MM RT Flex96c - WECS 9520 - Dynex - 2014 04

RT-flex96C
Maintenance Manual
Marine
WECS9520 / Dynex Servo Oil Pumps
Vessel:
Type:
Engine No.:
Document ID: DBAC352038
Wrtsil Switzerland Ltd

PO Box 414
CH-8401 Winterthur
Switzerland
E 2014-04 Wrtsil Switzerland Ltd, Printed in Switzerland
24hrs Support: +41 52 262 80 10

technicalsupport.chts@wartsila.com
Intentionally blank
Modification Service
Engine Documentation
RT-flex96C_WECS-9520_Dynex
Page No.
Modification
Date
Summary for Maintenance Manual

Title
Subject
(MM)
Page or
No.
Manual
new exch.
2008
Maintenance Manual, Issue 2008

Due to the major revision you receive a new complete
Maintenance Manuals Version with Dynex Servo Oil Pumps
Date of publication 2008-11-18

0352-1/A1 (2)
2008
Tightening Values of
Important Screwed
Connections
Number 15: Missing remark referring to retaining nut added
0330-1/A1, B1
(26 and 27)
3303-2/A1
(1, 5 to 8)
1.09
Clearance Table
Former key No. 5, 6, 8 deleted: No. 2, 3 (max. clearance),

5 corrected
Tool 94323: design adapted; paragraph 1.3 with Fig. 'H' added;
figures and and texts concerning the new tool 94323a adapted
Tool 94323: design adapted; figures and texts concerning the

new tool 94323a adapted
3303-3/A1, A2
1 to 5 (4)
7-67.364
Connecting Rod
7-67.364
Connecting Rod
3303-4/A1
3326-2/A1 (1)
Crosshead
3425-1/A1 (1)
7-65.977
Piston Rings
Reversible ratchet 94338b deleted
9403-5/A1
(21 and 26)
7-67.364
Tool List
Tool 94323a with special fixation adapted; tool 94338b deleted

Index Gr. 9
2.09
Tool list: Pages adapted correspondingly
0002-1/A1 (5)
Table of Contents
9403-5/A1 (52)
Tool List
x
x
SW-download package 94930 as standard tool added

Index 8
0002-1/A1
0380-1/A1 (7)
1132-2/A1 (2)
1132-2/A2 (2)
8135-1/A1
0002-1/A1
12.09
8135-1: Exhaust Waste Gate added

Table of Contents
Maintenance Schedule
Main Bearing (6-7
Cyl.) Bearing (8-14
Main
Cyl.)
Exhaust Waste Gate
2009
2010-07
8135-1: Exhaust Waste Gate (LLT) added

Table (5th - 7th rows) with available bearing types corrected
Table (5th - 7th rows) with available bearing types corrected
Low-Load Tuning
x
x
x
x
x
x
Table of Contents
0370-1 and 0370-2: Title Dimensions (and Material

Specification deleted); Tool List: Pages adapted
correspondingly
Clearance Table
Tightening Values
Key No. 3: altered to 0.12-0.24 mm (max. 0.3 mm)

2138-1: Description changed for 1-part lubricating quill; 27082_13, 2751-1_18, 5564-1_63: lubricant altered to Never-Seez
NSBT-8; 5610_118: tightening torque changed to 270 Nm;
5612-1_86: Elastic bolt M22x282 added
x
x
screw plug 94585 deleted therefore numbers sorted

accordingly
Index Gr. 0, 9
0330-1/A1 27
0352-1/A1 (1, 2,
5, 6, 8, 12, 13,
15, 16)
0352-1/A1 (8)
0352-2/A1 (1)
7-69.624
Tightening Values
Columns specified with "Thread diameter" and "Fine thread"
0370-1/A1 (2)
7-69.800
7-78.356
Dimension: O-rings
5556: O-ring 1.78x34.65 between flange - upper housing

added; 5612: O-ring between valve housing and lower cover
replaced with 2.62x59.99; Material specification deleted
0370-2/A1 (1)
7-77.791
Piston and Rod Seal 5556-1: former seal replaced with rod seal ring 70x3.53;
Rings
Material specification deleted
Maintenance Schedule 2745-1: relief valve to cylinder cover added; Gr. 8: General
remark concerning tightening of pipe holders and inspection of
vapor trap (fuel leakage system) added
Main Bearing
0380-1/A1 (2, 7)
1132-2/A1, A2
(13 or 16)
6.2 Lifting the crankshaft: remark for further lifting (0.8 mm) in
case of difficulties during removing lower bearing shell
1/6
31.3.2014
Page No.
Modification
Date

Title
Subject
(MM)
Page or
No.
Manual
new exch.
2138-1/A2
2708-1/A1 (4)
7-73.638
2010-07
2708-2/A1
Lubricating Quill on
Cylinder Liner
Cylinder Cover
Multi-part quill replaced with one-part quill introduced
Sec. 4, 6th: lubr. for nuts (2) altered to Never-Seez NSBT-8
Cylinder Cover
Protection cap (11) added and lubricant for nuts (2) altered to
Never-Seez NSBT-8
Injection Valve (O.M.T. 1.General: 4th sentence added; 3. Judging an injection valve:
Test Bench)
revised; Remark concerning opening pressure of 375 bar and
reference dimension 'x1'= 49.5 mm in Fig. 'E' added
2722-1/A2
(1, 3, 5, 6)
Injection Valve (OBEL 1.General: 4th sentence added; 3. Judging an injection valve:
Test Bench)
revised; Remark concerning opening pressure of 375 bar and
reference dimension 'x1'= 49.5 mm in Fig. 'B' added
2751-1/A1
(4-6)
2751-2/A1
Exhaust Valve
3. Fitting: lubricant for studs (1) and nuts (2) altered to NeverSeez NSBT-8; Sec. 4: Replacement of waisted studs revised
Rotation device 94290 deleted and therefore dismantling and
assembling procedure revised
Rotation device 94290 deleted; new valve grinding device
94291 introduced and therefore grinding procedure revised
2722-1/A1
(1, 3, 6, 7)
7-77.818
Exhaust Valve
2751-3/A1
Replacing and
Grinding the Valve
Seat
2751-4/A1 (1)
Grinding the Seating

Surface on Valve
Head
Vibration Damper
New valve grinding device 94291 introduced
1st sentence on page 1, addresses and information about

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

added
Remark concerning signs of wear of seal rings added
3146-1/A1 (4)
3403-3/A1 (6)
Piston
3425-1/A1 (1,
3)
4325-1/A1 (2)
Piston Rings
Securing agent LOCTITE No. 0648 specified for spraying

nozzle
Additional execution with 1xGTP1CC20 (GasTight) and
3xSCP2Cr20 piston rings added
Control valve modified
Application of lubricating device 94844 specifically adapted
3130-1/A1
(1, 4)
7-72.925
5552-5/A1
Shut-off Valve for

Starting Air
Supply Unit
5556-1/A3 (1, 2,
6-13, 15-17)
7-69.800
7-77.791
7-77.818
Fuel Pump
Fitting & dismantling device 94592 introduced instead of

rotation device 94290; tool 94550 and description concerned
added; dismantling and assembling procedures revised
5556-2/A1
7-72.876
Fuel Pump
Removal of a jammed pump plunger revised
5564-1/A1 (3)
7-69.624
Injection Control Unit
Lubricant of screw (10) altered to Never-Seez NSBT-8
5612-1/A1
7-78.356
Exhaust Valve Drive
Fitting instruction adapted and completed with new torques
8733-1/A1
(1, 2)
8750-1/A2
7-77.538
Fuel Pressure Piping
8752-1/A1
(1, 4-6)
7-78.121
Intermediate Fuel
Accumulator
Fixation of fuel pressure piping reinforced with an additional

holder (12)
Checking procedure revised, table with physical characteristics
for test & calibration fluid added
Regrinding device 94870 consisting of 94870i,j, k, l
implemented for fuel pressure pipe (with left-hand thread
M36x2 LH) between FP and intermediate fuel accumulator
9403-5/A1
7-77.818
7-75.992
Tool 94290, 94290b, 94278, 94278c, former 94291 and 94585

deleted
9403-5/A1
(1-5, 31, 38, 39,
40, 47, 49, 56)
7-77.818
7-78.121
EAAD082065
tool numbers for all general tools introduced (94000 - 94017,

94022, 94025, 94026, 94032, 94045, 94046, 94050); tool
94550, 94592 consisting of 94592a, b, c, d, e added; covers
94653, 94653a, b, c, d, e, 94655a, b, c specified for TPL85-B,
MET83MA, A190 and A185 TCs; tool box with No. 94720
specified for CLU4 only; new valve grinding device 94291
designed; regrinding device 94870 consisting of 94870i,j, k, l
added; tools newly sorted on 60 pages
Tool List
x
x

0002-1/A1
2010-11
Table of Contents
New group 7218-1/A2 added
Index Gr. 7
x
x
2/6
31.3.2014
Page No.
Modification
Date

Title
Subject
(MM)
Page or
No.
Manual
new exch.
0380-1/A1
(7, 8)
7218-1/A1
0380-1/A1 (8)
Maintenance Schedule 7218-1: Procedure specified for checking gas (nitrogen) precharge pressure
8750-2 Fuel pressure control valve: Replace filter (control oil)
added and therefore on page 5 deleted
2010
Lubricating Pump
CLU4
2011-02
Procedure specified for checking gas (nitrogen) pre-charge

pressure and refilling the accumulator
Maintenance Schedule 8744: Check of supply unit fuel drain pipings added:
8750: Check of non-return valves in IFA deleted
Lubricating Quill on
Test procedure of non-return valve modified (test medium
Cylinder Liner
altered to oil) and required tools added
Fuel Pump
Section 5: Oil flow check added
2138-1/A2
(1, 4)
5556-1/A3
(1, 20)
8750-2/A1 (3)
x
x
x
Fuel Pressure Control To prevent any clogging, new filter (35) is not secured with
Valve
LOCTITE, however fitted with oil and tightened with 10 Nm

Index 8
2011-03
0002-1/A1
2722-1/A1 (6)
8733-1/A2: Fuel pressure piping with spherical sealing

surfaces added
7-77.630
2722-1/A2
(5)
Table of Contents
Injection Valve (O.M.T. Fig. 'E': detail with spherical insert bush added
Test Bench)
x
x
Injection Valve (OBEL Fig. 'B': detail with spherical insert bush added
Test Bench)
8135-1/A1
EAAD082110 Exhaust Waste Gate

(Low-Load Tuning)
Air supply to LLT valve altered from control air to air spring air;
and connection between actuator and butterfly valve by means
of a cardan rod introduced
8733-1/A1 (1)
7-77.538
7-77.630
Attention concerning fuel leakage pipe added; reinforced

holder adapted
with spherical sealing surfaces added
Tool List
Regrinding device 94872 for spherical sealing surfaces added
8733-1/A2
2011
9403-5/A1 (49)
2011-03 7-57.949
2751-2/A1
2011-05 EAAD077748 Exhaust Valve
x
x
3403-1/A1
(1,4-8)
EAAD082346 Piston
6420-1/A1 (5)
A new valve stroke sensor 30 adapted. Former items 33, 34

deleted and therefore following items renumbered
Pages 1, 4: Protection 17, paragraph 4.2 and Fig. 'D' added.
Page 6: Remark concerning main lubricating pipe added
Scavenge Air Receiver Opening pressure of relief valve (15) specified for TIER I and II
9403-5/A1 (28)
EAAD082346 Tool List
Quantity of device 94350 reduced to 1 piece and 'X' adapted to

1174 mm
x
x
x
x

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

changed for redesigned pulse feed lubricating quill
2124-1/A1
Cylinder Liner
Measuring bore wear adapted with regard to setting screw (ST)

and compression shims
2124-3/A1
EAAD082901 Cylinder Liner
Collection / pressure reduction grooves (SN1) introduced
2138-1/A2
EAAD082645 Lubricating Quill on

Cylinder Liner
EAAD077748 Exhaust Valve
Arrangement of LEE non-return valve redesigned, i.e. placed

into screw-in union (7)
A new valve stroke sensor 30 adapted. Former items 33, 34
deleted and therefore following items renumbered
Pages 1, 4: Protection 17, paragraph 4.2 and Fig. 'D' added.
Page 6: Remark concerning main lubricating pipe added
2751-2/A1
3403-1/A1
(1,4-8)
EAAD082346 Piston
6420-1/A1 (5)
Scavenge Air Receiver Opening pressure of relief valve (15) specified for TIER I and II
9403-5/A1 (28)
EAAD082346 Tool List
Quantity of device 94350 reduced to 1 piece and 'X' adapted to

1174 mm
x
x
x
x

0380-1/A1(7)
2011-07
Maintenance Schedule 7218-1: Interval of checking gas pre-charge pressure adapted
3/6
31.3.2014
Page No.
Modification
Date

Title
Subject
(MM)
Page or
No.
Manual
new exch.
7218-1/A1
Lubricating Pump
CLU4
Procedure of checking / refilling the gas pre-charge pressure

adapted according to TB RT-110 (Issue 1, 31.05.2011)
9403-5/A1(47)
Tool List
Case 94720 changed to 94720c as new standard
Table of Contents
New group 5610-1/A1 added; Tool list specified with new page
numbers
0330-1/A1 (26)
Clearance Table
Fuel pump with connection pin and addidional O-ring updated
0352-1/A1
(1, 4, 9, 10)
Tightening Values
2124-2_8: Filling piece in cylinder liner deleted and following

items up to (12) renumbered; clamping part (12) deleted;
5562_54: tightening value changed to 150 Nm
0380-1/A1
(6, 8)
Maintenance Schedule 6735-1: Scavenge Air Waste Gate added; 8750-2: Interval of
36 000 Op.h changed to ''only necessary when PCV fails'';
9223-1: Work to be carried out and intervals revised
1903-1/A1
Tie Rod
2124-2/A1
(1, 5, 6, 7)
2138-1/A1
(1, 2, 3)
Cylinder Liner
EAAD083591 Lubricating Quill
(Pulse Jet)
Tensioning procedure altered to one step: 100 bar -> 1000 bar
with a tie rod elongation of 15.5 17.5 mm
Filling piece with waisted bolts deleted. Key of illustration and
numbering adapted
New lubricating quill with housing (11) and LEE non-return
valve introduced, tools 94720c, 94931, 94934h, 94934i and
94935 added
2138-1/A2
(1, 2, 3)
2722-1/A1
(1, 2)
2722-1/A2
(1, 2)
Lubricating Quill
(Pulse Feed)
Injection Valve with
O.M.T Test Bench
EAAD083679 Injection Valve with
OBEL Test Bench
Section3: Non-return valve revised;

tools 94720c, 94931, 94934h, 94934i and 94935 added
1. General: Test & Calibration fluid specified, therefore line
shifted to page 2
1. General: Test & Calibration fluid specified, therefore line
shifted to page 2; tool 94272b and view I replaced with 94272g
Exhaust Valve
Dismantling tool 94008a-M100 introduced. Figure 'G' added.
Exhaust Valve
Bore 'BO' in damper (33) and corresponding detail in Fig. 'B'

added.
Recon. conditions due to corrosion at the valve plate newly
defined. Case when reconditioning is not possible added
Fig. 'O' designed with a 2nd O-ring on lower housing; spring

dowel removed from guide piston / thrust piece
Pressure reducing valve with hydraulic accumulator (1) and
procedure for checking gas pre-charge pressure introduced

0002-1/A1
2012-05
Index Gr. 5, 9
2751-1/A1
(1, 5)
2751-2/A1
(1, 2)
2751-4/A1 (2)
Grinding the Seating

Surface on Valve
Head
5556-1/A3 (7)
5610-1/A1
6420-1/A1
(1, 2, 3)
6545-1/A1
EAAD082996 Fuel Pump

2012
EAAD082961 Lubricating Pump

CLU4
EAAD082683 Fuel Pressure Control
Valve (PCV)
Crank Angle Sensor
Unit
8750-2/A1
9223-1/A1
9403-5/A1
(3, 17, 28, 52)
x
x
2012-05 EAAD082712 Scavenge Air Receiver Relief valve with disc springs added. Opening pressure of RV
changed to 4.1 0.2 bar relative; section 3 added
Auxiliary Blower
All figures and items concerning execution 'Schmid' deleted.
7218-1/A1
(20, 21, 22)
EAAD082961 Pressure Reducing

Valve 8.11-1
2012
2012-05
Tool List
x
x
Figure 'E' changed (8.11-1 with hydraulic accumulator)
New maintenance concept for the PCV introduced according to

Technical Bulletin RT-125 (03.04.2012)
CAS modified according to Technical Bulletin RT-127, i.e. item
'MB' and paragraphs 3.2 & 3.7 added
New paragraphs 9.3, 4, 5, 6 and section 10 added
Tool 94272b deleted;

94008a-M100, 94272g, 94934h and 94934i added;
dimentions of 94272a, 94272c changed and 94350 redesigned
x
x
x
4/6
31.3.2014
Page No.
Modification
Date

Title
Subject
(MM)
Page or
No.
Manual
new exch.
0380-1/A1 (5)
5610-1/A1
(1, 2)
2012-05
2012
Maintenance Schedule Amendment: 5610-1 Checking gas (nitogen) pre-charge

pressure (min. 20 bar / max. 25 bar) adapted to same values
as specified for 7218-1
Pressure Reducing
Valve 8.11-1
x
x

2722-1/A1, A2
(1)
5564-1/A1 (1)
2012-11
Injection Valve
Cross reference to Operating Manual 2722-1 (Pressure release

and drainage of injection valve) added.
Further information regarding replacement of ICU added
x
x

0002-1/A1
2013-02
Table of Contents
Tool list specified with new page numbers
Index Gr. 9
1132-2/A1
(2, 19, 20)
1132-2/A2 (1,
2,3,17,24,25)
5552-5/A1
Removal and Fitting of Arrangement and characteristics of main bearings updated

a Main Bearing
according Service Bulletin RT-141
Removal and Fitting of
a Main Bearing
EAAD084033 Supply Unit
Instruction for the lubrication of SU during maintenance works
updated due to changes on the lubricating device
Hydr. Pre-tens. Jacks 94180: Allen screw M10x 97 (item 11) added
9403-3/A1 (6)
9403-5/A1 51,
(48, 49)
(50)
EAAD082083 Standard Tools

EAAD084033
SW-download P. 94930: 2 USB-keys (blue colour) deleted;

Tools 94844, a, b, c, d and e for lubrication of SU added;
Regrinding device 94872 adapted to a radius of 25 mm
x
x
x
x
x

5552-4/A1
2013-05 EAAD083955 Supply Unit
5552-5/A1
EAAD082818 Supply Unit
9403-5/A1 (16,
37, 50)
EAAD082818 Standard Tools
Instruction for the removal of the intermediate gear wheel

updated and extended by an additional tool (94571e and
94571f)
Instruction for the lubrication of SU during maintenance works

updated due to changes on the lubricating device
Retrofitted support tool 94266a for cradle added; support tools
94571e and 94571f added for the removing of the intermediate
gear wheel; tool 94844f for lubrication of SU added
x
x

0002-1/A1
2013-08
Table of Contents
3425-1/A1, A2: checking wear of ring grooves added
Index 3
0011-1/A1 (1)
0330-1/A1
(20, 21)
0370-2/A1 (5)
0380-1/A1
(2, 3)
x
x
Safety Measures and

Warnings
Clearance Table
Attention concerning clean areas (no water or cleaning fluids)

added
Key No. 6 and 7: points A and B added
Piston and Rod Seal 94215b with dimensions added

Rings
Maintenance Schedule 2728-1: Monthly check of nut on solenoid added according to
Technical Bulletin RT-143 (05.02.2013);
3103-1: Interval changed "according to classification society"
3403-1: Intervals changed to 18 000-36 000 operating hours
(3, 8)
x
x
x
x
3403-4: Intervals changed to 500-1000 operating hours

3425-1: Work to be carried out and intervals changed;
WECS electronic components: ALM-20 added
2722-1/A1
(1, 3, 5, 6, 9)
Injection Valve
(O.M.T. Test Bench)
Sec. 11 added; system oil as test media mentioned; Sec. 3:

keeping opening pressure changed from 10 to 30 seconds;
Remark concerning IMO technical file and detail of nozzle type
added; detail to Fig. 'E' added
2722-1/A2
(1, 3, 4, 8)
Injection Valve
(OBEL Test Bench)
Sec. 11 added; system oil as test media mentioned; Sec. 3:

keeping opening pressure changed from 10 to 30 seconds;
Sec. 4: => 4th sent, Sec. 5: => 3rd, 4th and 5th sent. added;
(5, 6)
2728-1/A1
(1, 3)
Detail to Fig. 'E' added; Remark concerning IMO technical file

and detail of nozzle type added
Starting Valve
CHECK: Periodical venting of starting air manifold (OM 03201) and monthly check of nut (18) on solenoid added
5/6
31.3.2014
Page No.
Modification
Date

Title
Subject
(MM)
Page or
No.
Manual
new exch.
3103-1/A1
3206-1/A1 (2)
3425-1/A1
9403-5/A1
(55, 56)
Measuring Crank
Deflection
Turning Gear
1. General aspects; 2. Condition of measuring and 4. Crank

deflection limits revised
Address of Lubrication Engineers Inc. changed
Piston Rings
(Four Piston Rings)
Tool List
Determination of wear rate of chrome-ceramic piston rings and

measuring piston ring grooves introduced
Tools 94291a, 94356 (only figure modified) and 94357 added
Tool List
Tools: 94211, 94212 deleted
x
x
x
x

9403-5/A1 (59)
2014-04
x
6/6
31.3.2014
MM / RTflex / Register
General Information
Bedplate and Tie Rod
Cylinder Liner and Cylinder Cover
Crankshaft, Connecting Rod and Piston
Driving Wheels and Shut-off Valve for Starting Air
Supply Unit, Injection and Exhaust Valve Control
Scavenge Air Receiver and Auxiliary Blower
Cylinder Lubrication
Piping
Crank Angle Sensor Unit, Tools
This page is intentionally left blank
RT-flex96C
Maintenance
General Information
Group0
Group 0
For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00001/A1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00011/A1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00021/A1
Engine Numbering and Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00081/A1
General Guidelines
for Maintenance: Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 00111/A1
for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts, etc. . . . . . . . . . . . . . 00121/A1
Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03301/A1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Crankshaft and Thrust Bearing (6 and 7 Cylinder Engines) . . . . . . . . . . . . . . . . . . . . . . 2, 3
Crankshaft and Thrust Bearing (8 14 Cylinder Engines) . . . . . . . . . . . . . . . . . . . . . . . 4, 5
Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15
Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
Supply Unit with Dynex Servo Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27
Tightening Values
of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03521/A1
of Standard Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03522/A1
Masses (Weights): Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . 03601/A1
Dimensions
O-rings and Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03701/A1
Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03702/A1
Back-up Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03702/A1
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) . . . . . . . . 03801/A1
Engine Cross Section and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08031/A1
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RT-flex96C
Maintenance
00001/A1
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.

