. Pull both taper dowels for bearing positioning from the gear train double column 18. In the same sequence loosen also the driving side bearing 6. Now raise the intermediate gear wheel including bearing pair 6/6a with the lifting tackle slightly out of mesh with split gear wheel 1 (on the crankshaft). Clean the toothing of both gear wheels carefully, then place a strip of clean canvas between the toothing. Lower the intermediate gear wheel carefully onto gear wheel 1, taking care that the toothing of the two gear wheels, protected by the canvas mate properly. Using the two lifting tackles, roll the intermediate gear wheel slowly along the toothing of gear wheel 1 protected by canvas. During this procedure the teeth of the two gear wheels must stay mated constantly and the steel wire cables of both lifting tackles must remain under tension. Roll the intermediate gear wheel on gear wheel 1 outward, till it can be lifted out of the engine by a crane 'c' (Fig. 'A') which is placed outside the engine. Remove the locking straps 7 with screws and locking plates (see Fig. 'C') then pull both bearings 6 and 6a off the bearing journal 5. Unless absolutely required do not change the position of the crankshaft or of the camshaft as long as the intermedi ate gear wheel is removed. Fitting The fitting of the intermediate gear wheel is effected analogous to the removal in reverse sequence, whereby the following points must be paid special attention to: Fit the bearing 6 and 6a onto the lavishly oil smeared bearing journals. Both bearings are in principle exactly alike, but in spite of this they must be again fitted to their original place, as their position within the column 18 has, in the maker's works, been determined by taper dowels 10 exactly. (Pay attention to the parts numbering!).
1989
4103/2.4
Maintenance
RTA84C
The intermediate gear wheel must be fitted in such a way, that the markings DRIVING END is viewed from the driving end. This marking is stamped into the face of the gear wheel rim (see Fig. 'A' and 'C'). If neither crankshaft nor camshaft were turned in the period since removing the intermediate gear wheel, then it can be fitted in any tooth mating. Should however one or both shafts position were changed, then crankshaft and cam shaft must first be brought to their correct fitting positions. The correct positions are perfect, when the following conditions are met (Fig. 'B'): a) The crankshaft is correctly positioned when the crank of cylinder No. 1 is in T.D.C. (Cyl. No.1 = first cylin der by the flywheel). b) The marks 'M' on the gear wheel 4 on the camshaft must correspond with the vertical outer edge 'U' of its bearing housing (hood 16 removed).
Remark! The position of the key for the split gear wheel 1 on the crankshaft is determined by the number of cylin ders of the respective engine size. The angle 'a' Fig. 'B' deviates from T.D.C. by the following (_: No. of cylinder 4 5, 6, 7 8 9, 10, 12 Angle a 40 0 40 0
Bring the completed intermediate gear wheel with the lifting tackles to its original place and fix both bearings provi sionally with two screws each in the gear train double column 18 in the approximate fitting position. Tighten the screws only so much that both bearings can, for driving in the taper pins 10, still be slightly shifted about. Drive the two taper pins 10 to both bearings with a copper pin and hammer carefully in; They must not protrude over the sealing face of the oil space cover 9 under any circumstance. Remove the provisionally fitted two screws 8 again. Apply a sealing compound on the sealing faces between gear train double column 18 and oil space covers 9. Fit both covers 9 with their waisted screws 8 and tighten them lightly but equally with a spanner by hand. In this position the waisted screws are marked with a line mark, after which they are to be fully tightened in alterna tive crossing small steps till a tightening angle of 45_ is reached. For safety's sake the tooth backlash between the gear wheels must now be checked (see clearance table 0330/8). Lock all the waisted screws 8 in groups of two with locking wire. Remark! Should it become necessary to replace a bearing, then its opposite must without fail also be replaced, as new bearings are machined in pairs. For their fitting the gear wheel must be accurately lined up; The same rule is valid also for the replacement of other camshaft drive gear wheels. The adjustment is to be carried out with the adjusting device tool 94410. As regards tooth backlash and bearing clearance please refer to Clearance Table 0330/8. Check also the tooth flank surface impression by applying marking blue, and note the results. In case new dowel pins have to be fitted, e.g. when a new set of gear wheels is fitted, then the already drilled pin holes in the double column must be used Such work should be carried out by an experienced fitter, who is in possession of the required instructions from the engine manufacturer.
1989
RTA84C
Maintenance
4103/2.5
Remarks for the replacement of a split design gear wheel on the camshaft (Fig. 'C') The removing and fitting is carried out as described above. The replacement of a damaged split design gear wheel on the camshaft may only be done in exchange for a complete gear wheel i.e. the geared rim must be screw fastened to the hub 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 mak er's works and guarantees the required perfect true running of the complete gear wheel. For this reason a split de sign gear wheel may only be installed if the final machining of the teeth had been carried out with assembled hub/ toothed gear rim. After the final machining of the teeth the rim may not be separated from the hub. 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 finishmachined is fitted to the hub, screwfastened and dowelled. Then its teeth can be finishma chined.
1989
RTA84C
Maintenance
4103/3.1
Camshaft Driving Wheels Replacing the 2part Gear Wheel on the Crankshaft
Tools: 1 Feeler gauge 94122 1 Hydr. tightening device 94412 comprising: 1 Socket spanner 94412a 1 Spanner 94412b 1 Plate with pins 94412c 1 Hydraulic pump 94931 1 HP hose 1 Jack 94938 2 Eye bolts 1 Gauge or outside micrometer Marking blue 1 2 3 3a 4 5 6 7 Key to Illustrations: Upper gear wheel half Lower gear wheel half Waisted bolt Castellated nut Locating screw Locking plate Dowel pin Bedplate K M R S Key way Marking DRIVING END Threaded holes for eye bolts Threaded holes for locating screws 4 T Blind holes for inserting the tightening and loosening device W Drilling for fixing the tool during removal of thrust bearing segments
A
I-I
T S
II
R K W
II
3a
S 1
L
M (DRIVING END)
6 3 S S 2
III
R
93.7174
5 4
1989
4103/3.2
Maintenance
RTA84C
Should it be necessary to replace the split gear wheel on the coupling flange pair of the crankshafts resp. thrust bear ing collar (hereafter referred to as gear wheel on crankshaft), with your order of a new gear wheel give exact details as to engine type and number. This information is essential since the precise diameters 'F1' and 'F2' as well as total width 'C' on the crankshaft are registered by the engine builder and the spare gear wheel will be manufactured to these dimensions. Under no circumstances may the ' F1' and ' F2' be altered by filing or otherwise cutting back at the circumferen tial contact faces (see illustration 'B'). Working procedure: Removing the gear wheel Engage the turning gear and remove the intermediate wheel according to sheet 4103/2. Remove the stopper bridge for the thrust bearing segments (4-7 cylinder engines) (see sheet 1224/1). Turn the gear wheel on the crankshaft to a position such that the nuts 3a of the four waisted bolts 3 can be loosened from above (wheel separation horizontal). Now position the tightening and loosening device 94412 with its pins inserted in the blind holes 'T' available for this purpose and together with the socket spanner 94412a onto one of the castellated nuts (see Fig. 'A1'). Turn the spanner using hydraulic pump 94931 and jack 94938, pressing back the extended piston and bringing the spanner back to a better position as necessary. Remove all the nuts 3a from the waisted bolts 3 and knock the bolts out. Attention! The locating screws 4 remain in place for the time being.
Screw two eye bolts into the threaded holes R and make the upper gear wheel half 1 fast with a rope to a lifting device. Remove the four locating screws 4 from the upper gear wheel half, raise it and remove it from the crankcase. Turn the crankshaft through 180_ and remove the second gear wheel half in the same way.
A1
94412b
3a
7 94412c
94412c T
94412a
94938
94935
3a
93.7173
94412b
1989
RTA84C
Preparations for fitting the new gear wheel
Maintenance
4103/3.3
Please pay particular attention to the following points: The flanging part of the crankshaft, as well as the bore, shoulders and butting faces of the gear wheel must be clean, undamaged and dry. The same applies to key and key way. With the aid of jacking screws, remove the key and slide it into the key way of the new gear wheel as a check (the key must fit exactly at the sides, but must not jam). The fitting of a new gear rim must be carried out with utmost care and accuracy as even relatively small errors can have a negative influence on the running behavior of all gear wheels of the camshaft drive. Fitting the new gear wheel Before finally fitting the gear wheel, it should be fitted provisionally as described below in order to check that the wheel sits perfectly on the crankshaft. 1. Turn the crankshaft until the key set into the shaft is at top center. In this position, apply to the seating part on the shaft for the upper gear wheel half as well as to the back of the key with marking blue. 2. Place the gear wheel half 1 (with key way) onto the crankshaft. Using feeler gauge 94122, check that the key does not touch the bottom of the key way. Attention! The marking DRIVING END, to be found on one side of the gear wheel must be situated on the side facing the flywheel. 3. Screw four locating screws 4 into the holes 'S' until the screw heads make contact with the gear wheel half. 4. Disconnect lifting device from gear wheel half and remove the eye bolts. 5. Turn crankshaft through 180_ and now also coat this part of the seating surface with marking blue and fit the gear wheel half. 6. Screw four locating screws 4 into holes 'S' of this gear wheel half until the screw heads make contact. 7. Fit the four waisted bolts 3 from top to bottom and tighten evenly, i.e. the gap separating the two wheel halves should always be approximately the same on both sides during tightening of bolts 3 so that the two dowel pins 6 enter the holes of the other gear wheel half without being forced. 8. Turn the crankshaft so that the nuts of the waisted bolts are accessible from above. 9. Using a spanner and hammer, evenly tighten the nuts of the waisted bolts 3 crosswise, taking care that the gap between the wheel halves remains equal on both sides (counterhold bolt heads!). 10. Check the clearance between keytop and keyway by feeler gauge. 11. Loosen the nuts of the waisted bolts 3 again and remove the bolts. Thereafter, the two gear wheel halves are removed once more (see section 'Dismantling'). Check that the contact surfaces of both gear wheel halves and of the contact surfaces are in order and that there are no dents. No marking blue may be visible at the bottom of the key way. If the contact surfaces are found to be in order, the wheel halves are refitted according to points 1 to 8 and the nuts tightened as described below.
1989
4103/3.4
Maintenance
RTA84C
Final tightening of waisted bolts
Gap: Gear halves fitted, bolts untensioned (only tightened by hand with spanner)
B
Measuring range for Fig. E Measuring range for Fig. E
Measuring range for Fig. D
Gap: Between the split faces in the measuring range for Fig. 'D' (acc. illustration 'B') bolts fully tightened
D
max 0.03mm max 0.03mm
Gap: In the measuring range for Fig. 'E' (acc. illustration 'B') bolts fully tightened
E
-0.20 -0.24 0.63 0.75 1.05+ -0.05 8500
Tolerance Clearance j Bolt elongation Tightening torque
F min. max. L
(mm) (mm) (mm) Nm
Gap = 0
Gap = 0
Threads and nut seating smeared with MOLYKOTE paste Gn
Attention!
The two bores of the gear wheel 'D1' and 'D2' (see illustration 'B') are smaller by D F than the corre sponding check measurements 'F1' and 'F2' on the crankshaft (during machining the average tol erance is aimed at).
Working sequence: After fitting the two gear wheel halves as per points 1 to 7, the total length 'L ' (see Fig. 'A') of the waisted bolts must be measured with a vernier caliper or a horseshoe micrometer and recorded (note the bolt numbers). Tighten the two screws of one gear wheel separation manually with a spanner (without extension or hammer) until the gap at this separation is = 0. Tighten the opposite two bolts in the same manner, whereby a gap j min. or j max. remains (see Fig. 'C').
1989
RTA84C
Maintenance
4103/3.5
Should the gap be larger than j max, the bores of the gear wheel must be enlarged by an extremely small amount. This can be done by careful scraping or grinding with emery cloth and a suitable piece of wood. When the described starting position is reached as per Fig. 'C' in the measuring range for Fig. 'D', loosen the two waisted screws of the wheel separation side with '0' clearance slightly and instead tighten the screws of the wheel separation side with clearance 'j' correspondingly more, so that in the end in the measuring range for Fig. 'D' (see illustration 'B') i.e. in the region of the teeth the clearance on both sides is exactly equal. Tighten the waisted bolts crosswise with tightening device 94412 equally till their total length (see Fig. 'A') has in creased by at least D L. In this condition between the teeth (in the measuring range for Fig. 'D' in illustration 'B' should the clearance be tween the two separating faces by maximum 0.03 mm (Fig. 'D'). In the measuring range for Fig. 'E', illustration 'B' i.e. on the outer edges between the shoulders the clearance should be practically zero (Fig. 'E').
1989
RTA84C
Maintenance
4203/1.1
Camshaft Removing and Fitting a Camshaft Section

Tools: 1 1 2 1 1 2 2 2 1 Holding strap Lifting device Pins Support Clamping bolt Holding straps Supports Special nuts Set tools for cutting out an actuating pump 94416 94417 94417a 94418 94419 94422 94423 94423a 94430 Key to Illustrations: 1 Actuating gear housing of the fuel and actuator pump 2 Camshaft (section) 3 Coupling 4 Reversing servomotor 5 Oil connections 6 6a 7 8 9 10 11 12 Inner bearing shell Bearing girder Bearing ring Bolts Orings Orings Feed shaft nut Locking ring
The complete camshaft comprising several sections should never be fitted or removed in one piece. The arrange ment and use of the devices and tools for each individual section is the same as is shown on illustration 'A' and 'C'. Valid only for engines with balancer on the free end Attention! For fitting or removing of a camshaft section the existence on the engine of a camshaft driven balancer must always taken into consideration. For this reason compliance with the instructions in the appendix sheet 7708/1 is unavoidable (otherwise danger of accident).
1989
4203/1.2
Maintenance
RTA84C
Removal of a camshaft section Remove the front and side casings from the fuel pump actuating gear housing. On a camshaft section, equipped with a vibration damper, it has to be removed before the removal of the camshaft section, so that during the rolling out of the camshaft section its tilting is prevented. Turn the engine with the turning gear and simultaneously raise the rollers together with their guides of all the fuel and actuator pumps from their cams. Refer the Service Instructions Manual for this. Make ready the cutout devices for cutting out the actuator pumps (one tool 94430 for each actuator pump). Slacken off and remove the tie rods with distance tubes which lie vertically in front of the camshaft bearings to rein force the fuel pump actuating gear housing. Release the shaft couplings which connect the camshaft section to be removed from its neighbouring units accord ing to the instructions given on sheets 4203/2 -/4 and -/5. The markings on the shafts and couplings make it pos sible to precisely reposition all the components during later reassembly. Now slide the released couplings onto the camshaft sections which will not be removed. Loosen screws 8 and draw oil connections 5 downwards till the locking ring 12 rests against housing 1 (please refer to Fig. 'A' and 'B'). As shown in Fig. 'A' attach a holding strap 94422 each on the front face of the drive housing; These prevent the camshaft accidentally slipping out of its bearings, while the bearing covers are being loosened and removed. Slacken off both bearing caps and remove them. Replace them with the supports 94423 with the related special nuts 94423a on the now accessible bearing girder 6a Remove both the holding straps 94422 and roll out the camshaft section onto the supports 94423. Lift the unit from there with the aid of a crane. When removal will be carried out using the procedure whereby the cams will be pulled off the camshaft section, this can be prepared with the tool set according to Fig. 'C' and carried out there and then. Where the fuel cams, e.g. to the right of the reversing servomotor will be pulled off the shaft then the holding clamp 94416 has to be mounted on the left of the drive housing. Fit support 94418 at the same time. Lay the lifting device 94417 on the support 94418 and position this at the same time with the two pins 94417a which have to be inserted up in the drive housing. Clamp the bearing ring 7 of the re versing servomotor 4 with clamping bolt 94419 (see detail Section II-II for RTA 58-84C, Section III - III for RTA 52,62,72). Use a screwdriver on the feed shaft nut 11 and thereby raise the cam shaft section enough to unload a support 94423 which can then be re moved. For further procedure, particularly for pulling off and on of a fuel and actuating cam, see information on sheets 4203/2 and -/3.
10.94
RTA84C
Maintenance
4203/1.3
1989
4203/1.4
Fitting a camshaft section
Maintenance
RTA84C
Fitting follows in the reverse order of removal. Please note the following points: The numbering of the individual parts which belong together must concur. The contact surfaces of the supports onto which the camshaft section to be fitted will be placed must be clean. The same applies to the camshaft bearing journals and bearings. Shortly before rolling the shaft into its bearings lubricate the bearing surfaces liberally with clean oil. When fitting the camshaft bearing shells particular care has to be taken to ensure that the pin in the bearing cap engages properly in the hole on the back of the outer bearing shell half. Furthermore, the inner bearing shell must be so placed in the axial direction that both its pins, which are in the but ting faces, can engage properly in the relevant holes in the outer bearing shell when fitting the bearing cap. The best thing is to put the bearing together provisionally before fitting the shaft, so long as the inner bearing shells can still be slid sideways. Attention! The clamping bolt 94419 must be removed from the reversing servomotor and the three oil connections 5 pulled up and led into the bearing ring 7 before the couplings 3 are pressed into the shaft connections. When sliding on and positioning the couplings, check that the locating marks on the shaft ends to be connected concur. With regard to pressing on the shaft coupling with hydraulic fitting tools, see sheets 4203/2 -/4 and -/5. Tightening the studs of the camshaft bearings Once the camshaft is in its bearings and their bearing caps are fitted, tighten down both the nuts evenly with a span ner by hand until metaltometal contact is obtained. Now tighten the nuts equally in little steps alternately, using the ring spanner and hammer. Following check the vertical bearing clearance of the camshaft bearings (see Table of Clearances 0330/10). The waisted screws with distance tubes, stiffening the actuating gear housing, are now fitted and tightened lightly by hand. Starting from this position the waisted screws are tightened by impact wrench and hammer by a further angle of ( 60_. Remark: After the refitting of camshaft sections the correct position of the exhaust valve and fuel cams of the re moved ones and cams of following cylinders must be checked (please refer to timing records).
1989
RTA84C
Maintenance
4203/2.1
Steuerwelle/Camshaft Demontage u. Montage der hydr. Pressverbaende Removing and Fitting of Hydraulic Locking Elements
Steuerwellenkupplung, Hubgebernocken und Brennstoff nocken werden mittels Hydraulikwerkzeug montiert, ausgerichtet (eingestellt) und demontiert. (Details siehe Blatt 4203/3 - /5)
Coupling for camshaft, actuator cam and fuel cam are fixed with the oil injection method. They are fitted, adjusted and taken off with separate hydraulic tool. (for details see sheets 4203/3 - /5)
Demontage / Removing Motor schalten und Rollen abheben. Hydr. Werkzeug auf Kupplung montieren. Kupplung lsen und diese axial wegschieben. Lagerdeckel entfernen und Umsteuerlanschlsse absenken. Turn engine and lift rollers. Hydraulic tool to be fixed to couplings. Couplings to be slid in axial direction. Bearing covers to be taken off and connec tions for regulating oil to be lowered.
Steuerwelle aus dem Gehuse rollen. Hydr. Werkzeug auf Hubgebernocken montieren.
Camshaft section to be rolled out of housing Hydraulic tool to be fixed to actuator cam.
Hubgebernocken entfernen und hydr. Werkzeug auf Brennstoffnocken montieren.
Actuator cam to be taken off Hydraulic tool to be fixed to fuel cam.
Brennstoffnocken entfernen.
Fuel cam to be taken off.
Montage: Gleich wie Demontage aber in umgkehrter Reihenfolge.
Fitting:
Same as removing, but in reverse order.
1989
RTA84C
Maintenance
4203/3.1
Camshaft Removing and Fitting of Hydraulic Locking Elements on the Camshaft