Winterthur
Switzerland
1/ 1
2008
RT-flex96C
Maintenance
00011/A1
Preface
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 experience.
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
containing also under 00101 explanations of the layout and structure of the Operating and Maintenance Manuals as well as of the used symbols, signs and special
characters.
More detailed instructions on the operation and maintenance of components from
sub-suppliers can be gathered from the instruction leaflets of the respective
manufacturers. Outside makes are, for example, such engine components, tools
or devices which are not manufactured in accordance with production drawings
from Wrtsil Switzerland Ltd.
The Maintenance Manual is divided into the following main chapters:
General guidelines for maintenance
Clearance tables, tightening values of screwed connections, masses

(weights), seal rings
Maintenance schedule
Design groups
Tool lists
A few explanations to the above:
The General Guidelines for Maintenance contain, in addition to recommendations on precautionary measures to be taken, also suggestions for carrying
out the work.
The above mentioned tables inform about normal and maximum acceptable
clearances, the tightening of important screwed connections, weights of individual engine components as well as the type and use of various sealing rings.
The Maintenance Schedule indicates nominal intervals in which various

maintenance operations are to be carried out. Please note that the maintenance intervals are based on experience and are subject to operation of the
engine under 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!
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Maintenance
00021/A1
Table of Contents
Table of Contents
General Information
Group 0
For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00001/A1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00011/A1
Engine Numbering and Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00081/A1
General Guidelines
for Maintenance: Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 00111/A1
for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts, etc. . . . . . . . . . . . . . 00121/A1
Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03301/A1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Crankshaft and Thrust Bearing (6 and 7 Cylinder Engines) . . . . . . . . . . . . . . . . . . . . . . 2, 3
Crankshaft and Thrust Bearing (8 14 Cylinder Engines) . . . . . . . . . . . . . . . . . . . . . . . 4, 5
Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15
Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
Supply Unit with Dynex Servo Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27
Tightening Values
of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03521/A1
of Standard Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03522/A1
Masses (Weights): Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . 03601/A1
Dimensions
O-rings and Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03701/A1
Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03702/A1
Back-up Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03702/A1
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) . . . . . . . . 03801/A1
Engine Cross Section and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08031/A1
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Group 1
Bedplate and Thrust Bearing: Checking the Foundation Bolts . . . . . . . . . . . . . . . . . 11121/A1

Main Bearing
Loosening and Tensioning of Waisted Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11321/A1
Removal and Fitting of a Main Bearing (6 and 7 Cylinder Engines) . . . . . . . . . 11322/A1
Removal and Fitting of a Main Bearing (8 14 Cylinder Engines) . . . . . . . . . . 11322/A2
Main Bearing Upside-down Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11323/A1
Thrust Bearing
Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12031/A1
Removal and Fitting the Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12241/A1
Engine Stays
with Friction Shims: Checking the Pre-tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 17151/A1
Hydraulic: Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17151/A2
Tie Rod: Checking the Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . 19031/A1

Group 2
Cylinder Liner
Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21241/A1
Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21242/A1
Removing the Wear Ridge, Re-dressing Lubricating Grooves
and Scavenge Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21243/A1
Lubricating Quill
and Accumulator: Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21361/A1
with Pulse Jet Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 21381/A1
with Pulse Feed Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . 21381/A2
Piston Rod Gland: Dismantling and Assembling, Measuring the Wear . . . . . . . . . 23031/A1
Cylinder Cover
Removal and Fitting of Cylinder Cover and Water Guide Jacket . . . . . . . . . . . . 27081/A1
Loosening and Tensioning of Cylinder Cover Waisted Studs . . . . . . . . . . . . . . . 27082/A1
Machining of Sealing Face for Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27083/A1
Injection valve
Checking, Dismantling, Assembling & Adjusting with O.M.T. Test Bench . . . . 27221/A1
Checking, Dismantling, Assembling & Adjusting with OBEL Test Bench . . . . . 27221/A2
Starting Valve: Removal, Fitting and Dismantling, Grinding-in & Assembling . . . . 27281/A1
Relief Valve for Cylinder Cover: Checking Blow-off Pressure . . . . . . . . . . . . . . . . . 27451/A1
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Exhaust Valve
Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs . . . . . . . . . 27511/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27512/A1
Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27513/A1
Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . 27514/A1
Group 3
Crankshaft: Measuring Crank Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31031/A1

Vibration Damper
Taking a Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31301/A1
Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31302/A1
Axial Damper: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31461/A1
Turning Gear: Checking the Toothing and Screwed Connections . . . . . . . . . . . . . . 32061/A1
Crankcase: Utilization of Working Platform and Ladder . . . . . . . . . . . . . . . . . . . . . . 33011/A1
Lower Platform: Platforms and Hatch Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33012/A1
Connecting Rod
Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . 33031/A1
Inspection, Removal and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . 33032/A1
Inspection, Removal and Fitting of Top End Bearing with Piston in Situ . . . . . . 33033/A1
Inspection, Removal and Fitting of Top End Bearing with Piston Removed . . . 33033/A2
Crosshead
Checking the Clearances and Fitting the Guide Shoes . . . . . . . . . . . . . . . . . . . . 33261/A1
Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33262/A1
Piston
Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34032/A1
Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34034/A1
Piston Rings: Checking Wear of Piston Rings and Ring Grooves . . . . . . . . . . . . . . 34251/A1
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Table of Contents

Group 4
Driving Wheels
Checking the Running and Backlash Clearances and Condition of Teeth . . . . 41031/A1
Removal and Fitting of Intermediate Wheel (610, 12 & 14 Cyl. Engines) . . . 41032/A1
Removal and Fitting of Intermediate Wheel (11 Cylinder Engines) . . . . . . . . . . 41032/A2
Replacing the Gear Wheel on Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41033/A1
Replacing the Gear Wheel on Crankshaft (Single Wall Column) . . . . . . . . . . . . 41033/A2
Shut-off Valve for Starting Air: Cleaning and Function Check . . . . . . . . . . . . . . . . . 43251/A1

Group 5
Supply Unit
Removal and Fitting of Dynex Servo Oil Pump and Servo Oil Pump Drive . . . 55521/A2
Removal and Fitting of Camshaft and Bearing Shells . . . . . . . . . . . . . . . . . . . . . 55522/A1
Removal and Fitting of Gear Wheel on Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 55523/A1
Removing and Fitting the Fuel Cams with Conical Bushes . . . . . . . . . . . . . . . . 55523/A2
Removal and Fitting of Intermediate Wheel to Camshaft . . . . . . . . . . . . . . . . . . 55524/A1
Lubrication of Supply Unit During Maintenance Works (Dynex SOP) . . . . . . . 55525/A1
Fuel pump
Removal of a Jammed Pump Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55562/A1
Injection Control Unit: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55641/A1
Pressure Reducing Valve 8.111: Checking the Gas Pre-charge Pressure . . . . . 56101/A1
Exhaust Valve Drive: Removal, Fitting, Dismantling and Assembling . . . . . . . . . . . 56121/A1
Regulating Linkage: Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58011/A1
Group 6
Checking the Air Flaps and Cleaning the Scavenge Air Receiver . . . . . . . . . . . . . . 64201/A1
Auxiliary Blower: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65451/A1
Scavenge Air Cooler

Removal, Fitting of Cooler Element & Cooler Pre-stage . . . . . . . . . . . . . . . . . . . 66061/A1
Removal, Fitting of Cooler Element & Cooler Pre-stage (Engine with Rail) . . . 66061/A2
Water Separator: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67081/A1
Scavenge Air Waste Gate: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . 67351/A1
Group 7
Lubrication Pump CLU4: Checking the Gas Pre-charge Pressure . . . . . . . . . . . . . 72181/A1
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Piping
Group 8
Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81351/A1
Servo Oil Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . 84471/A1
Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding . . . . 84601/A1

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

Checking and Setting of Relief Valve with O.M.T. Test Bench . . . . . . . . . . . . . . 87501/A1
Checking and Setting of Relief Valve with OBEL Test Bench . . . . . . . . . . . . . . . 87501/A2
Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling . . . . 87502/A1
Fuel Pressure Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . 87521/A1
Group 9
Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting . . . . . . . . . . . . . 92231/A1

Tools: Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94031/A1
Hydraulic Jacks and Pumps: Arrangement and Application . . . . . . . . . . . . . . . . . . . 94032/A1
Hydraulic Pre-tensioning Jacks

Storing, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94033/A1
General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94034/A1
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94035/A1

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 01 53
Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 54 58
Special Tools Obtainable on Loan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 59 62
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Maintenance
General
Engine Numbering and Designations
General:
Turbocharger
1
Turbocharger 2
DRIVING
END
Cylinder
Numbering
FREE END
10
11
011.945/04
Thrust Bearing Pads
Main Bearing Numbering
Rail Unit
FUEL SIDE
EXHAUST SIDE
Supply Unit
Clockwise
Rotation
013.059/05
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2008
00081/A1
Maintenance
RT-flex96C
Engine Numbering and Designations
flex Parts:
Fuel Pump Row
Bank A
Pump A4
Pump A3
Pump A2
Pump A1
Fuel Pump Row

Bank B
Counting Direction
Fuel Pumps
Actuator A2
Actuator A1
Pump B4
Pump B3
Pump B2
Pump B1
Supply Unit
Pump 3
Pump 2
Pump 1
Actuator B1
Actuator B2
Pump 4
Pump 5
Pump 6
Counting Direction
Servo Oil Pumps
DRIVING END
Control Oil Pumps
Pump 2
Crank Angle Sensors

Sensor 2
(GT5127C)
Pump 1
Sensor 1
(GT5126C)
FUEL SIDE
DRIVING
END
013.061/05
FREE END
FUEL SIDE
2008
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Maintenance
00111/A1
General Guidelines for Maintenance

Safety Measures and Warnings
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautionary measures before beginning of
maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommendations for performing work . . . . . . . . . . . . . . . . .
1/4
1/4
2/4
3/4
4/4
General
The maintenance work which is required to be carried out on the engine at regular
intervals is described in the Maintenance Schedule 03801 of this manual and is to
be understood as a general guide. The maintenance intervals are dependent on
the mode of operation, on the power as well as on the quality of the fuel used. Further details are set out in the maintenance schedule.
Experience will show whether the intervals may be extended or need to be shortened.
Strict compliance with the below mentioned recommendations regarding
safety measures and maintenance work is mandatory; the recommendations are not exhaustive.
2.
General safety precautions

D
It is the operators duty to assure that all personnel is familiar with all safety,
health as well as environment protection rules released for operating and
maintaining a diesel engine plant. In particular greatest attention has to be given to the functioning, handling and dangers of cranes and lifting devices.
The safety officer has to make sure that all precautions have been taken in
order to avoid dangerous situations.
The operator has to nominate a person responsible for assigning work tasks
to every person who is participating in maintenance work.
Make sure that fluids or gases draining or escaping cannot cause accidents,
fires or explosions during maintenance work. Keep the engine and the surroundings clean. Cleanliness increases the quality of the work and helps to
prevent accidents.
Before beginning maintenance work on the diesel engine the corresponding
systems which are influenced by the maintenance work must be relieved of
pressure and/or drained if necessary. A protocol must be established evidencing these activities.
Certain media, i.e. fuels etc., are highly inflammable, therefore all precautionary measures have to be taken that they do not come into in contact with fires,
glowing or hot parts. Smoking in the engine room is strictly forbidden.
Special attention has to be paid to the rules of fire fighting.
Make absolutely sure that in case of fire alarm no fire extinguishing gases can
be released into the engine room while people are still inside. Emergency escapes are to be marked and personnel is to be instructed of what to do in case
of fire.
Oils and other media can cause slippery surfaces. In order to avoid injury all
surfaces which can be stepped on must be kept clean and dry.
Attention! Do not use water or any cleaning fluid to clean the WECS electronic
components and control boxes on the engine as well as on the rail unit. Damage
can occur if water goes into these electronic components or control boxes.
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3.
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 shut-off valves on the starting air bottles.
Close all the shut-off valves in the control air supply unit, and open the drains
on both air bottles until it is depressurized.
Close by hand the (automatic) shut-off valve for starting air and open the vent
and drain valve to the main starting air piping on the engine as well as the vent
valves on the shut-off 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 them in this position
until maintenance work is completed.
Engage turning gear (gear pinion must be in engaged position) and lock the
lever (see also 32061 and 07501 in the Operating Manual).
D
Where the engine has been stopped due to overheated running gear or
bearings, wait at least 20 minutes before opening the crankcase doors.
The crankcase doors must always be locked with all the clamps whenever the engine is running, even if this is only for a short time in order to
make temperature checks (e.g. after changing bearings during an overhaul,
etc.).
In the case of a fire in the engine having been extinguished by means of CO2,
the spaces affected must be well ventilated before work can be carried out
within them.
Attention! When performing electric welding near or on the engine, electromagnetic fields or peak voltage may occur, which may damage the electronic components of the WECS (Wrtsil Engine Control System).
Therefore, prior to performing electric welding in the vicinity of the mentioned components, the following precautions must be taken:
2008
8
Stop the engine if it is in operation.
Power off the electronic system and wait one minute.
If the welding point is within a radius of two metres from an electronic module
and/or a sensor, disconnect the modules and/or sensors.
Close the covers of all electric boxes and protect cables, sensors, etc. against
sparking and heat.
Shield the check and control units with a conductive material and connect
them to earth.
Run the welding cable from the welding apparatus directly to the welding point
without any unnecessary loops; also, avoid leading the welding cable parallel
to cables of the electronic control unit.
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4.
Special safety measures

D
Prior to turning the crankshaft with the turning gear, make sure and take notice:
that no person is inside the engine and no loose parts, tools or devices
can get jammed.
bear in mind that the coupled propeller turns too (danger in surroundings).
that lubricating device 94844 has been installed to prevent bearing

bushes of the servo oil pump drive in the supply unit from being damaged
(dry running) due to turning the engine during overhaul works.
Prior to turning the crankshaft with the turning gear, make sure that no person
is inside the engine and no loose parts, tools or devices can get jammed. Also
bear in mind that the coupled propeller turns too (danger in surroundings).
At all times when somebody is inside the engine casing another person must
stand by in order that he can give the necessary aid if something unexpected
happens to the person inside the engine. The person who is inside the engine
casing must be equipped with all safety gears which are required to prevent
suffocation within the limited space and atmospheric conditions. Moreover an
antifall guard must be carried at dangerous places!
The allowed load capacity of the engine room crane, the lifting tools, ropes
and chains must be sufficient for the parts to be lifted (see 00121 and
03601).
Pay also attention to the weight distribution and attachment of the lifting tackle
in order that the part which must be lifted cannot tip over or crash down!
Sharp edges, mating faces etc. as well as ropes are to be protected by wooden pieces, leather or special edge guards which are placed between the part
and the rope or chain.
Always use gloves, a face shield and wear safety goggles when working with
hydraulic tools.
For your own safety keep away from under hanging loads, never undersling
hanging parts with your fingers or hands and never embrace lifting ropes with
your hands.
Removed parts must be secured in the engine room.
For reasons of safety, openings resulting from removed engine components

must be closed!
Remark: For further instructions see also Safety Precautions and Warnings (General Information) 02101 in the Operating Manual.
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5.
Recommendations for performing work

D
Pay attention to Utilization of Working Platform and Ladder 33011.
Carry out all work carefully, observing utmost cleanliness!
For maintenance work on the engine use the tools and devices intended for
the particular job, which, as a rule, are supplied with the engine (see tool list at
the end of this manual).
Tools and devices must be made ready prior to use, make sure they are in
perfect condition.
Calibrate gauge tools before using and at periodical intervals.
Check hydraulic tools periodically for tightness and perfect functioning.
Protect running faces and sealing faces of removed parts by suitable means
to prevent damages.
Close all openings which form when certain parts are removed e.g. pipes, oil
holes etc. to prevent dirt from entering the engine. (This includes also the
pipes which are removed).
Check all repaired, overhauled or replaced parts for perfect functioning before
starting the engine.
Check all pipes which have been removed, for tightness after they are refitted.
Clearances of moving parts must be checked periodically. Should the maximum permissible values (see Clearance Table 03301) have been reached or
even exceeded, these parts must be replaced.
Arrange to replace all parts taken from spares stock. When ordering new
parts refer to the Code Book, mention code numbers and description.
2008
When tightening studs, nuts or screws, take the utmost care not to damage
their thread. They must be screwed in by hand until metal to metal contact is
achieved. Always use the specified lubricants on the threads.
Adhere to tightening values wherever they are indicated. Use the specified
lubricant on the threads (see 03521 and 03522).
Locking devices of bolts, nuts, etc. must be fitted correctly and secured properly. Use locking plates and locking wires only once.
For threads of screws and studs which are getting very hot, (i.e. exhaust pipe
or turbocharger fastenings) apply a high temperature resistant lubricant before assembly, to prevent a heat seizure.
Used rubber rings must always be replaced by new ones when an overhaul of
any engine component takes place; they must conform in dimension and
quality to the specifications in the 03701.
The fitting of piston seal rings and rod seal rings requires the greatest of care
to prevent damage, over expansion or deformation. Before fitting the rings
heat them first in boiling water.
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General Guidelines for Lifting Tools

Wire Rope Slings, Span-sets, Eye Bolts, etc.
1.
General
The permissible capacities of the engine crane, lifting tools, ropes, chains, lifting
eye bolts, etc. must always correspond with the weights of the parts to be lifted
(see also Masses (Weights) 03601).
Remark: The admissible lifting (max. loading) capacity in kg corresponds to the
WLL = Working Load Limit.
For fitting and removal of engine components or their transportation, only the tools
which are in perfect condition and intended for this purpose may be used. Ropes
which have begun tearing or otherwise are defective and tools which are damaged
have to be exchanged.
For safe and proper handling of crane, suspension tools or transport of loads we
recommend to proceed as follows for safety reasons:
D
Determination of the weight of load
Determination of the suspension centres and weight distribution
Choice of attachment elements
Attaching and disconnecting
2.
Attachment elements
2.1
Wire rope slings

The lifting capacity of the wire rope slings is listed under their tool number in Tools
List 94035.
2.2
Span-sets
Span-sets have the advantage of easy and simple handling. The code and the
colour normally indicate the maximum admissible total load. Loops and knots in
the span-sets reduce their lifting capacity by one third.
2.3
Eye bolts and eye nuts

Only those eye bolts and eye nuts may be used which are in accordance with DIN
580 & 582:200308 or which fulfil or exceed these values, including the safety
factor.
All calculations for components and tools where eye bolts and eye nuts are used
are laid out accordingly and based on the mentioned standards.
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General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc.
Lifting capacity (for information purposes only):

Lifting capacity [kg]
Eye bolts &

eye nuts,
thread size
single-strand
double-strand (45)1)
45 _
M8
140
100
M10
230
170
M12
340
240
M16
700
500
M20
1200
860
M24
1800
1290
M30
3200
2300
M36
4600
3300
M42
6300
4500
M48
8600
6100
M56
11 500
8300
Remarks: The details listed in the table above are based on DIN 580 &
582:200308, requiring that the eye bolt or the eye nut:
2.4
is completely turned in or screwed down;
lies flat and fully on the seating surface;
was checked for visible damages (e.g. corrosion, deformation) before using it.
1) Full load is only permissible in the direction of the ring, therefore the
eye bolts or eye nuts must be brought to the right position, if necessary by using distance rings.
If there are through holes, a washer should be placed from the opposite side
under the nut or screw head.
Whenever possible, do not apply an angle of inclination bigger than 45 (in all
directions with regard to the ring level), and especially avoid lateral pulling!
For varying use on different objects to be carried, eye nuts or eye bolts with
thread diameters one size higher should be used.
RUD-eye bolts and RUD-swivel lugs

Only those RUD-eye bolts & RUD-swivel lugs may be used with a safety factor 4.
Manufacturer:
RUD Ketten
Rieger & Dietz GmbH u. Co
Friedensinsel
D73432 Aalen
Germany
http://www.rud.com
2008
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Maintenance
2.4.1 Remarks on the use of RUD-eye bolts
they must be completely screwed down, lying fully on the seating surfaces.
they are hand-screwed with their own star-profile wrenches (do not use any
extension).
In order that after tightening the ring of the RUD-eye bolt is freely rotatable, the
star-profile wrench must be removed from the inner hexagon of the screw as
shown in Fig. A.
Prior to loading the RUD-eye bolt adjust it in force direction (RUD-eye bolts
are not suitable to be turned under load).
Lateral loading is permitted in no circumstances! (Fig. B)
FORCE
DIRECTION
FORCE
DIRECTION
FORCE
DIRECTION
Ring
Star-profile
wrench
Screw
013.444/05
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Maintenance
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2.4.2 Remarks on the use of RUD-swivel lugs
they must be completely screwed down, lying fully on the seating surfaces.
they are hand-screwed with an open end wrench.
Prior to loading the RUD-swivel lug adjust it in force direction (Fig. C and D).
Loading as shown in Fig. E should be be avoided if possible!
FORCE
DIRECTION
FORCE
DIRECTION
FORCE
DIRECTION
013.445/05
2.5
Shackles
Only those shackles may be used which are in accordance with American Standard RRC271A or which fulfil or exceed these values, including the safety factor.
All calculations for components and tools where shackles are used are laid out accordingly and based on the mentioned standards.
Normally, the permissible lifting capacity of the shackles is specified for one single
strand.
Attention! If tools are combined (e.g. beams with shackles, RUD-eye bolts or
RUD-swivel lugs and ropes, etc.), it is always the weakest element which determines the maximum lifting capacity (see details in Tools List 94035).
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3.
Attaching and disconnecting

The following must be observed:
D
Distribution of load:
one strand carries the total of load weight
two strands carry each one half of the load weight
four strands carry each one quarter of the load weight if the load is distributed equally.
Angle of strand:
the flatter the strand angle, the more the strand is stressed
the more acute the strand angle is, the less the strand is stressed.
Place a soft-wood board between rope and engine component, because the
ropes tend to slide on smooth surfaces (e.g. tubes, shafts).
Protect the ropes against damages by providing a wooden pallet or a rag.

Sharp edges may even cut steel cables!
If possible always tie down the load. (danger of fall)
Wrapping the rope twice increases friction and adhesion in such a manner
that even a smooth, oily shaft is sliding less.
Hemp rope strands, wrapped around the hook, prevent sliding. Do not wrap
steel cables, but cross them instead.
Danger of injuries! For your own safety never stand beneath loads!
Hold the ropes in the flat of your hands and keep your fingers stretched out. Never
seize the load at the bottom, but always lead it laterally. Always put down the loads
on a perfect ground, and use sufficiently sized bases.
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Clearance Table
Overview
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/27
Crankshaft and Thrust Bearing (6 & 7 Cyl. Engines) . . . 2, 3/27
Crankshaft and Thrust Bearing (8 14 Cyl. Engines) . . 4, 5/27
Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . 6, 7/27
Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9/27
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11/27
Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13/27
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15/27
Top and Bottom End Bearings to Connecting Rod . . . 16, 17/27
Piston Cooling and Crosshead Lubricating Link . . . . . 18, 19/27
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21/27
Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . 22, 23/27
Supply Unit with Dynex Servo oil Pumps . . . . . . . . . . . 24, 25/27
Fuel Pump (V4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27/27
General
The clearances listed in the column Nominal dimension of the following table correspond to design and manufacturing values or to the settings on the new engine.
The values listed in the column Maximum clearance, dimension are such values
as may be reached after a lengthy operating period, which however may not be
allowed to be exceeded or fall below. On components where the clearance is adjustable by modifying the thickness of shims, discs, spacers etc. the value given as
Normal Clearance should always be arrived at, or striven to attain. Where this is
not possible, worn parts must be replaced by standard new ones or reconditioned
by suitable material buildup.
If, during an overhaul, clearances are measured which have almost reached the
permissible limit, it must be left to individual judgement to decide whether a component part should be replaced or remain fitted till the next overhaul. This depends for
example on the duration of the next operation period till the next overhaul and what
wear has to be expected based on experience gained.
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Clearance Table
Crankshaft and Thrust Bearing
6 and 7 Cylinder Engines
001.404/96
001.404/96
001.404/96
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Clearance Table
Key No.
Group
Description
1132
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
width
425
per side
15.5
Main bearing
Bearing shell
1
1203
Lateral clearance
Thrust bearing
1224
Thrust bearing pad
2
Thrust bearing clearance
Thrust bearing pad, lateral clearance
thickness
0.5
0.6
120
axial (total)
0.81.3
total
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Clearance Table
8 14 Cylinder Engines
001.404/96
1
3
011.332/03
2008
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Maintenance
Clearance Table
Key No.
Group
Description
1132
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
width
425
per side
15.5
Main bearing
Bearing shell
1
1203
Lateral clearance
Thrust bearing
1224
Thrust bearing pad
2
Thrust bearing clearance
Thrust bearing pad, lateral clearance
thickness
0.5
0.6
120
axial (total)
0.81.3
total
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Maintenance
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Clearance Table
Crankshaft and Main Bearing
30 mm
30 mm
50 mm
6 2
50 mm
7 3
3
008.298/01
008.298/01
MAIN BEARINGS
No. 2 ...
MAIN BEARING
No. 1
001.404/96
2008
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Maintenance
Clearance Table
Crankshaft and Main Bearing
Key No.
Group
Description
1132
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Main bearing No. 1

0
0.10
Crankshaft
outer
Main bearing
inner
990
Bearing clearance
vertical
0.30.6
*2
Lateral clearance
total
0.91.2
*3
Lateral clearance
total
0.50.8
**4
Positional tolerance (bearing cover)
vertical
max. 0.3
1132
990
0.75
Main bearing No. 2 and following

0
0.10
Crankshaft
outer
Main bearing
inner
990
Bearing clearance
vertical
0.30.6
*6
Lateral clearance
total
1.01.3
*7
Lateral clearance
total
0.81.1
**8
Positional tolerance (bearing cover)
vertical
max. 0.3
990
0.75
All main bearing clearances are only valid with tie rods and main bearing studs
tightened.
Pay attention to measuring point!
**
The difference between the two values (positional tolerance) must not be
greather than 0.3 mm when the studs are tightened!
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Clearance Table
Crosshead Guide
EXHAUST SIDE
6
8
7
014.087/06
4
5
2008
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Maintenance
Clearance Table
Crosshead Guide
Key No.
Group
Description
3326
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
1430
Crosshead guide
1
Guide way (column)
transverse
Guide shoe
transverse
*3
Guide shoe clearance
1430
0.20
0.35
0.201.10
1.4
Cylinder No. 1
4
Guide rail
Guide rail, lateral clearance Driving End
longitudinal
977.5978.5
T.D.C.
1.11.7
B.D.C.
1.11.3
Guide rail, lateral clearance Free End
0.30.9
Cylinder No. 214

4
Guide rail
Guide rail, lateral clearance
Guide shoe, lateral clearance
Guide shoe, bearing pin
outer
550
0.05
0.10
Guide shoe, bearing bore
inner
550
+ 0.07
0
longitudinal
978.30979.30
total
0.601.80
longitudinal
0.200.40
Bearing clearance
radial
0.050.17
2.2
0.30
For measuring of clearances see instructions in 33261.