Tools: 1 1 1 1 1 1 1 1 1 1 1 2 1 1 Hydr. jacking tool Connecting branch Connecting branch Connecting branch Centering disc Hose pipe (1500 bar) Suspension strap Cam setting template Oil pump Oil pump SKF HP hose HP hoses Controllable check valve Oil pump 94424 94425 94426 94427 94428 94429 94431 94432 94931 94931a 94935 94935a 94939a 94942 Key to Illustrations: 1 Fuel cam 1a Actuator cam 2 Piston carrier plate (2part) 3 Ring piece (2part) 4 Screws M20 x 200 4a Screws M30 x 220 5 Piston (total 6 pieces) 6 Camshaft 7 Sleeve 8 Bush 8a Bush 9 10 11 11a Flange coupling Guide plate Coupling sleeve Bush
E Vents H Connection from oil pump 94942 W Connection from oil pump 94931 S Connection from oil pump 94931a
For details of jacks and hydraulic pumps see sheets 9403/2 -/4. Remark: To carry out the work described below three high pressure pumps of different designs are required. These oil pumps (tools 94942, 94931 and 94931a) have to be filled with engine oil having a viscosity of SAE 30 to SAE 40 before starting them up. In exceptional cases oil pump 94942 may be filled with cylinder lubricating oil. The locking valve 94939a installed between oil pump and hydr. jacking tool 94424 must always be shut. In this valve position oil can reach the presses, but not flow back. By careful opening the locking valve, the drop of a pressure in the hydr. jacking tool can be controlled very minutely. Risk of accident! Cut out the corresponding fuel injection pumps when working on the fuel injection pump drive or on the fuel cam (i. e. adjusting) with the camshaft section in situ. Keep the control oil system under pressure and local manoeuvring lever 5.03 must be in position RUN AHEAD or ASTERN to prevent an unexpected turning of the reversing servomotor together with their fuel cams. Removing the cams for the fuel injection and actuator pumps Working sequence: Place the camshaft section at an easily accessible clean location. Push hydr. jacking tool 94424 over the shaft against the cam. Screw in and tighten, for connecting at 'H', the two connecting branches 94425 and 94426 in the threaded holes M16x1.5 (with oil passage bore 6 mm). Screw in by hand equally, but do not tighten, all screws 4 for fastening the hydr. jacking tool 94424 to sleeve 7 of the reversing servomotor, or directly to the actuator cam respectively. Connect by HP hoses and accessory fittings, as shown in illustrations, the oil pump 94931 to connections 'W' and oil pump 94942 to connections 'H'. Open the two vent screws 'E' on hydr. jacking tool 94424, and actuate oil pump 94931 until the oil flows out bubble free. Shut vent screws. Draw out pistons 5 and tighten all screws 4 equally. Only after the oil pressure in the hydr. jacking tool (connection 'W') has risen to 30-50 bar, may oil pressure be fed to connection 'H'. Pressure may only be raised on the connection 'H' when hydr. jacking tool 94424 has been correctly mounted and pressurized. Risk of accident!! When oil squeezes out all around the circumference of the press seats the oil pressure in the hydr. jacking tool 94424 can slowly be reduced, after which the cam will loosen. Dismantle the hydr. jacking tool. Attach suspension strap 94431 to the fuel or actuator cam as shown in the illustration on sheet 4203/3.8. Lift cams with the aid of a lifting tackle from sleeve 7 or camshaft 6 together with bushes 8 and 8a.
Attention!
3.03
4203/3.2
Maintenance
RTA84C
1989
RTA84C
Fitting the fuel cam
Maintenance
4203/3.3
Clean all seat surfaces before fitting Push cam 1 with bush 8 onto the sleeve 7 of the reversing servomotor. Make certain that cam and bush are flush. Push hydr. jacking tool 94424 against the cam, screw in connection branch 94426 for connection 'H' (Pay attention to bore 4 6)then tighten all fastening screws 4 by hand equally. Connect pump 94931 to connection 'W' and pump 94942 to connection 'H'. Open the two vent screws 'E' on tool 94424 and actuate pump 94931 till oil flows bubblefree. Shut vent screws. Actuate pump 94942 pressurizing taper through connection 'H' until the oil is squeezed out on both sides between the sleeve 7 of reversing servomotor and bush 8 and around the whole circumference. By slightly raising the pressure in tool 94424 the cam moves slowly in axial direction. The pressure at connection 'H' thereby rises continually to about 550 bar. During the full fitting procedure oil must continually squeeze out on both sides of the bush 8 of cam 1. When the end position is reached, i.e. the cam with bush pressed the sleeve shoulder, release first the pressure in connection 'H' and only after about 30 seconds the pressure at connection 'W' in the tool. Dismantle the tool and store back in tool box.
1989
4203/3.4
Fitting the actuator cam
Maintenance
RTA84C
Clean all seat surfaces before fitting. Push cam and bush 8 onto camshaft and position it (consider recess). Fasten Hydr. jacking tool to cam, whereby all screws 4 must be equally tightened by hand, Join pump 94931 to con nection 'W' and pump 94942 to connection 'H'. Open the two vent screws 'E' on tool 94424 and actuate pump 94931 till oil flows out bubblefree. Shut vent screws. Actuate pump 94942, pressurizing taper through connection 'H' till oil squeezes out on both cam ends around the whole circumference. Slowly raise pressure at 'W' in the tool whereby the cam is slowly moved up the taper bush. The pressure at connec tion 'H' continually rises to about 800 bar. During the whole fitting procedure oil must continually squeeze out on either side of the cam. The end position is reached when the cam is flush with the bush. Now release first oil pressure at connection 'H' and only about 30 seconds later the pressure at connection 'W'. Dismantle the tool and store back in tool box. Remark: When replacing an actuator cam 1a, its bush 8a must be replaced at the same time. Both parts form one unit and must not be interchanged. For spares orders bush and cam are always supplied together.
1989
RTA84C
Adjusting the fuel cam and the actuator cam
Maintenance
4203/3.5
Important Remarks: Before shifting the cams, the rollers with their roller guides of a respective fuel injection pump group must be lifted over their cams. For adjusting (Shifting) the cams the pump 94942 has to be joined to connections 'H'. Approximate pressures for cam shifting: fuel cam actuator cam 600 bar 800 bar
With the help of the setting template 94432 the cam can now be reset by the desired amount. Attention! Before pressurizing the fuel cam, check carefully whether the guide plates 10 (two pieces) are screwed to the side of the sleeve. They prevent sideways slipping of the fuel cam during the cam shifting. Their pres ence is therefore essential.
1989
4203/3.6
Removing and fitting the flange coupling
Maintenance
RTA84C
Removing the flange coupling
Insert centering disc 94428 into the shaft end recess. Fasten hydr. jacking tool 94424 to flange coupling with screws 4a but tighten screws only slightly by hand. Join pump 94942 to fitted connecting branch at 'H' and pump 94931 to fitted connecting branch at 'W'. Open the two vent screws 'E' on tool 94424 and actuate pump 94942 till oil flows out without bubbling. Shut vent screw. Draw out pistons and tighten all screws equally. Bring pressure in tool 94424 (Connection 'W') to about 100 bar, only after tool 94424 is pressurized may connection 'H' be charged with oil pressure At connection 'H' pressure may only be raised when tool 94424 is correctly fastened and pressurized. Danger of accident!! When oil squeezes out around the whole circumference, the oil pressure in the tool can slowly be reduced, where upon the flange coupling is loosened. Remove tool, remove centering disc.
1989
RTA84C
Fitting the flange coupling
Maintenance
4203/3.7
Clean all seating surfaces before fitting starts. Position flange with bush 8 onto camshaft end. Pay attention to the marks on bush, flange and camshaft. Bush ex actly flush with shaft end. Insert centering disc 94428 at shaft end. Fasten hydr. jacking tool 94424, by tightening all screws equally by hand. Join pump 94931 to connection 'W' and pump 94942 to connection 'H'. Open the two vent screws 'E' on tool 94424 and actuate pump 94931 till oil flows out bubblefree. Shut vent screws. Actuate pump 94942 pressurizing the taper through 'H', till oil squeezes out on both sides on the whole circumfer ence. By slowly raising the oil pressure in the tool at 'W' the flange moves slowly towards the shaft end. The pressure at connection 'H' rises continually during this procedure till about 1000 bar. During the whole fitting process oil must squeeze out on both sides of the flange. When the end position is reached i.e. flange flush with bush, release first the oil pressure at connection 'H' and only about 30 seconds later release the pressure in the tool. Remove the tool and the centering disc.
1989
4203/3.8
Maintenance
RTA84C
Aufhngelasche fr Transport von Brennstoffund Hubgebernocken SUSPENSION STRAP FOR TRANSPORT OF FUEL AND ACTUATOR CAMS
Brennstoffnocken FUEL CAM
1989
RTA84C
Maintenance
4203/4.1
Camshaft Removing and Fitting of the Camshaft Coupling

Removing the camshaft coupling Key to Illustrations: See sheet 4203/3
Screw tool 94424 lightly on with screws 4a, then join pump 94931 to connection 'W' and pump 94931a SKF to con nection 'S'. Open the two vent screws 'E' on tool 94424 and actuate pump 94931 until oil flows bubblefree. Shut vent screws. Draw pistons 5 out and tighten all screws 4a equally. Raise oil pressure in tool 94424 to 300 bar then charge connection 'S' by pump 94931a with pressure. At connection 'S' pressure may only be raised when the tool 94424 is correctly fitted and pressurized. Danger of accidents! When oil squeezes out on the whole circumference between coupling sleeve 11 and bush 11a the pressure can slowly be reduced in the tool whereupon the coupling sleeve will slowly slide off the bush 13. Remove tool 94424.
1989
4203/4.2
Fitting the camshaft coupling
Maintenance
RTA84C
220mm
Clean all seating surfaces before starting to mount. After mounting the shafts the axial gap between them may not exceed 1 mm. The two shaft ends must be exactly aligned. Check: Roller of Fuel cams must be aligned. Push coupling over the camshaft and place in correct position, dimension 220 mm. The marks on the shafts ends must coincide. Fit tool 94424, tightening all screws 4 equally by hand. Join pump 94931 at connection 'W' and pump 94931a to connection 'S'. Open both vent screws 'E' on tool 94424 and actuate pump 94931 until oil flows bubblefree. Shut vent screws 'E'. Charge connection 'S' with oil pressure onto taper until oil squeezes out around the whole circumference. Slowly raise the pressure in the tool 94424, whereupon the coupling sleeve 12 will slowly slide onto the bush 13. During the whole mounting process oil must continually squeeze out between the gap on both sides of the coupling. When the end position, coupling sleeve 12 and bush 13 flush is reached, release first the pressure in connection 'S' and only after about 30 seconds release the pressure in the tool 94424. Remove the tool.
1989
RTA84C
Maintenance
4203/5.1
Camshaft Removing and Fitting of an SKF Shaft Coupling

Tools: 1 1 1 1 HP oil pump SKF hand oil pump Pressure gauge HP hose 94931 94931a 94932 94935 Key to Illustrations: 1 2 3 4 5 6 7 8 9 Camshaft Inner bush Coupling sleeve Screw Valve screw Release valve Nut Seal ring Locking plates P Fit gap R Ring space 'HPC' High Pressure Connection 'LPC' Low Pressure Connection
A
94932
Achtung ! ATTENTION ! MAX. OIL PRESSURE 25MPa (250bar)
6 94931a 94931 94935 5
R=BSP
Anschluss HPC CONNECTION Anschluss LPC CONNECTION
10 mm
R=BSP
177 mm
P 9 4 3
Marken MARKS
93.7187
7 7 8 R 2
9.99
4203/5.2
Removing an SKF shaft coupling Working sequence: -
Maintenance
RTA84C
Loosen screws 4 and remove locking plates 9. Join pressure oil devices, consisting of the HP oil pump 94931, SKF hand oil pump 94931a as well as HP hose 94935 to the coupling as shown in Fig. 'A'. With HP oil pump 94931 raise at connection 'LPC' an oil pressure in the ring space of about 200 bar (20 MPa) and keep this constant. The pressure in this ring space may not exceed 250 bar (25 MPa) under any circumstances. Actuate SKF hand oil pump 94931a and press oil into connection 'HPC' until oil squeezes out all around the circumference between coupling sleeve and inner bush. On large couplings this may take several minutes. Should the coupling be cold and the oil difficult to press in, then warming up the coupling will help (approx temperature 20-30_C). As a rule the HP oil pump 94931 and SKF hand oil pump 94931a have to be filled with engine oil of viscosity SAE 30 to SAE 40. In exceptional cases cylinder lubricating oil can be filled into the SKF hand oil pump 94931a. Open the release valve 6 at HP oil pump 94931 until the coupling sleeve 3 slides slowly off the inner bush 2. Should the coupling sleeve not loosen continue pressing oil into fit gap 'P' between the sleeve and the bush with SKF hand oil pump 94931a. A slight tap on the inner bush can also start the loosening of the coupling sleeve. Clean the shaft surfaces on either side of the coupling. Shut connection and vent bores to the ring space, then push the coupling completely onto one camshaft end. Shutting connection and vent openings is necessary to ensure that the pushing force is transmitted only through the oil enclosed in the ring space, thereby preventing the jamming of seal ring 8.
Fitting an SKF shaft coupling Working sequence: Clean coupling seats on shaft and bore of inner bush. Slightly smear coupling seats with clean low viscosity oil. The marks on the shaft ends must coincide (Fig. 'A'). When joining the two shaft pieces the axial gap between them must be maximum 1 mm. Therefore, the two shaft ends must first be exactly lined up. Check: Roller to fuel pump cam aligned. Push shaft coupling onto the camshaft. Place inner bush 2 according to Fig. 'A'. Connect the HP hose 94935 to the HP oil pump 94931 and to the ring space 'R' of the coupling sleeve 3 and open vent bore nearby. Screw the SKF hand oil pump 94931a firmly into the connection bore 'HPC' in the coupling sleeve and press oil into the fit gap 'P' until it squeezes out at the thicker end of the inner bush 2. With the HP oil pump 94931 press now oil into the ring space 'R' until it flows bubblefree from the vent hole. Shut vent bore and drive the outer coupling sleeve by further pumping onto the inner bush, whereby care must be taken that the pressure gauge 94932 never shows more that 250 bar (25 MPa). During fitting keep pumping oil into the fit gap to maintain the oil film. Fitting is completed when the inner bush still protrudes by 10 mm (Fig. 'A'). After 'driving on' outer sleeve 3, open valve screw 5 of the SKF hand oil pump 94931a to allow the oil from the fit gap to flow back into the oil container in the pump. Only then release the pressure in the ring space 'R'. Remove HP hose to ring space 'R' and the connections. Shut the connecting bore with the threaded plug pro vided. The remaining oil from the ring space must not be drained any more. Fit locking plates 9 with screw 4. After the first fitting of the coupling the nut 7 must be retightened. Then fit locking plates 9 with screws 4.
Remark:
9.99
RTA84C
Maintenance
4203/6.1
Camshaft Removing and Fitting the Gear Wheel on the Camshaft

Tools: 2 Fixing stirrup 2 Supports 94420 94421 1 2 3 4 4a 5 Key to Illustrations: Bearing housing Camshaft section Shaft coupling Gear wheel on camshaft Gear wheel hub Adjusting screw 6 7 8 9 10 11 12 13 M S Bearing saddle Platform support Driving wheel for starting air distributor Screw plug Screw Driving shaft for starting air distributor Cover to auxiliary gear box housing Gear wheel for vertical drive Circular marking Screw
Only valid for engines with balancer Attention! When fitting or removing the gear wheel on the camshaft of a 4-6 cylinder engine one must without fail take into consideration that it may be equipped with a balancer, fitted at the free end and driven by the camshaft. To prevent accidents it is unavoidable that instructions in the appendix to sheet 7708/1 be fol lowed.
1989
4203/6.2
Maintenance
RTA84C
1989
RTA84C
Removal
Maintenance
4203/6.3
Should the gear wheel on the camshaft have to be removed, proceed as follows: Turn crank of first cylinder to T.D.C. (first cylinder near flywheel is cylinder No.1). Remove casing over the gear wheel from bearing housing 1. The marking lines on the gear rim must be flush with the outer edge of the bearing housing (see sheet 4103/2). Remove twopart closing cover to right and left on the bearing housing. On engines equipped with a chain driven balancer at the free engine end, the balancer weights must without fail pointing downwards before loosening a camshaft coupling (see addendum sheet 7708/1). Camshaft coupling 3 has to be loosened in accordance with the instruction sheets 4203/4 and -/5. After uncoupling check whether the markings on the uncoupled shaft ends coincide with each other. For safety reasons, measures must be taken that during the work in progress the turning gear remains engaged but cannot be put in motion. Fit two fixing stirrups 94420 to the bearing saddle 6 as per Fig. 'A'. They prevent the gear wheel with its shaft section from rolling out of their bearings while the bearing covers are loosened and removed. Loosen and remove both bearing covers, following which fasten the supports 94421 on the bearing saddles 6 just become accessible. Adjust the support with adjusting screws 5 so, that they rest solidly on the platform beams 7. By loosening and removing the fixing stirrups 94420, the gear wheel with its camshaft section 2 can be rolled out onto the supports 94421 and picked up from there with the crane. In case the gear wheel 4 with hub 4a have to be taken off the camshaft, it is essential to check whether gear wheel hub and camshaft section are marked together. Fitting The fitting of the gear wheel with its shaft section is effected in reverse sequence to the removal, whereby the follow ing points must be paid attention to: Remark! During assembly and later fitting of the gear wheel with the camshaft, consideration must be given that the marking DRIVING END on the gear rim must be viewed from the driving end. On the same side the marks are stamped in for the correct 'camshaftdrive wheel setting' (see Fig. 'B'). The markings (numbering) of the individual parts must coincide. All parts must be clean and undamaged, they must be slightly oiled before assembling. Crank of cylinder number one must be at T.D.C. (first cylinder near flywheel). After rolling the gear wheel on the camshaft back into its bearings and the fixing stirrup 94420 fitted to prevent its rolling out on its own, check whether: 1) The line marks on gear wheel 4 match the vertical outer edge of the housing (see sheet 4103/2). 2) The driving wheel 8 for the starting air distributor stands in the correct position in the auxiliary drive housing. This check is possible when the screw 10 (see Fig. 'C') is unscrewed from the screw plug 9. Then a round mark becomes visible on the driving wheel 8 if this is in the right position. Tighten the screws to the camshaft bearing covers equally, using ring spanner and hammer. Check if the vertical bearing clearance of the camshaft bearings (see Clearance Table 0330/10) is in order, if so, lock the screws with lock ing plates. Before tensioning shaft coupling 3 turn the crankshaft of the engine until the markings on the shafts, to be coupled, again coincide. Before finally fitting the hood, check with running oil pump, whether the oil supply to the bearings functions.
1989
4203/6.4
Maintenance
RTA84C
Remarks for the replacement of a split design gear wheel on the camshaft (Fig. 'B') The removing and fitting is carried out as described above. The replacement of a damaged split design gear wheel on the camshaft may only be done in exchange for a complete gear wheel i.e. the geared rim must be screw fastened to the hub 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 maker's works and guar antees 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/toothed gear rim. After the final machining of the teeth the rim may not be separated from the hub. 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 finishmachined is fitted to the existing hub. Then its teeth can be finishmachined.
1989
RTA84C Starting Air Distributor Dismantling and Assembling

Tools: 1 2 1 2 Grip screw M5 Grip screws M8 Snap ring tong Eye bolts M10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Maintenance
4303/1.1
Key to Illustrations: Control valve Roller pin Screws Protection pipe Housing Screws Guide flange Cover Thrust washer Cylinder Piston Cam Allen screws Flange Spring Roller Drive shaft Shaft 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Screws Inspection cover Intermediate piece Bearing flange Coupling Fitted bolt Drive shaft Screws Allen screws Snap ring Locking ring Pins Spring dowel pin Rod seal ring Piston seal ring Bearing bush Spacer tube Bearing bush 'DU'
The Starting air distributor requires generally no maintenance. It is however recommended to dismantle, clean and inspect it during general overhauls every for years. Attention! Before starting work on a starting air distributor it is essential to shut all valves on the starting air receivers. The turning gear must be engaged without fail, by which it is ensured that the starting air and control air piping to the starting air distributor are devoid of air pressure.
Dismantling Remark: Control valves 1 can only be removed after roller pins 2 have been taken out. For the dismantling of the starting air distributor proceed as follows: - Loosen screws 3 and remove protection pipe 4. - Undo the locking wire to screws 6 and loosen two screws diagonally and remove them. - Into the freed threaded holes screw in two grip screws M8. - Using a plastic or lead hammer knock gently and carefully against cylinder 10, so that guide flange 7 works free of housing 5. - The whole shifting mechanism consisting of the items 6 to 13 can now be pulled out with the grip screws. If neces sary this assembly can be dismantled into separate parts after loosening the remaining two screws 6 and allen screws 13 and removing them. Before removing control valves 1 blank off the opening from which the shifting mechanism has been extracted to protect the unit against entry of foreign particles, dust and dirt. - For the removal of air control valves 1 first remove flange 14.
1989
4303/1.2
Maintenance
RTA84C
- Push the control valves against the force of spring 15 slightly inwards and simultaneously pull roller pin 2 out with grip screw M5. Remove roller 16. - The control valves can now be removed together with springs 15. Should it be necessary to remove, in addition to the above mentioned items drive shaft 17 and shaft 18, then proceed as mentioned below: - Drive two eye bolts M10 into the threaded holes for screws 3 in housing 6 and connect them with a steel rope and lifting tackle. - Remove screws 19 for fastening the starting air distributor as well as the respective locating pin. - Remove inspection cover 20. - Using lifting tackle now carefully lift off housing 5 together with intermediate piece 21 and bearing flange 22. With these also drive shaft 17 and shaft 18 will be lifted out. - During this work phase pay careful attention that coupling 23, which is still fastened to shaft 18 by fitted bolt 24, slides out of the toothing of drive shaft 25 without jamming. This operation can be viewed without difficulty through the inspection opening when inspection cover 23 is off. After removing the complete starting air distributor it can be dismantled after removing screws 26 and allen screws 27. Drive shaft 17 can be separated from shaft 18 by removing snap ring 28 locking ring 29 and pin 30, in this sequence.
Assembling The assembling is done generally analogous to the dismantling but in reverse sequence, whereby the following points require special attention: - The metallic sealing faces on the starting air distributor have to be lightly smeared with a nonhardening sealing compound. - When inserting shaft 18 together with drive shaft 17, as well as housing 5, intermediate piece 21, and bearing flange 22 take care to ensure that the serration in coupling 23 mates the serration of drive shaft 25 without jam ming. During this work phase spring dowel pin 31 of coupling 23 must meet the respective longitudinal groove in drive shaft 25. This can be viewed through the inspection opening after inspection cover 20 is removed. - Before fitting control valves 1 smear them lightly with MOLYKOTE paste. - Before fitting the shifting mechanism fit rollers 16 by pushing control valve 1 including its spring lightly inwards until the roller pin can be inserted. Then check control valves for easy movement. - Rod seal rings 32 and piston seal ring 33 have to be checked for possible wear or damage and if necessary they must be replaced by new ones. For fitting them smear them lightly with oil. - For fitting cam 12 the crank of cylinder No. 1 must be in its T.D.C. The engraved mark on the cam now has to coincide with the middle of air control valve 1 for cylinder No. 1. The cylinder number is stamped into the hous ing. - After tightening screws 6 lock them with locking wire. - For fitting the coating of the upper thrust washer 9 must be facing upwards and the coating of the lower thrust washer 9 must be facing downwards if the thrust washers 9 have been changed. After fitting the starting air distributor connect control pipings to the air starting valves. Make quite sure that the control pipings are not fitted at the wrong connections. The cylinder numbers to the respective air starting valves are stamped in the housing of the starting air distributor.
9.99
RTA84C
Maintenance
4303/1.3
4 6 3 32 36 33 32 7 26 5
17 8 9 10 11 12 13 9 2 16 15 1 14
28 29 30 21 22 34 19 27 35 18 20
23 24
31 25
89.7188
1989
RTA84C
Maintenance
4325/1.1
Starting Air Shutoff Valve and Valve for Slow Turning Cleaning and Function Control
Key to Illustrations: 1 2 3 4 5 6 7 8 9 10 11 12 13 Valve seat Cover Spring Valve body Valve seat Valve guide Spring Valve body Control valve Piston seal ring Equalizing bores Piston Valve body *'A' *'B' *'C' *'D' *'E' (*) 14 15 16 17 18 19 20 21 22 23 24 25 26 Screw plug Spring Screw plug Bush Oring Piston Screws Cover Control valve Spring Valve body Screws Cover 27 28 29 30 31 32 33 34 35 36 37 38 'S' Spring Valve body Piston seal ring Piston seal ring Bush Spring dowel pin Piston Set screw Oring Bush Valve seat Spring dowel pin Clearance
To test valve 2.06 From pneumatic logic unit connection E3 To vent valve 2.21 To pressure gauge panel and pressure transmitter 308 HA From reversing mechanism of starting control 2.22 Please also refer to 'Engine Control Diagram' in the Operating Manual sheet 4003/1
Attention! Before starting work on the starting air shutoff valve or on the valve for slow turning it is essen tial that the valves on the starting air receiver are safely closed. The turning gear must be en gaged without fail and vent valve 2.21 to connection 'C' must be open. By these measures is as certained that the starting air and control air piping to the starting air shutoff valves and the valve for slow turning are devoid of pressure. Starting air shutoff valve (Fig. 'A') The shutoff valve must from time to time be dismantled cleaned and inspected. If necessary the valve seats of the non return valve as well as of the shutoff valve must be slightly ground in. For grinding in valve seat 1 remove first cover 2 including spring 3. Valve body 4 can then be pulled out. If valve seat 5 of the non return valve needs grindingin, then the shutoff valve must be completely dismantled. After removing valve guide 6 and spring 7 valve body 8 of the non return valve can be removed. When the above mentioned items are being checked, control valve 9 has also to be dismantled and cleaned. Before reassembling all above items replace any corroded springs by new ones. Damaged or much worn piston seal ring 10 has to be replaced. Check equalizing bores 11 for free passage. For the assembly smear all the parts lightly with MOLYKOTE paste. Check to ascertain that the clearance 'S' be tween piston 12 and valve body 13 of control valve 9 amounts to about 1 mm. After completing the assembly carry out a function check, for which the following precautions have to be taken: Initial position - The shutoff valving of the starting air receiver must still be closed. - Screw plug 14 of the shutoff valve has to be removed. - The engine has to be completely assembled, ready to start and the turning gear must be in the disengaged posi tion. - The area of flywheel, propeller shaft and propeller must be free of persons or objects. - During the functional check the reversing lever in the control desk must remain in the position STOP and the starting button may not be actuated under any circumstances.
1989
4325/1.2
Checking
Maintenance
RTA84C
a) Tightness Slowly open hand wheel valve of a starting air receiver to check whether the automatic shutoff valve is air tight, i.e. verify that no air escapes from the bore of screw plug 14. b) Automatic opening By opening test valve 2.06, which is fitted in piping 'A', the same effect is obtained as when actuating control valve 9. Upon opening test valve 2.06 the shutoff valve opens automatically. The air now escaping at the bore for screw plug 14 indicates that the two valve bodies 4 and 8 of the shutoff valve and of the non return valve have opened. Attention! Great care must be taken for this checking operation: To prevent accidents from compressed air suddenly escaping out of the bore for screw plug 14 a sufficient distance has to be kept away from the shutoff valve. - After shutting (control valve) test valve 2.06 no air must escape from the bore of screw plug 14. - After completing these checks fit and tighten screw plug 14 again. Remark: To avoid accumulation of water in the main starting air piping open water drain pipe on the main starting air piping after each starting operation for a brief time.
Valve for slow turning (Fig. 'B') On many propulsion engines a valve for slow turning is screw fastened to the automatic shutoff valve for starting air. During an overhaul of the shutoff valve for starting air the overhaul work on the valve for slow turning should also be taken in hand. Before however work is started on the valve for slow turning the safety measures mentioned at the start of this sheet must be observed. To remove piston 19 first unscrew screws 20 and remove cover 21 together with control valve 22 and spring 23. To remove valve body 24 of the non return valve loosen and remove screws 25 and remove cover 26 and spring 27. Furthermore control valve 22 has to be dismantled and cleaned. Before reassembling check seat surfaces of piston 19 and of valve bodies 24 and 28, and if worn or rough rectify them by lapping. Damaged or worn piston seal rings 29 and 30 must be replaced. When replacing bush 31 or 36 respectively take care that when fitting them spring dowel pin 32 or 38 respectively meets the respective bore. For the assembly smear all parts lightly with MOLYKOTE paste. check to verify that clearance 'S' between piston 33 and valve body 28 of control valve 22 measures about 1 mm. Remark: Set screw 34 for setting the speed for slow turning may only be adjusted in exceptional cases. The length of the set screw is the measure for the engine speed during slow turning. The correct length of the set screw has been set during the test run and should for this reason not be altered.
1989
RTA84C
Maintenance
4325/1.3
1989
4325/1.4
Maintenance
RTA84C
1989
RTA84C Rotation Direction Safeguard Inspection and Function Check I-I II

14 11 13 12 9
Maintenance
4506/1.1
Key to Illustrations: 1 2 3 4 5 6,6a 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 F Y Special bolt Driving disc Driving wheel Coupling element Housing Ball bearing Sleeve Rotary valve Bolt Spring plate Cover Compression spring Spring plate Pointer Split pin Castellated nut Gasket Stop pin Bolt Joint Key Cylindrical pin Sliding faces Air gap
15 16
x=63mm
17 5 7 8 19 20 10 6a 18
III
6 F 4 3 2 21 1 Y
III
II
19
III-III
22
50_
9 14 21
18
93.7206
1989
4506/1.2
Dismantling procedure
Maintenance
RTA84C
The rotating direction safeguard does not need any maintenance in service. However, we recommend that it be dismantled during a major overhaul (every 4 years). The components should be cleaned and checked for wear, in particular the sliding faces 'F'. Roughened sliding faces can possibly be reconditioned by careful polishing. By loosening the oil pipe connections and the four bolts 19, the complete rotation direction safeguard can be re moved. For the inspection of the rotating parts proceed as follows: Remove the pointer 14 after first knocking out the heavy type dowel pin. Unscrew the four bolts 9 which hold down the cover 11 and remove this along with gasket 17. Pull out the split pin 15 which locates and secures the castellated nut 16 and unscrew the nut. Remove spring plate 13 and 10 along with compression spring 12. The special bolt 1 can now be knocked out with a couple of light taps on the head end and removed. Driving disc 2 and coupling element 4 as well as the driving gearwheel 3 between, can now be pushed down from the rotary valve 8. This dismantled situation makes a complete inspection of the ball bearings 6 and 6a as well as the coupling element possible. Hints for reassembling The parts prepared for reassembling should be oiled slightly, in particular the faces marked 'F'. With sliding faces overhauled and any sharp edges removed, proceed for reassembling as for dismantling, but in reverse order. The air gap 'Y' must not be less that 2 mm. If it is less, the driving disc 2 and the coupling element 4 must be ma chined to restore the original air gap of 4 mm. The two spring plates 13 and 10 are not interchangeable. Fit first the one named 'inner spring plate' 10. The com pression spring 12 follows and finally the outer spring plate 13 which is compressed to the dimension 'X' about 63 mm by tightening the castellated nut 16. Lock with split pin 15. Before fitting the cover 11 with gasket 17 on the housing 5, turn the rotary valve 8 with a spanner (on the castellated nut) several times to and fro. This should be possible without much effort. The rotary valve should allow turning by about 50_ from one stop to the other, this can also be checked on the cover 11 where the mark on the pointer must coincide with the marks on the cover in 'Forward' and 'Reverse' during the function check. Function check After completing the assembly of the rotation direction safeguard its function should be checked as follows: With the engine ready for operation rotate crankshaft with the turning gear till about 50_ AHEAD. Then disengage the turning gear. Bring reversing lever to AHEADposition and watch whether pressure indicator 216HB of valve group 'B' for gov ernor and air cylinder are showing pressure (please also consult sheet 4003/1 of the Operating instructions). Bring reversing lever to ASTERN. The pressure indicator must now not show pressure. Engage turning gear and turn crankshaft back by about 50_. The reversing lever is still in the position ASTERN. Disengage turning gear. The pressure indicator must now show pressure. Move reversing lever to AHEADposition. The pressure indicator must now not show any pressure.
1989
RTA96C
Betrieb
Group5
Governor, Fuel Injection Pump and Actuator Pump
Group 5
Governor
Installing, Removing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5103/1
Safety Cut-out Device

Maintenance and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5307/1
Fuel Injection Pump

Adjusting and Checking the Control with Load-dependent V.I.T. (Variable Injection Timing) . 5512/1 Lapping the Sealing Faces for the Covers of the Suction, Delivery and Spill Valves . . . . . . . . 5512/2 Checking and Setting of the Relief Valve (with LORANGE Test Stand) . . . . . . . . . . . . . . . . . . . 5512/3 Checking and Setting of the Relief Valve (with O.M.T. Test Bench) . . . . . . . . . . . . . . . . . . . . . . . 5512/3 Tightening a Nipple for the Plunger Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5512/4
Actuator Pump
Determining the Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5513/1
RTA84C / MM / 9.01
RTA84C WOODWARD Governor PGA 200 Installing, Removing and Maintenance
Maintenance
5103/1.1
Key to Illustrations:
8 2 7 6 3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Governor cover Pneumatic speed control Accumulator Connection Oil drain plug Adjusting screw for needle valve Connection '2'/oil from booster Knob for manual speed setting Charge air connection Dip stick for checking oil level Governor output shaft Oil filter Cap for overspeed test device Oil filling connection Connection '1'/oil from booster Connection Connection/oil to booster Oil drain plug Governor drive shaft
30765
14
Installing and removing the governor on the engine When lifting off the governor or placing it on the en gine, care has to be taken to ensure that the splines on the lower end of the governor drive shaft do not get damaged. Furthermore, it must be possible to in sert the shaft without it jamming when fitting the governor onto the drive. Pipes and linkages must be connected up without stressing them. When the governor and booster are separated from each other, care has to be taken to prevent any dirt from entering the oil pipes and their connections For checking The governor positions '0' and '8' must be checked immediately after connecting the fuel pump linkage to the governor. They must absolutely correspond to the positions on the control plate on the fuel injec tion pump, the V.I.T. indicator must then stand in position '0'.
13
12
10
11
30766
1989
5103/1.2
Maintenance
Maintenance
RTA84C
14
Information about maintenance work, maintenance intervals and repairs can be gained from the WOOD WARD bulletin which is supplied separately with the governor. Repairs on the governor should be carried out by WOODWARD experts only (or by specially trained personnel). It is, therefore, advisable to keep on board a complete spare governor, carefully adjusted to suit the engine, which allows immediate replace ment if necessary. The defective governor should be returned to a WOODWARD service agency for re pair. It is imperative that a copy of the governor ad justment records which are included in the accep tance records of the engine, be handed to the agency as the governor will have to be readjusted according to these records.
6 15
30764
16
17
18
30767
19
Oil change Under favourable service conditions, the oil can remain in the governor for 6 months (approx. 3000 hours) or even more. Should, however, the oil become blackish or show signs of aging, it must be changed immediately. The used oil of the governor must be drained when hot by unscrewing the oil drain plugs 5 and 18 with the engine stopped. The oil in the booster must also be drained. Where an oil filter is fitted (governor with charging protection), remove the screw on top of the housing 12 and withdraw the filter element. This should be shaken in paraffin or clean fuel and then gently blown out with com pressed air. Replace the filter straight away since it is essential that it be in place when carrying out the following flushing procedure.
1989
RTA84C
Maintenance
5103/1.3
Thereafter, make ready the same amount of clean flushing oil, of which approx. 6 liters are poured in at oil filling connection 14. Now run the engine for 5-10 minutes at low speed. Since the oil can only reach the booster when the governor is working, the oil level will sink shortly after the engine has been started. The remaining oil must therefore be added in stages. At the same time, observe the level on the dip stick to see if the oil level is up to the mark 'Full'. Top up with more oil than necessary. During the short running time, the speed of the engine is to be changed frequently so that the governor is working. Afterwards drain off the flushing oil in the same way as the old oil from the governor, oil cooler and booster. After flushing has been completed, fill the system with new, filtered oil (for oil specification, see WOODWARD bulletin 25007). Filling with new oil and putting the governor back into service is done the same way as described at the start of this section. Venting oil system and adjusting needle valve When starting up the governor for the first time and after every oil change, the oil system of the governor must be vented as follows: Start up the engine and run at low speed, at the same time unscrewing the adjusting screw of needle valve 6 anti clockwise by a few turns. This should cause the engine to hunt and thus force the governor to work. Should opening the needle valve not cause the engine to hunt, this must be done by moving the speed adjusting lever on the control desk. Slowly close the needle valve little by little until the point is reached where the engine ceases to hunt. The correct needle valve position depends on engine characteristics. In principle, the needle valve should be open as far as pos sible to avoid sludge builtup. It should, however, not be opened by more than approx. 1/16 to 2 turns to ensure steady operation of the governor. Under no circumstances may the needle valve be screwed completely tight; the governor could never work satisfactorily in this condition. Maintenance of the spare governor Where a spare governor is kept for the installation, a check should be made at least annually to see that it is stored upright and that it is filled with oil to the mark on the dip stick.
1989
RTA84C Safety Cutout Device Maintenance, Function Check
Maintenance
5307/1.1
Key to Illustrations: 1 2 3a 3b 3c 3d 4 5 6 7 8 9 10 11 Cutout yoke guide Orings Oring* Slide ring* Oring** Slide ring** Compression spring Castellated nut with split pin Cover Cover plate Screwed rod with nut Cylinder (upper) Piston Bush 12 13 14 15 16 17 18 19 K L St * ** 3/2 way solenoid valve Valve plate Intermediate piece Cylinder (lower) Pull rod Fuel pump body Guide bush Cutout yoke Piston underside Air supply chamber Control air pipe for piston sealing for rod sealing
As a rule the safety cutout device requires no mainte nance. Should, however, excessive air leakage from either the air supply chamber 'L ' or from space 'K' (piston underside) be detected, the defective 0rings, piston or rod sealing rings must be replaced by new ones. As opposed to the other parts of the air cylinder, the pull rod 16 can only be removed from below. The fuel injection pump block must first be lifted. Before starting any maintenance work which may be necessary, fully release the control air pressure, vent the system and disconnect the control air pipe 'St' from the valve plate. When the air cylinder is being dismantled, all the parts of this unit have to be cleaned and their condi tion checked. If the compression spring is corroded it must be replaced. Lightly oil the cleaned parts prior to assembly. A function check has to be carried out after assembly and after putting the control air system under pres sure. Operate the electrical emergency stop button 126HB (see also sheet 4003/1 of the Service Instruc tions Manual). As a result, the cutout yoke will be pulled up to its stop on the underside of the fuel pump body.
Attention! Never press the emergency stop button as long as work is being done either manually or with tools on the underside of the fuel pump body.
1989
RTA84C
Maintenance
5512/1.1
Fuel Injection Pumps Adjusting and Checking the Control with Loaddependent V.I.T. (Variable Injection Timing)
Tools: 1 2 3 2 1 Device for measuring Devices for measuring Special spanners Special spanners Torque wrench with hex. plug spanner and extension Withdrawing device Withdrawing device Special spanner Grease gun 94552 94554 94555 94557 94559 Key to Illustrations: 1 Spill valve seat 2 Valve seats for suction/ delivery valves 3 Relief valve 5 Hand grip to manual shutdown 6/6a Pressure nipple 8 Push rod with guide bush 9 Cover 10 Pin (short) 11 Pin (long) 12 Compression spring 13 Compression spring 14 Plunger 14a Plunger guide 15 Waisted screw 16 Special screw 17 Stepped throttle 18 Connectors 19 Fuel pump body 20 Double nipple 21 Drain screw 22 Drain screw 23 Threaded plug 24 Regulating tappet 25 Shutoff valve 26 Shutoff valve 29 V.I.T. indicator 30 Pointer to setting shield 31 Setting shield 32 Load indicator 33 Speed governor 34 Regulating linkage to suction valve 35 Regulating linkage to spill valve 37 Valve housing 38 Stagnation pressure control valve 70 Spacer 71 Screws 72 Spacer 73 Nut 74 Withdrawing rod 74a Disc 75 Safety grip 76 Setting screw 77 Positioning unit 78 Distance sleeve 79 Link 80 Support 81 Setting screw 82 Setting screw 3.12 Fuel lever
1 1 1 1
94561 94564 94571
E K P R U1 U2 D1 D2 S1 S2
Fuel inlet Hand lever To the injection valves Fuel return Spill valve to pump 1 Spill valve to pump 2 Delivery valve to pump 1 Delivery valve to pump 2 Suction valve to pump 1 Suction valve to pump 2
Important! The fuel pump control can only be correctly adjusted, provided the fuel pump regulating linkage bores are not worn! Before starting preliminary measures to carry out checking and adjusting work on the fuel injection pumps, the engine must be changed over to diesel oil before shutting it down! A) Directions and permissible deviations The correct adjustment of the fuel injection pump control is extremely important. Changes to the effective plunger (delivery) strokes may only be attempted when, on the occasion of checks, inadmissible deviations from the re corded data of the setting table are established. The setting table which will be often mentioned in this description is handed over to the customer together with the shop trial documents. a) Replacement of parts: When parts of the fuel injection pumps (f.i. pumps for short) are replaced, which influence the fuel injection control in any way, then the f.i. pump controls must be checked and if necessary readjusted in compliance with the values of the setting table. b) Cutout checks: In order to ensure that the engine can be shutdown at any time and can never overspeed, the various cutout checks must be carried out after the fuel injection pumps have been newly adjusted (see paragraph 'E').
UG
1994
5512/1.2
Maintenance
RTA84C
c) Adjusting data in the setting table: The decisive adjusting data of the fuel injection pumps and fuel cams are established for a specified load indicator position and entered in the setting table. These are: Idle stroke, begin of injection, total stroke, end of injection The effective plunger stroke entered in the setting table is arrived at by subtraction of idle stroke from total stroke. d) Effective plunger (delivery) stroke in mm: The effective plunger stroke is adjusted by modifying the length of the regulating tappet 24 for the suction and spill valves. In this manner shortening the regulating tappet produces an increase in the effective plunger stroke, and lengthen ing the regulating tappet produces a reduction in the effective plunger stroke. Adjusting the regulating tappet during operation is forbidden! Equal effective plunger strokes on all f.i. pumps are necessary to obtain balanced power outputs on all the cylinders. For this reason the measured values of the individual f.i. pumps have to be compared with each other. The maximum admissible deviation between the biggest and the smallest effective plunger stroke on individual cylinders is 0.2 mm, and the deviation of the effective plunger stroke to the values in the setting table should not exceed 0.1 mm. e) Begin of injection: The begin of injection (( before or after T.D.C.) of a fuel injection pump may only be altered by turning the fuel cams and not by readjusting the regulating tappet of the suction valve. The deviation to the setting table shall not exceed 0.3_. f) Equalizing the maximum cylinder pressures: The equalizing of the maximum cylinder pressures may only be brought about by turning the fuel cam and not by changing the lengths of regulating tappets of suction and spill valves (condition is equal compression pressures). Directions on the turning of fuel cams are given in sheet 4203/3. g) Spacers for fuel delivery reduction: While adjusting and checking the f.i. pumps no spacers may be inserted for delivery reduction. Directions to this effect are given under sheet 5512/1 in the operating instructions. B) Preparations (see also sheet 4003/1 of the Operating Manual) 1. Start lubricating oil pumps for bearings and crossheads and set pressures for normal operation. 2. Bring reversing lever on the local manoeuvring stand to AHEAD (RUN AHEAD), for which the turning gear must be disengaged. 3. The pressure indicators (end position indicator) of the valve group 'D', located under the fuel pump, must be actuated. Check whether the reversing valve 5.02 is also in position AHEAD (see 'Engine Control Diagram' sheet 4003/1 in the Operating Manual) and that the position indicator is not protruding on the front side of the reversing valve. 4. Engage turning gear. 5. Close shutoff valves for starting air receivers. 6. Close shutoff cock of fuel feed and return piping, immediately behind the f.i. pump. 7. Slightly loosen the drain screw 22 arranged at the side at the height of the stepped throttles to drain the fuel from the pump body (Fig. 'E'). 8. Remove cover 9, springs and delivery valves (above the pump plunger). Remove also the cover above the suction and spill valves, unscrew the pressure nipples 6 and 6a and remove springs and valves (Fig. 'E'). 9. Wash suction and spill valves as well as their valve seats in clean diesel oil. Check that the valves slide easily in their guides and that the valve seats are undamaged. If necessary recondition the seat faces by careful grind ingin or replace the valves. Fit suction and spill valves (without their springs) again and tighten their pressure nipples 6 firmly with the special spanner 94571 to 300 Nm (31 mkp).
9.99
RTA84C
Maintenance
5512/1.3
10. Check whether the spacer 70 and 72 of the dial gauge holder slide well and the dial gauge functions properly. If so, mount the dial gauge holders and screw them tight (see Fig. 'D'). 11. Draw fuel lever 3.12 out of position REMOTE CONTROL and place in position '8'. This move vents the air cylinder to the governor / linkage connection (refer also to sheet 4003/1 of the Operating Manual). 12. Close the two shutoff valves 25 in the console to the control air supply and open both shutoff valves 26 for the air bottle drain (refer to Fig. 'A'). 13. Distance sleeve 78, shown on Fig. 'B2', must be fitted between strap 79 and strap of support 80. By this, the regu lating linkage 34 for the suction valves is locked i.e. the V.I.T. indicator 29 is forced to be in position '0'. Push regulating linkage 34 to position '0' with the aid of setting screw 81 and 82. 14. Recheck again to ascertain that pointer 30 to setting shield 31 is still exactly on position '8', if necessary correc tion can be achieved with fuel lever 3.12. 15. The V.I.T. indicator 29 must point to 'zero'. Remarks! After completing the checking, the spacer sleeve 78 must without fail be again disconnected and for storing be mounted as shown in Fig. 'B1'. Turn back to the original position and lock the ev. used setting screws 81 and 82. The linkage joints of the regulating linkage between the governor and the f.i. pumps are equipped with grease nipples. They must be weekly lubricated with MOLYKOTE G paste by a grease gun which is supplied with the tools. During a checkup on the fuel injection pumps, remove at the same time also stagnation pressure con trol valves 38, check and clean them. Slight damage to the seating surface of the valves body and of the valve housing can be remedied by lappingin with fine lapping paste. The parts of the stagnation pressure control valves may not be interchanged.
UG
1994
5512/1.4
Maintenance
RTA84C
B1
34 29 35 30 31
A
15 LITRE 15 LITRE
Steuerluftversorgung CONTROL AIR SUPPLY
89.7280
94.7099
26 77
25
80
79
78
B2
33
82
81
80
79
78
32
B
29 34 3.12
93.7061
35
77
30
31
1994
UG
RTA84C
Maintenance
5512/1.5
For removal of the valve seats use the devices 94561 and 94564 (see Fig. 'C'). These are used as follows: Push the withdrawing rod 74 with out any accessories right down through the valve body and pull it back until the spread forward end comes against the front end of the valve body. Mount disc 74a and screw on nut 73 but not right down yet. Lead the locking pin 75 through the withdrawing rod until its ring enters the slot at the upper end. By tightening the nut 73 the valve body can now be pulled out of the pump block.
75
C
94561
75 73 74a
73 74a
94564
74
a = Arrangement of the dial gauge above the plunger (delivery valve) b = Arrangement of the dial gauge above the suction and spill valves.
D
94554 15 94552 71 71
6 72 70 2 14a
14
93.7606
1989
5512/1.6
Maintenance
RTA84C
E
38 15 9
I-I
37 15 9 15
Gezeichnet fr RTA62U DRAWN FOR RTA62U
II
15
11
11 6 12
6 12 2
III
III
21 8 8
6a 10 13
14a
14
19
II III - III
20 22 S2 3 37 D2 16 U2 E 18 P R R P 18 E
S1 3 37 D1 U1
94.7073
17
21
23
23
1994
UG
RTA84C
C) Initial setting of injection pumps
Maintenance
5512/1.7
The following checking data is to be taken from the timing records. Then carry out the following adjustments ac cording to: 1. 2. 3. 4. 5. 6. Setting shield . . . . . . . . . . . . . . . . . . . . . . . . Load indicator, normal position 8 (F.Q.S. + V.I.T. position '0') Idle stroke 'a' in mm . . . . . . . . . . . . . . . . . Suction valve closes at a plunger stroke of 'a' Begin of injection before T.D.C. in ( . . . Suction valve closes before T.D.C. in ( Total stroke 'b' in mm . . . . . . . . . . . . . . . . Spill valve opens at a plunger stroke of 'b' End of injection after T.D.C. in ( . . . . . . Spill valve opens after T.D.C. in ( Effective plunger (delivery) stroke . . . . . . Total stroke - idle stroke ('b'-'a' in mm)
Carry out preparations as per section B. Adjusting of the effective plunger (delivery) stroke 1. Turn the engine until the cam roller of the injection pump to be adjusted lies on the cam peak. Place the dial gauge onto the suction valve (S), which is now closed, and set it to '0' (see Fig. 'G', detail 1). 2. Turn the engine ASTERN until the roller of the injection pump to be adjusted lies on the base circle of the cam. Install the dial gauges above the plunger and above the now closed spill valve (U) and set them to '0' with a cer tain amount of pretension (see Fig. 'G', detail 2). 3. Rotate engine crankshaft AHEAD until the dial gauge on the plunger has reached the value of the idle stroke 'a' (for value refer to setting table). 4. Adjust the regulating tappet of the suction valve (S) so that the dial gauge on the suction valve indicates 0.02 mm. (When taking the reading the tensioning nut of the respective regulating tappet must already be firmly tightened!). This position signifies: The suction valve shuts = begin of injection (see Fig. 'G', detail 3) 5. Read the crank angle in (_ before or after T.D.C. off the flywheel graduation and compare readings with the values in the setting table. If necessary turn fuel cam 'forwards' or 'backwards' (refer to sheet 4203/3). 6. Turn engine crankshaft further AHEAD, till the dial gauge on the plunger shows the dimension of the required total stroke 'b' (note the indications in the setting table). 7. Adjust the regulating tappet of the spill valve (U) with spanners (see Fig. 'F') so that the dial gauge on the spill valve indicates 0.02 mm. This position signifies: The spill valve opens = end of injection (see Fig. 'G', detail 4) 8. Read the crank angle in (_ after T.D.C. off the flywheel graduation and record it (for tolerances refer to section A).
1989
5512/1.8
Maintenance
RTA84C
D) Checking the fuel injection pumps The same setting values as given for the injection pump setting must be used. Carry out preparations in accordance with section B). 0.02 mm
G
U
Checking the begin of injection, end of injection and of the effective plunger stroke The description below applies to AHEAD rotation. 1. Turn the engine until the cam roller of the fuel pump to be checked rests on the peak of the cam. Fit the dial gauge over the now closed suction (S) and set it to '0' (see Fig. 'G', detail 1). 2. Turn engine ASTERN, until the cam roller rests on the base circle of the cam. Fit the dial gauges over the plunger as well as over the now closed spill valve (U) and adjust to '0' with a slight pretension (see Fig. 'G' detail 2). 3. Turn engine crankshaft AHEAD until the dial gauge on the suction valve 'S' indicates only 0.02 mm. This position signifies:
93.7628
0.02 mm
The suction valve is closing = begin of injection (see Fig. 'G', detail 3)
1989
0.02 mm
RTA84C
Maintenance
5512/1.9
4. Read the idle stroke 'a' off the dial gauge on the fuel plunger and record the value. Read the crank angle in (_ before or after T.D.C. off the flywheel graduation and record it. 5. Turn engine crankshaft AHEAD until the dial gauge on the spill valve (U) shows 0.02 mm of stroke. This position signifies: The spill valve opens = end of injection (see Fig. 'G', detail 4) 6. Read off the flywheel gradation the crank angle for end of injection in (_ after T.D.C. and record it. Read also the value off the dial gauge on the fuel plunger and record this as stroke 'b'. The effective plunger stroke is ar rived by subtraction of 'b' - 'a' (for admissible tolerances consult section A). 7. Finally, carry out the cutout checks (see section E). E) Cutout checks The cutout checks for the injection pumps are of major importance and must therefore be carried out after every resetting of the injection pumps. We further recommend that these checks also be made after every major overhaul of the injection pumps. The following points have to be checked: 1. Checking the fuel injection pump valves at setting shield position '0': With the setting shield position '0' suction and spill valves of the same fuel injection pump may never be closed at the same time, i.e. when one valve is closed the other must be open, so that a fuel injection is excluded. At the moment that the suction valve shuts, the spill valve must be lifted by the value entered in the timing records. 2. Checking the '0' positions: The '0' positions on the load indicator 32 and the setting shield 31 on the fuel injection pumps must correspond (Fig. 'B'). 3. Checking the manual cutout on the injection pumps: When the injection pump drives are cut out with the manual lever 'K' a visible clearance must exist between the (timing) roller and the peak of the fuel cam (see Fig. 'H'). For instructions on the cutting out and - in of fuel injec tion and exhaust valve actuator pumps refer to the instruction book sheet 5512/2. 4. Checking the safety cutout device: The instructions of the Operating Manual sheet 5307/1 must be followed without fail. F) Installing the valves after a check The following points must be observed when fitting the valves: All the valves and springs must be dipped in clean diesel oil before fitting them. If the pressure nipples 6 and 6a were once more removed after the resetting, they must also be rinsed in clean diesel fuel and then tightened with the special spanner tool 94571 to 300 Nm (31 mkp) (see Fig. 'E'). During the assembly tighten the screws 15 carefully crosswise and in small steps with 60 Nm (6 mkp) with the torque wrench 94559. Use MOLYKOTE G paste as lubricant (Fig. 'E'). G) Fitting the stepped orifices When a pump body has been replaced, a check must be made to see if the stepped orifices are fitted in the new part. It may be necessary to use the ones from the old pump body. When fitting them, please note the following: Both the stepped orifices are of identical design and can be used in either position. They have first to be located with the drain plugs 21 and then tightened with the special bolts 16 (Fig. 'E').
1989
5512/1.10
Maintenance
RTA84C
1989
RTA84C
Maintenance
5512/2.1
Fuel Injection Pumps Lapping the Sealing Faces for the Covers of the Suction, Delivery and Spill Valves
Tools: 1 Torque wrench with hex. socket 1 Centering ring 1 Lapping mandrel 1 Lapping mandrel 94559 94565 94566 94567 Key to Illustrations: 6/7 Pressure nipple 9 Covers for the valves 19 Fuel injection pump body A Assembly cover B Lapping the sealing face on the pump body C Lapping the sealing face on the cover SF Flat sealing face SF1 Sealing face with slope of 0_ 10'
In case of leakage between cover and pump body, although the Allen screws have been tightened to the prescribed torque of 60 Nm (6 mkp), it may be possible that the sealing faces are no longer in perfect condition. Additional tightening of the screws will not solve the problem; the sealing faces will have to be dressed. Slight damage can be rectified with the lapping mandrels 94566 and 94567 contained in the tool kit. For lapping the flat sealing faces on the pump body, the tool is to be used as shown in fig. 'B'. In order to avoid that, after a certain time, a groove is ground in the lapping face of the tool, the lapping mandrel must be moved in circles over the whole sealing face and not only around its own axis. The cover sealing face and the corresponding lapping mandrel 94567 are tapered by 0_10' (see Fig. 'C'). The mandrel 94567 for lapping of the cover sealing face (Fig. 'C') is guided by centering ring 94565 so that it can only be rotated around its own axis. In case rectification of the lapping face of the tool becomes necessary, the above taper must be borne in mind. Very fine lapping paste must be used for lapping. Attention! Under all circumstances, prevent lapping paste from getting into the pump body!
The threads of the Allen screws must be coated with MOLYKOTE paste G before being screwed in. The screws must be tightened crosswise and in even stages to 60 Nm (6 mkp).
C A
60Nm 6mkg 94566
94567
9 19 6 7
SF SF1 19
0 _10
0 _10
94565 9
93.7459
1989
RTA84C
Maintenance
5512/3.1
Fuel Injection Pumps Checking and Setting of the Relief Valve