*
Clearance 3 is only valid with tie rods tightened.
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Maintenance
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Clearance Table
Cylinder Liner
2
3
approx. 220240 mm
014.090/06
2008
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Maintenance
Clearance Table
Cylinder Liner
Key No.
Group
Description
2124
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Water guide jacket on cylinder

cover
Water guide jacket
1
Clearance
total
Water guide jacket

2
Clearance
total
Water guide jacket

3
Clearance
total
Water guide jacket

4
2124
Clearance
total
+ 0.70
0.50
1425 +
0.801.20
+ 0.70
0.50
1290 +
0.801.20
+ 0.70
0.50
1360 +
0.701.10
+ 0.70
0.50
1425 +
0.701.10
Supporting ring for cylinder liner

Supporting ring
5
2124
Clearance
total
1181.5
+ 0.20
0
1.01.4
Cylinder jacket
Cylinder jacket
6
2124
Clearance
1150
+ 0.20
0
total
2.202.60
radial
960
Cylinder liner
*7
Cylinder liner bore
966.7
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Clearance Table
Piston Rod Gland
4
5
1
6
1
7
2
7
99.7406
011.333/03
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Maintenance
Clearance Table
Piston Rod Gland
Key No.
Group
Description
2303
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Piston rod gland

*1
Ring width
radial
31
min. 25
*2
Ring width
radial
24
min. 22.20
*3
Ring width
radial
min. 3.20
Ring clearance
axial
0.100.26
0.50
Ring clearance
axial
0.100.26
0.50
Ring clearance
axial
0.050.16
0.40
Ring clearance
axial
0.100.17
0.40
Ring wear
The differential value between nominal dimension and max. wear is equal for all
rings, i.e. also for undersize rings.
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Clearance Table
Exhaust Valve
VALVE SPINDLE
L = LENGTH
~ 1/3 L
~ 2/3 L
GUIDE BUSH
001.400/97
011.334/03
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Maintenance
Clearance Table
Exhaust Valve
Key No.
Group
Description
2751
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Valve spindle
1
2751
Spindle
outer
95
0.35
0.40
94.50
Guide bush
*2
Bore
inner
95
+ 0.035
0
95.50
*3
Bore
inner
95
+ 0.035
0
96.50
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Clearance Table
Top and Bottom End Bearings to Connecting Rod
10 mm
10 mm
50 mm
10 mm
001.399/97
2008
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Maintenance
Clearance Table
Top and Bottom End Bearings to Connecting Rod
Key No.
Group
Description
3303
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Top end bearing
3326
0
0.10
Crosshead pin
outer
Bearing
inner
900
Bearing clearance
vertical
0.500.90
*2
Lateral clearance
total
0.751.05
*3
Lateral clearance
total
0.600.85
Axial clearance
total
0.40.8
3303
900
1.05
1.2
Bottom end bearing

0
0.10
Crankshaft
outer
Bearing
inner
990
Bearing clearance
vertical
0.500.80
*6
Lateral clearance
total
0.520.74
*7
Lateral clearance
total
0.751.0
Axial clearance
total
34
990
0.95
17/ 27
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Piston Cooling and Crosshead Lubricating Link
3
2
3
3
4
4
003.314/00
003.314/00
2008
18/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Piston Cooling and Crosshead Lubricating Link
Key No.
Group
Description
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
outer
72
Piston cooling and crosshead

lubricating link
Pin
1
Bearing clearance
radial
0.030.09
Bearing
width
173
Lateral clearance
total
min. 1.0
Lateral clearance
total
2.0
19/ 27
0.20
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Piston and Piston Rings
2
3
9
10
11
2013-08
20/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Piston and Piston Rings
Key No.
Group
Description
3403
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Piston crown
1
Crown
outer
951.7
Crown
outer
956.7
3403
Piston ring grooves
3425
+ 0.50
0.45
Height of the two uppermost grooves
vertical
20 +
Height of the two lower grooves
vertical
20 +
Groove depth
3425
radial
+ 0.40
0.35
31
Piston rings
Ring height
vertical
20
0
0.03
Point A
Point B
Ring clearance
vertical
0.440.52
0.75
0.95
Ring clearance
vertical
0.350.43
0.65
0.80
Ring width
radial
30 0.45
3403
Piston skirt
9
Skirt
outer
958.9
0
0.2
10
Rubbing ring
outer
959.3
0
0.1
outer
370
3403
min. 957
Piston rod
11
Rod
0.062
0.119
min. 368.80
Used piston rings may be refitted if they will keep within their min. ring width until
the next overhaul (for judging and reusing piston rings see also 34251).
For evaluating and reusing piston heads see 34251).
21/ 27
2013-08
03301/A1
Maintenance
RT-flex96C
Clearance Table
Driving Wheels for Supply Unit
6
4
1
5
011.501/04
2008
22/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Driving Wheels for Supply Unit
Key No.
Group
Description
4103
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Intermediate wheel
1
Shaft
outer
340
Bearing clearance
vertical
0.1820.288
0.40
*3
Axial clearance
total
0.61.5
1.9
Tooth backlash
0.400.62
0.85
Tooth backlash
0.540.78
1.00
Tooth backlash
0.400.59
0.80
Clearance 3 is only valid with tie rods tightened.
23/ 27
2008
03301/A1
Maintenance
Clearance Table
Supply Unit
RT-flex96C
with Dynex Servo Oil Pumps
3 2
5
4
014.096/06
10
2008
24/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Supply Unit
with Dynex Servo Oil Pumps
Key No.
Group
Description
5552
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Supply unit
1
Pinion
outer
120
0
0.022
Bearing (fitted)
inner
120
+ 0.23
+ 0.14
Bearing clearance
radial
0.140.252
Axial clearance
total
0.250.54
5552
0.7
Camshaft unit
Cam shaft
Bearing clearance
radial
0.220.34
Axial clearance
total
0.30.6
Tooth backlash
*8
Minimum clearance
5552
outer
0
0.032
300
0.8
0.160.29
3
Intermediate wheel
9
Bearing clearance
radial
0.220.34
10
Axial clearance
total
0.30.6
0.8
Minimum clearance between cam and roller with fuel pump cut out.
25/ 27
2008
03301/A1
Maintenance
RT-flex96C
Clearance Table
Fuel Pump
PLUNGER & CYLINDER

42
29
A
B
149
73 mm
C
1
D
4
3
PLUNGER & CYLINDER
46
33
A
B
145
C
73 mm
5
WCH00832
014.104/06
2012-05 / V4
26/ 27
RT-flex96C
03301/A1
Maintenance
Clearance Table
Fuel Pump
Measuring
Nominal
Maximum clearance,
direction
dimension
dimension
(method of
measuring)
(normal, new)
(due to wear)
[mm]
[mm]
Clearance (plunger / cylinder) AB
radial
0.0350.038
0.045
Clearance (plunger / cylinder) BC
radial
0.0250.028
0.035
Clearance (plunger / cylinder) AB
radial
0.0350.038
0.045
Clearance (plunger / cylinder) BC
radial
0.0250.028
0.035
Clearance (plunger / cylinder) D
radial
0.0400.043
0.5
Guide piston
outer
185
Lower housing
inner
185
Key No.
Group
Description
5556
Fuel pump
Plunger (42 mm)
1
Plunger (46 mm)

1
Clearance
radial
0.220.68
0.8
Piston / lower spring carrier
axial
0.120.24
0.3
Regulating sleeve / upper spring

carrier
axial
0 .50.7
5556
0.8
Roller guide
Pin
outer
80
0
0.013
Guide piston (bore)
inner
80
+ 0.04
+ 0.01
Clearance
radial
0.0100.053
Total clearance between guide piston

and roller with pressure discs
axial
0.260.54
0.08
0.7
Plunger conically machined in range CD; i.e. clearance increases in diameter of 0.015 mm.
27/ 27
V4 / 2010-07
RT-flex96C
03521/A1
Maintenance
Tightening Values of Important Screwed Connections
Group
Description
Thread
Tightening values
1
[bar]
2
[Nm]
Lubricant
3
[_; mm]
1
1106
Bedplate parting faces, screw
M36
2090
Oil
Bedplate parting faces, screw
M56
4970
Oil
Foundation bolts (metal and

synthetic chocks)
M64
11121
11321
Main bearing, nut for waisted stud
17151
Engine stays (friction type)
19031
Tie rod
1000
1st
MOLYKOTE G
step 600 bar
M64x6
1000
M64
200
MOLYKOTE G
1000
MOLYKOTE G
M140x6
(130_)
Oil
1st step 100 bar
(see instructions in 19031)
2nd step 1000 bar
2
2106
21242
*
*
Cylinder jacket bolting-up / bolt

Cylinder jacket bolting-up / fitted bolt
M64
M64
Lifting gear (tool 94202(a), screw
M24
30
no additional
lubricant required
M48
30
no additional
lubricant required
M24
400
see details in
21242
Elongation 0.55 0.04 mm
Oil
Elongation 0.45 0.04 mm
Oil

9
Special screw (tool 94207)

10
Supporting ring, screw
21361
11
Lubricating quill, set screw
M16x20
50
see details in
21361
21381
12
Lubricating quill (Pulse Jet), screw
M8x150
10
see details in
21381/A1
21381
12
Passage for lubricating quill and

screw-in union (Pulse Feed)
M22x1.5
30
see details in
21381/A2
27082
13
Cylinder cover, nut for waisted stud
M110x6
1
2
3
1000
(390_)
Never-Seez
NSBT-8
When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp
1 bar = 1.02 kp/cm 2
Tightening torque
Tightening angle or elongation
Numbers in f refer to illustrations on pages 9 to 18.
Values in parentheses (...) are for information only, to be used for comparison.
Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
Tightening procedure not mentioned in this Manual.
1/ 18
2012-05
03521/A1
Maintenance
RT-flex96C
Group
Description
Thread
Tightening values
1
[bar]
27221
14
Injection valve, screwed connection

with cylinder cover
M12

15
Injection valve, retaining nut, nozzle

body nozzle holder
M65x1.5
27281
16
Starting valve spindle, nut
2
[Nm]
Lubricant
3
[_; mm]
Equally tighten Allen

screws until spring guides
are flush with spring cages
Never-Seez
NSBT-8
1st step 100 Nm
Never-Seez
NSBT-8
1st step to 2nd step
30_
(loosen retaining nut after initial

assembly and then repeat tightening procedure)
M36x3
(1215)
50_
MOLYKOTE G
(1340)
85_
Never-Seez
NSBT-8
(230_)
Never-Seez
NSBT-8
(spindle thread not to be lubricated in region

of locking ring)
17
Starting valve, nut for waisted stud
M33
27511
18
Exhaust valve cage, nut for waisted

stud
M110x6
27512
19
Exhaust valve, head screw for

measuring cone piston
1000
M20
250
Oil

1st step
20
Exhaust valve, screw for lower

housing valve cage
M36
21
Exhaust valve, screw for damper
M30
22
Flywheel, nut for coupling bolt
M56
20_
MOLYKOTE G
23
Crankshaft division, nut for coupling

bolt
M85x4
50_
no additional
lubricant required
24
Crankshaft propeller shaft, nut for

coupling bolt
M85x4
55_
MOLYKOTE G
31302 *
25
Crankshaft vibration damper, nut

for coupling bolt (standard flange)
M85x4
40_
MOLYKOTE G
25
Crankshaft vibration damper, nut

for coupling bolt (small flange)
M42x3
90_
MOLYKOTE G
26
Crankshaft counterweight, nut for

coupling bolt
M85x4
35_
MOLYKOTE G
27
Axial damper bedplate, fixing bolt
M36
50_
MOLYKOTE G
130 Nm
Oil
30_
2nd step
1200
Oil
3
3103
3114
31461
1
2
3
(2300)
1 bar = 1.02 kp/cm 2
Tightening torque
2010-07
2/ 18
RT-flex96C
03521/A1
Maintenance
Group
Description
Thread
Tightening values
1
[bar]
32061
28
Turning gear, screwed connection
M52
2
[Nm]
1000
Lubricant
3
[_; mm]
(60_)
Oil
1st step 600 bar

2nd step 1000 bar
33031
29
Connecting rod, stud for top end

bearing
M80x6
1000
Oil
1st step 600 bar (gap = 0)

2nd step 1000 bar
Check: 1st step to 2nd step

30
Connecting rod, stud for bottom end

bearing
(30_)
M110x6
1000
Oil
1st
step 300 bar (gap = 0)

2nd step 1000 bar
Check: 1st step to 2nd step
33261
31
Middle piece of crosshead guide

shoe, screwed connnection
(80_)
M36
2000
(30_)
MOLYKOTE G
(60_)
Oil
(115_)
Oil
(HYTORC torque machine approx. 600 bar)
34031
32
Piston rod crosshead, nut to

waisted stud
M52
1000
1st
step 600 bar
2nd step 1000 bar
34033
M48x3
1000
33
Piston rod piston crown, nut to

waisted stud
34
Spraying plate piston rod, waisted

screw
M20
35
Intermediate wheel bearing, waisted

screw
M56
50_
MOLYKOTE G
36
Gear rim hub of intermediate

wheel, screwed connection
M42x3
80_
see details in
41032
1st step 60 Nm
1st
step to
2nd
step
40_
no additional
lubricant required
4
41032
(nut secured with LOCTITE No. 262)
41033
37
Gear wheel on crankshaft, waisted

stud (spare wheel)
M48x3
38
Gear wheel on crankshaft, nut for

waisted bolt to flanged connection
M42x3
Elongation 1.75 0.08mm

(4400)
80_
see details in
41033
no additional
lubricant required
(secured with LOCTITE No. 262)
1
2
3
1 bar = 1.02 kp/cm 2
Tightening torque
3/ 18
2008
03521/A1
Maintenance
RT-flex96C
Group
Description
Thread
Tightening values
1
[bar]
2
[Nm]
Lubricant
3
[_; mm]
5
55521
39
Servo oil pump, screw
M24
55522
40
Supply unit, waisted bolt
M42
1000
Oil
55523
41
Camshaft wheel, waisted bolt
M42
1000
Oil
117
Camshaft Bolt
M42
140
Oil
42
Supply unit housing of intermediate

wheel, screw
M16
170
Oil
43
Supply unit housing of intermediate

wheel, screw
M36
(2100)
44
Bearing cover of intermediate wheel

to camshaft, waisted bolt
M56
45
Supply unit support, waisted screw
M42
(2850)
46
Fuel pump cover upper housing,

screw (16 x)
M24
320
Never-Seez
NSBT-8
46
Fuel pump cover upper housing,

screw (12 x)
M27
480
Never-Seez
NSBT-8
47
Fuel pump supply unit, screw
M30
(1250)
48
Fuel pump cover fuel pipe, screw
M12
70
Never-Seez
NSBT-8
49
Non-return valve
M36x2
450
Never-Seez
NSBT-8
50
Nipple
M36x2
400
Never-Seez
NSBT-8
51
Screw plug
M27x2
300
Never-Seez
NSBT-8
52
Transition nipple to pressure

transmitter
M27x2
300
Never-Seez
NSBT-8
53
Pressure transmitter
M14x1.5
25
Never-Seez
NSBT-8
54
Cover fuel rail, screw
M16x100
150
Never-Seez
NSBT-8
55524
5553
55561
5562
1
2
3
600
Oil
47_
Oil
1000
Oil
60_
Oil
64_
Oil
1 bar = 1.02 kp/cm 2
Tightening torque
2012-05
4/ 18
RT-flex96C
03521/A1
Maintenance
Group
Description
Thread
Tightening values
1
[bar]
5562
5564
5571
1
2
3
3
[_; mm]
55
Valve block cover, screw
M16
150
Never-Seez
NSBT-8
56
Stop valve in valve block, screw
M10
35
Never-Seez
NSBT-8
57
Intermediate piece, screw
M16
190
Never-Seez
NSBT-8
58
Fuel quantity sensor fuel quantity

housing, screw
M8
20
Never-Seez
NSBT-8
59
Fuel quantity housing intermediate

flange, screw
M10
25
Never-Seez
NSBT-8
60
Fuel quantity sensor fuel quantity

housing, screw
M12
75
Never-Seez
NSBT-8
61
Flange injection control block,

screw
M14
145
Never-Seez
NSBT-8
62
Injection control unit fuel pipe,

screw
M16
110
Never-Seez
NSBT-8
63
Pre-control valve, screw
M4
2.5
Never-Seez
NSBT-8
64
Injection control unit connection

piece
M42x2
700
Never-Seez
NSBT-8
65
Connecting nipple
M42x2
350
Never-Seez
NSBT-8
66
Valve block, screw
M10
35
Oil
67
Press. reducing valve valve block
M24x1.5
60
Oil
68
Drain screw
M24x2
200
Oil
69
Transmitter
25
Oil
70
Valve block, screw
M10
35
Oil
71
Shut-off valve valve block, screw
M18x1.5
67
Oil
72
Nipple
M30x2
220
Oil
73
Shut-off valve valve block, screw
M18x1.5
70
Oil
74
Drain screw
M24x2
200
Oil
55641
5566
2
[Nm]
Lubricant
1 bar = 1.02 kp/cm 2
Tightening torque
5/ 18
2010-07
03521/A1
Maintenance
RT-flex96C
Group
Description
Thread
Tightening values
1
[bar]
5571
5610
2
[Nm]
Lubricant
3
[_; mm]
75
Distributor block press. relief valve
M22x1.5
80
Oil
76
Distributor block press. relief valve
M28x1.5
120
Oil
77
Connection piece 3/2-way valve,

screw
M16
170
Oil
78
Connection piece connecting

element, screw
M16
130
Oil
79
Connection piece closing piece,

screw
M16
130
Oil
80
Valve block servo oil rail, screw
M20
260
Oil
81
Waisted screws to flanges
M16
170
Oil
118
Elastic bolt
M16x120
270
Oil
82
Pressure transmitter and screw plug
25
Oil
83
Stop valve on valve block, screw
M16
130
Oil
84
Connection piece 3/2-way valve,

screw
M16
170
Oil
85
Connection piece, nut
M12
60
Oil
86
Elastic bolt
Housing support, nut
M20x282
M20
20
350
no additional
lubricant required
56121
Oil
87
Non-return valve cover
60
Oil
88
3/2-way valve housing, screw
M20
350
Oil
119
Oil filter
120
Oil
89
Stop valve in valve block, screw
M16
130
Oil
90
Servo oil piping, screw
M16
170
Oil
91
Spindle to shut-off valve
M30x2
200
Oil
92
Non-return valve
80
see details in
84471
93
Fuel pressure piping, screw
M12
40
Never-Seez
NSBT-8
8
8447
84471
87331
1
2
3
1 bar = 1.02 kp/cm 2
Tightening torque
2010-07
6/ 18
RT-flex96C
03521/A1
Maintenance
Group
Description
Thread
Tightening values
1
[bar]
8750
2
[Nm]
Lubricant
3
[_; mm]
94
Pressure control valve, screw
M16
190
Never-Seez
NSBT-8
95
Flange and end flange, screw
M16
190
Never-Seez
NSBT-8
96
Stop valve in end flange, screw
M10
35
Never-Seez
NSBT-8
97
Flange with relief valve, screws
M16
190
Never-Seez
NSBT-8
98
Flange of fuel pressure piping, screw
M16
190
Never-Seez
NSBT-8
87511
99
Relief valve
M30x2
300
Never-Seez
NSBT-8
87521
100
Fuel pressure piping, screw
M12
60
Never-Seez
NSBT-8
101
Spindle to shut-off valve
M20
100
Never-Seez
NSBT-8
102
Non-return valve
80
see details in
87521
103
Connecting unit, adjusting disc

coupling disc, screw
M10
35
MOLYKOTE G
104
Nut to waisted screw
M16
140
MOLYKOTE G
105
Shaft nut
M40x1.5
25
MOLYKOTE G
106
Shaft nut
M35x1.5
25
MOLYKOTE G
107
Screw to shaft encoder bearing

housing
M8
16
MOLYKOTE G
108
Screw to distance piece
M12
60
MOLYKOTE G
109
Screw to connecting unit driving

wheel
M12
60
MOLYKOTE G
9
9923
92231
1
2
3
1 bar = 1.02 kp/cm 2
Tightening torque
7/ 18
2008
03521/A1
Maintenance
RT-flex96C
Group
Description
Thread
Tightening values
1
[bar]
92231
9314
Screw to spring tensioner coupling

disc
M12
60
MOLYKOTE G
111
Screw to spring tensioner
M10
35
MOLYKOTE G
112
Clamping nut to oil mist detector
15
Oil
113
Screws for opening head of oil mist

detector
Oil
114
Lifting device 94660(a), screw
M30
500
no additional
lubricant required
115
Tools 9469094692 for rail unit

transport
Lifting support, screw
M20
450
no additional
lubricant required
116
Lifting tool, screw
M24
800
no additional
lubricant required
*
*
2
3
3
[_; mm]
110
66061
2
[Nm]
Lubricant
1 bar = 1.02 kp/cm 2
Tightening torque
2010-07
8/ 18
RT-flex96C
03521/A1
Maintenance
LIFTING GEAR FOR

CYLINDER LINER
ENGINE STAY
(FRICTION TYPE)
LIFTING DEVICE FOR

COOLER ELEMENT
9
012.385/04
012.376/04
114
12
012.377/04
11
13
33
10
34
7
29
113
112
30
28
3
017.616/08
9/ 18
2012-05
03521/A1
Maintenance
RT-flex96C
12
11
32
31
36
35
37
26
38
A
25
017.617/08
24
2012-05
22
23
10/ 18
27
RT-flex96C
03521/A1
Maintenance
21
19
18
20
17
14
93
16
15
93
014.647/08
64
FUEL PRESSURE
PIPINGS
100
014.648/06
11/ 18
2008
03521/A1
Maintenance
RT-flex96C
95
98
99
97
95
101
96
91
94
89
48
47
46
40
014.641/06
43
117
74
41
CONTROL OIL PUMP

RAIL UNIT
42
76
75
014.642/06
73
2010-07
12/ 18
RT-flex96C
03521/A1
Maintenance
FUEL RAIL
I
57
63
101
56
II
54
54
55
II
51
50
53
49
52
61
58
59
60
62
102
014.581/06a
65
13/ 18
2010-07
03521/A1
Maintenance
RT-flex96C
SERVO OIL
90
90
90
014.582/06
39
44
45
2008
14/ 18
RT-flex96C
03521/A1
Maintenance
SERVO OIL RAIL
86
III
77
78
III
79
84
81
85
I
II
82
I
III - III
88
80
87
119
118
II
118
83
91
92
014.583/06a
15/ 18
2010-07
03521/A1
Maintenance
RT-flex96C
II
CONTROL OIL
SUPPLY
71
II
III
II - II
III
72
67
66
CONTROL OIL
SUPPLY
012.375/04a
69
2010-07
68
70
16/ 18
RT-flex96C
03521/A1
Maintenance
CRANK ANGLE SENSOR UNIT
I
106
I-I
104
I
010.293/02
109
107
105
008.566/01
CONNECTING UNIT TO CRANK