Tools: 1 L ' ORANGE valve test stand 1 Mounting angle bracket 1 HP hose line 1 Testing device 1 Special spanner 1 Slide gauge 94272 94273 94275 94277 94556 1 2 3 4 5 6 Key to Illustrations: Valve housing Valve needle Stop ring Distance ring Oring Belleville spring washers (11 pieces) 7 Thrust washer
with L ' ORANGE Test Stand
8 9 10 11 12 12a A H MA D
Circlip Spring plate Closing plug Ball 12 mm Flushing valve Spindle for 12 Delivery pipe connection Pump lever Pressure gauge (0-1600 bar) Drain bore
10
11
94.7240
Before dismantling a relief valve for overhaul (grinding in of the valve needle), the distance 'X' must be accurately measured and the figure recorded as 'X'. For this purpose, the distance ring 4 must be pressed against the stop ring 3 by the closing plug 10. After grinding the valve needle 2 into the seat of the valve housing 1, all the parts must be thoroughly cleaned, the valve needle 2 lightly oiled and parts 6, 7, 9 and 11 sprayed with MOLYBDENUM DISULPHIDE. During assembly, care must be taken that the belleville spring washers 6 are correctly positioned (see Fig. 'A'). The distance ring 4 should not yet be fitted. Tighten the closing plug 10 until the distance 'X' is about the same as before dismantling. For testing and setting a relief valve for the fuel pump, use tool 94373 which belongs to the tools of the L ' ORANGE valve test stand. Use connection 'A' (see Fig. 'C') for this together with the right hand pump lever 'H' and pressure gauge 'MA' (0-1600 bar).
L'ORANGE
10.95
5512/3.2
Maintenance
RTA84C
1989
L'ORANGE
RTA84C
Maintenance
5512/3.3
Working procedure for setting the injection pressure Fit the testing device 94277 to the mounting angle bracket 94273 and bolt it down. Place the relief valve into the testing device (without joint) and tighten it with special spanner 94556. Connect high pressure hose to connection 'A' and lead it to the testing device. Once the connection has been made, the flushing valve 12 should be opened a little by spindle 12a. Operate pump lever 'H' until the pressure chambers are filled and diesel oil escapes bubblefree. Close flushing valve spindle 12a. Operate the pump lever and at the same time observe the pressure gauge 'MA' to see at what pressure the relief valve opens. Correct opening pressure = 1150 bar. The prescribed pressure can be set by moving the closing plug 10. Measure the distance 'X' and note it as 'X1' (Fig. 'A'). Now reduce the height 'Y' of the distance ring 4 by the difference between the distances 'X1' and 'X'. Finally, reas semble the relief valve (this time with distance ring 4) and tighten the closing plug 10 until it is fully down on the distance ring 4. Carry out another check of the opening pressure on the fully assembled relief valve. When this is correct, the valve can be refitted to the injection pump body.
Remark: Before screwing the relief valve into the injector pump body, check that the sealing faces of the relief valve and the injector pump body are clean since the sealing of these faces is metallic i.e. without sealing ring! Use the special spanner 94556 to tighten the relief valve (see Fig. 'B'). Further check the respective drain bore 'D' for free passage in the valve housing 1 as well as in the fuel pump body.
L'ORANGE
10.95
RTA84C
Maintenance
5512/3.1
Fuel Injection Pumps Checking and Setting of the Relief Valve

Tools: 1 O.M.T. test bench 1 Special spanner 1 Slide gauge 94272 94556 Key to Illustrations: 1 2 3 4 5 6 Valve housing Valve needle Stop ring Distance ring Oring Bellewille spring washers (11 pcs.) 7 Thrust washer 8 Circlip
9 10 11 12 12a 13
Spring plate Closing plug Ball 12 mm Flushing valve Spindle for flushing valve Adapter (testing head)
D Drain bore
10
11
94.7240
Before dismantling a relief valve for overhaul (grinding in of the valve needle), the distance 'X' must be accurately measured and the figure recorded as 'X'. For this purpose, the distance ring 4 must be pressed against the stop ring 3 by the closing plug 10. After grinding the valve needle 2 into the seat of the valve housing 1, all the parts must be thoroughly cleaned, the valve needle 2 lightly oiled and parts 6, 7, 9 and 11 sprayed with MOLYBDENUM DISULPHIDE (MoS2). During assembly, care must be taken that the Bellewille spring washers 6 are correctly positioned (see Fig. 'A'). The distance ring 4 should not yet be fitted. Tighten the closing plug 10 until the distance 'X' is about the same as before dismantling. For testing and setting the relief valve for the fuel pump use the test bench 94272 (Fig. 'B') which belongs to the standardtools.
O.M.T.
1995
5512/3.2
Maintenance
RTA84C
Working procedure for setting the opening pressure - Place the relief valve into the adapter 14 (without joint) already screwed into the test bench and tighten it with special spanner 94556. - Pay attention to the manufacturer's detailed instructions and working specifications of the test bench, in partic ular prior to commissioning as well as for the various operations of the test bench. - At the adapter 14, open the flushing valve a little by spindle 12a and operate pump of testing bench until the pressure chambers are filled and Diesel oil escapes. Close flushing valve spindle 12a. - Increase the pressure on the test bench and at the same time observe the pressure gauge to see at what pressure the relief valve opens. Correct opening pressure = 1150 bar. The prescribed pressure can be set by moving the closing plug 10. Measure the distance 'X' and note it as 'X1' (Fig. 'A'). Now reduce the height 'Y' of the distance ring by the difference between the distances 'X1' minus 'X'. Finally, reas semble the relief valve (this time with distance ring 4) and tighten the closing plug 10 until it is fully down on the distance ring 4. Carry out another check of the opening pressure on the fully assembled relief valve. When this is correct, the valve can be refitted to the injection pump body.
Remark
Before screwing the relief valve into the injector pump body, check that the sealing faces of the valve housing 1 and the injector pump body are clean since the sealing of these faces is metallic i.e. without sealing ring! Use the special spanner 94556 to tighten the relief valve (see Fig. 'B'). Further check the respective drain bore 'D' for free passage in the valve housing 1 as well as in the fuel pump body.
94556
I
13
94272
12a 12
13
94.7243
94.7242
1995
O.M.T.
RTA84C
Maintenance
5512/4.1
Fuel Injection Pumps Tightening a Nipple for the Plunger Guide

Tools: 1 Impact wrench 1 Sledge hammer 94551 1 Pump block 2 Nipple Key to Illustrations: 3 Plunger guide 4 Heavy metallic underlay
Tightening a nipple for the plunger guide in the fuel injection pump block as follows: - Place pump block on a heavy metallic underlay. - Clean all contact faces (plunger guide - pump block) with greatest care and keep them dry; after this insert the plunger guide into the pump block. - Smear MOLYKOTE paste G on thread and pressing face of the nipple. - Push nipple over plunger guide and drive by hand till the stop. - Place impact wrench 94551 into toothed portion of the nipple and firm the latter up with a light hammer stroke. - In this position mark position on one tooth of the nipple and on the pump block (initial position for pretension ing the nipple). - Make another mark on the pump block over the 4th nipple tooth to the right starting from the initial position, this gives the measure for the following pretensioning of the nipple (see Fig. on sheet 5512/4.2). - Using a sledge hammer (5-6 kg) on impact wrench 94551 tighten the nipple till the rotation of the nipple has reached the premarked position (= four tooth pitches). Attention! At the first tightening of the nipple together with a plunger guide in a new pump block, the fasten ing must be once more loosened and the whole tightening process repeated in order to make up the setting losses.
9.99
5512/4.2
Maintenance
RTA84C
Marken, NippelAusgangsstellung MARKS, NIPPLE STARTING POINT Marke, Nippel festgezogen MARK, NIPPLE TIGHT
6kg Vorschlaghammer SLEDGE HAMMER Vier Zahnabstnde FOUR TOOTH PITCHES 94551 1
2 3
9.99
RTA84C Actuator Pump Determining the Shim Thickness

Tools: 1 Depth gauge 94126
Maintenance
5513/1.1
Key to Illustrations: 1 2 3 4 5 6 Actuator housing Bush Piston Shim Intermediate piece Pump housing 7 8 9 10 11 12 Compression spring Roller guide Rotational safety stud Actuator cam Nut Nut
Remark:
The shim 4 must never be interchanged with one of another actuator pump, as each one has been ex actly machined to the required thickness by the engine builder.
Should parts of the roller guide 8, the bush 2 or the piston 3 have been replaced during overhaul, the thickness 'S' of the shim 4 must be redetermined. For this purpose the actuator pump has to be fitted according to Fig. 'A' and 'B', however, with the nuts 11 provision ally tightened. After final fitting of the shim 4 the nuts 11 must be tightened equally and diagonally across by the specified tighten ing angle of 90_.
A
I
B
I-I
1 2 3 4 5 6 8 7 9
11 1
4 12
10
008.418/01
008.419/01
2001
5513/1.2
Determining the shim thickness 'S' D D
Maintenance
RTA84C
Turn the engine until the roller guide 8 lies on the base circle of the actuator cam 10 (Fig. 'B'). Establish with depth gauge 94126 the measure 'A' from the top edge of the actuator housing 1 to the piston 3. The shim thickness 'S' is calculated by the formula: The actual thickness of the shim may differ by S = 286 mm A from the calculated value.
+ 0.4 0 mm
94126
3 4
S
10
A
008.420/01
2001
RTA96C
Betrieb
Group6
Charge Air Receiver and Auxiliary Blower
Group 6
Charge Air Receiver

Maintenance of the Valve Groups, Air Flaps and Cleaning the Charge Air Receiver . . . . . . . . 6420/1
Auxiliary Blower
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545/1
Charge Air Cooler

Cleaning (Water Side) on Engine at Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606/1 Removing and Fitting a Cooler Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606/2
Water Separator
Maintenance of Water Separator Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708/1
RTA84C / MM / 2001
RTA84C
Maintenance
6420/1.1
Charge Air Receiver Maintenance of the Valve Groups, Air Flaps and Cleaning the Charge Air Receiver
Tools: 1 Socket Spanner 1 Cleaning container Various spanners 94645 Key to Illustrations: 1 2 3 4 5 6 7 8 9 Flap cover Screws Cover Valve groups Air flaps Relief valve Drain pipe Water drainage piping Spring sheet 10 11 12 13 14 15 16 17 Water drainage piping Valve plate Front piece Center piece End piece Tie bolt Round nut (short) Round nut (long)
11
12
14
13
16
15
17
93.7626
Cleaning The valve groups arranged in the charge air receiver are to be cleaned periodically, the interval between cleanings having to be adapted to operating conditions (see sheet 0380/1). At the same occasion the air flaps 5 must be checked for damage, movability as well as fouling. Access to the valve groups 4 is obtained through openings in the receiver, which are closed by flap covers 1. If the valve groups 4 must be removed, unscrew first the screws 2 holding the hinged cover 3. When the cover is open the valve groups can be removed after loosening their fastening screws. For inspection and removal of the air flaps 5 of the auxiliary blowers, the cover on the front face of the suction space to the auxiliary blower must first be removed.
UG
1994
6420/1.2
Maintenance
RTA84C
The valves assembled into valve groups must be cleaned in a cleaning container with kerosene or gas oil without dismantling them. The solving time depends on the degree of dirt accumulation and on the solvent used. Should chemical cleaning agents be utilized, take into consideration that the valve plates (steel) and the valve bo dies (aluminium) are not attacked by them. Blow the washed valve groups with compressed air. We recommend keeping a complete set of valve groups as spare, to permit quick replacement. The cleaning of the dirtied valves can be carried out later during operation or during longer standstills. Checking Broken or cracked valve plates must be replaced by new original valve plates of the same thickness. The aluminium valve bodies must be free from burrs and cracks; The seating surfaces for the valve plates must be even. Assembling a valve group If a valve group has been dismantled, it must be reassembled in the following manner: First join the valve group loosely together. (Note curvature of the valve plates, concave side to face the air duct, see Fig. 'A'). Screw on round nuts 16 and 17, but do not tighten as yet. Knock the valve stack (the flat part downwards) carefully on a face plate, then tighten the round nuts moderately with spanner 94645. Should individual valve plates not close all over, loosen the round nuts 17 and tighten them again. When all the valve plates lie snug against the valve bodies, lock the round nuts and fit the valve groups in the charge air receiver (fitting positions, see Fig. 'B'). Relief valves 15 to the charge space (piston underside) During a major overhaul dismantle the relief valves 15, fitted on the front faces of the cylinder block, clean them and check their mobility. The relief valves are set for an opening pressure of 3.4 to 3.8 bar. Cleaning the charge air receiver Cleaning and checking of the charge air receiver must always be carried out after a piston overhaul. The inside of the charge air receiver has to be cleaned at regular intervals. At these opportunities check also whether water drain pipings 8 from the charge air receiver are not clogged, so that a permanent drainage is assured during operation (fig. 'B').
1994
UG
RTA84C
Maintenance
6420/1.3
B I
I-I
II
II
1
5
7
Freies Ende FREE END
I
3 8 8 4 8 2 10
II
III
III
5 9
94.7297
88.7028
UG
1994
RTA84C Auxiliary Blower Maintenance

Tools: 2 Centring studs Various jacking screws Various spanners 94652
Maintenance
6545/1.1
Key to Illustrations: 1 2 3 4 4a 5 6 7 8 9 Electric motor Motor plate Spiral casing Impeller Hub to item 4 Screw Spring washer Screw M 16 Motor shaft Shaft seal 10 11 12 13 14 15 16 17 S V Sealing bush Gland housing Gasket Cover sheet Screw Jacking yoke Screw Support piece Suction pocket Connecting pipe
The following instructions apply to the auxiliary blowers of DEFOR make with which the engines of the RTseries are generally equipped. For dismantling an auxiliary blower for cleaning or overhaul proceed as follows: Separate the electrical leads from the electric motor. Attach the electric motor 1 to a hoist (Fig. 'B'). Unscrew two horizontally opposed screws, fastening the motor plate 2 to the spiral casing 3, and fit in their place the two centring studs tool 94652 (see Fig. 'B'). Unscrew and remove all remaining screws of the motor plate. Using two jacking screws press the motor plate 2 from the spiral casing (Fig. 'B'). Guide the electric motor 1 including motor plate 2 and impeller 4 horizontally out of the spiral casing 3. Place the removed assembly on a flat underlay, with the electric motor at the bottom and the impeller on top. Attention! When upending the assembly from the horizontal position to the vertical, take great care not to knock the impeller against anything or damage it in any way.
Should further dismantling be required, proceed as follows: Dismantling Loosen screw 5 and remove together with spring washer 6. Use a puller as shown in Fig. 'D' and by tightening the screw 7 pull the impeller 4 off the motor shaft 8. Normally the shaft seal ring 9 remains stuck on the motor shaft 8 or on the sealing bush 10. If it is withdrawn along with the impeller, then the gland housing 11 must be removed from the motor plate 2 and the shaft seal ring 9 again fitted. A replacement of the shaft seal ring (GARLOCK P/Sseal type 61 90x110x10) is recommended, for such a disman tling. Assembling Remark! Please note that the impeller 4 is statically and dynamically balanced, and therefore must in no way suffer deformation or other damage.
Working sequence: Fit gland housing 11 with shaft seal ring 9 in motor plate 2. Smear motor shaft 8 moderately with oil. Push impeller 4 onto motor shaft 8 (pay attention to the key position)! Screw threaded bar into motor shaft, fit a strong washer and by tightening a nut, push the impeller onto the motor shaft until the impeller hub 4a rests snugly against the sealing bush 10. Remove washer and threaded bar and fit in their place spring washer 6 and screw 5. Tighten the screw firmly.
1989
6545/1.2
Maintenance
RTA84C
Bring the assembly consisting of electric motor 1, motor plate 2 and impeller 4 with the hoist carefully to a horizontal position and lift it. Should the gasket 12 between motor plate 2 and spiral casing 3 not be in good condition, replace it by a new one of 2 mm thickness. Screw the two centring studs 94652 into the spiral casing (as for the dismantling). Guide the assembly carefully into the spiral casing and fasten the motor plate 2 to the spiral casing with the screws. Unscrew centring studs 94652 and store away with the engine tool set. In their place fit the two remaining screws and tighten them firmly. Connect the electric motor again to the mains (check sense of rotation). Remark! Auxiliary blowers which are out of service for a longer period should be started up twice monthly for a short time. Where this is not feasible, the impeller should be turned by hand by several turns. This is nec essary to protect the bearings from corrosion damage.
1989
RTA84C
Maintenance
6545/1.3
1989
6545/1.4
Maintenance
RTA84C
1989
RTA84C
Maintenance
6606/1.1
Charge Air Cooler Cleaning (Water Side) on Engine at Standstill