ANGLE SENSOR UNIT
103
108
111
110
B
008.750/01
008.567/01
17/ 18
2008
03521/A1
Maintenance
RT-flex96C
TOOL FOR RAIL UNIT

TRANSPORT
116
115
014.643/06
2010-07
18/ 18
RT-flex96C
03522/A1
Maintenance
Tightening Values of Standard Screwed Connections
1.
Standard screws
This table is valid for all screws that are not considered in 03521.
It is recommended to lubricate the threads for screws which come into contact with
hot parts like exhaust pipings, expansion pieces, etc. with a heat-resisting lubricant, e.g. THREAD GARD or Never-Seez NSBT-8, etc.
Attention! These tightening instructions are valid only if:
screws are made of the 8.8 material
threads have been lubricated with oil
Standard thread
Fine thread
Tightening torque [Nm]
M8
M8 x 1
20
M10
M10 x 1.25
40
M12
M12 x 1.25
70
M14
M14 x 1.5
110
M16
M16 x 1.5
170
M18
M18 x 1.5
250
M20
M20 x 1.5
350
M22
M22 x 1.5
450
M24
M24 x 2
600
M27
M27 x 2
900
M30
M30 x 2
1200
M33
M33 x 2
1600
M36
M36 x 3
2100
M39
M39 x 3
2500
M42
M42 x 3
2900
M45
M45 x 3
3300
M48
M48 x 3
3700
M52
M52 x 3
4100
M56
M56 x 4
4600
M60
M60 x 4
5200
1/ 2
2010-07
03522/A1
Maintenance
RT-flex96C
Tightening Values of Standard Screwed Connections
2.
Waisted studs
Waisted studs must be tightened according to the values in the following diagram.
D
Before fitting a waisted stud clean its thread and corresponding tap hole. The
sealing faces must be degreased (e.g. using white spirit) and subsequently
primed.
Screw in the waisted stud without lubricant on the thread right to the bottom of
the tap hole, and tighten. Always utilize a stud driver or two nuts.
Tools like a pipe wrench etc. which would damage the stud shank must never be
used.
D
For the protection of the waisted stud in the cylinder jacket and cylinder cover,
fill the annular space above the thread with a non-hardening jointing compound (see 27511).
TIGHTENING TORQUE FOR WAISTED STUDS
3500
TIGHTENING TORQUE [Nm]
3000
400
2500
300
2000
1500
200
1000
100
500
001.769/97
10 20 30 40 50 60 70 80 90 100 110 120
0
10
20
30
40
50
60
THREAD DIAMETER [mm]
2008
2/ 2
RT-flex96C
03601/A1
Maintenance
Masses (Weights)
Individual Components per Piece in kg
Group
Component
Execution
kg
1
1134
Main bearing shell
184234
1137
Main bearing cover
850949
1224
Thrust bearing pad
119161
1717
Casing
Casing
1720
Oil baffle, upper part

Oil baffle, lower part
1903
Tie rod
Tie rod nut
Intermediate ring for tie rod nut
driving end
free end
812
2044
585
306
complete
1335
49
2244
2
2106
Waisted stud in cylinder jacket
166
2120
Supporting ring
3580
2124
Cylinder liner
9058
2130
Water guide jacket
2303
Piston rod gland
2708
Waisted stud for valve cage

Cylinder cover without accessories
Cylinder cover with valves and water
guide jacket
453
complete
368
complete
88
6893
10 547
2722
Injection valve
complete
26.6
2728
Starting valve
complete
104
2751
Exhaust valve
complete
2927
2754
Exhaust valve spindle
234
3122
Flywheel
40707800
3122
Counterweight
3140
Axial damper cylinder
3206
Turning gear with planetary gear
4521718
2-part
1/ 3
1992
22552356
2008
03601/A1
Maintenance
RT-flex96C
Group
3303
Component
Connecting rod
Waisted stud with nut for bottom end
bearing
Waisted stud with nut for top end
bearing
Execution
complete
kg
7900
79
29
3306
Connecting rod shank
5330
3309
Lower bearing half for bottom end

bearing with waisted studs
3310
Bearing shell for bottom end bearing
3312
Upper bearing half for top end bearing
854
3315
Bearing shell for top end bearing
202
3326
Crosshead
Crosshead with guide shoes
Guide shoe
complete
1226
91
complete
complete
4680
7417
1325
3403
Piston with piston rod

Piston crown
Piston skirt
Piston rod
Spraying plate with oil pipe
complete
5444
1420
361
3287
256
3603
Toggle lever to piston cooling and

crosshead lubrication
complete
208
4106
Gear wheel on crankshaft

1-part
2-part, complete
2315
3517
4108
Intermediate wheel with bearing

pins and bearings for camshaft drive
Bearings for intermediate wheel to
camshaft drive
complete
3216
160
4120
Intermediate wheel with shaft in

housing to supply unit
1697
4325
Shut-off for starting air
497
5550
Driving wheel to camshaft
853
5551
Servo oil pump to supply unit
227
2008
2/ 3
RT-flex96C
03601/A1
Maintenance
Group
Component
Execution
5552
Gear wheel with shaft to driving wheel

Gear wheel on shaft to driving wheel
Camshaft with cams and gear wheels
Camshaft
Camshaft
Camshaft
Cam
complete
5556
Fuel pump
complete
408
5564
Injection control unit
complete
207
5572
Control oil pump
complete
222
5612
Exhaust valve drive
complete
235
6506
Turbocharger
Turbocharger
TPL85B11
MET83SEII
6545
Auxiliary blower with electric motor

Electric motor
complete
6606
Scavenge air cooler

Tube stack to main cooler
Tube stack to pre-stage
Connection chamber
Connecting bend
Pipe segment
GEA240/48/24
6708
Water separator
6735
Scavenge air waste gate
complete
235
Expansion piece between exhaust

manifolds and before turbocharger
Expansion piece after exhaust valve
DN 1000
150
DN 500
142
complete 6, 7 Cyl.
compl. 810 Cyl.
compl. 1114 Cyl.
6, 7 cylinder
810 cylinder
1114 cylinder
kg
934
387
2869
3269
3613
725
975
1169
150
6
10 527
10 500
13802005
6301170
4550
3000
550
550
400
50
800
8
8138
8139
3/ 3
2008
RT-flex96C
03701/A1
Maintenance
Dimensions
O-rings and Round Rubber Rings
Group
Thickness
[mm]
Inner
[mm]
1903
Tie rod
6.99
129.54
2106
Cylinder jacket division
1130
Cylinder liner
Cylinder liner water guide jacket
Cylinder liner water guide jacket
Cylinder liner supporting ring
Cylinder liner cylinder jacket
9
9
9
9
1320
1380
1130
1110
2136
Lubricating quill (bush)
3.53
36.09
2138
2138
Lubricating quill (bush) (Pulse Jet Lubrication)

Lubricating quill (bush) (Pulse Feed Lubrication)
5.33
3.53
69. 22
36.09
2303
Piston rod gland

Housing cylinder jacket
Ring cylinder jacket
Housing ring
6.99
6.99
6.99
658.88
658.88
481.46
2708
Cylinder cover
Cylinder cover water guide jacket
Cylinder cover water guide jacket
9
9
1240
1380
2722
Injection valve adjusting screw
3.53
36.09
2728
Starting valve
Starting valve housing cylinder cover
Connection pipe starting valve
Starting valve cover 5/2-way valve
6.99
1.78
2
151.77
14
12
Exhaust valve
Valve cage cylinder cover
Valve seat cylinder cover
Valve seat valve cage
Guide bush valve cage
Lower housing valve cage
Lower housing intermediate flange
Bush to leakage passage valve cage
Piston valve spindle
Lower housing valve stroke sensor
Upper housing intermediate flange
Vent screw upper housing
Damper upper housing
7
6.99
6.99
5.33
6.99
5.33
3.53
5.33
5.33
5.33
2.62
5.33
685
608.08
456.06
129.54
417.96
291.47
37.69
94.62
28.17
291.47
23.47
91.44
Vibration damper (GEISLINGER)

Intermediate flange GEISLINGER damper
1100
Piston
Piston rod oil pipe
Piston rod spraying plate
Piston crown spraying plate
6.99
9
9
151.77
620
630
2124
2751
3130
3403
Place of application
1/ 5
201007
03701/A1
Maintenance
RT-flex96C
Dimensions: O-rings and Round Rubber Rings
Group
Thickness
[mm]
Inner
[mm]
Shut-off valve for starting air

Shut-off valve for starting air housing
Shut-off valve cover liner bush
Housing valve block
Valve block housing
Pressure switch valve block
Valve block double check valve
6.99
6.99
3.53
2.62
1.78
2
253.37
227.97
56.74
13.94
6.07
10
Control air supply unit

A
Pressure reducing valve corner union
Valve body pressure transmitter
2.4
1.78
20.30
6.86
Supply unit
Flange servo oil pump
3.53
202.79
5552
Spray nozzle housing

Spray nozzle housing
Housing cover housing
Pump support flange
3.53
3.53
3.53
3.53
28.17
18.64
47.22
202.79
5554
Pump support housing
3.53
202.79
Fuel pump
Lower housing housing of supply unit
Upper housing lower housing
Valve block upper housing
Valve block pump cover
Connection pin lower spring carrier
Adapter piece lower and upper housing
Pump cover flange
Guide pin lower housing
Flange upper housing
6.99
6.99
5.33
5.33
2.62
3.53
5.33
3.53
1.78
227.97
227.97
158.12
158.12
15.54
9.12
59. 69
37. 69
34. 65
Fuel rail
Flange heating pipe
Spindle guide valve block
Non-return valve
Drain screw valve block
5.33
3.53
1.5
1.78
59.69
32.92
16
12.42

Sensor fuel quantity piston
Fuel quantity piston housing intermediate flange
Pre-control valve valve unit
3.53
3.53
1.78
40.87
40.87
5.28
Control oil supply

Non-return valve
Stop valve valve block
Stop valve spindle screw plug
2.62
1.5
1.78
1.78
15.54
16
14
9.25
4325
4605
5551
5556
5562
5564
5566
201007
2/ 5
RT-flex96C
03701/A1
Maintenance
Group
Thickness
[mm]
Inner
[mm]
Control oil pump rail unit

Stop valve distributor block
Stop valve spindle screw plug
Drain screw distributor block
Non-return valve
Blind flange distributor block
Piping flange distributor block
Piping flange distributor block
1.78
1.78
2.62
1.5
3.53
2.62
3.53
14
9.25
15.54
16
50.39
32.99
44.04
Oil return
Oil pipe pressure retaining valve
Valve valve block
Non-return valve
5.33
2.62
1.5
1.78
132.72
29.82
16
12.42
Exhaust valve drive

3/2-way valve connecting element
3/2-way valve partition device
3/2-way valve connecting piece
Pre-control valve 3/2-way valve
Non-return valve screw-in sleeve
3/2-way valve, valve housing lower cover
3/2-way valve, lower cover valve housing
3/2-way valve, spring housing valve housing
3.53
3.53
3.53
1.78
1.5
2.62
1.78
3.53
32.92
32.92
85.32
5.28
16
59.99
6.07
72.62
6420
Scavenge air receiver

Doors, round rubber cord (developed length 2996 mm)
7206
Cylinder lubricating pump

Flange oil inlet pipe
3.53
40.87
8310
Cylinder cooling water outlet main throttling orifice
6.99
227.97
8446
Inlet pipe control oil pump

Flange valve block
Flange inlet pipe control oil pump
3.53
3.53
50.39
26.57
Servo oil piping

Servo oil piping collector block
Servo oil piping servo oil pump
Flange collector block
Screw plug collector block
Drain screw collector block
Support supply unit housing
Support collector block
Support collector block
3.53
3.53
3.53
3.53
2.62
1.78
1.78
1.78
47.22
37.69
47.22
47.22
15.54
75.92
75.92
33.05
Servo oil piping

Flange servo oil piping
Flange distributor block
5.33
5.33
75.57
85.09
5571
5610
5612
8447
8453
3/ 5
201007
03701/A1
Maintenance
RT-flex96C
Group
Inner
[mm]
8460
Hydraulic piping for exhaust valve
5.33
129.54
8704
Fuel pressure retaining valve
2.62
15.54
Fuel pressure piping

Connection piece injection control unit
Flange connection piece
Flange pressure piping
Flange pressure piping (star tube)
2.62
3.53
3.53
3.53
37.77
37.69
32.92
31.34
Intermediate fuel accumulator

Flange fuel pressure
Flange intermediate fuel accumulator
Intermediate fuel accumulator end flange
Shut-off valve end flange
3.53
5.33
5.33
3.53
40.87
59.69
148.49
32.92
3.53
3.53
1.78
1.78
2.62
2.62
2.62
1.78
2.62
2.62
2
2.62
3.53
3.53
1.4
50.39
32.92
20.35
6.07
113.97
18.72
15.54
6.07
64.77
61.60
10
3.63
18.64
66.27
69.60

Flange fuel pressure piping
Flange distributor block
Flange intermediate piece
Flange end flange / intermediate fuel accumulator
5.33
5.33
5.33
5.33
46.99
66.04
66.04
66.04
9223
Crank angle sensor drive

Retaining ring housing
3.53
72.62
9258
Measuring instruments
Pressure switch and transmitter
1.78
6.07
8733
8750
Fuel pressure control valve (3.06)

Intermediate piece end flange
Intermediate piece fuel pressure control valve
Cylinder cover
Cylinder cover
Cover valve body
Piston cover
Piston cover
Valve tip piston
Cover valve body
Cover valve body
3/2-way valve valve body
Slide valve body
Fuel pressure control valve
Fuel overpressure saftey valve intermediate piece
Fuel overpressure saftey valve interm. p.
(backup ring)
8752
201007
Thickness
[mm]
4/ 5
RT-flex96C
03701/A1
Maintenance
Group
Thickness
[mm]
Inner
[mm]
9434
Tools
94349: Pressure testing device for piston
6.99
342.27
9455
94430: Device for cutting out / in of a fuel pump
2.62
34.59
8484
94843: High pressure pipe (spare)
3.53
47. 22
5/ 5
201007
RT-flex96C
03702/A1
Maintenance
Dimensions
Piston and Rod Seal Rings
Group
Ring
type
Dimension [mm]
4325
Shut-off valve for starting air valve

Shut-off valve for starting air, cover flange
PSR
RSR
240 x 234 x 5.8

30 x 33 x 2.8
5556
Fuel pump, flange regulating (toothed) rack
RSR
24 x 26 x 1.8
Fuel pump, lower housing guide piston
RSR
70 x 3.53
Tools
94424: Hydr. jacking tool
PSR
65 x 61 x 3.8
940810
Piston Seal Ring (PSR)

Nominal dimension o x i x b
Rod Seal Ring (RSR)

Nominal dimension i x o x b
Cylinder
Bush
O-ring
Seal ring
Seal ring
O-ring
Piston
Rod
i
1/ 6
2010-07
03702/A1
Maintenance
RT-flex96C
Dimensions: Rod Seal Rings
Group
Ring
type
Dimension [mm]
2751
Exhaust valve guide
RSR
110.1 x 95 x 6.1
Rod Seal Ring (RSR)

Nominal dimension da x di x b
Bush
O-ring
Seal ring
00.7384
Rod
di
da
da = Groove diameter
di = Rod diameter
b = Groove width
2010-07
2/ 6
RT-flex96C
03702/A1
Maintenance
Dimensions: Piston Seal Rings
Group
Ring
type
Dimension [mm]
2751
Exhaust valve piston
PSR
230 x 209 x 7.8
Piston Seal Ring (PSR)

Nominal dimension da x di x b)
Cylinder
b
Seal ring
O-ring
Piston
di
da
da = Cylinder diameter
di = Groove diameter
b = Groove width
3/ 6
2010-07
03702/A1
Maintenance
RT-flex96C
Dimensions: Back-up Rings
Tool
No.
Place of application of pre-tensioning

jack
Part
Back-up ring
O-ring
(slotted)
Dimension [mm]
o x i x t
94145
Foundation bolt and engine stay
94252
Waisted stud to valve cage
94314
Waisted stud to bottom end bearing
94315
Waisted stud to top end bearing;

gear wheel and cam to supply unit
Piston rod and turning gear
94340
94556
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
Waisted bolt to bearing of intermediate shaft

to supply unit
O-ring
i x s
135 x 125.6 x 1.7

104.4 x 95 x 1.7
280 x 267.8 x 2.5
159 x 150 x 1.7
260 x 247.8 x 2.5
182.2 x 170 x 2.5
190 x 177.8 x 2.5
137.2 x 125 x 2.5
125 x 115.6 x 1.7
89.4 x 80 x 1.7
137.8 x 150 x 2.5
85 x 94.4 x 1.7
123.19 x 5.33
94.62 x 5.33
266.07 x 6.99
148.49 x 5.33
240.67 x 6.99
170.82 x 6.99
177.17 x 6.99
126.37 x 6.99
113.67 x 5.33
78.74 x 5.33
6.99 x 135.89
5.33 x 85.09
Back-up ring
i
o
002.696/98
2013-04
4/ 6
RT-flex96C
03702/A1
Maintenance

Tool
No.
Place of application of pre-tensioning

jack
Part
Back-up ring
O-ring
(un-slotted)
Dimension [mm]
o x i x t
94114
Waisted stud to main bearing
94215a
94215b
94346
Cylinder cover stud
94180
Tie rod
94557
Gear wheel and waisted bolt of bearing to

camshaft
94595
Jack for jacking-out of jammed pump

plunger
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
piston
cylinder
piston
Waisted bolt to piston crown
O-ring
i x s
122 x 112.6 x 1.7

76.4 x 67 x 1.7
268 x 255.8 x 2.5
158.2 x 146 x 2.5
102 x 92.6 x 1.7
84.2 x 78 x 1.4
370 x 357.8 x 2.5
252.2 x 240 x 2.5
115 x 105.6 x 1.7
76.2 x 70 x 1.4
112 x 102.6 x 4.7
110.49 x 5.33
66.04 x 5.33
253.37 x 6.99
145.42 x 6.99
91.44 x 5.33
78.97 x 3.53
354.97 x 6.99
240.67 x 6.99
104.14 x 5.33
69.44 x 3.53
100.97 x 5.33
Back-up ring
s
o
i
o
011.032/03
5/ 6
2013-08
03702/A1
Maintenance
RT-flex96C
Group
8453
Part
HP servo oil piping

Connecting piece collector block
Adapter piece connecting piece
O-ring
Back-up ring
O-ring
(un-slotted)
Dimension [mm]
o x i x t
i x s
68 x 59.4 x 1.7
56.52 x 5.33
68 x 59.4 x 1.7
56.52 x 5.33
Back-up ring
014.687/06
2010-07
6/ 6
RT-flex96C
03801/A1
Maintenance
Maintenance Schedule
Inspection and Overhaul Intervals (Guidelines)
Group
Component
Work to be carried out
Intervals
0
Lubricating oil
Laboratory analysis
3000 Op. h (operating

hours)
Cooling water
Determine quality and concentration of inhibitor

(follow instructions of inhibitor manufacturer)
weekly
Bedplate
Check pre-tension of foundation bolts,

first time after 1500 Op. h
12 000 Op. h
Crankcase
Visual examination
100 Op. h after overhaul works
15003000 Op. h
Main bearing
Remove bearing cover for inspection,

random inspection every 12 000 Op. h
according to
classification society
Remove bearing shell for inspection
acc. to class. society
Check axial and radial clearances
60008000 Op. h
Check bottom drain for free passage
60008000 Op. h
Remove thrust bearing pads for inspection
1
11121
11322
12031
Thrust bearing
12241
17151
Engine stays with Check pre-tension of waisted studs,

friction shims
first time after sea trial
60008000 Op. h
19031
Tie rod
Check pre-tension, if necessary re-tension

first time after one year
24 00030 000 Op. h
Cylinder liner
Establish wear in bore (in fitted condition)
at every piston removal
Remove cylinder liner
as required
Replace O-rings
at every removal
Replace (soft iron) joint ring between cylinder liner

and cylinder cover
Water guide jacket, replace O-rings
Check condition of antipolishing ring
Grind off wear ridge in bore
Refinish lubricating grooves
as required
Clean scavenge ports and refinish their edges
as required
Check function and tightness
Check function of non-return valves
at every liner removal
Replace O-rings
Random check of diaphragm to accumulator
6000 Op. h
2
21241
21242
21243
21361
Lubricating quill
and accumulator
1/ 9
2008
03801/A1
Maintenance
RT-flex96C
Group
Component
21381
Lubricating quill
(Pulse lubrication)
Intervals
Check function and tightness
Check function of non-return valves
Replace O-Rings
23031
Piston rod gland
Clean rings, establish wear
27081
Cylinder cover
Check combustion space for damage and wear
27221
Injection valve
Check externally for tightness
before starting engine

after a longer standstill
Check spray pattern, opening pressure, tightness

condition of nozzle tip, readjust opening pressure
(life time of nozzle tip about 6000 Op. h)
3000 Op. h
Check piping before the valve during operation,

if piping is too hot, dismantle starting valve
weekly
Remove and dismantle one starting valve at

random. From its condition determine time of
overhaul for remaining valves
60008000 Op. h
Make sure that nut on solenoid is tight,

if necessary tighten nut
monthly
Solenoid valve, random functional check

overhaul
6000 Op. h
18 000 Op. h
27281
Starting valve
27451
Relief valve to
cylinder cover
Check blow-off pressure
as required
27511
to
Exhaust valve
General inspection of valve housing, valve

spindle and valve seat
(without dismantling of exhaust valve)
Check condition and wear of valve spindle

(if necessary regrind seat by machining)
24 00036 000 Op. h
Check piston seal ring / air spring & rod seal ring /
guide bush
24 00036 000 Op. h
Check condition and wear of valve seat

(if necessary regrind seat by machining)
24 00036 000 Op. h
Random check of valve drive, outside and

inside pistons, damper, thrust piece
18 000 Op. h
Random check of screwed connection to

measuring cone
18 000 Op. h
Measure crank deflection
according to
classification society
27514
3
31031
Crankshaft
Always in case of grounding of the ship as well as

before and after every docking
2013-08
2/ 9
RT-flex96C
03801/A1
Maintenance
Group
Component
Intervals
31301
Torsional
vibration damper
Take a silicon oil sample from viscous vibration

damper (based on results of 1st sample, interval
for taking further samples will be decided)
first time after 15 000

18 000 Op. h
Inspection interval and dismantling of vibration

damper
acc. to instructions of
damper manufacturer
31302
31461
Axial damper
Dismantling and inspection
36 00048 000 Op. h
32061
Turning gear
Inspection interval of turning gear
acc. to instructions of
turn. gear manufacturer
Re-lubrication of tooth flanks of pinion & flywheel,

depending on visual inspections, however every
2000 Op. h of diesel engine
Check screwed connections,
first time after one year (if necessary retighten)
12 000 Op. h
Check bearing clearances (see 03301)
60008000 Op. h
33032
Inspect bottom end bearing

(life time of shell 60 00072 000 Op. h)
30 00036 000 Op. h or

33033
Inspect top end bearing
30 00036 000 Op. h or

Check clearances
60008000 Op. h
Remove crosshead
as required
Remove, clean and measure ring grooves

(cylinder liner with antipolishing ring and chromeceramic piston rings)
18 00036 000 Op. H

(condition based)
Check tightness on piston in situ and with running

oil pump, visual check through scavenge ports
after refitting
34033
Dismantling and assembling (open cooling space

& clean same, min. one piston every three years)
as required
34034
Check condition of the piston top surface
Visual check through scavenge ports to piston,

piston rings and cylinder liner
(rotate crankshaft with turning gear)
5001000 Op. h
Check condition of space and clean it as required
15003000 Op. h
Check drains for free passage
15003000 Op. h
Measure thickness of chrome-ceramic layer
15002000 Op. H
Replace piston rings based on remaining coating

thickness
18 00030 000 Op. H

(condition based)
Connecting rod
bearings
33261
Guide shoe,
crosshead pin
33262
34031
Piston
Piston underside
34251
Piston rings
3/ 9
2013-08
03801/A1
Maintenance
RT-flex96C
Group
Component
Intervals
41031
Start interlock
Check electric and pneumatic interlocks