Tools: Tube brushes Various spanners Key to Illustrations: 1 Cover with water inlet and outlet branches 2 Flow reversing cover 3 Air duct before cooler 4 5 6 7 Cooling tubes Cooling fins Tubeplate Cooler casing
Depending on the cleanliness of the utilized cooling water a cleaning of the cooler tubes is required after a shorter or longer operating period. The necessity to clean becomes evident either by measuring the pressure difference or by the temperature difference between cooling water inlet and outlet, and comparing this with the values of the clean cooler. When using clean, neutral cooling water, cooling tube cleaning will be only rarely necessary. Cleaning methods The cooling tubes can be cleaned either by mechanical, by hydraulically or by chemical means. a) Mechanical Cleaning in fitted Condition After removing the covers 1 and 2 (Fig. 'A') the dirt, loosened by water, is removed by special tube brushes, then the tubes flushed through. b) Hydraulic Cleaning in fitted Condition Firmly adhering sediment which is not dislocated by the brush can be removed with high pressure water jets. Spray devices with special nozzles are used, which can be ordered from the cooler manufacturers. c) Cleaning by chemical Solvents in removed Condition (Removal see 6606/2) Should the above mentioned methods not be successful then chemical means must be utilized. By this the tube stack is immersed in a chemical cleansing bath for a time depending on the degree of fouling then flushed through with a strong water jet. During the cleansing process the effectiveness can be increased by circulating the chemical through the tubes, whereby the immersion time can be reduced. For this type of cleaning the instructions of the cleaning agent makers must be strictly followed. When choosing the cleaning agent we recommend using only products of renowned firms of this line such as e.g.: DREW, VECOM, GAMLEN, HENKEL, etc. Locating and sealing of leaking cooler tubes in service Due to corrosion or mechanical damage tube leakages may occur. This causes cooling water to enter the air duct 3 and the charge air receiver. The following procedure permits locating leaking cooler tubes 4 and sealing them. Reduce engine power, until the air temperature after the blower reaches about 65 to 70_C, then shut off the water valves before and after the defective cooler and drain the cooler. Remove the side covers 1 and 2 (see also 6606/2) and seal the cooler tubes on one side of the cooler with cardboard or similar. On the opposite end brush soapy water over the cooler tubes, leaking tubes will be revealed by bubbles. Defective tubes are sealed up by hammering in slightly tapered plugs of hardwood, copper etc. Cooler tubes sealed in this manner must be replaced at the next opportunity in accordance with maker's instruc tions. Transportation of cooler tubestacks Always utilize specially provided suspension straps 'T' (see sheet 6606/2 Fig. 'C') which can be swung sideways. Where only holes are provided, use suitable shackles for transportation. It is recommended to cover the finned surfaces, protecting the cooling fins and preventing the entrance of foreign particles during transportation and storage.
1989
6606/1.2
Maintenance
RTA84C
1989
RTA84C
Maintenance
6606/2.1
Charge Air Cooler Removing and Fitting a Cooler Element

Tools: 1 Device complete consisting of: 1 Roller plate 2 Slide rails 2 Eye bolts 94661 94662 94663 94664 1 2 3 4 5 6 7 8.8a 9 10 11 11a Key to Illustrations: Cover with water connections Gasket Round rubber ring Screw Sealing flange Cooler casing Side wall Screw to cover Cooler tubes Cooling fins Tube plate Screws 12 13 14 15 'A','B' K S T U W Gasket Flow reverse cover Gasket Clamp screws with guides and washers Arrester stops Stop lever Setting screws Transport straps Reversing side Water inlet and outlet side
When a cooler element (tube stack) has to be removed, this has always to be effected towards the side opposite the water inlet/outlet connections, i.e. towards 'U' on Fig. 'A'. At the underside of the beams to the upper platform rails are fitted on which a cooler element can be attached with a roller plate and thus rolled out or rather pulled out respectively. For this the device 94661, contained in the tools collection of the engine, is to be used. The cooling water pumps must be stopped and the cooler drained. After this proceed as follows:
1990
6606/2.2
Removal
Maintenance
RTA84C
Loosen all the screws fastening the cooling water inlet/outlet pipes to the cover 1 of the cooling element, and re move them (Fig. 'A'). Unscrew all the screws 4 and remove sealing flange 5 with round rubber ring 3. (Fig. 'A'). Unscrew on the flow reversal side 'U' all the screws 11a (Fig. 'A'). Approach roller plate 94662 hanging on the runner rail and attach to it flow reversal cover 13 with clamp screws 15. Loosen the cooler element with the aid of jack screws. As soon as the element is free i.e. the gasket 14 come off, press the clamp screws 15 with the setting screws 'S'- while simultaneously slackening the clamp screws 15, whereby the cooler element is slightly raised in the casing (see Figs. 'A', 'B' and 'C'). Tighten clamp screws. Drive eye bolts 94664 into the flow reversal cover (see Fig. 'B'). Attach pulling tackle on ring screws and pull the cooler element out of the cooler casing till stop 'A' (see Fig. 'C'). Flap the four transport straps 'T' of the cooler element upwards and attach with these ropes the cooler element to the crane (see Fig. 'C'). Fit both slide rails 94663 at the bottom of the cooler casing with 2 screws M20 each. Press stop lever 'K' upwards and now pull cooler element out till the stop 'B' (see Fig. 'B' and 'C'). Loosen clamp screws 15 by a few turns and lift the cooler element by about 10 cm. with the crane. Bring roller plate to the end of the runner rail. Remove both slide rails 94663 from the bottom of cooler casing. Lower cooler element with the crane and move it out of engine room. Fitting Lift cooler element by crane till both slide rails 94663 can be fitted at bottom of cooler casing. Bring roller plate 94662 till the stop 'B'. Lower cooler element till it rests on the two slide rails. Fix roller plate to flow reversal cover 13 with both screws 15. Drive both eye bolts 94664 into cover 1. Attach pulling tackle on ring screws and pull cooler element till the stop 'A' into the cooler casing. Remove suspension ropes from crane and flap the four transport straps 'T' in. Remove both slide rails. Pull cooler element completely into the casing. Remove roller plate; screw the clamp screws 15 with washers and guides into the threaded holes in the roller plate, for storage. Fit sealing flange with round rubber ring 3 for cooler seal and fasten it with screws 4 to the cooler casing, tighten screws. Connect water pipes. Shut drain on cooler element and open vent. Start cooling water pumps and inspect cooler for possible leakage.
1990
RTA84C
Maintenance
6606/2.3
1990
6606/2.4
Maintenance
RTA84C
1990
RTA84C
Maintenance
6708/1.1
Water Separator Maintenance of Water Separator Elements

Key to Illustrations: 1 2 3 4 5 Element unit (water separator) Screw with spring washer Girder Screw with spring washer Screw with spring washer A Space for placing the removed element unit B Space for separated condensate G Bifurcation
Water separator elements should be inspected after completing the first operating year. On the basis of the degree of contamination found, the cleaning interval for future servicing should be established. When the air suction filter of the turbocharger is well maintained, the degree of contamination of the water separator should not be consider able. During an inspection, check particularly the air inlet side, of the individual water separator elements. For each exhaust gas turbocharger one element unit 1 has to be removed. If required the remaining element units are also to be removed and cleaned. Removing an element unit Working sequence: Open flap cover nearest to water separator elements on the receiver. Loosen all screws 5 and remove them. After removing screws 4, girder 3 can be taken off together with element unit 1. Take great care that the element unit does become damaged by dropping down. To remove an element from the whole element unit, the screws 2 must be loosened and removed. While checking the individual removed elements, attention to bifurcations 'G' of the lamina for accumulated dirt (see section IV-IV Fig. 'A'). From the condition of these random removed element units establish whether the remaining elements must also be removed and whether cleaning is at all required. This check should serve to estab lish the intervals for future inspections. For cleaning the elements if at all required use the same agent which is used on cleaning the charge air cooler in service. Do not use any hard sharp object for the cleaning. Fitting Before fitting the element unit clean the space 'B' as it is later not accessible. For fitting proceed analogous to removing but in reverse sequence.
UG
1994
6708/1.2
Maintenance
RTA84C
I-I II
II - II I
4 3
IV
IV
III
III
1 5
II
III - III
IV - IV
1
93.7022
1 G Gezeichnet fr RTA72U DRAWN FOR RTA72U
1994
UG
RTA62U-B
Betrieb
Group7
Cylinder Lubrication, PTO and Balancer
Group 7
Cylinder Lubricating pumps

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7203/1
Flow Control Valve

PTO Gearbox
Checking Clearances and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7403/1 Removing and Fitting of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7403/2
Geislinger Couplings
External Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7412/1
Balancer 2nd Order

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7708/1
Integrated Balancer of 2nd Order

Removal and Fitting of Balancer Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7722/1
RTA84C / MM / 2001
RTA84C Cylinder Lubricating Pumps Cleaning
Maintenance
7203/1.1
Key to Illustrations: 1 2 3 4 5 6 7 8 9 10 11 12 Dust cover Stroke setting screw Housing cover Gasket Stroke operating disc Stroke control disc Operating plunger Control plunger Pump element Base plate Housing Helical gearwheels 13 Cylinder lubricating pump shaft (drive shaft) 14 Free wheel 15 Pump shaft 16 Nonreturn valve 17 Oil outlet connection 18 Spring 19 Hand crank 20 Relief valve upper part 21 Pin of upper spring plate 22 Spring 23 24 25 26 27 28 29 30 31 32 A B C E Oring Relief valve lower part Pressure adjusting ring Membrane Valve Screw Key Shaft sealing ring Gasket Bearing bush
Suction pipe Discharge pipe Oil drain screw Vent screw with relief valve (2 bar opening pressure) F Filling pipe connection
1989
7203/1.2
Procedure for cleaning
Maintenance
RTA84C
To clean (flush) a cylinder lubricating pump, shut off the feed pipe to the housing and unscrew oil drain screw 'C' and vent screw 'E'. Fill clean paraffin or flushing oil into the hole for vent screw 'E' until the oil sludge is flushed out. Before refitting oil drain screw 'C', slightly open the shutoff cock of the feed pipe so that the remaining paraf fin or flushing oil can be flushed out. To refill the housing with fresh oil, first completely screw in vent screw 'E' and then unscrew it by 1-2 turns while fully opening the shutoff cock. After venting, retighten vent screw 'E'. Before putting the cylinder lubricating pump back into service, turn pump shaft 15 with the hand crank 19 until the visual flow control situated on to of the cylinder lubricating pump shows that all operating plungers 7 are discharging oil. Note: When installing a spare cylinder lubricating pump during replacement we recommend that it be cleaned inter nally as described above before putting it into service. The individual pump elements 9 which are connected to a lubricating point should also be adjusted to the data given in the timing records since the operating plungers are set by the manufacturers to full stroke. The effective stroke, and therefore the oil delivered per pump element, can be adjusted with the stroke set ting screw 2 (with click stop) as follows: by turning clockwise by turning anticlockwise = reduced oil delivery = increased oil delivery
1989
RTA84C
Maintenance
7212/1.1
Driving Shaft to the Flow Control Valve of the Cylinder Lubrication Dismantling and Assembling
Key to Illustrations: 1 2 2a 3 4 5 Screw Locking plate End plate Spur gear Screw Casing 6 7 8 9 10 11 Driving shaft Key Synthetics ball Threaded pin Flow control valve Shaft to flow control valve
Should the trouble free functioning of the flow control valve (REXROTH) not be assured for any reason, it has to be exchanged against a new one. The removal of the valve from its driving shaft and the fitting of the new one re quires particular care, it is therefore recommended to follow carefully the instructions given here below. The company (REXROTH) will take care of reconditioning the defective valve upon request. Dismantling Loosen the screw 4 and gently try to lift the casing 5 off the valve 10. If this is not easily achieved the flow control valve is of the newer type which is equipped with clearancefree coupling between driving shaft and throttling bush. On the new valves, the spur gear 3 has to be removed. The fastening of the coupling can be loosened by turning back the threaded pin 9. Attention: When removing the driving shaft 6 from the shaft to flow control valve 11 the small synthetics ball 8 may fall out.
It is recommended to mark the correct fitting position for the reassembling after removing the coupling.
[l/mm] 60 50 Symbolische Darstellung SYMBOLIC DIAGRAM A B 40 Durchfluss FLOW 30 20 10 T 0 0 30 60
Durchflusskennlinie FLOW CHARACTERISTIC
90 120 150 180 Drehwinkel ANGLE OF ROTATION
240
300
1989
7212/1.2
Assembling
Maintenance
RTA84C
In case the correct fitting position of the driving shaft to the throttling bush has not been marked, the valve must be removed from the valve plate to check the through flow from A to B with compressed air. In the zero stop position (driving shaft turned in anticlockwise direction) may be no flow from A to B. When turning the driving shaft in clockwise direction the valve should begin to open after 15_ and the flow must reach its maxi mum at the end stop after a turn of 300_. After correctly fitting the driving shaft 6, insert the small synthetics ball 8 and the threaded pin 9 and tighten lightly so that no clearance remains in the hexagon connection. Adjust the drive gear casing 5 in such a way that after tightening the fastening screws 4 the driving shaft turns easily.
1989
RTA84C
Maintenance
7403/1.1
PTO Gearbox Checking the Tooth Backlash, Aligning the Gearbox Housing, Checking the Running Performance
Tools: 1 Feeler gauge Lead wire 4 1.5 mm Oil proof indian ink. 94122 0-6 7 8 9 a,b,c f Df Key to Illustrations: Tooth profiles Pinion on Geislinger shaft Intermediate gear Gear on crankshaft Lead wires Backlash Obliquity 10 11 12 13 14 Bedplate Column Gearbox housing Shims Shims
Remark! Before checking the tooth profile parallelism and the tooth backlash 'f' between the pinion 7 on the Geislinger shaft and the intermediate gear wheel 8, the tie rods of the engine and the pressure studs of the crankshaft main bearings must be fully tightened. For the same reason the tooth backlash and the profile parallelism be tween pinion 7 and intermediate gear wheel 8 must be checked after the first recommended retightening of tie rods according to sheet 1903/1. Measuring tooth backlash with lead wire Use a fresh piece of lead wire Pb 99.9 fine with a diameter of 1.50 mm for each measurement. Place three lead wire pieces a, b, c of about 200 mm length by hand around the contour of the pinion 7 on the Geislinger shaft and attach them with scotch tape (see Fig. 'A' and 'B'). Number the pinion profiles in accordance with Fig. 'B'. The middle lead wire 'c' (Fig. 'A') serves to verify the total tooth backlash 'f' (Fig. 'C'). With the two outer lead wires 'a' and 'b' (Fig. 'A') the tooth profile parallelism is checked. The lead wires are turned only once in operating direction through the teeth meshing, by rotation the engine crankshaft. The total tooth backlash 'f' is calculated from: f = fc0 + fc1 resp. fc1 + fc2 etc. The obliquity 'Df' is calculated from the difference in thickness of the squashed lead wires along the bearing tooth profiles: Df = a1 - b1 resp. a3 - b3 etc. The admissible deviation of tooth profile parallelism amounts to 0.03 mm across the width of the pinion. For admissible tooth backlash pl. refer to sheet 0330/9. Aligning the gearbox housing Should the measured values lie beyond the admissible limits, then the gearbox housing 12 must be realigned, the shims 13 and 14 adapted and the housing redoweled. Changing the thickness of shims 14 by 1 mm in the Xaxis (minus or plus) alters the tooth backlash by 0.698 mm (Fig. 'D'). For such a case of realignment the position of the neighbouring components must also be corrected (couplings, conspeed. generator). Checking the running performance with ink To enable judgeing the running performance of the gearbox after recommissioning, three teeth each of pinion 7 and gear wheel 8 are smeared with a thin coat of oil proof indian ink equally spread. This check of the mating appearance of the teeth is necessary although the realignment of the gearbox has been made with utmost care, by the use of lead wire. One brand of oil proof indian ink. is for example Dykem Layout Red Dx-296.
1989
7403/1.2
Maintenance
RTA84C
1989
RTA84C
Maintenance
7403/2.1
PTO Gearbox Removing and Fitting the Gearbox Components as well as of the Intermediate Gear Wheel
Tools: 1 1 1 2 1 1 Feeler gauge Depth gauge Connecting branch Suspension flange HP hose Airhydraulic HP pump 1 Withdrawing device for taper dowel pins 2 Eye bolts 94122 94124 94425 94702 94935 94942 1 2 3 4,4a 5 6 7 7a 8 9 10 11 12 13 14 15 16 23 24 25 25a 26 27 Key to Illustrations: Driving column Cover Cover Bearing Gear wheel Geislinger coupling Geislinger shaft (intermediate shaft) Pinion Vent screw Waisted bolts Pinion shaft Coupling ring (2part) Housing upper part Housing lower part Cover Cover Coupling flange Bearing Bearing Disc Screw Slinger ring Intermediate gear 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 'a' 'b' 'c' 'd' 'f' x' 'OE' Intermediate gear bearings Screws End cover Locating dowels Locking strap Guide pin Oring Distribution block Waisted screw Bush Outer end flange Spring pack Inner end flange Split ring Oring Waisted screw Connecting thread Connecting thread Lifting device Rope Mounting surface Pressingon measure Oil inlet
Removing and fitting the Geislinger shaft For removing the Geislinger shaft 7 (Fig. 'A' and 'B') proceed as follows: Disconnect and remove all connecting piping for oil and, possibly air. Loosen all screws to driving column 1 and remove the cover. Loosen all the screwed fastenings between housing upper part 12 and housing lower part 13. The housing lower part remains fastened to the column of the main engine. Remove distribution block 35 and guide pin 33. Loosen and remove the screwed fastenings to covers 2 and 3 as well as 14 and 15. Lift housing upper part 12 with lifting tackle up and take care that the upper part does not jam in the bearing guides. The Geislinger shaft can now be lifted out from the housing lower part together with the two bearings 4 and 4a and the two suspension flanges 94702. Take care that the two bearings slide out of their guides without jamming and that the gear teeth are not being damaged. Fitting the Geislinger shaft is carried out analogous to the removing but in reverse sequence. Removing and fitting the pinion on the Geislinger shaft as well as the gear wheel on the Geislinger coupling, see Fig. 'A' and 'B' (Execution with one coupling). After removing the Geislinger shaft and the removal of the bearing 4 the pinion 7a can be withdrawn with the aid of a hydraulic jack. For this, mount the connecting branch 94425 on the front face of the Geislinger shaft at connection 'a'. Raise the pressure slowly with HP pump 94942 until the pinion can be pushed off the Geislinger shaft. Attention! The pinion may suddenly slide off the shaft, it must therefore be secured against a wooden block. For the removal of gear wheel 5 from the Geislinger coupling 6 slightly loosen waisted screws 9, place Geislinger shaft 7 with the help of one suspension flange 94702 in vertical position onto trestles, with Geislinger coupling up permost. The Geislinger shaft/coupling assembling can now be pulled upwards out of the wheel.
1989
7403/2.2
Maintenance
RTA84C
For assembling proceed analogous to dismantling but in reverse sequence, thereby pay attention to the following: Tapped holes and the thread of the waisted bolts 9 for screw fastening the gear wheel 5 to the Geislinger coupling must be oil free. All the waisted bolts are locked with LOCTITE type 'A'. Tighten the waisted bolts to ( 60_ (please refer also to sheet 0352/1). Prior to fitting the pinion 7a onto the Geislinger shaft 7 heat the same to 170-180_C. Before fitting the pinion make sure that all contact surfaces on the shaft and inside the pinion bore are clean and free from grease. After fitting the pinion check immediately with the feeler gauge that it rests snug without clearance against the seat ing surface 'f' (Fig. 'B'). For the removal and fitting of pinion and gear wheel on the Geislinger coupling please refer to Fig. B1 (Execu tion with twin coupling) For removing pinion 7a its coupling must first be pulled off Geislinger shaft 7. Working sequence for removing and fitting pinion 7a Attach Geislinger shaft assembly with suspension flange tool 94702 and raise it to the vertical position. Rest the coupling of gear wheel 5 on wooden blocks. Secure the complete shaft assembly against toppling over. Loosen and remove only waisted screws 43 at the outer end flange of the pinion coupling. Unscrew both vent screws 8 of the coupling and insert eye bolts. Using crane or lifting tackle lift outer end flange 38 including leaf spring stack 39 off the shaft. Attention: The spring pack must remain completely unchanged (please also refer to Geislinger instructions. Side wise remove split ring 41, which is fastened by four LOCTITEsecured slotted screws to inner end flange 40. Loosen and remove waisted screws 36. Pull out dowels 31 which are used to position inner end flange 40 to pinion 7a. Lift off inner end flange. Pull pinion 7a with pressedin bush 37 off the shaft. For fitting proceed along the same lines as for removal but in reverse sequence, paying attention to the following points: Check Orings for possible damage and replace them if necessary. Smear Orings well with oil before fitting them. Fit waisted screws 36 with LOCTITE type 'A' then tighten them with min. ( 34_. Waisted screw 43 with the spring washer stack must be tightened in accordance with instructions from Geislinger, then locked carefully. Working sequence for removing and fitting gear wheel 5 Attach Geislinger shaft assembly with suspension flange tool 94702 and bring it to vertical position. Rest pinion coupling 7a on wooden blocks. Secure the complete shaft assembly against toppling over. Loosen and remove only waisted screws 43 in the outer end flange of the coupling. Unscrew and remove both vent screws 8 and insert eye bolts. Using crane or other lifting tackle lift outer end flange 38 including leaf spring stack 39 off the shaft. Attention: The spring packs must remain completely unchanged (please also refer to instructions linger)! from Geis
1989
RTA84C
Maintenance
7403/2.3
Side wise remove split ring 41, which is fastened by four slotted LOCTITEsecured screws to the inner end flange. Loosen and remove waisted screws 9. Pull gear wheel 5 including pressedin bush off the shaft. For fitting proceed along the same lines as for the removal but in reverse sequence, paying attention to the following points: Check Orings 42 for possible damage and replace them if necessary. Smear Orings well with oil before fitting them. Carefully keep tapped holes in the inner end flange for waisted screws 9 dry (free from oil). Fit waisted screws 9 with LOCTITE type 'A' then tighten them to ( 60_ (see also sheet 0352/1). Waisted screws 43 with spring packs 39 must be tightened in accordance with instructions from Geislinger, then locked carefully. Removing and fitting the pinion shaft For removing the pinion shaft 10 proceed as follows: Disconnect and remove all connecting piping for oil and, possibly air. Loosen all screws to driving column 1 and remove the cover. Loosen all the screwed fastenings between housing upper part 12 and housing lower part 13 (Fig. 'A'). Housing lower part remains screw fastened to the column of the main engine. Loosen the screwed fastenings to covers 2 and 3 as well as to 14 and 15 (Fig. 'B'). Lift casing upper part 12 off with suitable lifting tackle, paying attention that the upper part 13 does not jam in the bearing guides. Should a clutch be fitted immediately near the gearbox (e.g. Lohmann + Stolterfoth clutch) then the coupling studs to the coupling flange 16 must be removed and the 2part coupling ring 11 taken off. To prevent damage to the clutch follow also instructions of clutch manufacturers. The pinion shaft 10 can now be lifted out of the housing lower part 13 by suitable lifting tackle. Should an air connec tion be built into the pinion shaft for the clutch actuation, dismantle same before removing the pinion shaft. Refitting the pinion shaft 10 is done analogous to its removal but in reverse sequence, thereby be sure to follow the instructions of the coupling or clutch manufacturers. If the bearing 24 on the side of a clutch have to be removed proceed as follows: Drive connecting branch tool No. 94425 into the threaded bore 'b' of the coupling flange 16 (Fig. 'E'). Connect HP hose 94935 and hydr. HP pump 94942 to the connecting branch. Fasten disc 25 by screw 25a firmly to the front face of the pinion shaft. For pullingoff the coupling flange raise oil pressure very slowly till the coupling flange floats (freely movable on the shaft) then loosen screws 25a and slide it off the pinion shaft (maximum pressure 1200 bar). Exceptionally the coupling flange can also be withdrawn by heating it. Bearing 24 can now be removed. For assembling proceed as follows: Push bearing 24 as well as slinger ring 26 onto the pinion shaft 10. Keep all contact surfaces in coupling flange 16 and on pinion shaft 10 clean and free of oil.
1989
7403/2.4
Maintenance
RTA84C
Push coupling flange in cold condition onto the pinion shaft (Fig. 'F'). Measure the distance 'X' from the front face of the coupling flange to the front face of the pinion shaft with depth gauge 94124. (Shrinkon distance). This distance should measure between 10.4 and 12.5 mm. (Any corrections may only be carried out in the flange bore). Heat coupling flange to 200 - 220_C. Use disc 25 and screw 25a to press the coupling flange on until it rests against the shoulder of the slinger ring 26. Leave disc 25 with screw 25a fitted until the coupling flange has cooled to about 45_C. Check with feeler gauge whether the coupling flange rests snug without clearance against the shoulder of the slinger ring 26 (Fig. 'B'). Removing and fitting the complete PTO gearbox Should the complete PTO gearbox have to be taken off, then the previously described possible clutch connection to the pinion shaft 10 (Fig. 'A') as well as all piping connections to the PTO gearbox must first be removed. Loosen screw fastenings to driving column 1 and remove the cover. Loosen the screwed fastenings between the PTO gearbox and the main engine. The PTO gearbox can then be lifted away with the crane. After refitting the PTO gearbox to the main engine the tooth backlash between the pinion 7a and the intermediate gear wheel 27 must be checked (see 7403/1). The coupling/clutch neigbouring the pinion shaft 10 must be also checked in accordance with manufacturers instructions for correct alignment. Removing and fitting the intermediate gear wheel 27 to the PTO gearbox For the removal of the intermediate gear wheel 27 to the PTO gear wheel proceed as follows: Remove PTO gearbox complete from the main engine as described above. Rotate the engine crankshaft so, that the screws 29 fastening the intermediate shaft bearings 28 are easily accessible from the crankcase (Fig. 'B'). Secure turning gear against accidental starts. Remove the oil supply pipe to the bearing lubrication of the intermediate gear wheel. Mount a lifting tackle 'c' in the gear column (Fig. 'G'). A further steel rope 'd' to be fastened to the crane outside the engine. Stretch steel rope 'c' taut, loosen screws 29 to the two intermediate bearings 28 and remove together with the two end covers 30. Remove two each locating dowels 31 in both intermediate gear wheel bearings 28 with the aid of the withdrawing tool. Use lifting tackle 'c' together with the crane rope 'd' (Fig. 'G') to lift the intermediate gear wheel together with its two bearings out of the engine. After the removal of the intermediate gear wheel the two bearings can be pulled off, after dislocating the locking straps 32. For fitting the intermediate gear wheel proceed analogous to its removal but in reverse sequence. The two bearings to the intermediate gear wheel must without fail be refitted in the original position, as they were exactly dowelled. The intermediate gear wheel must be fitted in such a way that the marking DRIVING END faces towards the driv ing end. (Additional information are given in sheet 4103/1 -/3). After the fitting the tooth backlash must for safeties sake be checked (see also clearance table sheet 0330/9). Remark: Metallic sealing surfaces on the PTO housing must be sealed with a thin spreading sealing compound.
1989
RTA84C
Maintenance
7403/2.5
1989
7403/2.6
Maintenance
RTA84C
1989
RTA84C
Maintenance
7403/2.7
1989
RTA84C
Maintenance
7412/1.1
Geislinger Couplings External Inspection for Oil Leaks and constant Venting
Key to Illustrations: 1 2 3 4 Inspections External inspection: It is recommended to inspect the coupling externally for oil leaks in intervals of 1000 - 2000 operating hours. Leak ing Orings are easily diagnosed when the coupling is subjected to oil under pressure. Constant venting through the nozzles 3 must be guaranteed. The openings of these nozzles must be cleaned at each inspection. Their free passages may not be enlarged under any circumstance! Complete inspection (removal, dismantling): According to the manufacturer's specifications a complete inspection should be carried out, whereby part subject to wear are to be replaced. Extrascheduled inspections: Should any defects be noticed on the crankshaft bearings or the gearbox bearings due to the water contents in the lubricating oil, then it is essential at the next opportunity also to inspect the coupling for corrosion damage or wear at the spring ends respectively. For overhauls the instructions of the coupling manufacturers must be followed con scientiously. Remark: Design and position for the constant venting through the nozzle 3 (see illustration), can differ depending of the coupling design. Maintenance on and servicing of the Geislinger couplings is carried out by: Dr. Ing. Geislinger & Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5023 Salzburg/Austria Atteliers et Chantiers de Bretagne . . . . . . . . . . . . . . . . . . . . . . . . F-44040 Nantes/Cedex FRANCE AlsthomAtlantique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Departement Moteurs F-93202 St. Denis FRANCE Etablissement Mecanique F-44550 Montoir de Bretagne Oy Waertsilae AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF-20810 Turku 81 FINLAND Ishikawajima Harima Heavy Industries Co. Ltd. . . . . . . . . . . . . Tokyo 100, JAPAN Niigata Engineering Co. Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tokyo 100, JAPAN Nippon Kokan Kabushiki Kaisha . . . . . . . . . . . . . . . . . . . . . . . . . Yokohama, JAPAN Blohm & Voss AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2000 Hamburg 1 GERMANY A.P.E. Grossley Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GB-Manchester M11 2DP GREAT BRITAIN Van Stigt B.B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Avelingen West 30 NL- 4204 MS Gorinchem NETHERLANDS Eaton Corporation, Industrial Drives Operations . . . . . . . . . . . Cleveland, Ohio 44144, USA Marine & Diesel Service Pty. Ltd. . . . . . . . . . . . . . . . . . . . . . . . . Artarmon, N.S.W. Australia 2064 Orings (for shaft sealing) Orings (for side plates) Nozzles for constant venting Vent screws
1989
7412/1.2
Maintenance
RTA84C
1989
RTA84C
Maintenance
7708/1.1
Balancer 2nd Order Fitting, Removing, Tensioning the Roller Chain (at the Free End) Fitting, Removing the Flexible Coupling and a Camshaft Section
Tools: 1 Proppingup device 1 Rivet puller 1 Fitting tool 1 Pretensioning jack 1 Feeler gauge 94703 94704 94705 94706 94122 1 2 3 4 5 6 7 8 9 9a 10 11 12 13 14 15 16 17 18 19 20 Key to Illustrations: Balancer case Eccentric Chain tensioner Roller chain Spray nozzles Inspection cover Side cover Chain drive sprocket Balancer masses with Chain sprockets Sheave sprocket Cover in case bottom Spindle Upper setting nut Spacer ring Tensioning sleeve 'Belleville' springs Spacer disc Bearing pin Lower setting nut Toothed segment 21 22 23 24 25 26 27 28 29 30 30a E M S V Z OA OE OG Locking plate Pin Holding screws Flexible coupling Oil catcher Coupling bolts Coupling on camshaft Camshaft section Inspection cover Closing plugs to Inspection bores Setting measure Mark on balancer masses Supporting face Chain lock link Checking measure Oil outlet Oil inlet Oil inlet to the Geislinger coupling
According to requirement a four to six cylinder engine can be equipped with an integrated balancer at the driving end, and if necessary with a chain driven balancer (see sheet 7722/1) at the free end. Attention! Before any removal of the chain, or removal operations on the camshaft or the camshaft drive the ba lancer masses must be brought to the B.D.C. position without fail. We recommend checking the roller chain tension about 500 hours after the first commissioning or after fitting a new chain, and if necessary retension it. Further checks with retensioning are then due in intervals of 1500 operat ing hours. In the same intervals the chain and the chain sprockets should be inspected. Check the chain for cracks, seizure marks, jammed rollers and pins as well as for elongation due to wear. The admis sible elongation amounts to 1.5% of original length, i.e. if the length over five chain pitches has reached 580 mm the chain has to be replaced. Pl. refer also to the measuring method in illustration 'B', 'B1' where the balancer weights must stand downwards and the measuring is done on the stretched chain over five pitches. Here x - y provides the effective length. Only chains to required quality may be fitted. Check also the chain sprockets for cracks and wear. If their teeth have become sharp edged from wear, blunt these at a radius of about 1 mm. Lubrication The spray nozzles must be directed exactly to the slot between outer and inner straps of the roller chains. Spray direction and oil flow are also to be checked in an interval of 1500 hours. On the same occasion inspect also the nozzles for continuous venting of the Geislinger coupling in the balancer drive (if equipped therewith) (see Fig. 'E' and sheet 7412/1). Remark: When a new chain or sprocket is installed the new parts must be run in. (Please refer to section 'Running in' in the operating manual).
1989
7708/1.2
Removing the roller chain 1) Remove cover on the balancer case.
Maintenance
RTA84C
2) Turn engine crankshaft to crank position according to Fig. 'B', 'B1', so that the balancer masses point vertically downward (otherwise risk of accidents). Remove electrical fuses from the turning gear switchboard, thus preventing any likelihood of the gear to be set into motion while removal work is in progress. Remark: The required position of the first cylinder crank varies with the number of engine cylinders and also with the rotation direction of the engine. For the applicable alternative the corresponding indications are taken from the table Fig. 'B', 'B1'. 3) The chain is now slackened in the following manner (Fig. 'C'): Remove toothed segments 20 locking the upper and lower setting nut 13 and 19 by removing the holding screws 23, which in turn are locked by locking plate 21. Turn upper setting nut 13 with the spanner upwards till sufficient slackening of the chain is attained. Grind off riveted link pins on a suitably located outer link between the balancer masses. Pull chain ends together (using block and tackles, hoists etc,) Using rivet puller 94704 pull off the outer strap and remove the outer link. Pull chain out of the balancer case with suitable lifting tackle, proceeding in reverse sequence as described in the following paragraph for the fitting of a roller chain, depicted in Fig. 'D'. Fitting the roller chain Turn the crank of the first cylinder to the position shown in table 'B', 'B1' for the respective engine. Insert the roller chain in the sequence a,b,c,d, as shown in Fig. 'D'. (Weight of roller chain: RTA84C = 642 kg). Pull lose chain ends together (using block and tackles). Insert new locking link, and force loose strap with a hammer lightly onto the chain link pins. Previously utilized locking links may not be refitted a second time. Set fitting tool onto the locking link, so, that the solid plate comes to lie onto the already riveted side. Tighten nuts on fitting tool 94705 equally in sequence by half a turn till the strap lies against the shoulder of the pin. Remove tool 94705. Using steel block as anwil rivet the annealed link pins. Now tension the chain as specified in the section 'tensioning procedure'. Remark! In case of unusual chain wear the alignment of the chain sprockets can be checked through the inspection bores 30a. Checking measure Z = 128.5 0,8 mm. The B.D.C. position (vertical downwards) of the balancer masses 9 can be checked through the transparent inspec tion covers 29. In this position the mark 'M' on the balancer masses corresponds with the mark on the inspection covers.
1989
RTA84C
Maintenance
7708/1.3
1989
7708/1.4
Maintenance
RTA84C
Engine - clockwise rotation B