(see Operating Manual 40031)
quarterly
Driving wheels
Check condition of teeth
60008000 Op. h
Check running clearance and backlash of teeth
60008000 Op. h
Vent
after each manoeuvring

period
Dismantle, clean and check

(particularly seat, springs and seal rings)
24 00036 000 Op. h
Overhaul common start valve
18 000 Op. h
Drain filter
weekly
Clean filter
6000 Op. h
Starting air
shut-off valve
43251
Control air filter
2008
4/ 9
RT-flex96C
03801/A1
Maintenance
Group
Component
Intervals
5
55521
Replace servo oil pump either with new one or a

pump overhauled by a Wrtsil workshop
24 000 Op. h
Check pinion and driving wheels to servo oil

pump drive
3000 Op. h
Check bearing bushes to pinion
24 000 Op. h
Camshaft, check running surface of cams,

rollers & roller guides (first time after 500 Op. h)
3000 Op. h
Camshaft, check bearing clearances at random
12 000 Op. h
Camshaft, check thrust bearing clearances
36 000 Op. h
Replace O-rings in valve block
18 000 Op. h
Random visual check of plunger & cylinder,

roller and roller guide
18 000 Op. h
Replace unit (incl. rail valves) either with new

one or a unit overhauled by a Wrtsil workshop
24 00036 000 Op. h
Replace filter before rail valve (control oil)
18 000 Op. h
Check coupling, adjust working pressure

according to instruction of manufacturer
18 000 Op. h
Replace ball-bearing on electric motor
36 000 Op. h
Replace pump element on HP pumps according

to instruction of pump manufacturer
36 000 Op. h
Distributor block
Replace safety valves (control oil)

36 000 Op. h
Servo oil rail
Replace hoses
18 00030 000 Op. h
56101
Pressure
reducing valve
Checking gas (nitrogen) pre-charge pressure:

the same criteria apply as specified for 72181
56121
Exhaust valve
control unit
Random check of piston and slide rod
18 000 Op. h
Replace rail valve (pre-control valve)
30 00036 000 Op. h
Replace filter
18 000 Op. h
Check for free movement, lubricate all movable

parts
3000 Op. h
Supply unit
55522
55561
55641
5571
5610
58011
Fuel pump
Injection control
unit
Control oil pump
Regulating
linkage
5/ 9
2012-05
03801/A1
Maintenance
RT-flex96C
Group
Component
Intervals
6
64201
Scavenge air
receiver
Exhaust gas
turbocharger
Air filter
65451
66061
67081
67351
2012-05
Auxiliary blower
Scavenge air
cooler
Water separator
Scavenge Air
Waste Gate
Check and clean air flaps
40006000 Op. h
Clean receiver
40006000 Op. h
Check water drain pipings for free passage
15003000 Op. h
Wash-cleaning of blower in service
(see Operating Manual)
Wash-cleaning or dry cleaning of turbine in

service
(see Operating Manual)
Check filter
half yearly
Cleaning of filter at a p increase of 50%

compared to the shop test value at same engine
load
as required
Clean impeller and casing
24 00036 000 Op. h
Replace ball-bearing
24 00036 000 Op. h
Cleaning of scavenge air cooler (air side) in

service at the beginning weekly, later at a p
(pressure drop through SAC) increase of 50%
compared to the shop test value at same engine
load
as required
Check condensate collector through sight glass

daily
Check condensate collector for free passage

15003000 Op. h
Check scavenge air cooler sealing
quarterly
Vent
daily
Remove scavenge air cooler for general overhaul
as required
Check condensate collector through sight glass

daily
Check condensate collector for free passage

15003000 Op. h
Check water separator elements (if necessary

clean them)
15003000 Op. h
Remove water separator for general overhaul
as required
Check function
half yearly
6/ 9
RT-flex96C
03801/A1
Maintenance
Group
Component
Intervals
7
Cylinder
lubricating pump
72181
Drain and wash out casing,

first time after 1000 Op. h
Lubricating pump General maintenance works

and accumulator
(Pulse lubrication)
Checking gas (nitrogen) pre-charge pressure:

CLU4
min. 20 bar / max. 25 bar
directly after installation of a new accumulator >
then at least once in first week after start-up >
afterwards >
18 00024 000 Op. h

according to instruction
of pump manufacturer
according to instructions
of equipment
manufacturer
every three months
8
81351
Exhaust Waste
Gate (LLT)
During a longer operation period at low engine

load, manually open butterfly valve at least once
per week (see Operating Manual 81351)
General inspection
according to instruction
of valve manufacturer
Servo oil
automatic filter
Follow manufacturers instructions
Collector block
Replace safety valve (servo oil)
36 000 Op.h
Servo oil system
Check spindle of shut-off valve for free

movement
6000 Op.h
84471
Servo oil piping
Regrind sealing faces
as required
84601
Hydraulic piping
to exhaust valve
as required
Starting air
piping
Drain (de-water)
before and after every

manoeuvring period
Pressure gauges
and pyrometers
Compare and calibrate according to master

instruments
60008000 Op.h
Fuel and
lubricating oil
filters
Clean or replace filter elements

(depending on make, follow manufacturers instructions)
as required
Pipe holders
Check tightness of fastenings periodically, if

necessary retighten screws
(first time after 100 Op.h, then half yearly)
as required
8447
7/ 9
2011-07
03801/A1
Maintenance
RT-flex96C
Group
Component
Intervals
Vapor trap (fuel

leakage system)
Open vapor trap for cleaning once per three

years (see Operating Manual 80191)
Inspect ball valves and temperature indicator
as required
87331
Fuel pressure
piping (on
cylinder cover)
as required
8744
Supply unit fuel

drain piping
Check regularly for free passage at least once a

year
6000 Op.h
87501
Relief valve
(fuel overpressure
safety valve)
Function check on test bench
18 000 Op.h
87502
Fuel pressure
control valve
(PCV)
Check shut-down function

3000 Op. h
Function check
6000 Op. h
General overhaul
only necessary when

PCV fails
Replace filter (control oil)
18 000 Op. h
Fuel pressure
piping
as required
Crank angle
sensor unit
Check tension visually

Check cracks and wear of tooted belt visually
Visual lubricating oil check
3000 Op.h
Replace toothed belt
24 000 Op.h
Overhaul drive (ball bearing, sealing ring etc.)

and check shaft eccentricity of CAS drive
48 000 Op.h
Check shaft eccentricity of CAS drive
at every CAS exchange
Replace crank angle sensor
48 000 Op.h
(only if new soft belt is
applied from beginning)
Oil mist detector
Follow manufacturers instructions
half yearly
WECS electronic
components
Replace FCM20, ALM20 modules

36 00050 000 Op. h
Check cabling
quarterly
87521
9
92231
2013-08
8/ 9
RT-flex96C
Maintenance
03801/A1

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 07101 and
07501)
Engine load
Fuel, lubricating oil and cooling water care (see Operating Manual 07201
and 07601)
Overhaul according to Maintenance Manual
Genuine spare parts used
Engine monitoring
Engines according to specifications of Wrtsil Switzerland Ltd.
On the engine sectional drawings 08031, those parts are marked with group
numbers, as they are found in the Maintenance Manual.
Group numbers exist of the following engine components, although these parts
are not marked on the sectional drawings:
Engine component
Group No.
Engine stays with friction shims / hydraulic engine stays . . . . . . . 17151
Regulating linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58011
Scavenge air waste gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67351
Engine Control System WECS

Control works in the WECS (Wrtsil Engine Control System) are described in the
following groups of the Operating Manual:
Regular checks and recommendations . . . . . . . . . . . . . . . . . . . . . . 40024
Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40031
9/ 9
2008
RT-flex96C
08031/A1
Maintenance
Engine Cross Section and Longitudinal Section
Cross Section:
84601
87331
27281
27221
55641
56121
65451
84471
64201
87521
87501
55561
55562
33012
66061
55521 to
55525
67081
41031 to
41033
33011
11121
013.297/05
1/ 2
2008
08031/A1
Maintenance
RT-flex96C
Engine Cross Section and Longitudinal Section
Longitudinal Section:
27511 to
27514
27081 to
27083
21361
21381
34251
21241 to
21243
19031
34031 to
34034
43251
23031
33261
33262
33031 to
33034
31461
11321
11322
32061
92231
31031
12031
12241
31301
31302
011.860/04
2008
2/ 2
RT-flex96C
Maintenance
Group1
Group 1
Bedplate and Thrust Bearing: Checking the Foundation Bolts . . . . . . . . . . . . . . . . . 11121/A1

Main Bearing
Loosening and Tensioning of Waisted Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11321/A1
Removal and Fitting of a Main Bearing (6 and 7 Cylinder Engines) . . . . . . . . . 11322/A1
Removal and Fitting of a Main Bearing (8 14 Cylinder Engines) . . . . . . . . . . 11322/A2
Main Bearing Upside-down Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11323/A1
Thrust Bearing
Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12031/A1
Removal and Fitting the Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12241/A1
Engine Stays
with Friction Shims: Checking the Pre-tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 17151/A1
Hydraulic: Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17151/A2
Tie Rod: Checking the Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . 19031/A1
1/ 3
RTflex96C / MM / 2008
RT-flex96C
11121/A1
Maintenance
Bedplate and Thrust Bearing

Checking the Foundation Bolts
Tools:
1
1
1
1
1
1
1
1
1
1.
Key to Illustrations:
Feeler gauge
Pre-tensioning jack
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
HP hose
94122
94145
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
7
8
9
10
Pin
Vent screw
Cylinder
Piston
Sealing ring
Nut
Bedplate
Foundation bolt
Foundation fitted stud
Bush
11
12
13
14
15
EV
KO
RS
SA
Sleeve
Chock
Ships foundation plate
Nut
Conical socket
Relief valve
Slot
Round bar
Gap
General
The pre-tension of the foundation bolts (holding down studs) must be checked at
longer intervals e.g. during overhauls (see 03801).
In the area of the thrust bearing the bedplate may be fastened with foundation bolts
8, bushes 10 and sleeves 11 (Fig. A) or with foundation fitted studs 9 (Fig. B).
The remaining area is fastened with foundation bolts 8 and bushes 10 (Fig. C),
however without sleeves 11.
Remark: Pay attention to General Application Instructions 94034 for hydraulic
pre-tensioning jacks.
6
8
10
9
10
7
11
014.286/06
014.285/06
8
10
12
13
014.287/06
15
14
1/ 3
2008
11121/A1
Maintenance
RT-flex96C
2.
Checking the pre-tension

Clean the threads of the foundation bolts and the seating surfaces. Subsequently apply MOLYKOTE G paste to the threads.
Place pre-tensioning jack 94145 on foundation bolt 8 or fitted stud 9 to be
checked, and screw it completely down with vent screw 2 open until there is
only little or no clearance at x (Fig. D).
Connect the pre-tensioning jack with HP oil pump 94931 as shown in Fig. D,
whereby one side of hydr. distributor 94934a must be closed with plug piece
94934e.
Shut relief valve EV at the HP oil pump. Actuate HP oil pump till oil flows
bubble-free at vent screw 2.
Close vent screw 2, tension the foundation bolt with 1000 bar and keep pressure constant.
D
CHECK
Attention should be paid to ensure that pin 1 always protrudes slightly

compared with piston 4 on the pre-tensioning jack!
Check with feeler gauge through slot KO if there is any clearance between nut 6
and its seating.
If there is no clearance, this means that the tightening condition of the foundation bolt has remained unchanged since the last check. The pressure can be
released to zero with relief valve EV and the pre-tensioning jack removed.
Should a clearance be found, nut 6 must be tightened down onto its seating
with round bar RS while the pressure is kept at 1000 bar (check with feeler
gauge). Subsequently lower the pressure to zero.
D
94932a
94935a
94934e
94934a
2
1
94935
94932
5
6
RS
KO
EV
94931
10
8(9)
014.295/06
Remark: If the foundation bolts have completely loosened and have to be tensioned again, then all foundation bolts have to be pre-tensioned first with 600 bar
(1st step) and subsequently tensioned with 1000 bar (2nd step).
2008
2/ 3
RT-flex96C
11121/A1
Maintenance
3.
Loosening the foundation bolts

First screw down pre-tensioning jack 94145 as for checking the pre-tension,
then turn back by turn (gap SA in Fig. E).
Connect the pre-tensioning jack with HP oil pump 94931 as shown in Fig. E.
Close vent screw 2 and pump until a pressure of 1020 bar has been reached.
D

Turn back nut 6 by one turn, and release the pressure to 0.

Remove the pre-tensioning jack.
E
94932a
94935a
94934e
94934a
2
1
4
3
5
94935
94932
6
SA
EV
94931
10
8(9)
014.297/06
4.
Tensioning the foundation bolts
Tensioning of the foundation bolts must be carried out in two steps without exception, for both metal & synthetic chocks, i.e. tension all foundation bolts first
with 600 bar (1st step), then finish tensioning with 1000 bar (2nd step).
Tensioning must be carried out as described in Checking the pre-tension.

3/ 3
2008
RT-flex96C
11321/A1
Maintenance
Main Bearing
Loosening and Tensioning of Waisted Studs
Tools:
2
1
1
1
1
1
1
2
1
Double pre-tensioning jacks

Feeler gauge
Special feeler gauge
Depth gauge
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94114
94122
94123
94126
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
Waisted stud
Main bearing cover
Nut
Round nut
Piston
Cylinder
Cover
Tension sleeve
Distance sleeve
Main bearing girder
Vent screw
KO Slot
RS Round bar
1.
General
The double pre-tensioning jacks 94114 must always be used for loosening as well
as for tensioning the waisted studs 1 for the main bearing.
Prior to screwing the nuts onto the waisted studs, threads and the nut seating surfaces must be clean. Apply oil to the threads. Pay attention to the free movement of
the nuts.
2.
Loosening the waisted studs

Screw tension sleeves 8 onto waisted studs 1 (Fig. B).
Place distance sleeve 9.
Place both cylinders 6 with pistons 5 onto the distance sleeves.
Connect both double pre-tensioning jacks 94114 by HP hoses 94935 and
94935a, hydr. distributor 94934a and pressure gauge 94932a with hydraulic
unit 94942 (arrangement see Fig. C).
Open vent screw 11.
Screw on round nuts 4 of the double pre-tensioning jacks till pistons 5 fully
seat on cylinders 6 (Fig. B).
CHECK
The pistons are fully down on the cylinders when distance L1 is about 13 mm,
measured from the top of the piston to the upper edge of cover 7.
Check the oil level in hydraulic unit 94942.
Close vent screw.
Subsequently loosen all round nuts 4 by about to 1 turn.
Raise the pressure to 1020 bar at the hydraulic unit.
Unscrew nuts 3 by one turn with round bar RS.
Release the pressure to zero at the hydraulic unit and then remove both
double pre-tensioning jacks.
1/ 3
2008
11321/A1
Maintenance
RT-flex96C
Main Bearing: Loosening and Tensioning of Waisted Studs
3.
Tensioning the waisted studs

Fit the main bearing cover as described in 11322.
Tighten nuts 3 with round bar RS till firmly seated and mark these against the
bearing cover = 1st step (Fig. A).
Determine with depth gauge 94126 distances a1 and a2. The difference between
the two values must not be greater than 0.3 mm. If necessary adjust the bearing
cover correspondingly by loosening and tensioning nuts 3 (Fig. C).
CHECK
Place both double pre-tensioning jacks 94114 onto waisted studs 1 for the
main bearing as described under section 2 (Fig. C).
Connect both double pre-tensioning jacks by HP hoses 94935 and 94935a,
hydr. distributor 94934a and pressure gauge 94932a with hydraulic unit
94942 (arrangement see Fig. C).
Open vent screw 11.
Screw on round nuts 4 of the double pre-tensioning jacks till piston 5 fully seat
on cylinders 6 (Fig. B).
The pistons are fully down on the cylinders when distance L1 is about 13 mm,
measured from the top of the piston to the upper edge of cover 7.
Check the oil level in hydraulic unit 94942.
CHECK
Close vent screw.
A
y
1ST STEP
Actuate the hydraulic unit, adjust the

pressure to 1000 bar (2nd step) and
keep it constant.
2ND STEP
Tighten all nuts 3 with round bar RS

till firmly seated.
CHECK
130 _
y
x
CHECK
98.7672
Using feeler gauge 94122 inserted in slot

KO, check if there is no clearance at
hand between the nuts and the seating
surfaces.
Release pressure to zero at the hydraulic unit and then remove both
double pre-tensioning jacks.
TIGHTENING
ANGLE
Check if all the nuts have been turned by about the same value, i.e. the tightening angle should be 130_ between the 1st and 2nd step (Fig. A). If bigger
differences occur the tensioning procedure must be repeated.
Finally check the horizontal and vertical clearances by means of special feeler
gauge 94123 (see Clearance Table 03301 Crankshaft and main bearing).
Recheck distances a1 and a2. If the difference exceed 0.3 mm, loosen the waisted
studs, adjust the bearing cover correspondingly and repeat the tensioning procedure.
Remark: All main bearing clearance values are valid only with tightened tie rods
and waisted studs.
2008
2/ 3
RT-flex96C
11321/A1
Maintenance
Main Bearing: Loosening and Tensioning of Waisted Studs
94114
L1
11
5
6
8
RS
3
011.639/04
94935
94934a
94932a
94935a
94942
94935a
a1
a2
94114
10
011.638/04
3/ 3
2006
RT-flex96C
11322/A1
Maintenance
Main Bearing
Removal and Fitting of a Main Bearing
Tools:
1 Lifting tool
2 Roller supports
1 Turning-out device
for narrow bearing shell
for broad bearing shell
for last bearing shell at free end
1 Lifting yoke
1 Lifting eye bolt
2 Ropes with shackle
(300 mm)
1 Rope with shackle
(500 mm)
1 Rope with shackle
(600 mm)
1 Rope with shackle
(800 mm)
1 Rope with shackle
(1000 mm)
1 Rope with shackle
(1200 mm)
1 Rope with shackle
(1500 mm)
1 Rope with shackle
(1600 mm)
1 Rope with shackle
(1700 mm)
1 Rope with shackle
(1900 mm)
1 Rope with shackle
(2000 mm)
1 Rope with shackle
(2200 mm)
1 Rope with shackle
(2800 mm)
1 Rope with shackle
(3200 mm)
2 Ropes with 2 shackles (1000 mm)
1 Special feeler gauge
1 Support
1 Working platform
1 HP oil pump
1 Hydr. distributor
1 HP hose
2 HP hoses
2 Hydraulic jacks
94116
94117
94118b
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
94118c
94118d
94119
94120a
94120b
94120c
94120d
94120e
94120f
94120g
94120h
94120i
94120k
94120l
94120m
94120n
94120o
94120p
94120q
94123
94141
94142
94931
94934a
94935
94935a
94936
HO
HZ
H1...
OB
RC
RC1
RC2
Crankshaft
Main bearing cover
Main bearing shell
Locating dowel pin
Groove
Key
Flywheel
Main bearing girder
Guide shoe middle part
Support
Waisted stud
Nut
Axial damper
Support
Intermediate wheel
Spur-geared chain block
Connecting rod
Blank flange
Jack
Suspension eye
Suspension eye
Strap
Wooden board
Lifting tackle
Lifting tackles
Oil bore
Eye bolt M24
Eye bolt M20
Eye bolt M20
Overview
1.
2.
3.
4.
5.
6.
7.
Arrangement and characteristics of main bearings . . . . . . 2/22

Removal of main bearing cover No. 1 . . . . . . . . . . . . . . . . . . . 3/22
Removal of main bearing cover No. 4 . . . . . . . . . . . . . . . . . . 10/22
Removal of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . 12/22
Fitting of main bearing shell and main bearing cover . . . 19/22
Remark: Pay attention to:

General Guidelines for Lifting Tools 00121.
Utilization of Working Platform and Ladder 33011.
1/ 22
2008
11322/A1
Maintenance
RT-flex96C
Cross section of main bearing:
12
2
11
2
6
4
1
6
3
8
3
008.871/01
1.
Arrangement and characteristics of main bearings
Characteristics of main bearings
Type A
Type B
Type D
Type E
Narrow bearing shell and cover
Wide bearing shell and cover
Bearing shell and cover cylindrically machined
Matching pair shell and cover conically machined
Keys not stepped in bearing shell
Keys stepped in bearing shell
Wide bearing cover and bearing shell with shot peened surface at
the back side
DF 11352
DF 11304
DF 11342
DF 11344
Code No. of main bearing cover
DF 11377
DF 11302
DF 11365
DF 11365
Code No. of key
DF 11353
DF 11343
DF 11343
DF 11343
DF 11300
Code No. of standard main bearing shell

Code No. of double conical main bearing shell
Code No. of paired main bearing shell and cover
TYPE OF MB
B
D or E
D or E
D or E
D or E
D or E
FREE
END
DRIVING
END
Cyl. #1
Cyl. #2
Cyl. #3
THRUST BEARING
LOCATION
2013-02
2/ 22
RT-flex96C
11322/A1
Maintenance

2.
Removal of main bearing cover No. 1
Turn crank 1 to exhaust side approx.

100_after T.D.C.
Remove upper part of oil baffle at the
driving end.
15
Remove oil piping from thrust bearing.
10
Loosen nuts 12 for waisted studs 11

(Fig. A) hydraulically (see 11321).
Screw eye bolt RC into main bearing
cover (bearing cover for short) 2.
H2
H1
Pull rope a (94120f) through a hole in

intermediate wheel 15 and connect it
with eye bolt RC and lifting tackle H1.
7
b
Fasten lifting eye bolt 94120a to the

column.
a
94120a
RC
2
Connect rope b (94120b) with eye

bolt RC and lifting tackle H2 which is
fastened to the inner suspension eye
of support 10.
Lift bearing cover 2 over the waisted
studs with ropes a and b and then
swing it towards flywheel 7.
014.584/06
Detach rope a.
I-I
D
21 H6
20
H5
H2
Fasten lifting tackle H5 to suspension eye 20 and connect

rope c (94120b) with bearing
cover 2 and subsequently
swing it towards fuel side with
ropes b and c.
Fasten lifting tackle H6 to suspension eye 21 and connect it to
bearing cover 2 and then swing
the latter fully towards fuel side.
Remove rope c.
RC
2
014.585/06
3/ 22
2008
11322/A1
Maintenance
RT-flex96C

3.
II - II
Remove upper part of oil baffle at the
driving end.
Turn corresponding crank to exhaust
side approx. 90_after T.D.C.
Install working platform 94142.
Loosen nuts 12 to waisted studs 11
94117
H1
RC
a e
2
94142
Fasten roller support 94117 to guide

shoe middle part 9 using screw
M30x60 and washer 68 mm between
tool and guide shoe middle part as
shown in the detail.
Screw eye bolt RC into bearing cover.
Connect rope e (94120k) with eye bolt
RC and lifting tackle H1 via roller support as shown in Fig. E and F.
014.586/06
II
Fasten lifting tackle H2 to the outer

suspension eye of support 10.
intermediate wheel 15 and connect it
10
Provide protection for the crank web.
H2
H1
9
a
15
94117
RC
017.862/08
PROTECTION
014.587/06
II
2008
4/ 22
RT-flex96C
Maintenance
11322/A1
Lift bearing cover with ropes a and e.

Loosen rope a until bearing cover lies
at the crank web.
Instead of rope a connect rope d
(94120c) with lifting tackle H2 as
shown in Fig. H.
H2
H1
014.588/06
H
Screw two eye bolts RC1 and RC2
laterally into the bearing cover.
Connect rope f (94120q) with eye
bolts RC1 and rope d.
H2
H1
d
RC1
e
f
RC2
014.589/06
5/ 22
2008
11322/A1
Maintenance
RT-flex96C
Lift the bearing cover carefully over the

crank web with ropes d, f and e.
Remove ropes d and f.
Fasten lifting eye bolt 94120a to the column
as shown in Fig. I and detail concerned in
Fig. C.
H2
H1
RC
e
d
Connect rope f (94120q) with eye bolts

RC2 and lifting tackle H3.
94120a
H3
The further removal of the bearing cover is carried out analogously as described for Fig.
KM.
RC2
014.590/06
Fasten lifting tackle HZ to strap 22.

Connect rope g (94120e) with eye
bolts RC and lifting tackle HZ.
94117
RC
22 HZ H1
Lift the bearing cover carefully over

the crank web with ropes e and f towards middle of cylinder (Fig. I) and
pull it with rope g to fuel side at the
same time (Fig. K).
014.591/06
2008
6/ 22
RT-flex96C
11322/A1
Maintenance
H4
Guide the bearing cover to fuel side
with ropes g and e until rope h
(94120m) can be connected with lifting tackle H4 and eye bolt RC.
h
g
RC
014.592/06
Place bearing cover on working platform 94142.

Remove rope e.
Lift the bearing cover out of the crankcase using ropes g and h.
014.593/06
94142
7/ 22
2008
11322/A1
Maintenance
RT-flex96C
4.

Turn the corresponding crank to exhaust side approx. 90_ after T.D.C. (Fig.
E).
Install working platform 94142 (Fig. E).
Loosen nuts 12 for waisted studs 11 (Fig. A) hydraulically (see 11321).
Screw a roller support 94117 each onto guide shoe middle parts 9 as shown in
Fig. N and detail concerned in Fig. F.
Fasten lifting eye bolt 94120a to the column (see detail concerned in Fig. C).
Connect rope e (94120k) with eye bolt RC and lifting tackle H1 as shown in
Fig. E and N.
Connect rope x (94120np) with eye bolt RC and lifting tackle H2 (ropes x
differ in lengths depending on the position of the guide shoes).

the crank web with ropes x and e
and detach rope x.
Screw two eye bolts RC2 laterally
into the bearing cover and connect
them with rope f (94120q) and lifting
tackle H3.
9
94117
Pull bearing cover with ropes e and

f towards middle of cylinder.
9
H2
H1
94117
e
PROTECTION
The further removal of the bearing cover is

carried out analogously as described for
Fig. OQ .
94120a
H3
RC
RC2
008.889/01
2008
8/ 22
RT-flex96C
11322/A1
Maintenance
O
the crank web with ropes e and f towards middle of cylinder (Fig. I) and
pull it with rope g (Fig. O) to fuel
94117
side at the same time.
RC
H1
22 HZ
014.599/06
P
H4

h
RC
014.600/06
9/ 22
2008
11322/A1
Maintenance
RT-flex96C
Q
Remove rope e.
h
014.601/06
94142
5.
Turn crank of the last cylinder to exhaust

side approx. 90_ after T.D.C. (Fig. E).
14
Loosen nuts 12 for waisted studs 11 (Fig. A)

hydraulically (see 11321).
H2

Remove blank flange 18 from casing upper
part.
9
H1
18
94117
e d
13
PROTECTION
RC
Fasten lifting tackle H2 to support 14 and

connect rope d (94120c) with eye bolt RC.
Fasten roller support 94117 to guide shoe
middle part 9 (see detail concerned in Fig.
F).
Connect rope e (94120k) with eye bolt RC
and lifting tackle H1 via roller support 94117
as shown in Fig. E and R.
014.602/06
2008
10/ 22
RT-flex96C
Maintenance
11322/A1
S
Lift the bearing cover carefully as much as
possible with ropes d and e and detach
rope d from eye bolt RC.
H2
H1
e
RC
014.613/06
T
Screw two eye bolts RC1 and RC2 laterally into the bearing cover.
(see detail concerned in Fig. C).
Connect rope d with eye bolt RC2 and lifting tackle H2.
H2
Connect rope f (94120q) with eye bolt RC1

and lifting tackle H3.
Lift the bearing cover carefully over the
crank web with ropes d, e and f towards
middle of cylinder.
94120a
e
H3
RC1
RC2
The further removal of the bearing cover is carried out analogously as described for Fig.
OQ.
014.603/06
11/ 22
2008
11322/A1
Maintenance
RT-flex96C

6.
Removal of main bearing shells

Never remove two neighbouring bearing shells at the same time.
D
The same lifting tackles are used for the removal of the corresponding bearing
shells as for the removal of the corresponding bearing covers.
For the removal of bearing shells No. 1 and 2 the flywheel must also be
pressed up with the additional hydraulic jack 19. To protect the flywheel toothing, put a copper or aluminium plate between the hydraulic jack and the flywheel (Fig. Z).
6.1
Fitting the hydraulic jacks
Turn crankshaft 1 to exhaust side

approx. 90_ after T.D.C.
Put support 94141 on two main bearing girders 8 parallel to the engine
axis.
94936
Place hydraulic jacks 94936 on support 94141.
94141
8
Connect the hydraulic jacks with HP

hoses 94935 and 94935a, as well as
hydr. distributor 94934a to HP oil
pump 94931.
008.893/01
I
94942
I-I
94931
94935
94934a
94935a
94936
94141
008.894/01
2008
12/ 22
RT-flex96C
11322/A1
Maintenance

6.2
Lifting the crankshaft
Using hydraulic jacks 94936 and lift crankshaft at

bearing to be removed by value x = 0.4 0.5 mm.
Attention! Lift the crankshaft max. to the point where the
neighbouring main bearings show vertically no clearance
any more between main bearing cover and crankshaft.
In case the bearing shell cannot be turned out, both

of the adjoining bearing covers have also to be loosened. Thus the crankshaft can be correspondingly
lifted somewhat farther (approx. 0.8 mm) and the
bearing shell taken out.
8
004.844/98
6.3
CHECK
Check procedure with a dial gauge installed above the

crankshaft, and verify the bearing clearance at the neighbouring main bearings using special feeler gauge 94123.
Turning out the main bearing shells

Bearing No. 1, see Fig. Z:
D
The same ropes and arrangement are used for turning out and lifting of the
bearing shells, however, rope 94120g must be replaced by rope 94120h.
Bearing No. 2, see Fig. A1 :

D
bearing shell, however, rope 94120i must be replaced by rope 94120l, and
rope 94120g must be replaced by rope 94120h.
Bearing No. 3, see Fig. Y:

D
bearing shells, however, rope 94120i must be replaced by rope 94120l.
Bearing No. 4, see Fig. B1 :

D
bearing shells, however, rope 94120i must be replaced by rope 94120l, and
rope 94120d must be replaced by rope 94120f.
The turning-out procedure is the same for all bearing shell as described for
Fig. X.
Turning-out devices 94118b, 94118c or 94118d are provided depending on

the location of the bearing shell as shown in Fig. W.
DRIVING
END
008.872/01
94118b
94118c
13/ 22
94118d
2010-07
11322/A1
Maintenance
RT-flex96C
6.3.1 Turning out the main bearing shell No. 3 (example)

Fasten turning-out device 94118c on the joint face of the bearing shell utilizing
its proper screws (view III).
Lead both ropes of the turning-out device along the lateral edges of the main
bearing shell 3 to the other side and connect them with lifting yoke 94119 as
shown in view II.
Remark: By means of a wire attached to the ropes they can be pulled below the
bearing journal to the other side. This may be of help primarily for bearings No. 1, 2
and 4.
With ropes x (94120np) and e (94120l) connected to lifting tackles H2 and
H1 pull bearing shell slowly out from the bearing girder till both ends of the
bearing shell are free (no meshing).
Remove lifting yoke 94119 and rope e.
I-I
94117
94117
H2
H1
x
H2
94117
H1
e x
II
94119
94119
III
3
3
94936
94141
014.605/06
014.604/06
III
II
x
94118c
94119
008.900/01
2008
14/ 22
008.901/01
RT-flex96C
11322/A1
Maintenance
6.4
Removal of main bearing shells No. 3

Fasten lifting tool 94116 onto bearing shell 3 and connect it with ropes x
(94120np) and e (94120i) as shown in view II.
Lift the bearing shell carefully over the crank web with ropes x and e.
Loosen and remove rope x.
Connect lifting tackle H3 directly to lifting tool 94116 and pull bearing shell together with rope e towards middle of cylinder.
Connect rope g (94120f) with lifting tackle HZ and lifting tool, and then pull
the bearing shell together with rope e and lifting tackle H3 to fuel side (view
I-I).
The further procedure is carried out analogously as shown in Fig. P and Q (Removal of main bearing cover).
I-I
22
HZ
H1
94117
H1
H2
94120a
H3
II
014.606/06
94116
x e
94116
014.607/06
II
94116
3
008.913/01
15/ 22
2008
11322/A1
Maintenance
RT-flex96C
6.5
Removal of main bearing shell No. 1

Fasten lifting tool 94116 onto the bearing shell 3.
Fasten lifting eye bolt 94120a to the column (see detail concerned in Fig. C).
Pull rope a (94120g) through a hole in intermediate wheel 15 and connect it
Connect rope b (94120b) with lifting tool 94116 and lifting tackle H2 which is
fastened to the inner eye of support 10.
Lift bearing shell with ropes a and b and then swing it towards flywheel 7.
Detach rope a.
Fasten lifting tackle H5 to suspension eye 20 and connect rope c (94120b)
with lifting tool, and subsequently swing it towards fuel side with ropes b and
c as shown in view I.
Fasten lifting tackle HZ to suspension eye 21 and connect it to bearing shell 3
and then swing the latter fully towards fuel side.
Remove rope c.
I
21 H6
15
20
10
H2
H5
H2
b
a
94116
94120a
H3
94116
3
7
19
014.609/06
014.608/06
PROTECTION
2008
16/ 22
RT-flex96C
11322/A1
Maintenance
6.6

Pull rope a (94120g) through a hole in intermediate wheel 15 and connect it
with lifting tool.
Lead rope e (94120i) over roller support 94117 and connect it with lifting
tackle H1 and lifting tool.
Lift the bearing shell carefully over the crank web with ropes a and e.
Remove rope a.
I-I).
The further procedure is carried out analogously as shown in Fig. L and M (Removal of main bearing cover).
A1
I-I
15
10
H2
94117
H1
a
94120a
H3
H1
94117
22
HZ
94116
a e
94116
3
014.611/06
014.610/06
PROTECTION
17/ 22
2008
11322/A1
Maintenance
RT-flex96C
6.7

Connect rope d (94120d) with lifting tool.
Lift the bearing shell carefully over the crank web with ropes e and d.
Remove rope d.
Connect lifting tackle H3 directly to lifting tool and pull bearing shell together
with rope e towards middle of cylinder.
I-I).
The further procedure is carried out analogously as shown in Fig. P and Q (Removal of main bearing cover).
B1
I-I
22 HZ
14
H1
H2
94117
94117
94120a
H3
94116
94116
ed
014.627/06
014.612/06
2008
18/ 22
RT-flex96C
11322/A1
Maintenance
7.
Fitting of main bearing shell and main bearing cover

D
Prior to fitting a new bearing shell or bearing cover pay attention to the Arrangement and characteristics of the main bearings on page 2, and to the upset down test 11323.
Remark: All bearing shells are marked with their proper code numbers (see table
on page 2). In addition bearing shells and bearing covers are laterally marked with
DRIVING END. Therefore, they must be fitted correspondingly.
Attention! Always fit bearing shells No. 1 and 2 in direction of arrow as shown in
Fig. D1.
Furthermore refer to Service Bulletin RT141.
D
Step of key 6 must faces inwards as shown in Fig. C1.
Bearing shell and bearing cover should be fitted into the bearing girder in their
original positions.
Oil bore OB in the bearing girder must be clean and without particles of white
metal.
Crankshaft journal, girder bore for main bearing and all parts to be fitted must
be clean and undamaged!
C1
014.690/06
I-I
STEPPED
KEYS
I
014.689/06
014.694/06
D1
TYPE OF MB
B
D or E
D or E
D or E
D or E
D or E
FREE
END
DRIVING
END
Cyl. #1
Cyl. #2
Cyl. #3
THRUST BEARING
LOCATION
19/ 22
2013-02
11322/A1
Maintenance
RT-flex96C
Cross section of main bearings (types):
E1
Type B:
Narrow, asymetrical
and conical
Type A:
Narrow, asymmetrical
DRIVING
END
F1
369
369
Type D or E:
Wide
425
014.629/06
OB
2013-02
OB
20/ 22
RT-flex96C
11322/A1
Maintenance
The fitting of bearing shell and bearing cover is carried out analogously but in reverse sequence to the removal.
Directly before fitting (turning in) bearing shell 3 apply a very thin layer of
MOLYKOTE paste G to the back of it.
The crankshaft journal and the running surface of the main bearing shell must
be thoroughly lubricated with clean engine oil.
7.1
Turning in the main bearing shell

(see Fig. G1 as an example for main bearing No. 3)
G1
Connect ropes x and e with lifting yoke
94119.
Lead both ropes of turning-out device
94118c below of the crankshaft journal to
the fuel side and connect them with lifting
yoke 94119.
D
H2
H1
So that bearing shell does not glide jerkily, it

must be held and guided slowly into the
bearing girder at the ends of the ropes.
Pull bearing shell to its proper position with

ropes x and e.
x e
END OF ROPE
Release the pressure at the HP oil pump

and fit bearing cover 2. The latter can be
94118c
fitted by means of lifting tackles and ropes
as described for the removal, but in reverse
sequence.
94119
3
Be careful that keys 6 mesh with the corresponding keyways in bearing cover 2 (Fig.
A).
Tighten nuts 12 for waisted studs 11 following the instructions in 11321.
014.630/06
CHECK
Remove all the tools from the engine and

below of the flywheel.
The bearing clearances and the crank deflection must be measured after a new
bearing shell has been fitted and the bearing cover has been tightened (see
03301 and 31031).
After assembly, check if lubricating oil is supplied to the main bearing with the oil
pump in operation!
21/ 22
2008
11322/A1
Maintenance
RT-flex96C
Remark: Should the crankshaft need to be turned before the bearing cover is
fitted, then care must be taken that the bearing shell does not turn. Therefore,
bearing shell 3 must be blocked with two suitable wooden boards HO.
H1
12
HO
11
1
3
8
008.925/01
2008
22/ 22
RT-flex96C
11322/A2
Maintenance
Main Bearing
Tools:
1 Lifting tool
2 Roller supports
for narrow bearing shell
for broad bearing shell
for bearing shell at free end
1 Lifting yoke
1 Lifting eye bolt
2 Ropes with shackle
(300 mm)
1 Rope with shackle
(500 mm)
1 Rope with shackle
(600 mm)
1 Rope with shackle
(800 mm)
1 Rope with shackle
(1000 mm)
1 Rope with shackle
(1200 mm)
1 Rope with shackle
(1500 mm)
1 Rope with shackle
(1600 mm)
1 Rope with shackle
(1700 mm)
1 Rope with shackle
(1900 mm)
1 Rope with shackle
(2000 mm)
1 Rope with shackle
(2200 mm)
1 Rope with shackle
(2800 mm)
1 Rope with shackle
(3200 mm)
2 Ropes with 2 shackles (1000 mm)
1 Support
1 Working platform
1 HP oil pump
1 Hydr. distributor
1 HP hose
2 HP hoses
2 Hydraulic jacks
94116
94117
94118b
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
94118c
94118d
94119
94120a
94120b
94120c
94120d
94120e
94120f
94120g
94120h
94120i
94120k
94120l
94120m
94120n
94120o
94120p
94120q
94123
94141
94142
94931
94934a
94935
94935a
94936
HO
HZ
H1...
OB
RC
RC1
RC2
Crankshaft
Main bearing cover
Main bearing shell
Locating dowel pin
Groove
Key
Flywheel
Main bearing girder
Guide shoe middle part
Support
Waisted stud
Nut
Vibration damper
Support
Intermediate wheel
Connecting rod
Blank flange
Jack
Suspension eye
Cover
Casing, upper part
Suspension eye
Strap
Wooden board
Lifting tackle
Lifting tackles
Oil bore
Eye bolt M24
Eye bolt M20
Eye bolt M20
Overview
1.
2.
3.
4.
5.
6.
7.
8.
Arrangement and characteristics of main bearings . . . . . . 2/27

Removal of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . 16/27
Fitting of main bearing shell and main bearing cover . . . 24/27

1/ 27
2013-02
11322/A2
Maintenance
RT-flex96C
Cross section of main bearing:
12
2
2
6
4
11
1
6
3
8
3
008.871/01
1.
Arrangement and characteristics of main bearings
Characteristics of main bearings
Type A
Type B
Type C
Type D
Type E
Narrow bearing shell and cover
Wide bearing shell and cover
Wide bearing cover and inner diameter of shell double conically machined
(MB No. 5 on 1114 Cyl. engines
only)
Bearing shell and cover cylindrically

machined
Matching pair shell and cover conically machined
Keys not stepped in bearing shell
Keys stepped in bearing shell
Wide bearing cover and bearing shell

with shot peened surface at the back
side
DF 11352
DF 11304
DF 11351
DF 11342
DF 11344
Code No. of double conical main

bearing shell
DF 11379
DF 11378
Code No. of main bearing cover
DF 11377
DF 11302
DF 11377
DF 11365
DF 11365
DF 11365
DF 11365
Code No. of key
DF 11353
DF 11343
DF 11343
DF 11343
DF 11343
DF 11343
DF 11343
DF 11300
Code No. of standard main bearing

shell
Code No. of paired main bearing shell

and cover
2013-02
2/ 27
Type F
Type G
RT-flex96C
11322/A2
Maintenance
B
CENTRE DRIVE
D or E
D or E
DRIVING
END
Cyl. #1
Cyl. #2
D, E, F or G
D or E
D or E
FREE
END
TYPE OF MB
Cyl. #3
THRUST BEARING
LOCATION
3/ 27
2013-02
11322/A2
Maintenance
RT-flex96C

2.
Turn crank 1 to exhaust side approx.

100_after T.D.C.
Remove upper parts of oil baffle and casing
at the driving end.
10
H2

Screw eye bolt RC into main bearing cover
(bearing cover for short) 2.
Connect rope b (94120b) with eye bolt RC
and lifting tackle H2 which is fastened to the
outer eye of support 10 and lift bearing cover.
RC
2
1
014.650/06
I-I
D
24 H6
20
H2
H5
Fasten lifting tackle H5 to suspension eye 20 and connect

rope c (94120b) with bearing
cover 2, and subsequently
swing it towards fuel side with
ropes b and c.
Fasten lifting tackle H6 to suspension eye 24 and connect it to
bearing cover 2 and then swing
the latter fully towards fuel side.
Remove rope c.
RC
2
014.585/06
2008
4/ 27
RT-flex96C
11322/A2
Maintenance

3.
II - II
Turn corresponding crank to exhaust

side approx. 90_after T.D.C.
94117
2
94142

shoe middle part 9 using screw
M30x60 and washer 68 mm between
tool and guide shoe middle part as
shown in the detail.
RC
b e

Connect rope e (94120k) with eye bolt
RC and lifting tackle H1 via roller support as shown in Fig. E and F.
014.655/06
II
Remove cover 21 from casing upper
part 22.
Fasten lifting tackle H2 to the inner side
of the casing upper part.
Connect rope b (94120b) with lifting
tackle H2 and eye bolt RC.
21
9
22
H2
b
RC
94117
017.862/08
PROTECTION
23
014.656/06
II
5/ 27
2008
11322/A2
Maintenance
RT-flex96C
Lift the bearing cover carefully over the crank web

with ropes b and e.
Remove rope b.
H1
H2
e
b
014.657/06
Screw two eye bolts RC2 laterally into the

bearing cover.
Fasten lifting eye bolt 94120a to the column.
94120a
Connect rope f (94120q) with eye bolts

The further removal of the bearing cover is carried out analogously as described for Fig. IL.
e
f
H3
RC2
014.658/06
2008
6/ 27
RT-flex96C
11322/A2
Maintenance
I
the crank web with ropes e and f towards middle of cylinder (Fig. H) and
pull it with rope g (Fig. K) to fuel side
94117
at the same time.
RC
H1
25 HZ
014.599/06
K
H4

h
RC
014.600/06
7/ 27
2008
11322/A2
Maintenance
RT-flex96C
L
Remove rope e.
Lift the bearing cover out of the
crankcase using ropes g and
h.
014.601/06
94142
2008
8/ 27
RT-flex96C
11322/A2
Maintenance

4.

Turn the corresponding crank to exhaust side approx. 90_ after T.D.C. (Fig.
E).
Loosen nuts 12 for waisted studs 11 (Fig. A) hydraulically (see 11321).
Screw a roller support 94117 each onto guide shoe middle parts 9 (see detail
concerned in Fig. F).
Fasten lifting eye bolt 94120a to the column (see detail concerned in Fig. H).
Connect rope e (94120k) with eye bolt RC and lifting tackle H1 as shown in
Fig. M and E.
Connect rope x (94120np) with eye bolt RC and lifting tackle H2 (ropes x
differ in lengths depending on the position of the guide shoes).

the crank web with ropes x and e
and detach rope x.
Screw two eye bolts RC2 laterally
into the bearing cover and connect
them with rope f (94120q) and lifting
tackle H3.
9
94117
Pull bearing cover with ropes e and

f towards middle of cylinder.
9
H2
H1
94117
e
PROTECTION

Fig. IL.
94120a
H3
RC
RC2
008.889/01
9/ 27
2008
11322/A2
Maintenance
RT-flex96C

5.
I-I
Turn the corresponding crank to ex
haust side approx. 90_ after T.D.C.
shoe middle part 9 as shown in Fig. N
O and detail concerned in Fig. F.
Screw eye bolt RC into bearing cover
94117
Connect rope e (94120k) with eye bol

RC and lifting tackle H1 via roller sup
port as shown in Fig. N and O.
RC

intermediate wheel 15 and connect i
with eye bolt RC and lifting tackle H2
H1
2
94142
a e
014.586/06
I
column (see detail concerned in Fig
H).
15
9
H1
94120a
H2
94117
a
e
RC
PROTECTION
014.663/06
I
2008
10/ 27
RT-flex96C
Maintenance
11322/A2
Lift bearing cover with ropes a and e.