Max. allowable lenght over 5 pitches 'x' - 'y' = 580 mm
Number of pitches 13 1/ 2
Number of pitches 11
Worn chain New chain
Center of camshaft
90.7044
Center of crankshaft View on to free end 4 Cyl. engine Pos. of crank cyl. 1 Theoretical New chain Worn chain
270 _ after TDC ~ 270.5 _ after TDC after TDC ~ 269 _
5 Cyl. engine Pos. of crank cyl. 1 Theoretical New chain Worn chain
after TDC 279 _ ~ 279.5 _ after TDC after TDC ~ 278 _
after TDC 285 _ ~ 285.5 _ after TDC after TDC ~ 284 _
1989
RTA84C
Maintenance
7708/1.5
Engine - anticlockwise rotation B1

Max. allowable lenght over 5 pitches 'x' - 'y' = 580 mm
Number of pitches 13 1/ 2
Number of pitches 11
Worn chain New chain
Center of camshaft
90.7044
Center of crankshaft View on to free end 4 Cyl. engine Pos. of crank cyl. 1 Theoretical New chain Worn chain
1989
7708/1.6
Maintenance
Supporting face 'S'
RTA84C
C
13 14 15
12
16 17
Surfaces flush, before point 6 of description
18
20 30mm 19
87.7018
Tensioning procedure (Fig. A, B and C) 1. Turn crankshaft to crank position in accordance with indica tions in Fig. 'B', 'B1' so that the balancer masses 9 hang verti cally downwards. 2. Remove locking elements (20,21 and 23), with which the set ting nuts 13 and 19 are locked. 3. Loosen lower setting nut 19 by about 20 - 30 mm, so that it does not come to bear when retensioning (see Fig. 'C'). 4.Tighten upper setting nut 13, till the upper edge of the spacer ring 14 and of tensioning sleeve 15 are flush. 5.Turn crankshaft with turning gear alternately short AHEAD and ASTERN. This causes the spacer ring 14 to move slightly up and down in the tensioning sleeve 15. For the mean value the upper edges mentioned under point 4 are flush. 6. Tighten up lower setting nut slightly by hand. In this position lock it with toothed segment 20 and locking plate 21. After this the spacer ring 14 must still be flush with the tensioning sleeve 15. 7.Fully tighten upper setting nut 13, i.e. first till the spacer ring 14 rests at 'S' against the supporting face of the tensioning sleeve, which makes itself felt by a noticeably increased tightening torque. The tightening angle required to bring the setting nut to firm seating is about 65_. After firm seating the setting nut must be tightened by further 10_ (1,4 teeth) before it is locked by the toothed segment 20, locking plate 21 and screws 23. 8. Loosening of the chain is carried out in reverse sequence.
1989
RTA84C
Maintenance
7708/1.7
Ansicht auf freies Ende VIEW ON TO FREE END
Anzahl Glieder 18 NUMBER OF LINKS 18
c Anzahl Glieder 38 NUMBER OF LINKS 38
d V
Anzahl Glieder 58 (inkl. Verschlussglied) NUMBER OF LINKS 58 (INCL. CONNECTING LINK)

90.7023
1989
7708/1.8
Maintenance
RTA84C
Fitting a flexible coupling or a camshaft section In order to ensure the alignment of the chain in the balancer, pay particular attention, when refitting the flexible coupling or a camshaft section, that the dimension 'E' between coupling on the camshaft and end column corre sponds to the referred value, when the axial clearance at the camshaft drive gear wheel is evenly distributed. If necessary the camshaft section or the coupling on the camshaft must be axially shifted to obtain this distance 'E' (Fig. 'E'). Checks: The crank position of cylinder No. 1, and the balancer masses must stand as shown in Fig. 'B', 'B1'.
1989
RTA84C
Maintenance
7708/1.9
Directions for removing and fitting work in connection with the balancer
fuel injection and actuator pumps balancer
gear wheel on camshaft
free end
driving end
last camshaft section flexible coupling coupling flange
middle camshaft section
first camshaft section
87.7012
Coupling sleeves
1.) When removing the flexible coupling: - Remove roller chain, as per directions on sheet 7708/1.2. - After removing oil catcher 25 support the shaft to flexible coupling 24 with tool 94703 as shown on Fig. 'F'. - Press out coupling bolts 26. - Remove flexible coupling 24 (Fig. 'E') 2.) When removing the last camshaft section at the 'free end': - Turn the crankshaft, so, that the balancing masses of the balancer at the 'free end' hang vertically downward (Fig. 'B', 'B1'). When this instruction is neglected, RISK OF ACCIDENT prevails! - Loosening the chain (sheet 7708/1.6) - After removing oil catcher 25 support the shaft to flexible coupling 24 with tool 94703 as shown on Fig. 'F'. - Press out coupling bolts 26. - Push the flexible coupling a little towards the 'free end', to provide space between the coupling flanges. - Loosen the coupling sleeve (sheet 4203/4 and 5) at the other end of the camshaft section and push it onto the neighbouring section. - Remove camshaft section (sheet 4203/1). 3.) When removing a first and a middle camshaft section: - Turn the crankshaft, so, that the balancing masses of the balancer at the 'free end' hang vertically downwards (Fig. 'B', 'B1'). When this instruction is neglected, RISK OF ACCIDENT prevails. - Loosen the coupling sleeves at both ends of the camshaft section to be removed (sheets 4203/4 and 5). - Remove camshaft section (sheet 4203/1). 4.) When removing the gear wheel on the camshaft: - Turn the crankshaft, so, that the balancing masses of the balancer at the 'free end' hang vertically downwards (Fig. 'B', 'B1'). When this instruction is neglected, RISK OF ACCIDENT prevails. - Loosen coupling sleeve at the gear wheel on the camshaft (sheets 4203/4 and 5) and push it towards the 'free end' onto the neighbouring camshaft section - Remove camshaft section with gear wheel (sheet 4203/6). Remark: For fitting the above components proceed in analogous but reverse sequence to the removing.
1989
RTA84C Integrated Balancer of 2nd Order Removal and Fitting of Balancer Shafts
Maintenance
7722/1.1
Tools: 2 Setting tools 1 Lifting tackle 1 Removal frame for upper balancer shaft 1 Removal frame for lower balancer shaft 1 Support for tool 94724 94721 94722 94723 94724 94724a 1 2 3 4 5 6/6a 7 8
Key to Illustrations: Upper balancer shaft Lower balancer shaft Waisted screws Oil space closing cover Taper dowels Bearing pair Rip Balancer masses 9 10 11 12 Screws Locking strap Screws Oil connection
R Round bars x Spacings
According to requirements, four to six cylinder engines can be equipped with an integrated balancer on the driving end, and if necessary with a chain driven balancer (see sheet 77008/1) on the free end. Before starting any work on an integrated balancer, the upper and lower balancer shafts have to be rotated in such a way that their balancer masses 8 come to the B.D.C. position. This is absolutely necessary to prevent accidents. The correct crankshaft position for permitting the removal of the balancer shafts differs with the number of cylinders and the engines direction of rotation. The respective crankshaft position is shown in table illustration 'A'. After turning the crankshaft to the correct position, the electric fuse must be removed from the fuse box of the turning gear for safety reasons. This is to prevent with all certainty that the engine be set into motion Removal of the balancer shafts To remove the upper balancer shaft 1 proceed as follows: - Remove the upper casing cover of the camshaft drive on the exhaust side. - Mount lifting tackle 94722 as shown in Fig. 'C' and 'D'. Make sure that the distance space 'X' between the eyelet screws and the tensioning nuts is equal. - Tension the two tensioning screws of lifting tackle 94722 slightly but equally using round bars 'R', whereby the shaft of the lifting tackle must stay horizontal. - Remove both taper dowels 5 of the bearing positioning. - Loosen bearing 6 (towards the engine) from the crank space of cylinder No. 1 and remove it together with oil space closing cover 4. - Loosen in the same sequence bearing 6a, (towards the driving end) the taper dowels and waisted screws to which are accessible from outside. - Tighten now tensioning screws to lifting tackle 94722 with round bar 'R' equally till the gear wheel of the balancer shaft has been lifted clear of the tooth meshing. - Mount removal frame 94723 to upper balancer shaft as shown in Fig. 'D' and fasten it with the screws proper to it. The respective threaded holes have been provided in rib 7 of the double column. - Smear sliding surfaces of the removal frame well with grease. - Pull the balancer shaft with a crane, fitted outside the engine, out of the engine till balancer masses 8 of the ba lancer shaft come to rest on the removal frame after the tensioning screws have been loosened. - With the help of the crane the balancer shaft together with its balancer masses can now sliding on the removal frame, be removed outside. The same removal instructions that apply for the removal of upper balancer shaft 1 are also applicable to the re moval of lower balancer shaft 2, whereby however the following differences must be observed: - Remove casing cover to the camshaft drive on the fuel pump side. - After mounting lifting tackle 94722 and loosening the flanges of the two bearings 6 and 6a as described above, lift the lower balancer shaft with lifting tackle 94722 and assisted by a crane. Lift the balancer shaft simultaneously by crane and lifting tackle until the removal frame 94724 for the lower balancer shaft 2 can be mounted, as shown in Fig. 'D'.
1989
7722/1.2
Maintenance
RTA84C
- Contrary to the procedure for the upper balancer shaft the removal frame for the lower balancer shaft has not to be screw fastened. Removal frame 94724 for the lower balancer shaft has to be supported in the engine with sup port 94724a in such a way, that the U-profile of the removal frame is placed over the longitudinal member of the engine. As shown in Fig. 'D' the removal frame must be further supported outside the engine stable and of suffi cient strength. Fitting the balancer shafts The fitting of the balancer shafts is done analogous to their removal but in reverse sequence. The following points must be specially taken care of: - Should the two bearing pairs 6 and 6a have been removed after taking off screws 9 (locked by locking wire) and locking strap 10 (Fig. 'B') then smear bearing journals of the balancer shaft with oil before fitting them. Both bearings are generally equal, nontheless they must be again fitted in the same initial place, where they have been exactly located during erection of the engine, with taper dowels 5. - Fit the balancer shafts in such a way that the marking 'DRIVING END' appears when viewed from the driving end. The writing is punch marked on the face of the gear rim. - For correct fitting of the balancer shafts their balancer masses 8 must be at B.D.C. The correct position of the crankshaft in respect to the location of these masses differs depending on number of cylinders and engine direc tion of rotation. The corresponding crankshaft position is shown in the table Fig. 'A'. - Fix both bearings 6 and 6a provisionally with two screws in the double column at the approximate end position. Only tighten the screws lightly so that the bearing flanges can still be slightly moved for driving in the taper dow els. Carefully drive in taper dowels 5 to both bearings, using a copper hammer. The dowels must on no account pro trude beyond the sealing surfaces of oil space closing cover 4. - Remove the screws, provisionally on both sides, again. Apply sealing compound to the sealing surfaces between oil space closing covers 4 and double column. Place both covers 4 with their waisted screws 3 in place and tighten the latter equally, lightly with a spanner by hand. - In this position mark the head of the waisted screws with a line, after which tighten them across in steps, till a tightening angle of 60_ has been reached on all. - For safety sake check now the tooth backlash between the gear wheels (Please refer to the clearance table sheet 0330/17.1 for correct value). - Lock all waisted screws 3 in groups of two by locking wire. Remarks: 1.) If new balancer masses 8 are fitted, lock screws 11 with liquid locking compound. 2.) Should it become necessary to replace a bearing, then its pair must also be exchanged, as new bearings are manufactured in pairs. For their fitting an exact setting of the balancer shaft is essential, for which setting tools 94721 (Fig. 'C') has to be utilized. 3.) Regarding tooth backlash and axis spacing, see clearance table sheet 0330/17.1. After an eventual replacement of a gear wheel or of a bearing pair of the balancer shaft the teeth con tact must be checked with marking blue for a correct contact. Should it become necessary to redowel the bearing flanges, e.g. following the fitting of a new gear wheel set etc., then the predrilled pin holes in the column must be used.
1989
RTA84C
Maintenance
7722/1.3
rechtsdrehend 4 Zyl. Motor Kurbelstellung Zyl. 1 theoretisch linksdrehend 4 Zyl. Motor Kurbelstellung Zyl. 1 theoretisch rechtsdrehend 5 Zyl. Motor Kurbelstellung Zyl. 1 theoretisch linksdrehend 5 Zyl. Motor Kurbelstellung Zyl. 1 theoretisch rechtsdrehend 6 Zyl. Motor Kurbelstellung Zyl. 1 theoretisch linksdrehend 6 Zyl. Motor Kurbelstellung Zyl. 1 theoretisch 165_ n. OTP 195_ n. OTP 171_ n. OTP 189_ n. OTP 180_ n. OTP 180_ n. OTP
CLOCKWISE ROTATION 4 CYL. ENGINE CYL. 1 CRANK POSITION THEORETICAL 180_ AFTER TDC
COUNTER CLOCKWISE ROTATION 4 CYL. ENGINE CYL. 1 CRANK POSITION THEORETICAL 180_ AFTER TDC
1989
7722/1.4
Maintenance
RTA84C
1989
RTA84C
Maintenance
7722/1.5
1989
RTA96C
Betrieb
Group8
Piping
Group 8
Hydraulic Piping for the Exhaust Valve Drive

Removing and Fitting the Pipes and Refacing the Sealing Faces . . . . . . . . . . . . . . . . . . . . . . . . 8460/1
Fuel Pressure Piping

Fitting and Dismantling, Reconditioning the Sealing Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8733/1
RTA84C / MM / 2001
RTA84C
Maintenance
8460/1.1
Hydraulic Piping for the Exhaust Valve Drive Removing and Fitting the Pipes and Refacing the Sealing Faces
Tools: 1 Lifting device 1 Milling/grinding device 1 Grease gun Allen wrench Hoist/rope Carborundum grinding paste (No. 200 and 500) 94833 94834 1,1a 2,2a,2b 3,3a,3b 4,4a 5,5a 6 7 8 9,9a,9b 10 Key to Illustrations: Sealing ring HP pipe section Props Casing Casing Screws Screws Cladding Orings Spindle 11 12 13 14 15 16 17 18 19 20 Grinding head Milling cutter Special nut Grip bar Shoulder Grease nipple Bearing bush Simmer ring Cover Screw
OE Opening S Sealing face X Clearance about 3 mm Removal of hydraulic pipes The following points must be noted: Take absolute care that the sealing faces 'S' on the pipe ends are not damaged. When separating the connections draw the pipe first axially out of the sealing ring 1,1a and only afterwards move it off to the side. For the removal of HP pipe section 2b on the actuating pump the middle HP pipe section 2a must be slightly raised by rope and hoist after loosening the props 3,3a,3b (see Fig. 'C'). The sealing faces at the pipe ends must be protected from any possible damage. Fitting hydraulic pipes The following points must be noted: Check carefully that the sealing faces 'S' at the pipe ends as well as the landing faces in the sealing rings 1,1a are clean and undamaged. The joining up of the pipes to their connectors must be done axially i.e. the pipes may not be joined sideways so that any damage to the sealing faces 'S' is prevented. The casings 4 and 4a for the connection to the valve drive housing (Fig. 'B') and actuator pump respectively (Fig. 'D') must be screwed onto pressure pipes 2 and 2b in such a way that after tightening screws 6 a clearance 'X' of about 3 mm remains. The two casings 5 and 5a of the connections (Fig. 'C') must be screwed onto the hydraulic pipes during assembling in such a way that each protrudes the sealing ring 1a by a little less than half. After tightening the screws 7 together make sure that a clearance 'X' of about 3 mm exists in the separation face of the two casings 5 and 5a. Should this not be the case, loosen the screws 7 again and remove them. Then turn both casings 5 and 5a back by the same amount, till the above clearance 'X' exists after retightening the screws 7. Refacing the sealing faces 'S' Should it become necessary to recondition the sealing faces 'S' (Fig. 'B', 'C' or 'D'), then utilize tool 94834 (see Fig. 'E' and 'F'). Unscrew casings 4,4a, 5,5a of the respective pressure pipes and push cladding 8 back until the pressure pipe can be held in the vice and tool 94834 can be screwed on. Tool 94834 shall bind with its shoulder 15 (Fig. 'E' and 'F') fast against the pressure pipe. To prevent dirt entering the piping during the grinding or milling, plug the bore with a piece of rag. After grinding or milling rinse the pressure piping and blow it through with compressed air.
10.94
8460/1.2
Maintenance
RTA84C
Should the spherical sealing faces be only slightly rough or only very lightly damaged regrinding can be done. For this use tool 94834 without the cover 19 (Fig. 'F'). The cover 19 has to be removed for this. While turning the spindle 10 slowly by hand with the tap wrench apply from time to time some CARBORUNDUM grinding paste through the opening 'OE'. During this grinding operation withdraw the grinding head 11 by the spindle 10 axially in short inter vals to unload the surface to be ground. For roughing, paste No. 200 is used and for finishing paste No. 500. Should the damage be more considerable it may be necessary to machine the sealing surface slightly by milling with the tool assembled as per Fig. 'E'. In place of the grinding head 11 fit milling cutter 12. Cover 19 must be screwed to the special nut. Here too, rotating the cutter must be done very slowly and with moderate loading. The loading of the milling cutter is achieved by turning the special nut 13 with grip bar 14. Use some drilling oil for the milling. In either case use the tool in such a position that falling grinding paste or milling chips can fall through the opening 'OE' without assistance. Before each use of the tool press some grease through the grease nipples 16. After grinding or milling rinse the pressure piping and blow it through with compressed air.
10.94
RTA84C
Maintenance
8460/1.3
1989
8460/1.4
Maintenance
RTA84C
E
20 13 14
Frsen mit Werkzeug 94834 MILLING WITH TOOL 94834
18
15
2, 2a, 2b
93.7437
10
19 16
17
16
12
OE
F
13 14
Schleifen mit Werkzeug 94834 LAPPING WITH TOOL 94834
18
15
2, 2a, 2b
93.7437
10
16
17
16
11
OE
10.94
RTA84C
Maintenance
8733/1.1
Fuel Pressure Piping Fitting and Dismantling, Reconditioning the Sealing Faces
Tools: Regrinding device 1 Special spanner 94872 94874 Key to Illustrations: 1 2 3 4 5 5a 6 7 8 Cylinder cover Fuel valve Metal hose Fuel distributor Fuel HP pipe Claw Connecting piece Coupling nut Connecting piece 9 10 11 12 13 14 Coupling nut Coupling nut Casing Bush for 94872 Lapping body for 94872 Priming valve
DF Metallic sealing face G Collar
After dismantling fuel high pressure piping check the condition of the sealing faces 'DF' and if necessary recondi tion them by lapping. When assembling the fuel high pressure piping the sealing faces 'DF' must be meticulously clean and dry. Dismantling (Fig. 'A') - Remove cover plate 11 of fuel distributor 4. - Completely loosen coupling nut 10 of metal hose 3. - Loosen coupling nut 7 on the fuel injection valve as well as coupling nut 9 on the fuel distributor, whereby it may be necessary to prevent connecting piece 6 or 8 from turning, with a spanner. - Remove fuel high pressure pipe including metal hose. Fitting - Before fitting a fuel high pressure pipe between fuel distributor and fuel injection valve check whether claw 5a to high pressure pipe 5 is screwed on as shown in Fig. 'A', i.e. collar 'G' of claw 5a must be flush with the threaded end of the fuel high pressure pipe. Attention: Left hand thread. Claw 5a should jam slightly in the thread of the high pressure pipe and should just not be able to turn by hand (without spanner). If necessary slightly open collar 'G' on claw 5a with a chisel in order to obtain the necessary clamping action. Claw 5a can be placed on the respective fuel pressure pipe 5 by means of the special spanner 94874 (Fig. 'A1') as described above. (The special spanner 94874 is used only for the fuel HP pipe between the fuel injection pump and the fuel dis tributor).
- Fit all parts after smearing them lightly with oil. Do not use MOLYKOTE. - Tighten both coupling nuts 7 and 9 with 250 Nm and fit metal hose 3 and cover plate 11. Reconditioning the sealing faces on the fuel pressure piping Should the sealing face 'DF' (Fig. 'C') have to be remachined, push tool 94872 with screwedon bush 12 over fuel high pressure pipe 5 (claw 5a remains fitted). To prevent any traces of carborundum paste entering the bores of the fuel high pressure piping, plug the same with a piece of rag. Remark: Use carborundum paste grain: No. 200 for first lapping No. 500 for final lapping After the lapping process rinse fuel pressure piping with clean diesel oil, then thoroughly blow through with compressed air. For the reconditioning of a fuel pressure piping between fuel injection pump and fuel distributor (Fig. 'B'), use tool 94872 with bush 12. The lapping procedure is the same as above.
UG / 9.99
8733/1.2
Maintenance
RTA84C
I-I
3 5
1 2
9 5a 8 14 DF
II
4
II
5
I
11 5a
C
G
II - II
3 DF
94872 13
5 10 7 5a 5 7 2 DF 6 1 5a
A1
12
DF 5a 5
B
94872 13 12
DF
99.7493
94874
9.99 / UG
RTA96C
Betrieb
Group9
Tools
Group 9
Tools
Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/1
Hydraulic Jacks and Pumps

Arrangement and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/2
Hydraulic Pre-Tensioning Jacks

Storing, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/3 General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/4
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403/5

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 136 Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3739 Special Tools Obtainable on Loan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 40
RTA84C / MM / 2001
RTA84C Tools Explanation
Maintenance
9403/1.1
The tools required for erection and maintenance of the engine are divided into three groups as per the following 'Tool List': S S S Standard tools Recommended special tools Special tools available on loan
Standard tools (sheet 9403/5.1 to /5.36) 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 de vices which are mentioned in the above sheets are not required for specific maintenance work, and are therefore not part of the engine tools supply. Recommended special tools (sheets 9403/5.37 to /5.39) are tools and devices which allow certain maintenance work to be done with more ease, and in a shorter time, than with the standard tools. These tools can be ordered separately either with the engine or at a later date. Special tools available on loan (sheet 9403/5.40) are such tools and devices which are loaned for transportation and for erection of the engine. They are to be returned to the engine manufacturer after completion of engine erection. A separate set of tools is issued for certain components from subsuppliers, which should also be stored separately from the engine tools. When ordering additional tools or replacements, the tool number as well as the tool description including engine type must be indicated (see tool list). Detailed instructions on the arrangement and application, storing, servicing and maintenance of the hydraulic pre tensioning jacks are given on sheets 9403/2 to 9403/4. When oil must be added to the hydraulic pumps, the specification regarding oil quality issued by the pump manufac turers must be followed. Utilize generally an engine lubricating oil having viscosities SAE 30 to SAE 40. A cylinder lubricating oil also can be used in exceptional cases.
UG / 9.99
RTA84C Hydraulic Jacks and Pumps Arrangement and Application
Maintenance
9403/2.1
FOR ARRANGEMENT OF THE HYDRAULIC JACKING TOOLS FOR WORK ON THE CAMSHAFT, SEE GROUP 4203.
A = Tightening / loosening of tie rods, thrust bolts to main bearing covers and the connecting rod studs to top and bottom end bearings. B = Removing and fitting main bearing shells. Jacking out the cylinder liner. C = Tightening / loosening the waisted studs of valve cage and cylinder cover. G = Tightening / loosening the 2part gearwheel on the crankshaft. H = Tightening foundation bolts. Tightening / loosening the balancer.
UG / 4.01
9403/2.2
Maintenance
RTA84C
Key to the Arrangement of the hydr. jacks on sheets 9403/2.1 and 4203/3.2
Tool No. 2 Hydr. jack 500 kN (50t) 5 Hydr. jack 45 kN (4.5t) Locking valve 94936 94938 94939a
Enerpac RC-504 CRC-55 V66
Holmatro -HTJ5S12 -A109N
OTC -C556C 9596
Raripress -BS-46-RM --
Haskel ----
Amtech ----
8 HP oil pump 700 bar
94931
P-462
HTW 7500
PW 460
RP-1404 -2-10
--HF-B300
-S100 --
9 Pneumatic/hydraulic 94941 oil pump 700 bar Pneumatic/hydraulic94942 oil pump 3000 bar HP oil pump SKF 226400 94931a
BPA-20280 AHS 9000 ---
Y-26-LD RP-705-AG ---
12 Connection piece 13 Oil branch piece 14 Connecting piece 15 Pressure gauge (0-1000 bar) 16 Pressure gauge connecting part 17 Connecting piece 18 Coupling socket 19 Coupling plug 20 HP hose (1800 mm long)
94934a 94934 94933 94932
----94935 CR-400 CH-604 H-909 H-917 A-118 A-119 H2M H06M 9796 9798 9767 9765 RP-6A RP-6B TR-2-H TR-06-H
21 High pressure hose 94935a (600 mm long) 24 Double nipple
4.01 / UG
RTA84C Hydraulic Pretensioning Jacks Storing, Servicing and Maintenance
Maintenance
9403/3.1
When not in use store the hydraulic pretensioning jacks carefully in a clean place, where they are safe from damage (after greasing them and closing the connections with dust plugs). After lengthy storage or frequent use the Orings can become hard, when they no longer seal perfectly. Therefore, we recommend to always keep a sufficient number of new Orings, slide and support rings of the specified quality and dimensions in stock, in order to ensure efficient work at any time. When fitting new slide and support rings proceed with extreme care, to avoid their damage, over expansion or deformation; do not use any sharp edged utensils for assistance. Heat slide rings of the piston seal rings as well as support rings in boiling water before fitting them. Below are given keys to the pretensioning jack illustrations on the following pages: Tool 94145 Pretensioning jack to the foundation bolts of the generator support 1 2 3 3a 3b 4 4a 4b 4c 4d 5 11 Relief valve Vent screw Draw nut Locking ring Screw M6 Piston Oring * Slide ring * Oring ** Slide ring ** Cylinder Coupling socket * To piston seal ring ** To rod seal ring 130x125x3.8 85x89x3.8 4 5 6 7 7a 7b 7c 7d 8 9 Tool 94180 Pretensioning jacks to the tie rods Allen screw Cylinder lower part Cylinder upper part Piston Oring * Slide ring * Oring ** Slide ring ** Flange ring Disc spring (41 pieces/screw) B 45x22.4x1.75 10 Screw 11 Vent screw * To piston seal ring ** To rod seal ring 380x372x5.8 220x226x5.8
Tool 94252 Pretensioning jacks to exhaust valve cage 1 2 2a 2b 2c 2d 3 4 5 6 7 8 Cylinder Piston Oring * Slide ring * Oring ** Slide ring ** Flange ring Connecting nipple Spacer ring Pulling screw Bolt Disc spring (32 pieces/screw) B 28x14.2x1x1.8 9 Vent screw 10 Threaded sleeve 11 Locating screw * To piston seal ring ** To rod seal ring 210x204x5.8 120x125x3.8 1 2 2a 2b 2c 2d 3 4 5 6 7 8
Tool 94215 Pretensioning jacks to the cylinder cover studs Cylinder Piston Oring * Support ring* Oring ** Support ring** Cover Coupling socket Distance piece Round nut Screw Disc spring (50 pieces/screw) 34x16.3x1.5 (15 at top, 35 at bottom) 9 Vent screw * To support ring ** To support ring 280x267.8 149.4x140
UG / 4.01
9403/3.2
Tool 94314
Maintenance
Tool 94315
RTA84C
Pretensioning jacks to connecting rod studs of the bottom end bearing 3 6 6a 6b 6c 6d 7 8 8a 9 Cylinder Piston Oring * Slide ring * Oring ** Slide ring ** Vent screw Screw Cover with grip Disc spring (32 pieces/screw) 23x12.2x1.25x1.85 * To piston seal ring ** To rod seal ring Tool 94314 (1part connecting rod) Pretensioning jacks to connecting rod studs of the bottom end bearing 3 4 5a 5b 5c 5d 6 Piston Cylinder Oring Supporting ring Oring Supporting ring Tension nut 200x194x5.8 140x145x3.8 3 6 6a 6b 6c 6d 7 8 8a 9
Pretensioning jacks to connecting rod studs of the top end bearing Cylinder Piston Oring * Slide ring * Oring ** Slide ring ** Vent screw Screw Cover with grip Disc spring (32 pieces/screw) 23x12.2x1.25 * To piston seal ring ** To rod seal ring 200x194x5.8 120x125x3.8
Tool 94424 Hydr. jacking tool to the camshaft 1 1a 1b 2 3 4 5 6 7 8 9 10 Piston Oring* Slide ring* Ring piece (2part) Piston carrier plate Cylinder screw Head screw Pins Ring screw Threaded pin ** Steel ball 4 11 mm ** Coupling socket * To piston seal ring ** For venting 100x95x3.8 1 2 2a 2b 2c 2d 3 4 5 6 7 8 9
Tool 94706 Pretensioning jack to the balancer Cylinder Piston Oring * Slide ring * Oring ** Slide ring ** Disc spring (42 pieces/screw) B28x14.2x1.5x2.15 Guide stud Nut Cover with grip Coupling socket Safety ring Round bar 4 10 mm * To piston seal ring ** To rod seal ring 140x135x3.8 80x84x3.8
4.01 / UG
RTA84C Hydraulic PreTensioning Jacks General Application Instructions
Maintenance
9403/4.1
For distinct screwed connections different designs and sizes of waisted bolts or waisted studs (bolts/studs) are used, which are pretensioned by hydraulic pretensioning 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 preten sioning jack is supplied. The bolts/studs are pretensioned with the pretensioning jacks, therefore, the nuts are only threadedon manually until seated. Prior to the mounting of the pretensioning jacks, depending on the design execution, its inside thread or else the inside thread of the round nut as well as the thread of the waisted bolts/studs which are to be tightened/loosened must be carefully cleaned. The thread must be undamaged and freely working. Concerning utilization of lubricant for screwing on nuts the instructions on sheet 0352/1 must be followed. Working procedure for loosening Thread the pretensioning jack by hand onto the extending thread end of the bolts/studs to be loosened until it is landed on the component part and the piston on the cylinder without any clearance. On pretensioning jacks with round nuts these have to be slightly tightened. Then, depending on the design of the pretensioning jack, turn it or the round nut back by about to 1 turn. The clearance thus obtained between pretensioning jack and landing face of the component part or round nut and piston is essential, before starting the pretensioning of the bolts/studs. It enables the loosening of the nut till total relaxation of the bolts/studs in one single working sequence. Connect pump and pretensioning jack with the HP hoses. If provided open the vent screw on top of the pretensioning jack a little. Actuate the hydraulic pump. As soon as oil flows out bubblefree close the vent screw at the pretensioning jack. The piston of the pretensioning jack must be now in its neutral position, it must not be situated in an end posi tion. Raise the pressure about 20 bar over the tightening value (see sheet 0352/1). The nut is now slack, loosen it with a round bar, while keeping the pressure constant. Release the pressure and remove the pretensioning jack.
Working procedure for tensioning Use a felt pen and mark the positions of the nuts, which already have been firmly seated against their landings on the component part. The marks are later a reference for judging the correct pretensioning. Thread on by hand the pretensioning jack onto the protruding thread end of the bolts/studs until it is fully seated without any clearance between the jack and the component part. On pretensioning jack with round nut tighten it lightly. It may be necessary to turn the jack back a little to gain easy access through the slot in the jack cylinder for manipulating a round bar to tighten the nut. Connect pump and pretensioning jack by the HP hoses. If provided open the vent screw on top of the pretensioning jack a little. Actuate the hydraulic pump. As soon as oil flows out bubblefree close the vent screw at the pretensioning jack. The piston of the pretensioning jack must be now in its neutral position, it must not be situated in an end posi tion. Raise the pressure with the pump, in accordance with the indication on the tightening of important screwed connections (see sheet 0352/1). 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 with the feeler gauge whether actually no clearance remains between nut and seating. Release the pressure and remove the pretensioning jack. Check with the referenced markings, whether all the nuts of a screwed connection have been turned by the same value as mentioned on sheet 0352/1. If big differences are noted their causes have to be investigated and the tensioning procedure must be repeated.
For operation and maintenance of pneumatic/hydraulic oil pumps refer also to the manufacturer's documentation.
9.99
9403/4.2
Maintenance
RTA84C
94145
1 2 3 4 11 4a 4b
5 3a 3b 4d 4c
93.7458
M 64
10
94180
11
7a
7b
6 5 4 7d 7c
M 160
93.7457
9.99
RTA84C
Maintenance
9403/4.3
94215
M 90 3 9 6 5 2 2b 2a 8 4
2c 2d
1
93.7455
9.99
9403/4.4
Maintenance
RTA84C
94314
M90
94314
(1-part connecting rod)
3 5b 5a
5c 5d
00.7752
94315
M76
4.01 / UG
RTA84C
Maintenance
9403/4.5
M56 1989
RTA84C Tool List D Standard tools
Maintenance
9403/5.1
Open end ring spanner 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces 2 Pieces AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF 7 8 9 10 11 12 13 14 17 19 22 24 27 30 32 36 41 46 50 55 60
Open end spanner 1 Piece 1 Piece 1 Piece 1 Piece 1 Piece 1 Piece 1 Piece AF AF AF AF AF AF AF 65 70 75 85 95 105 110
Open end impact spanner 1 Piece AF 195
1990
9403/5.2
Maintenance
RTA84C
Ring spanner 1 1 1 1 Piece Piece Piece Piece AF AF AF AF 17 19 22 24
Impact ring spanner 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF AF 27 30 32 36 41 46 50 55 60 65 70 75 85 95 105 110 145
Impact ring spanner 1 Piece AF 130
1990
RTA84C
Maintenance
9403/5.3
Double end tubular box spanner 1 1 1 1 Piece Piece Piece Piece AF AF AF AF 8/10 13/17 19/22 24/27
Socket spanner 1 1 1 1 1 1 1 1 Piece Piece Piece Piece Piece Piece Piece Piece AF 30 x 190 AF 32 x 190 AF 36 x 220 AF 41 x 260 AF 46 x 300 AF 50 x 350 AF 55 x 350 AF 65 x 350
Eyelet screw 6 Pieces M16 x 145
3 Rods each diameter for pretensioning jacks 4 4 4 4 8 mm 10 mm 14.6 mm 20 mm
Bar for socket spanner AF 65 x = 800 mm
1990
9403/5.4
Maintenance
RTA84C
Hexagon plug spanner 1 1 1 1 1 1 1 1 1 1 Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece AF AF AF AF AF AF AF AF AF AF 11 12 14 17 19 27 32 41 50 60
Allen wrench 1 1 1 1 1 1 1 1 1 1 1 Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece AF AF AF AF AF AF AF AF AF AF AF 5 6 8 10 12 14 17 19 22 24 27
Screw driver 1 1 1 1 1 1 Piece Piece Piece Piece Piece Piece b= b= b= b= b= b= 6.5 mm 8 mm 10 mm 13 mm 16 mm 18 mm
Right angle screw driver 1 Piece 1 Piece 1 Piece b = 10 mm b = 12 mm b = 25 mm
1990
RTA84C
Maintenance
9403/5.5
Snap ring tongs 1 Piece 1 Piece 1 Piece Type C 8 Type C 19 Type C 40
1 Piece 1 Piece 1 Piece
Type A 10 Type A 19 Type A 40
Ring nut 4 Pieces M45 (for suspension of the fuel injection pump)
Eye bolt 8 8 8 8 8 8 8 4 2 Pieces Pieces Pieces Pieces Pieces Pieces Pieces Pieces Pieces M 10 M 12 M 16 M 20 M 24 M 30 M 36 M 48 M 56
1990
9403/5.6
Maintenance
RTA84C
Grip screw 2 2 2 2 2 Pieces Pieces Pieces Pieces Pieces ..... ..... ..... ..... ..... M M M M M 4 x 150 5 x 150 6 x 150 8 x 150 10 x 150
93.7474
Puller for taper and cylindrical dowels and pins 1 1 1 1 Piece . . . . . . Piece . . . . . . Piece . . . . . . Piece . . . . . . M M M M 6 8 10 12
93.7475
Jacking screw 4 Pieces . . . . . M 16 x 160 4 Pieces . . . . . M 20 x 100