Loosen rope a until bearing cover lies at the
crank web.
Instead of rope a connect rope d (94120c)
with lifting tackle H2 as shown in Fig. Q.
H1
e
H2
014.664/06
Screw two eye bolts RC1 and RC2 laterally into the bearing cover.
Connect rope f (94120q) with eye bolt RC1
and rope d.
Lift the bearing cover carefully onto the
crank web with ropes d, f and e.
Subsequently remove ropes d and f.
H1
H2
d
f
RC2
RC1
014.665/06
11/ 27
2008
11322/A2
Maintenance
RT-flex96C
I
(see detail concerned in Fig. H).
Connect rope f (94120q) with eye bolt
H1
RC
94120a
H3
RC2
014.666/06
I-I

H1
25 HZ
94117
RC
g

the crank web with ropes e and f towards middle of cylinder (Fig. R)
and pull it with rope g to fuel side at
the same time (Fig. S).
014.591/06
2008
12/ 27
RT-flex96C
11322/A2
Maintenance
H4
h
g
RC
014.592/06

Remove rope e.
014.593/06
94142
13/ 27
2008
11322/A2
Maintenance

6.
RT-flex96C
Turn crank of the last cylinder to exhaust

side approx. 90_ after T.D.C. (Fig. E).
9
H1
94117
PROTECTION
e d
14

H2
18
Fasten lifting tackle H2 to support 14 and

connect rope d (94120c) with eye bolt RC.
13
Fasten roller support 94117 to guide shoe

middle part 9 (see detail concerned in Fig.
F).
RC
2
Remove blank flange 18 from casing upper

part.
Connect rope e (94120k) with eye bolt RC

and lifting tackle H1 via roller support 94117
as shown in Fig. E and V.
014.670/06
Lift the bearing cover carefully as much as

possible with ropes d and e and detach
rope d from eye bolt RC.
H2
H1
e
RC
PROTECTION
014.660/06
2008
14/ 27
RT-flex96C
Maintenance
11322/A2
X
Screw two eye bolts RC1 and RC2
laterally into the bearing cover.
column (see detail concerned in Fig.
H).
H2
Connect rope f (94120q) with eye

bolt RC1 and lifting tackle H3.
94117

the crank web with ropes d and f towards middle of cylinder.
H1
94120a
H3
RC1
Connect rope d with eye bolt RC2

and lifting tackle H2.
e
f
RC2

Fig. IL.
PROTECTION
014.661/06
15/ 27
2008
11322/A2
Maintenance
RT-flex96C

7.
Removal of main bearing shells

Never remove two neighbouring bearing shells at the same time.
D
The same lifting tackles are used for the removal of the corresponding bearing
shells as for the removal of the corresponding bearing covers.
For the removal of bearing shells No. 1 and 2 the flywheel must also be
pressed up with the additional hydraulic jack 19. To protect the flywheel toothing, put a copper or aluminium plate between the hydraulic jack and the flywheel (Fig. D1).
7.1
Fitting the hydraulic jacks
Turn crankshaft 1 to exhaust side

approx. 90_ after T.D.C.
Put support 94141 on two main bearing girders 8 parallel to the engine
axis.
94936
Place hydraulic jacks 94936 on support 94141.
94141
8
Connect the hydraulic jacks with HP

hoses 94935 and 94935a, as well as
hydr. distributor 94934a to HP oil
pump 94931.
008.893/01
I
94942
I-I
94931
94935
94936
94934a
94935a
94141
008.894/01
2008
16/ 27
RT-flex96C
11322/A2
Maintenance
6.2
Lifting the crankshaft
Using hydraulic jacks 94936 and lift crankshaft at

bearing to be removed by value x = 0.4 0.5 mm.
Attention! Lift the crankshaft max. to the point where the
neighbouring main bearings show vertically no clearance
any more between main bearing cover and crankshaft.
In case the bearing shell cannot be turned out, both

of the adjoining bearing covers have also to be loosened. Thus the crankshaft can be correspondingly
lifted somewhat farther (approx. 0.8 mm) and the
bearing shell taken out.
8
004.844/98
7.3
CHECK
Check procedure with a dial gauge installed above the

crankshaft, and verify the bearing clearance at the neighbouring main bearings using special feeler gauge 94123.
Turning out the main bearing shells

Bearing No. 1, see Fig. D1:
bearing shell.
D
Bearing No. 2, see Fig. E1:
Bearing No. 3, see Fig. C1:
D
bearing shells, however, rope 94120i must be replaced by rope 94120l.
Bearing No. 4, see Fig. F1 and F2:

D The same ropes and arrangement are used for turning out and lifting of the
bearing shells, however, rope 94120i must be replaced by rope 94120l, and
rope 94120g must be replaced by rope 94120h.
Bearing No. 5, see Fig. G1:
D The same ropes and arrangement are used for turning out and lifting of the
bearing shell, however, rope 94120i must be replaced by rope 94120l, and
rope 94120d must be replaced by rope 94120f.
D
The turning-out procedure is the same for all bearing shell as described for
Fig. B1.
Turning-out devices 94118b, 94118c or 94118d are provided depending on

the location of the bearing shell as shown in Fig. A1.
A1
CENTRE DRIVE
FREE
END
DRIVING
END
008.928/01
94118b
94118c
94118b
17/ 27
94118c
94118d
2013-02
11322/A2
Maintenance
RT-flex96C
7.3.1 Turning out the main bearing shell No. 3 (example)

Fasten turning-out device 94118c on the joint face of the bearing shell utilizing
its proper screws (view III).
Lead both ropes of the turning-out device along the lateral edges of the main
bearing shell 3 to the other side and connect them with lifting yoke 94119 as
shown in view II.
Remark: By means of a wire attached to the ropes they can be pulled below the
bearing journal to the other side. This may be of help primarily for bearings No. 1, 2,
4 and 5.
With ropes x (94120np) and e (94120l) connected to lifting tackles H2 and
H1 pull bearing shell slowly out from the bearing girder till both ends of the
bearing shell are free (no meshing).
Remove lifting yoke 94119 and rope e.
I-I
B1
94117
94117
H2
H1
H2
94117
H1
x
e
e x
II
94119
94119
III
3
3
94936
94141
014.605/06
014.604/06
III
II
x
94118c
94119
008.900/01
2008
18/ 27
008.901/01
RT-flex96C
11322/A2
Maintenance
7.4
Removal of main bearing shells No. 3

Fasten lifting tool 94116 onto bearing shell 3 and connect it with ropes x
(94120np) and e (94120i) as shown in view II.
Lift the bearing shell carefully over the crank web with ropes x and e.
Loosen and remove rope x.
I-I).
The further procedure is carried out analogously as shown in Fig. K and L (Removal of main bearing cover).
I-I
C1
25
HZ
H1
94117
H1
H2
94120a
H3
II
014.606/06
94116
x e
94116
014.607/06
II
94116
3
008.913/01
19/ 27
2008
11322/A2
Maintenance
RT-flex96C
7.5

Connect rope b (94120b) with lifting tool 94116 and lifting tackle H2 which is
fastened to the outer eye of support 10.
Lift bearing shell with ropes b.
Fasten lifting tackle H5 to supension eye 20 and connect rope c (94120b)
with lifting tool, and subsequently swing it towards fuel side with ropes b and
c as shown in view I-I.
Fasten lifting tackle HZ to suspension eye 24 and connect it to bearing shell 3
and then swing the latter fully towards fuel side.
Remove rope c.
D1
I-I
24 H6
20
10
H2
H5
H2
94116
94116
3
7
19
014.662/06
2008
014.609/06
PROTECTION
20/ 27
RT-flex96C
11322/A2
Maintenance
7.6

Connect rope b (94120b) with lifting tool 94116 and lifting tackle H2.
Lift the bearing shell carefully over the crank web with ropes b and e.
Remove rope b.
I-I).
The further procedure is carried out analogously as shown in Fig. K and L (Removal of main bearing cover).
E1
I-I
25
HZ
H1
94117
H1
H2
94120a
H3
014.651/06
19
94116
3
b e
014.659/06
PROTECTION
21/ 27
2008
11322/A2
Maintenance
RT-flex96C
F1
7.7
Fasten lifting tool 94116 onto bearing shell 3.

Pull rope a (94120g) through a hole in intermediate wheel 15 and connect it with lifting
tool and lifting tackle H2.
Lead rope e (94120i) over roller support
94117 and connect it with lifting tackle H1
and lifting tool.
15
94117
H1
94120a
H2
Lift the bearing shell carefully over the crank

web with ropes a and e (Fig. F1).
Remove rope a.
94116
3
Connect lifting tackle H3 directly to lifting tool

94116 and pull bearing shell together with
rope e towards middle of cylinder as shown
in Fig. F2.
Connect rope g (94120f) with lifting tackle
HZ and lifting tool, and then pull the bearing
shell to fuel side (view I-I).
The further procedure is carried out analogously
as shown in Fig. S to U (Removal of main bearing cover).
014.685/06
I-I
F2
H1
94117
25 HZ
g
94116
3
a e
014.667/06
2008
22/ 27
H3
014.668/06
RT-flex96C
11322/A2
Maintenance
7.8

Connect rope d (94120d) with lifting tool.
Lift the bearing shell carefully over the crank web with ropes e and d.
Remove rope d.
Connect lifting tackle H3 directly to lifting tool and pull bearing shell together
with rope e towards middle of cylinder.
I-I).
The further procedure is carried out analogously as shown in Fig. L and M (Removal of main bearing cover).
G1
I-I
25 HZ
14
H1
H2
94117
94117
94120a
H3
e d
94116
94116
ed
014.627/06
014.612/06
23/ 27
2008
11322/A2
Maintenance
RT-flex96C
8.
Fitting of main bearing shell and main bearing cover

D
Prior to fitting a new bearing shell or bearing cover pay attention to the Arrangement and characteristics of the main bearings on page 2, and to the upset down test 11323.
Remark: All bearing shells are marked with their proper code numbers (see table
on page 2). In addition bearing shells and bearing covers are laterally marked with
DRIVING END. Therefore, they must be fitted correspondingly.
Attention! Always fit bearing shells No. 1 and 2 in direction of arrow as shown in
Fig. I1.
Furthermore refer to Service Bulletin RT141.
D
Step of key 6 must faces inwards as shown in Fig. H1.
Bearing shell and bearing cover should be fitted into the bearing girder in their
original positions.
Oil bore OB in the bearing girder must be clean and without particles of white
metal.
Crankshaft journal, girder bore for main bearing and all parts to be fitted must
be clean and undamaged!
H1
I-I
014.690/06
I
014.689/06
014.694/06
I1
CENTRE DRIVE
TYPE OF MB
B
D or E
D or E
DRIVING
END
Cyl. #1
Cyl. #2
D, E, F or G
D or E
D or E
FREE
END
STEPPED
KEYS
Cyl. #3
THRUST BEARING
LOCATION
2013-02
24/ 27
RT-flex96C
11322/A2
Maintenance
Cross section of main bearings (types):
K1
Type B:
Narrow, asymetrical
and conical
Type A:
DRIVING
END
L1
369
369
Type D or E:
Wide
425
014.629/06
OB
OB
M1
N1
Type C:
(both sides of centre drive)
Type F or G:
Wide, double conical shell
(1114 Cyl. only)
369
369
425
014.653/06
OB
25/ 27
OB
2013-02
11322/A2
Maintenance
RT-flex96C
The fitting of bearing shell and bearing cover is carried out analogously but in reverse sequence to the removal.
Directly before fitting (turning in) bearing shell 3 apply a very thin layer of
MOLYKOTE paste G to the back of it.
The crankshaft journal and the running surface of the main bearing shell must
be thoroughly lubricated with clean engine oil.
8.1
Turning in the main bearing shell

(see Fig. O1 as an example for main bearing No. 3)
O1
Connect ropes x and e with lifting yoke
94119.
Lead both ropes of turning-out device
94118c below of the crankshaft journal to
the fuel side and connect them with lifting
yoke 94119.
D
H2
H1
So that bearing shell does not glide jerkily, it

must be held and guided slowly into the
bearing girder at the ends of the ropes.
Pull bearing shell to its proper position with

ropes x and e.
x e
END OF ROPE
Release the pressure at the HP oil pump

and fit bearing cover 2. The latter can be
94118c
fitted by means of lifting tackles and ropes
as described for the removal, but in reverse
sequence.
94119
3
Be careful that keys 6 mesh with the corresponding keyways in bearing cover 2 (Fig.
A).
Tighten nuts 12 for waisted studs 11 following the instructions in 11321.
014.630/06
CHECK
2008
Remove all the tools from the engine and

below of the flywheel.
The bearing clearances and the crank deflection must be measured after a new
bearing shell has been fitted and the bearing cover has been tightened (see
03301 and 31031).
After assembly, check if lubricating oil is supplied to the main bearing with the oil
pump in operation!
26/ 27
RT-flex96C
11322/A2
Maintenance
Remark: Should the crankshaft need to be turned before the bearing cover is
fitted, then care must be taken that the bearing shell does not turn. Therefore,
bearing shell 3 must be blocked with two suitable wooden boards HO.
P1
12
HO
11
1
3
8
008.925/01
27/ 27
2008
RT-flex96C
11323/A1
Maintenance
Main Bearing
Main Bearing Upside-down Test
Tools:
1 Measuring device
1 Template
1 Feeler gauge
1.
94113
94113a
94122
1 Key
2 Main bearing cover
3 Main bearing shell
General
The main bearing upside-down test is best carried out on all main bearings before
fitting them in the engine.
If a conical shell is fitted in main bearing No. 2 , with a non-matching cover (conical
or standard, new or used), then an upside-down test must be carried out before
fitting (see also 11322, Characteristics of main bearings).
2.
Upside-down test set-up

Place the bearing cover 2 upside-down and fit the bearing shell 3 on top of the inverted cover. Check that both keys 1 have inside contact to the cover as follows:
Put engineers blue on the inner key surface.
Put the cover in an upside-down position and lower the shell down onto the
cover.
Lift off the shell and verify that the keys have inside-contact.
The edges of the bearing shell 3 and bearing 2 cover should be parallel across the
length of the bearing.
A
3
014.689/06
017.024/08
Attention! Lift off the shell from the cover carefully so that both keys 1 slip out at
the same time. Otherwise there is a risk of damaging the keys.
1/ 4
2008
11323/A1
Maintenance
RT-flex96C
2.1
Check for a step between shell and cover

Measure dimensions X and Z in the figure below on both sides (fuel/exhaust
sides), in both postitions at driving and free ends.
Measure dimension Z at 30 mm below the contact surface between bearing
cover 2 and bearing shell 3.
94113a
X
30 mm
017.024/08
2008
2/ 4
RT-flex96C
11323/A1
Maintenance
2.2
Pass conditions for the main bearing upside-down test

The main bearing passes the upside-down test if the conditions 1a and either 2a or
2b are met:
1a The outer surface of the cover protrudes beyond the outer surface of the bearing shell. The protrusion X should be less than 0.50 mm.
2a If the running surface of the bearing shell protrudes beyond the cover: dimension Z should be max 0.20 mm, except on main bearing No. 1 which should
be max 0.30 mm.
2b If instead the cover protrudes beyond the running surface of the bearing shell,
then by max 0.05 mm, otherwise the white metal of the cover has to be
scraped by hand, as long as the maximum scrape depth is less than 0.30 mm
(see Fig. C).
Remark: If the pass conditions are not met, then Wrtsil can provide advice as
to what action should be taken.
2.3
Scraping the main bearing cover

A slight protrusion of the main bearing cover beyond the shell can be corrected by
scraping the bearing cover.
The cover should only be scraped if the maximum scrape depth is less than
0.30 mm.
Rig up the cover as shown in Fig.C.
Scrape the cover using a run-out length of maximum scrape-depth x 500 mm,
e.g. 0.3 x 500 = 150 mm.
Scrape until dimension Z (Fig. B) is within the allowed range.
C
RUN-OUT
LENGTH
MAX. SCRAPE DEPTH
017.023/08
3/ 4
2008
11323/A1
Maintenance
RT-flex96C
3.
Main bearing outside diameter check

The main bearing is assembled upside-down and tested as descirbed in section 2.
Use template 94113 to check the shell ouside diameter.
For main bearing No. 1 use feeler gauge 94122 in combination with the template.
TOUTCH POINT ON
BEARING SHELL
TOUTCH POINT ON
BEARING SHELL
94122
94113
Limits of bearing shell outside diameter:

All main bearings
except No. 1
Main bearing No. 1
min. 1080.42 mm
1080.22 mm
max. 1080.66 mm
1080.48 mm
The values in the table represent the normal range for new parts. The outside diameter of the bearing shell can be lower when the shell has been used.
2008
If the outside diameter is not within the limits in the above table, then correct
the outside diameter by fitting offset keys. If offset key is oversized, then machine it to the correct size.
It is better for the outside diameter to be between 1080.55 mm and 1080.68

mm at the upper of the range, in order to reduce the risk of fretting.
4/ 4
RT-flex96C
Maintenance
12031/A1
Thrust Bearing
Checking the Axial Clearance
Tools:
1 Inside micrometer
1 Feeler gauge
1 Dial gauge with magnetic base
1.
94101
94238
1
2
3
4, 4a
5
6
Coupling flange
Oil baffle, lower part
Holder
Thrust flange
Crankshaft
7 Thrust bearing pads

ASTERN
7a Thrust bearing pads
AHEAD
8 Cover
9 Screw plug
Measuring method 1
The total displacement which results from pushing the crankshaft axially both
ways until it contacts the thrust bearing pads AHEAD and ASTERN, is measured
with a dial gauge. This is then checked against the figure marked on the sheet
Check Dimensions in the engine documents supplied (see also Clearance Table
03301 Crankshaft and main bearing).
An increase compared with the nominal figure signifies wear of the thrust bearing
pads.
2.
Measuring method 2
Displace the crankshaft axially until it rests on the engine side thrust bearing
pads (AHEAD) and then fix it in this position.
Measure the distance between the coupling flange and the upper part of the
oil baffle with the inside micrometer 94101 at the position indicated (see Fig.
C). The amount by which distance X is smaller than that given on the sheet
Check Dimensions corresponds to the wear of the engine side thrust bearing
pads (AHEAD).
Displace the crankshaft axially until it rests on the thrust bearing pads for
ASTERN. Determine the total axial clearance with the inside micrometer.
Remark: After major works have been carried out in the thrust bearing space dismantle cover 8 for a check-up on the thrust bearing housing. Remove any foreign
matters through the opening.
1/ 3
2008
12031/A1
Maintenance
RT-flex96C
Thrust Bearing: Checking the Axial Clearance
612 CYL. ENGINES
2
4
4a
6
THRUST
8
7a
CHECK HOLE FOR

FREE PASSAGE EVERY
60008000 OP. HOURS
7
3
0.81.3 mm
014.162/06
14 CYL. ENGINES
2
4
5
4a
6
9
THRUST
7a
7
3
CHECK HOLE FOR

FREE PASSAGE EVERY
60008000 OP. HOURS
0.81.3 mm
014.164/06
2008
2/ 3
RT-flex96C
12031/A1
Maintenance
Thrust Bearing: Checking the Axial Clearance
011.344/04
I-I
001.495/97
94101
3/ 3
2008
RT-flex96C
12241/A1
Maintenance
Thrust Bearing
Removal and Fitting the Thrust Bearing Pads
Tools:
for 6 and 7 Cyl. engines,
with 1-part gear wheel
for 6 and 7 Cyl. engines,
with 2-part gear wheel
for 812 and 14 Cyl. engines
94155
1
2, 2a
3
4
5
6
7
8
94155a
94155b
Thrust bearing flange

Thrust bearing pads
Gear wheel
Holder
Screw with distance sleeve
Bearing cover
Temperature sensor
1 Eye bolt M16
1.
Removal
Loosen both holders 4 above thrust bearing pads 2 or 2a to be removed.
In addition, to ensure a better access for the removal of thrust bearing pads 2
(ASTERN), the upper part of oil baffle 7 (Fig. B and D) is also to be removed.
Remove temperature sensors 8 from their bores (page 5) on 812 cylinder
engines.
Insert and laterally fasten turning-out device 94155 or 94155a or 94155b respectively to the gear wheel or the thrust bearing flange as illustrated on Fig.
B or D.
The crankshaft is then to be turned with the turning gear until an eye bolt M16
can be screwed into a pad which can then be lifted up and removed one by
one.
Remark: When only a few thrust bearing pads of a row are to be removed the
crankshaft is located in its axial position by the remaining pads. When all thrust
bearing pads must be removed then the crankshaft must be prevented from sliding
axially. Therefore, insert a piece of hardwood of the same thickness in place of the
thrust bearing pad.
1/ 5
2008
12241/A1
Maintenance
RT-flex96C
2.
Fitting
CHECK
Make absolutely sure that all the thrust bearing pads are meticulously clean
and smeared with fresh engine oil; the thrust bearing pads must all be replaced in their original position. Note also numbering of the individual pads!
For fitting the thrust bearing pads tool 94155 or 94155a or 94155b respectively can also be utilized. Note in this respect that the first pad, when pushed in,
rests against the tool. The following thrust bearing pads can then be fitted one
after the other while simultaneously turning the crankshaft. The thrust bearing
pads should slide in without effort to their end position.
With all the thrust bearing pads in position, the distances from the outermost pads
on fuel side and exhaust side to the upper edge of the bedplate must be equal to be
able refitting holders 4. Subsequently check the clearance between holder and
thrust bearing pads 2 and 2a (see Clearance Table 03301 Crankshaft and thrust
bearing).
D
Prior to fitting screws 5 clean threads, tap holes and coat screw threads with
LOCTITE No. 222.
Attention! After fitting the thrust bearing pads immediately remove tool 94155 or
94155a or 94155b respectively.
Remark: When fitting new or remetalled thrust bearing pads, care must be taken
that their thickness (final dimension) corresponds exactly with the neighbouring
pads.
When replacing a complete row of new or remetalled thrust bearing pads the clearance must be adjusted to the original values (see Clearance Table 03301 Crankshaft and thrust bearing and 12031).
2008
2/ 5
RT-flex96C
12241/A1
Maintenance
A
6
4
5
FUEL SIDE
EXHAUST SIDE
2/2a
001.490/97
II - II
I-I
II
II
1
2/2a
94155
94155a
3
1
2a
001.490/97
94155
94155a
DRAWN FOR 6 AND

7 CYL. ENGINES
001.490/97
3/ 5
2008
12241/A1
Maintenance
RT-flex96C
C
6
4
5
FUEL SIDE
EXHAUST SIDE
2/2a
012.075/04
II - II
D
I-I
II
II
1
2/2a
94155b
1
2a
94155b
DRAWN FOR 812 and

14 CYL. ENGINES
2008
4/ 5
RT-flex96C
12241/A1
Maintenance

ARRANGEMENT OF THRUST BEARING PADS
FOR CLOCKWISE ROTATING ENGINES WITH
FIXED PITCH PROPELLER
6 and 7 CYLINDERS
AHEAD
ASTERN
016.725/08
VIEW FROM DRIVING END

PADS AT DRIVING END
ASTERN
VIEW FROM DRIVING END

PADS ON ENGINE SIDE
812 and 14 CYLINDERS
AHEAD
SUPPORT SURFACE
014.063/06
DRIVING END
ENGINE SIDE
PROPELLER THRUST
ASTERN
PROPELLER THRUST
AHEAD
003.685/95
PADS FOR ASTERN
PADS FOR AHEAD

SUPPORT SURFACE
5/ 5
2008
RT-flex96C
17151/A1
Maintenance
Engine Stays with Friction Shims

Checking the Pre-tension
Tools:
1
1
1
1
1
1
1
1
1
Feeler gauge
Pre-tensioning jack
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
HP hose
1.
94122
94145
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
7
8
Engine stays
Friction shims
Screw
Nut
Disc spring
Vent screw
Pin
Piston
9 Cylinder
10 Sealing ring
EV
KO
PP
RS
Relief valve
Slot
Closing piece
Round bar
General
Two friction type stays 1 are installed on the exhaust side of the engine (Fig. A).
CHECK
The pre-tension of screws 3 must be checked at specified intervals (see 03801).

FREE END
EXHAUST SIDE
II
011.408/03
II
SHIP SIDE
3
4
1/ 2
008.312/01
2008
17151/A1
Maintenance
RT-flex96C
Engine Stays with Friction Shims: Checking the Pre-tension
2.