99.7494
High pressure grease gun for lubricating grease nipples on injection pump regulating linkage
93.7476
Torque wrenches with open end spanner inserts AF 36, 46, 50, 60 Tightening range 140-620 Nm 500-1300 Nm
99.7495
4.01 / UG
RTA84C
Maintenance
9403/5.7
94101
Inside micrometer with case (Measuring range 50-1010 mm)
94101a
Extensions (also used for adjusting the gear wheels of the camshaft drive of the P.T.O. and of the integrated balancer) X = 480 mm
94111
Suspension device for lifting the main bearing cover including 4 screws M20 X = 140 mm
94117
Roller support for the removal of the main bear ings, consisting of 1 Support X = 114mm 1 Screw M 30
94118
Device for the removal of the main bearing shells X = 410 mm
94119
Steel ropes for the removal of the main bearing shells as well as for assembling and dismantling the bipartited cylinder of the integrated damper, incl. two shackles X = 3700 mm
1990
9403/5.8
Maintenance
RTA84C
94122
Feeler gauge
94123
Special feeler gauge for main bearings X = 625 mm
94124
Depth gauge measuring range 250 mm Depth gauge measuring range 700 mm
94126
94141
Support for the removal of main bearing shells X = 1286 mm
94142
94.7298
94143
Working supports X = 920-1170 mm
009.323/01
94145
Pretensioning jack for foundation bolts and generator support X = 150 mm
94146
Casing cover (only for engine with P.T.O.) X = 1555 mm

3.03
Working platforms consisting of three grids each X = 1490 mm
RTA84C
Maintenance
9403/5.9
94155
Carrier bolt M 20 with nut for the removal of thrust bearing pads X = 190 mm
94155a
Turningout device for removing thrust bearing pads. (for engines having the camshaft drive gear wheel fitted on the crankshaft coupling flange) x = 316 mm
94180
Hydraulic pretensioning jacks for tie rods X = 4 465 mm
94201
Lifting device for fitting and transporting cylinder liner, consisting of: Suspension bracket X = 1366 mm Suspension straps with 2 screws each X = 250 mm Special screws for fastening the straps 94206 to the cylinder liner Suspension straps with screws M16x25 for removal and fitting of the antipolishing ring X = 101 mm
94202
94206
94207
94208
99.7816
UG / 4.01
9403/5.10
Maintenance
RTA84C
94215
Hydraulic tensioning device with connecting elements for tensioning the cylinder cover studs, consisting of: a = pretensioning jack b = pneumatic/hydraulic pump (see also tool 94941) c = high pressure hoses 1 x 3000 mm, 2 x 1800 mm long d = compr. air hose 30 m long e = suspension device
c b d
a
93.7496
94224
Ladder for access to measuring cylinder liner bore X = 3050 mm
93.7497
94225
Measuring gauge for measuring cylinder liner bore (accessory for it inside micrometer see tool 94101) X = 2926 mm
94238
Feeler gauge (10 items) for checking bearing clearances Leaf length = 600 mm
9.99
X
93.7498 93.7499
RTA84C
Maintenance
9403/5.11
94252
Tensioning device for valve cage consisting of: Pretensioning jacks and connecting stirrup
94259
Thrust pin for exhaust valve 1 piece for 4 and 5 cyl. engines 2 pieces for 6 to 12 cyl. engines X = 562 mm
94261
Valve seat fitting and extracting device X = 680 mm
99.7497
X 9.99
9403/5.12
Maintenance
RTA84C
94262
Valve protector (only to be applied for transporting a complete exhaust valve) X = 650 mm
94263
Fitting and removing device to guide bush of exhaust valve M16 x 180
94265
Suspension device for cylinder cover and exhaust valve cage X = 820 mm further: a = 2 special eye nuts X = 352 mm b = 3 protection caps X = 100 mm
94267
Jacking screws for the valve gage M24 x 110
1990
RTA84C
Maintenance
9403/5.13
94269
Hydraulic tightening device for the cap nut of the fuel injection nozzle consisting of: a) 1 special spanner b) 1 hydr. jack (e.g. ENERPAC type CRC55) c) 1 high pressure hand oil pump (e.g. ENERPAC type P14) (accessory to L 'ORANGE test stand, tool 94272)
94270
Device for overhauling the fuel injection valve seat in the cylinder cover X = 560 mm
94271
Protection cap for fuel nozzle (1 pieces each nozzle) X = 60 mm
94272
L ' ORANGE valve test stand (GXOG004) for the setting and testing of: Fuel injection valve, Relief valves for cylinder cover, and relief valve of the fuel injection pump. X = 1100 mm (supplied in place of the O.M.T. test bench)
10.95
9403/5.14
Maintenance
RTA84C
94272
O.M.T. test bench for setting and testing of a: - Fuel injection valve - Relief valve in the cylinder cover - Relief valve for the fuel injection pump X = 2030 mm X (supplied in place of the L ' ORANGE test stand)
95.7681
94273
Holding angle for fastening the fuel injection valves on L ' ORANGE test stand X = 368 mm X (only for L ' ORANGE test stand)
95.7682
94274
Connection piece with closing nipple for setting and testing fuel injection valves X = 55 mm (only for L ' ORANGE test stand)
94.7100
94275
HP hose with quick release coupling 1400 mm long (1500 bar) for testing of a: - Fuel injection valve - Relief valve in the cylinder cover - Relief valve for the fuel injection pump (only for L ' ORANGE test stand) R 1/4
94276
Device for testing a relief valve in the cylinder cover X = 530 mm (only for L ' ORANGE test stand)
10.95
X
95.7683
M 14x 1,5
X
95.7684
RTA84C
Maintenance
9403/5.15
94277
Device for testing the relief valves of fuel injection pump blocks X = 165 mm (only for L 'ORANGE test stand)
98.7465
94278
Valve seat grinding machine complete with pneumatic. drive (maker: CHRIS MARINE) or Valve seat grinding machine complete with electr. drive (maker: HUNGER) Accessories to it:
94278a
94278a 94278b 1 1 Pilot Holding strap (only for valve seat grinding ma chine with electr. drive)
94278b
98.7466
94278c
Milling cutter for cleaning the pilot receiving cone in the valve guide bush
94278c
94279
Gauge for checking the wear on the exhaust valve seat X = 160 mm
98.7463
8.98
9403/5.16
Maintenance
RTA84C
94290
Rotation device for valve cage (to be used on fitting and dismantling and grinding operations) X = 1500 mm
98.7035
94292
Gauge for checking the wear on the disc of the exhaust valve spindle X = 257 mm
98.7464
94305
Crank web deflexion checking set (in wooden box) X = 364 mm

93.7505
94310
Roller support for assembling and dismantling the 2part cylinder of the axial detuner X = 290 mm
93.7506
8.98
RTA84C
Maintenance
9403/5.17
94314
Pretensioning jacks (1part connecting rod) for tensioning connecting rod studs of the bottom end bearing X = 310 mm
00.7750
94314
Pretensioning jacks for tensioning connecting rod studs of the bottom end bearing X = 248 mm
94315
Pretensioning jacks for tensioning connecting rod studs of the top end bearing X = 250 mm
00.7750
94316
Tensioning screws for bottom end bearing (crankpin) with 2 washers and nuts X = 1150 mm (Tool is needed for transportation and storing of bottom end bearing; delivered only for 2part bearing)
UG / 4.01
9403/5.18
Maintenance
RTA84C
94323
Retaining pins to prop the crosshead guide shoes for fitting or removing of connecting rod or crosshead X = 125 mm
94324
Masking and suspension plate to the crosshead X = 420 mm
94326
Device for removal and fitting of the bear ing shell for the bottom end bearing X = 375 mm (supplied only for engines with 1part connecting rod) X
00.7170
94338
Piston ring expander X = 324 mm
94341
Piston suspension device X = 608 mm

00.7766
4.01 / UG
RTA84C
Maintenance
9403/5.19
94342
Insertion funnel for fitting the working piston X = 1070 mm

93.7512
94342a
Insertion funnel for fitting the working piston (only for cylinder liner with antipo lising ring) X = 945 mm including: 2 Holders 2 Screws M16x30 2 Screws M42x60
99.7815
94345
Distance pipe (2part) for removal and fitting of a piston rod gland and working piston X = 595 mm Templates for fitting of the rings to the lower gland group X = 343 mm X X
98.7455 98.7443 98.7455
94345c
94345d
Cover plate for covering bore of the gland in the cylinder jacket (when working piston and gland are removed) X = 640 mm
94345e
Fitting tools for tension of the tension spring to the piston rod gland X = 100 mm
98.7443
94345f
Distance pieces for fitting of the rings to the upper gland group 2 pieces each 9 mm thick 2 pieces each 8 mm thick X = 393 mm
X
99.7498
UG / 4.03
9403/5.20
Maintenance
RTA84C
94347
Propping device consisting of two segments for changing the compression shims X = 690 mm
98.7129
94348
Threading tap M24 for cleaning carbon deposits in threaded holes of the piston crown X = 160 mm
93.7519
94350
Device for supporting working piston and for removing the piston rod gland X = 1610 mm
00.7767
X 94363 2 Jacking screws M20 for separating piston crown from piston skirt X = 320 mm
98.7130
94364
Screws M24 for separating the piston rod from piston skirt (with the use of jacking screws 94363) X
705603/F101198
94366
Template for shape of top of piston crown X = 892 mm
97.7055
X 94366a 1 Template for shape of top of piston crown (for use with working piston in situ) X = 936 mm
97.7056
4.01 / UG
RTA84C
Maintenance
9403/5.21
94410
Adjusting devices to the intermediate gear wheel X = 250 mm Accessory for it: 8 pins (interchangeable) for intermediate gear wheel to P.T.O. gear box (if provided) inside micrometers to be used with it see tool 94101
94410a
94412
Tightening device for split gear wheel on crankshaft, consisting of: Socket spanner X = 930 mm, AF 95
94412a
94412b
Spanner X = 541 mm, AF 95
94412c
Plate with 2 pins X = 584 mm
1990
9403/5.22
Maintenance
RTA84C
Device for removal and fitting of a fuel cam consisting of: Holding strap X = 1120 mm
94416
94417
Lifting device X = 1060 mm Accessory for it: Pins
94417a
94418
Support X = 780 mm
94419a
Clamp screw X = 65 mm
1990
RTA84C
Maintenance
9403/5.23
94420
Fixing stirrup for blocking the camshaft driving gear wheel X = 590 mm
94421
Device for mounting and removing the camshaft drive gear wheel on its shaft journal, consisting of: 2 Supports 2 Screws 'a' 2 Screws 'b' X = 1150 mm
94422
Holding straps for blocking a camshaft section X = 930 mm
94423
Device for fitting and removing one cam shaft section, consisting of: 2 Supports 2 Special nuts 'a' X = 1040 mm
1990
9403/5.24
Maintenance
RTA84C
94424
Hydr. jacking for mounting all pressseats on the camshaft X = 540 mm
94425
Connecting branch for mounting the pressseats on the camshaft X = 108 mm Connecting branch for mounting the pressseats on the camshaft X = 252 mm
94426
94427
Connecting branch for setting the cams of fuel injection pump and actuating pump X = 138 mm
1990
RTA84C
Maintenance
9403/5.25
94428
Centring disc for positioning the pressing tool 94424 on the camshaft when mounting a flange coupling to the torsional balancer X = 330 mm
94429
Hose pipe (1500 bar) X = 1800 mm
94430
Device for cutting out an exhaust valve actuator pump (1 piece per pump) X = 200 mm
94431
Suspension strap for cam of actuator or fuel injection pump, with one screw X = 60 mm
94432
Gauge for setting the cams X = 545 mm
1990
9403/5.26
Maintenance
RTA84C
94551
Spanner for backing union of the plunger guide bush of the fuel injection pumps X = 625 mm
94552
Device for measuring the stroke of the fuel injection pump plunger X = 540 mm including 2 screws
94554
Devices for measuring the strokes of suction and spill valves in the fuel injection pump X = 330 mm
94555
Special spanners for setting suction and spill valves in the fuel injection pump X = 525 mm AF = 27 mm
94556
Special spanner to the relief valve of the fuel injection pump X = 250 mm AF = 80 mm
1990
RTA84C
Maintenance
9403/5.27
94557
Special spanner for setting suction and spill valves of the fuel injection pump X = 120 mm AF = 22 mm
94558
Spacers for laying under the push rod of the fuel injection pump suction valves (fuel charge reduction) X = 28 mm
94559
Torque wrench with extension, with socket spanner for the tightening of cover screws of fuel pump
94560
Blocking device for excenter shaft (1 piece each per pump body, for mounting and transportation) X = 580 mm
94561
Withdrawing device for spill valve seat of fuel injection pump (for 7 mm bore) X = 238 mm
94564
Withdrawing device for seats of suction and delivery valves of fuel injection pump (for 8 mm bore) X = 238 mm
1990
9403/5.28
Maintenance
RTA84C
94565
Centring piece to the lapping pin, tool 94567 X = 4 108 mm
94566
Lapping pin for lapping seal surface on fuel injection pump body (for valve covers) X = 4 75 mm
94567
Lapping pin for lapping seal surface on valve covers of fuel injection pump X = 4 80 mm
94571
Spanner for pressure nipple to valves of fuel injection pump X = 450 mm
94582
Dismantling and assembling tool for spherical bearing of the regulating linkage X = 112 mm
X
93.7547
1994
UG
RTA84C
Maintenance
9403/5.29
94645
Socket spanner for dismantling and assembling valve groups of charge air receiver X = 150 mm
94652
Centring studs M20 for fitting and removing flange motor of auxiliary blower X = 320 mm
In case of a turbocharger breakdown Engine with 2 to 4 turbochargers 94653 94654 94654a 94655 Cover to gas inlet 1 to 3 pieces acc. to design Cover to gas transfer 1 to 3 pieces acc. to design Cover for air outlet casing 1 to 3 pieces acc. to design Cover to air transfer on diffusor 1 to 3 pieces acc. to design
94661
Device for fitting and removing charge air cooler tube stack consisting of:
94662
Roller plate for coolertype: GEA / SERCK 150/38/21/6 220/42/21/4 X = 495 mm
1990
9403/5.30
Maintenance
RTA84C
94663
Slide rails X = 350 mm
94664
Eye bolts M20
94701
Spur geared hoist trolley (capacity = 5T) for fitting and removing parts of P.T.O. X = 650 mm
94702
Suspension flange for the Geislinger shaft of the P.T.O.
1990
RTA84C D
Maintenance Engines with chain driven balancer
9403/5.31
94703
Proppingup devices for the flexible coupling X = 415 mm
94704
Rivet puller with spanner 'a' and round bar 'b' to roller chains
94705
Fitting tool for the chain locking link of the roller chain
94706
Pretensioning jack for fastening balancer housing to end column and for fastening clamp cover waisted bolts of balancer shafts X = 160 mm
1990
9403/5.32 D
Maintenance Engines with integrated damper
RTA84C
94721
Setting tools for adjusting the balancer shafts X = 215 mm
94722
Lifting tackle for lifting the balancer shafts X = 300 mm
94723
Removal frame for upper balancer shaft X = 1228 mm
94724
Removal frame for lower balancer shaft X = 2016 mm
94724a
Support for tool 94724 X = 680 mm
1990
RTA84C
Maintenance
9403/5.33
94831
Blind flange for closing starting air pipe in case of breakdown X = 200 mm
94832
SERTO connecting nut M14 x 1 SERTO plugging pin for plugging starting valve control pipes during emergency operation X = 12 mm
94833
Lifting device for hydraulic pipes with two screws belonging to it X = 2927 mm
94834
Refacing tool for sealing surfaces on hydraulic pipes of the exhaust valve drives X = about 250 mm
94871
Filling device for air vessel of fuel inlet and return piping X = 400 mm
UG / 9.99
9403/5.34
Maintenance
RTA84C
94872
Regrinding devices to fuel high pressure piping
93.7569
94874
Special spanner for fitting the claw on the fuel pressure pipes AF 27
98.7741
9.99 / UG
RTA84C
Jacks and pumps for fitting and removal 94931 1 Pump working pressure 700 bar Make ENERPAC HOLMATRO OTC RARIPRESS 94931a 1 Oil pump SKF Type P462 HTW 7500 PW 460 RP1404210
Maintenance
9403/5.35
226400
94932
Pressure gauges 4 100 Working pressure 0-1000 bar connecting branch G " Connectors Oil distributors Connection pieces High pressure hoses length about 1800 mm High pressure hoses length about 600 mm
94933 94934 94934a 94935
2 3 2 5
94935a
94936
Jacks 500 kN (50t) ENERPAC RC504
94938
Jack 45 kN (4,5t) ENERPAC CRC55 HOLMATRO HTJ 5S 12 OTC C55C RARIPRESS BS46 RM
94939a
Locking valve ENERPAC V66 OTC 9596 HOLMATRO A 109N
UG / 4.01
9403/5.36
Maintenance
RTA84C
94941
Pneumatic/hydraulic pump ENERPAC BPA20280 HOLMATRO AHS 9000 OTC Y26LD RARIPRESS RP705AG AMTECH S100 (belongs to hydr. tensioning device 94215)
94942
Pneumatic/hydraulic HP pump HASKEL HFB300
9.99 / UG
RTA84C D
Maintenance Recommended special tools
9403/5.37
94203
Supporting beam for jacking out the cylinder liner X = 1040 mm X

00.7765
94280
Tool case (complete) for reconditioning fuel injection nozzles, contents: Wooden case Lapping disc 4 46x36 Copper pin 4 15x70 Face plate 4 54 Steel wire brush Box with drills for cleaning spray holes Pin gauge for checking spray holes Box lapping powder Lapping plate 200x300x40
94280a 94281 94282 94283 94284 94285
1 1 1 1 1 1
94286
94287 94288
1 1
UG / 4.01
9403/5.38 D
RTA84C
94291
Valve grinding device complete X = 1870 mm
94299
Grinding device for removing a possibly builtup wear ridge at top of cylinder liner running surface X = about 292 mm
94300
Tool cabinet X = 1120 mm X
X 94335 1 Support for removing of the connecting rod X = 1650 mm
94.7101
4.01 / UG
RTA84C D
9403/5.39
94336
Connecting flange for prelubrication of crosshead and bottom end bearing X = 165 mm
96.7855
X 94345a 1 Taper ring (2part) for fitting of the rings to the lower gland group X = 430 mm
93.7514
94345b
Clamp ring (2part) for tool 94345a X = 55 mm
93.7515
94349
Pressure testing device for working piston X = 340 mm
94350
Device for supporting working piston X = 1610 mm
98.7073
X
93.7576
UG / 4.01
9403/5.40 D
Maintenance Special tools obtainable on loan
RTA84C
94105
Measuring apparatus for the bedplate consisting of: 4 Supports 4 Weights with wire 1 Measuring underlay X = 1480 mm
93.7578
94174
Thread protectors to upper threads of tie rods, when fitting a cylinder jacket X = 185 mm
93.7579
M36
X 94177 1 Thread protector to lower thread of tie rod X = 173 mm

93.7579
94211
Fitting device for insulation tubes X = 706 mm X
94212
Extractor for insulation tubes X = 890 mm
9.99 / UG
X
97.7351

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RTA84C

Vessel: Type: Engine No.: Book No.:

Wrtsil Switzerland Ltd PO Box 414 CH-8401 Winterthur Switzerland

24hrs Support: +41 52 262 80 10 technicalsupport.chts@wartsila.com

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Bedplate and Tie Rod

Cylinder Liner and Cylinder Cover

Crankshaft, Connecting Rod and Piston

Camshaft and Control Elements

Governor, Injection Pump and Actuator Pump

Scavenge Air Receiver and Auxiliary Blower

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Tightening Values of Important Screwed Connections

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Dimensions and Material Specification

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For Particular Attention

Wrtsil Switzerland Ltd Winterthur Switzerland

Wrtsil Switzerland Ltd

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Wrtsil Switzerland Ltd

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RTA84C Table of Contents General information

Bedplate and tie rod

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Cylinder liner and cylinder cover

Lubricating quills and accumulators Piston rod gland Cylinder cover

Fuel injection valve

Starting valve Relief valve for cylinder cover Exhaust valve

Crankshaft, connecting rod and working piston

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

Connecting rod (1part)

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Camshaft and control elements

Dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4303/1 Cleaning and function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325/1

Inspection and function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4506/1

Governor, fuel injection pump and actuator pump

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

Charge air receiver and auxiliary blower

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Cylinder lubrication, PTO gear box and balancer

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7203/1 Dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7212/1

Wrtsil Switzerland Ltd

RTA84C Engine Numbering and Designation

Thrust Bearing Pads

Main Bearing Numbering

Fuel Pump Side

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RTA84C General Guidelines for Maintenance Safety Measures and Warnings

Wrtsil Switzerland Ltd

Wrtsil Switzerland Ltd

Wrtsil Switzerland Ltd

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RTA84C Clearance Table Main and Thrust Bearings

Nominal dimension B = 870 b = 870 d = 415

Clearance max. due normal, new to wear

Clearance max. due normal, new to wear f 1 = 0.8 - 1.3 2.5

f = 150 -0.5 -0.6

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0330/2.1 Clearance Table Crosshead Guide

d Brennstoffseite FUEL SIDE

Nominal dimension A = 790 a = 790

Clearance max. due normal, new to wear

Nominal dimension c = 400