Clean the screw thread and the seating surface. Subsequently apply MOLYKOTE G paste to the thread.
Place pre-tensioning jack 94145 on the screw to be checked, and screw it
completely down with vent screw 6 open until there is only little or no clearance
at x (Fig. B).
Connect pre-tensioning jack 94145 with HP oil pump 94931 as shown in Fig.
B, whereby one side of hydr. distributor 94934a must be closed with plug
piece 94934e.
Close relief valve EV at the HP oil pump, then actuate the HP oil pump until
the oil comes out without bubbles from opened vent screw 6.
Close vent screw 6, tension the screw with 200 bar and keep the pressure
constant.
CHECK
and its seating.
If there is no clearance, this means that the tensioning condition of the screw
has remained unchanged since the last check. The pressure can be released
to zero and the pre-tensioning jack removed.
Should a clearance be found, nut 6 must be tightened down onto its seating
with round bar RS while the pressure is kept at 200 bar (check with feeler
gauge). Subsequently lower the pressure to zero.
94935a
94932a
94145
94934e
6
7
8
94934a
94935
94932
9
4
10
3
KO
1
RS
94931
EV
2
5
011.674/04
3.
Loosening the screws

If the screws must be loosened, first screw on pre-tensioning jack 94145 completely, then loosen it by about turn. Afterwards tension the screw with 210 bar, and
turn nut 4 back by one turn. Attention should be paid to ensure that pin 7 always
protrudes slightly compared with piston 8 on the pre-tensioning jack!
2008
2/ 2
RT-flex96C
17151/A2
Maintenance
Hydraulic Engine Stays

Checking the Oil Pressure
1
2
3
4
1.
Hydraulic engine stays

Hydraulic cylinder
Bladder accumulator
Rod
5 Ball valve
6 Plug 3/8 NPT
7 Pressure gauge
General
Two hydraulic type stays 1 are installed each on the exhaust side and fuel side of
the engine.
CHECK
The oil pressures on the pressure gauges of the hydraulic cylinders must be
checked and compared with each other at regular intervals.
If one of the hydraulic cylinders shows a pressure below 30 bar, which could be
caused by defective O-rings, leaking valves or screwed connections, the opposite
hydraulic cylinder must also be released of its pressure till 30 bar.
The defective engine stays must be repaired at the first opportunity. Afterwards the
oil pressure must be readjusted to the required value on all the engine stays,
whereby the detailed instructions of the respective maker must be considered.
I
1
1
EXHAUST SIDE
FREE END
II
014.577/06
II
SHIP SIDE
004.078/98
1/ 1
2008
RT-flex96C
19031/A1
Maintenance
Tie Rod
Checking the Pre-tension and Tensioning the Tie Rods
Tools:
1
2
1
1
1
2
1
Feeler gauge
Pre-tensioning jacks
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94122
94180
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
12
Cylinder jacket
Upper intermediate ring
Upper tie rod nut
Cylinder
Piston
Round nut
Vent screw
Tie rod
Protection cover
Bore for solvent
Clamp screw
Column
13
14
15
16
17
AN
BN
KO
MS
RS
SA
Bearing girder
O-ring
Lower intermediate ring
Lower tie rod nut
Bush
Drain slot
Limiting groove
Slot
Measuring place
Round bar
Gap
Overview
1.
2.
3.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
Checking the pre-tension of tie rods . . . . . . . . . . . . . . . . . . . . . 1/5
Loosening and tensioning the tie rods . . . . . . . . . . . . . . . . . . . 3/5
General
We recommend that about one year after commissioning the engine all tie rods are
checked for their correct pre-tensioning and if necessary to tension them to the
specified value. Later it is sufficient to make random checks during major overhauls, or the pre-tension of all tie rods has to be checked within four years.
Remark: For such checks it is not required to loosen the waisted studs of the main
bearings nor the clamp screws 11 (Fig. D).
Pay attention to General Application Instructions 94034 for hydraulic pre-tensioning jacks.
2.
Checking the pre-tension of tie rods

Remove protection cover 9 from all tie rods and clean the contact face of upper intermediate ring 2.
Place both pre-tensioning jacks 94180 onto two tie rods lying opposite each
other.
Turn the pre-tensioning jacks so that the holes in tie rod nuts 3 are accessible.
Open vent screws 7 (Fig. A).
Tighten the round nuts 6 until there is only little or no clearance at x.
Connect both pre-tensioning jacks with hydraulic unit 94942 according to Fig.
A.
Actuate the hydraulic unit until bubble-free oil flows out through the vent
screws.
Remark: Hydraulic oil flowing out can be drained into a container by means of
hoses which are put over the vent screws.
Close the vent screws, operate the hydraulic unit up to 1000 bar and maintain
the pressure constant.
Never move the piston 5 of the pre-tensioning jack further up than to the red limiting groove BN (Fig. A).
1/ 5
2012-05
19031/A1
Maintenance
RT-flex96C
6
7
94935a
SA
x
94932a
5
4
94934a
BN
10
3
RS
KO
94935
MS
1
8
94942
PRE-TENSIONING JACK
PLACED FOR TENSIONING
CHECK
011.663/04
PRE-TENSIONING JACK
PLACED FOR LOOSENING
Using the feeler gauge 94122 inserted through slot KO, on the measuring place
MS, check whether tie rod nut 3 rests on intermediate ring 2 without any clearance.
If any clearance exists, tighten the tie rod nut with round bar RS until it rests
firmly on the intermediate ring (check with feeler gauge). Subsequently release the pressure to 0 bar at the hydraulic unit. If no clearance exists, the
pressure can immediately be released and the pre-tensioning jacks removed.
Check all the tie rods in this manner and, wherever necessary, tighten the tie
rod nut.
Protect the tie rod threads against corrosion by coating them with non-acidic
grease after the checking has been completed. Fit and fasten the protection
cover 9 (Fig D).
Remark: If the tie rod nut 3 is blocked/seized, it may be attempted to press in oil or
solvent through the bore 10 (G x 4 mm) with the pre-tensioning jacks placed
and pressurized so that the tie rods are lifted. At the same time insert a brass or
copper bar into a hole in the tie rod nut through the slotted aperture of cylinder 4
and first loosen, then tighten the nut with several heavy hammer blows. Make sure,
however, that the edge of the hole is not seriously deformed or it will be impossible
to remove the pre-tensioning jack. Seal off the bore 10.
2012-05
2/ 5
RT-flex96C
Maintenance
19031/A1
3.
Loosening and tensioning the tie rods

Should the tie rods have to be removed or fitted, the following principles have to be
observed:
Remove clamp screws 11 (Fig. D).
D
Tensioning has to be carried out in one procedure. The sequence is shown in

Fig. B, i.e. in pairs, first tie rods a/a, then b/b, etc.
Never move piston 5 of the pre-tensioning jack further up than to the red limiting
groove BN (Fig. A).
D
3.1
If the tie rods have been newly tightened, then the waisted studs of the main
bearings also have to be checked for correct pre-tensioning (see 11321).
Loosening
The procedure for loosening the tie rods is the same as the one described in section 2 Checking the pre-tension, except that round nuts 6 must be turned back by
four turns after being completely screwed down the pre-tensioning jacks (gap SA
in Fig. A). At this starting point connect the jacks with hydraulic unit 94942 and
operate it until a pressure of approx. 1030 bar is reached.
Turn the tie rod nuts 3 up until they fully seat on the pistons of the pre-tensioning jacks and then screw back them by four turns with round bar RS.
Release the pressure to 0 bar and remove the pre-tensioning jacks.
3.2
Tensioning
Preliminary works:
D
Clamp screws 11 must not be tightened up.
The lower tie rod nut 16 is screwed on.
Clean the seating surface for upper intermediate ring 2 and upper tie rod nut 3
and smear them with MOLYKOTE G paste.
Smear the tie rod thread for upper tie rod nut 3 lavishly with MOLYKOTE G
paste and screw the nut on (check for easy threading).
Screw the eye bolt into the tie rod and lift carefully until the lower tie rod nut
rests snugly against the bearing girder.
Risk of accident! Use a manual ratchet hooked onto the crane, with which the tie
rod can be lifted manually until the lower nut is snug on its seating, as with the crane
alone the landing of the nut cannot easily be felt and the rope might break.
In this position tighten the upper tie rod nut with round bar RS until firmly
seated on the intermediate ring, and separate the manual ratchet from the tie
rod.
CHECK
There must now be no clearance between bearing girder and lower tie rod nut and
the lower tie rod nut must be flush with the tie rod end (Fig. D).
Place pre-tensioning jacks 94180 onto the tie rods a/a.
Turn the pre-tensioning jacks so that the holes in tie rod nuts 3 are accessible.
Tighten round nuts 6 until there is only little or no clearance at x (Fig. A).
3/ 5
2012-05
19031/A1
Maintenance
RT-flex96C
Tie Rod
Tensioning in one procedure:
Connect the pre-tensioning jacks with the hydraulic unit 94942 (see Fig. A).
Actuate the hydraulic unit until bubble-free oil flows out through the vent
screws 7. Close the vent screws.
Raise the pressure to 100 bar, keep it constant and firmly tighten the two upper tie rod nuts 3 with the round bar RS.
Measure and record the distance L (the measurements can be taken directly
on the mounted pre-tensioning jacks, i.e. from the top edge of the tie rod 8 to
the cylinder 4).
Subsequently tension the tie rods with 1000 bar, keep it constant and firmly
tighten the two upper tie rod nuts 3 with the round bar RS.
Never move pistons 5 of the pre-tensioning jacks further up than to the red limiting
grooves BN (Fig. A).
Measure again the distance L and record it as L1.
The tie rods are correctly tensioned with 1000 bar when the following reference
value of a total elongation L (L1L) is measured:
L = 15.5 ... 17.5 mm
Release the pressure to 0 bar.
Proceed in the same way by following the required sequence for all tie rods
b/b, c/c, d/d ect.
After completing the tensioning, smear the protruding thread portions of all the
tie rods lavishly with an acid-free grease and fit the protection cover 9 (Fig D).
TIE ROD
ELONGATION
SEQUENCE
L1
FREE END
DRIVING END
DRAWN FOR 6 CYLINDERS
4
RS
3
DRAWN FOR 8 CYLINDERS
011.665/04
011.663/04
2012-05
4/ 5
RT-flex96C
19031/A1
Maintenance
Tie Rod
D
IV
IV
III - III
8
9
11
10
II
17
12
II
17
III
III
11
1
I
13
8
13
14
AN
16
I
FLUSH
011.665/04
15
5/ 5
2012-05
RT-flex96C
Maintenance

Group2
Group 2
Cylinder Liner
Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21241/A1
Removing the Wear Ridge, Re-dressing Lubricating Grooves
and Scavenge Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21243/A1
Lubricating Quill
and Accumulator: Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21361/A1
with Pulse Jet Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 21381/A1
with Pulse Feed Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . 21381/A2
Piston Rod Gland: Dismantling and Assembling, Measuring the Wear . . . . . . . . . 23031/A1
Cylinder Cover
Removal and Fitting of Cylinder Cover and Water Guide Jacket . . . . . . . . . . . . 27081/A1
Loosening and Tensioning of Cylinder Cover Waisted Studs . . . . . . . . . . . . . . . 27082/A1
Machining of Sealing Face for Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27083/A1
Injection valve
Checking, Dismantling, Assembling & Adjusting with O.M.T. Test Bench . . . . 27221/A1
Checking, Dismantling, Assembling & Adjusting with OBEL Test Bench . . . . . 27221/A2
Starting Valve: Removal, Fitting and Dismantling, Grinding-in & Assembling . . . . 27281/A1
Relief Valve for Cylinder Cover: Checking Blow-off Pressure . . . . . . . . . . . . . . . . . 27451/A1
Exhaust Valve
Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs . . . . . . . . . 27511/A1
Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27513/A1
Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . 27514/A1
1/ 1
RT-flex96C
21241/A1
Maintenance
Cylinder Liner
Measuring Bore Wear
Tools:
1 Inside micrometer
1 Ladder
1 Measuring gauge
94101
94224
94225
1 Cylinder liner
2 Antipolishing ring
ST Setting screw
SETTING SCREW ST DRAWN FOR COMPRESSION SHIM THICKNESS = 0 mm.

ST
94225
The cylinder liner wear is to be determined after every piston removal with the cylinder liner
in situ.
000.786/99
To permit comparisons with previous measures always carry out measuring in the same
place and note down the values in a log.
Always use the properly adjusted measuring
gauge 94225.
CHECK
Check setting screw ST. Its lower protruding length must correspond to the
mean thickness of the built-in compression shims. This ensures that the topmost
measuring point is located between the top
ring wear ridge and the antipolishing ring.
The unrun position must be thoroughly
cleaned from any deposits or lacquer before
measurement.
Hook the measuring gauge over the top face

of the cylinder liner.
The measurements have to be taken in longitudinal and transversal directions to the engine axis by putting the inside micrometer
94101 into the holes provided in the measuring gauge.
94101
CHECK
For maximum permissible inside diameter refer to Clearance Table 03301 Cylinder liner.
The ridge at the top of the cylinder bore has to

be removed carefully without damaging the
running surface for the piston rings (see
21243).
Remove the lower part of the measuring
gauge 94225 for measuring the cylinder liner
with piston in situ. Turn piston to B.D.C.
014.242/06
1/ 1
2011-05
RT-flex96C
21242/A1
Maintenance
Cylinder Liner
Removal and Fitting
Tools:
1 Device
94201(a)
consisting of:
1
2
2
2
2
4
1
1
1
1
1
1
2
2
Lifting gear
Plates
Guide elements
Suspension straps
Special screws
Suspension straps
Lifting hook
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydr. jacks
94202(a)
94202b
94202c
94206(a)
94207
94208
94209
94931
94932
94932a
94934a
94935
94935a
94936
1
2
3
4
5
6
7
8
9
10
11
Screw
Water guide jacket
Supporting ring
Cylinder liner
Cylinder jacket
Allen screw
Centring pin
Centring pin
Cylinder cover
Screw
Lifting ring
12
13
13a
14
15
16
Antipolishing ring
O-ring
O-ring
O-ring
O-ring
Bush
AF
EV
HU
RC
Seating surface
Relief valve
Wooden underlay
Eye bolt M16
Overview
1.
1.
Preparations for removal of cylinder liner . . . . . . . . . . . . . . . . 1/9
2.
Removal of cylinder liner (with small crane hook) . . . . . . . . 2/9
3.
Removal of cylinder liner (with big crane hook) . . . . . . . . . . 3/9
4.
Removal of jammed cylinder liner . . . . . . . . . . . . . . . . . . . . . . . 4/9
5.
Removal and fitting of antipolishing ring . . . . . . . . . . . . . . . . 5/9
6.
Removal and fitting of supporting ring . . . . . . . . . . . . . . . . . . 5/9
7.
Preparations for fitting cylinder liner . . . . . . . . . . . . . . . . . . . . 7/9
8.
Fitting cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/9
9.
Laying down and raising cyl. liner (w. small crane hook) . . 8/9
10.
Laying down and raising cyl. liner (w. big crane hook) . . . . 9/9
Preparations for removal of cylinder liner

Drain cylinder cooling water from the respective cylinder and remove cylinder
cover (see 27081). Remove the screws to the connection of the cooling water inlet from supporting ring 3.
Remove the piston together with piston rod gland (see 34031 and 23031).
Loosen and remove screws 1 which fasten supporting ring 3 to cylinder liner
4 (Fig. G).
Separate all piping connections for cylinder oil from the lubricating quills. All
passages and lubricating quills as well as their protecting bushes must
be removed whenever a cylinder liner is being pulled out (see 21361 or
21381).
General Application Instructions 94034 for hydraulic pre-tensioning jacks.
1/ 9
2012-05
21242/A1
Maintenance
RT-flex96C
Cylinder Liner: Removal and Fitting
2.
Removal of cylinder liner (with small crane hook)

A cylinder liner can be removed normally by crane and lifting gear, whereby the
following must be observed:
2.1
Placing lifting gear

Place lifting gear 94202a with the lightly fastened suspension straps 94206a
onto cylinder liner 4.
Loosen screws 10 correspondingly so that suspension straps can be fastened
to cylinder liner with special screws 94207. Hand-tighten the latter with
approx. 30 Nm.
Equally screw in the four screws 10 until the suspension straps touch the special screws. Hand-tighten screws 10 with approx. 30 Nm.
Remark: Subsequently length x of the thread screwed-in should be min. 1.2-fold
of the thread diameter.
Fasten plates 94202b and guide elements 94202c to the lifting gear (Fig. A).
10
94202a
94206a
94207
4
012.061/04
94202c
94202b
2008
2/ 9
RT-flex96C
Maintenance
21242/A1
3.
Removal of cylinder liner (with big crane hook)

A cylinder liner can be removed normally by crane and lifting gear, whereby the
following must be observed:
3.1
Placing lifting gear

Place lifting gear 94202 with the lightly fastened suspension straps 94206
onto cylinder liner 4.
Loosen screws 10 correspondingly so that suspension straps can be fastened
to cylinder liner with special screws 94207. Hand-tighten the latter with
approx. 30 Nm.
Equally screw in the four screws 10 until the suspension straps touch the special screws. Hand-tighten screws 10 with approx. 30 Nm.
Remark: Subsequently length x of the thread screwed-in should be min. 1.2-fold
of the thread diameter.
10
94202
94206
94207
4
003.333/00
3/ 9
2008
21242/A1
Maintenance
RT-flex96C
4.
Removal of jammed cylinder liner

If a cylinder liner jams in the cylinder jacket bore, proceed as follows:
Place both wedges 94203 at the bottom of cylinder jacket 5 as shown in Fig.
C. Thereby the bigger end of the wedges must point towards fuel side.
Place both hydr. jacks 94936 on wedges 94203 and push them against the
cylinder liner.
Connect hydr. jacks by HP hoses 94935 and 94935a as well as hydr. distributor 94934a to HP oil pump 94931.
Close relief valve EV at the HP oil pump, and jack out the cylinder liner of its
guide portion by slowly pumping.
C
FUEL SIDE
001.465/97
94935a
94203 94936
I-I
4
94932a
94934a
94932
001.465/97
94931 EV
2008
94935
94935a
4/ 9
94936
RT-flex96C
21242/A1
Maintenance

5.
Removal and fitting of antipolishing ring

Four suspension straps 94208 are fitted for removing and fitting the antipolishing ring as shown in Fig. D.
The latter can be moved with the aid of lifting hook 94209 connected to the
suspension straps and the crane.
Before fitting, clean seating surfaces on antipolishing ring and cylinder liner.
Smear the antipolishing ring lightly with oil.
Further pay attention that one of the holes for fastening the suspension straps
lies on fuel side.
94209
94208
12
4
012.073/04
6.
Removal and fitting of supporting ring
6.1
Removal
Supporting ring 3 (Fig. E and G) is fastened with three Allen screws 6 and
Bush 16 to cylinder jacket 5 and located on fuel side by centring pin 7. For the
removal of the supporting ring the three Allen screws 6 can be used as jacking
screws (see Fig. F).
6.2
Fitting
The sealing surfaces on supporting ring and cylinder jacket must be cleaned
and then smeared with a non-hardening sealing compound (e.g. silicone).
Place the supporting ring.
Oil threads of screws 6, fit them with bushes 16 and apply a torque of 400 Nm.
3
16
7
5
004.087/98
5
016.844/08
5/ 9
004.087/98
2012-05
21242/A1
Maintenance
RT-flex96C
8
1
II
I-I
II
III
2
8
III
AF
3
000.785/99
008.325/01
000.785/99
EXHAUST SIDE
II - II
IV
1
FUEL SIDE
9
2
14
15
1
IV
4
3
000.785/99
3
4
13
008.326/01
13a
5
WCH00860
2012-05
6/ 9
RT-flex96C
Maintenance
21242/A1
7.
Preparations for fitting cylinder liner

Clean all guide areas and sealing surfaces on cylinder liner 4, cylinder jacket 5
and on supporting ring 3.
Place O-rings 13 and 13a of the specified quality and dimension into the
grooves on the cylinder liner.
Smear O-rings and guide areas of cylinder liner, cylinder jacket and supporting ring with lubricating oil.
Clean the seating surfaces AF of supporting ring 3 and cylinder liner 4 carefully (Fig. G section I-I).
8.
Fitting cylinder liner

Mount lifting gear 94202a according to Fig. A or 94202 to Fig. B.
Move the cylinder liner hanging on the crane above the supporting ring 3.
Lower the cylinder liner and apply a non-hardening sealing compound to the
seating surfaces AF (Fig. G section I-I).
Turn cylinder liner and align the centring pin 8 with the centring holes of the
supporting ring and cylinder liner. Lower cylinder liner.
Fit screws 1 and tighten them firmly for locking the cylinder liner onto the supporting ring (Fig. G section II-II).
7/ 9
2012-05
21242/A1
Maintenance
RT-flex96C

9.
Laying down and raising cylinder liner (with small crane hook)
Place lifting gear 94202a as described in paragraph 2.1.
Connect rope a (lifting capacity 10 000 kg) with crane and lifting ring 11. Lay
down the cylinder liner as shown below and secure it against rolling away.
Raising the cylinder liner is carried out in reversed sequence.
Risk of accident! Laying down and raising a cylinder liner must not be done
in any other way than as shown in the figures!
11
94202a
HU
HU
012.065/04
9.1
Preparation for raising a cylinder liner

Install the eye bolt RC on the side of lifting gear 94202a.
Use the crane to transport the lifting gear to the cylinder liner.
Mount the lifting gear to the cylinder liner as described in paragraph 2.1.
Lift the cylinder liner as described above.
J
RC
94202a
HU
012.065/04
2008
8/ 9
RT-flex96C
21242/A1
Maintenance

9
10.
Laying down and raising cylinder liner (with big crane hook)
Place lifting gear 94202 as described in paragraph 3.1.
Connect rope a (lifting capacity 10 000 kg) with crane and lifting gear. Lay
down the cylinder liner as shown in Fig. L to N and secure it against rolling
away.
D
Raising the cylinder liner is carried out in reversed sequence.
Risk of accident! Laying down and raising a cylinder liner must not be done
in any other way than as shown in the figures, i.e. in longitudinal direction of
lifting gear 94202!
a
94202
HU
HU
9/ 9
HU
012.066/04
2008
RT-flex96C
21243/A1
Maintenance
Cylinder Liner
Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports
Tools:
1 Wear ridge grinding device 94299
1.
1
2
3
4
5
6
7
8
Roller support
Holder
Holder
Spacer roller
Pipe (column)
Grinder
Air hose
Hose oiler
9
10
11
12
Thread nozzle
Carbide milling cutter
Cylinder liner
Top piston ring
SI Scavenge port
SN Lubricating grooves
SN1 Collection / pressure reducion
grooves
General
Due to wear in the cylinder liner a ridge is formed on top to where the piston rings do
not reach. By that also the lubricating grooves in the cylinder liner lose their depth,
and the corner radii of the scavenge port edges become smaller.
After every piston removal measure the bore of the cylinder liner (see 21241) and
remedy any irregularities. For that the following points are of importance:
2.
Protect the space below the cylinder liner from falling particles.
After completing the reconditioning clean the bore of the cylinder liner thoroughly (particularly the lubricating grooves).
Remove waste particles which may have passed into the scavenge space
through the ports.
Actuate the cylinder lubrication until oil flows from all the lubricating points,
thereby flushing away any metal dust.
Removing the wear ridge

When grinding away the wear ridge take greatest care not to damage the running
surface. The machining of the wear ridge has to be carried out as shown in Fig. B.
Therefore, always use wear ridge grinding device 94299 for carrying out this work.
3.
Re-dressing the lubricating grooves

If the depth of the lubricating grooves has worn to less than 1.5 mm re-dress them
to their original depth and slightly round their edges with an oil stone.
Remark: For collection / pressure reducing grooves SN1 there are two possible
groove-machining options according to section II-II in Fig. A.
4.
Re-dressing the edges on the scavenge ports

The shape of the scavenge ports shown in Fig. A corresponds to new cylinder liners. When reconditioning (depending on the degree of wear or damage) aim at
matching these shapes. Take care not to damage the running surface in the cylinder liner bore! Polish (round) the passages into the running surface with emery
cloth.
1/ 3
2011-05
21243/A1
Maintenance
RT-flex96C
Cylinder Liner: Re-dressing Lubricating Grooves and Scavenge Ports
I-I
III
SN
III
I
I
EDGES ROUNDED OFF
II
II
003.267/00
II-II
SI
SN1
III-III
I
WCH00442
011.350/04
2011-05
2/ 3
RT-flex96C
21243/A1
Maintenance
Cylinder Liner: Removing the Wear Ridge
94299
11
10
10
2
3
T.D.C.
2 3 mm
1 mm
12
11
009.004/01
3/ 3
2008
RT-flex96C
21361/A1
Maintenance
Lubricating Quill and Accumulator

Function Check
1
2
3
4
5
6
7
8
9
10
11
12
13
14
24
23
22
Accumulator cylinder
Spring
Accumulator piston
Cap nut
Diaphragm
Accumulator casing
Cap nut
Backing screw
Copper sealing rings
Cylinder liner
Lubricating quill
Passage for lubricating quill
Filling pin
Steel ball
21
20 19
16
15
16
17
18
19
20
21
22
23
24
Non-return valve housing

Flange ring
Screw
Support ring
Flange
Joint
Protecting bush
O-ring
Piston ring
Piston
DF Sealing surface
LB Leak oil bore
LB
1
2
3
4
5
6
14
15
7
8
014.252/06
17 11
DF
1.
General
1.1
Function check
10
13
18
12
Actuate the cylinder lubricating pump until oil emerges from all the lubricating
points in the bore of the corresponding cylinder liner. Note that on cylinder liners
with two rows of lubricating grooves (Multi-Level Lubrication) the oil delivery for
upper and lower row of lubricating grooves may be differently set (correct setting is
recorded on the acceptance records). Whatever the settings, make sure that on all
the lubricating points of the same row of lubricating grooves the oil outflow quantity
is equal.
1/ 2
2008
21361/A1
Maintenance
RT-flex96C
Lubricating Quill and Accumulator: Function Check
1.2
Check of accumulator
During a major overhaul check at random several accumulators or if there are oil
leakages through bores LB (Fig. A), open the relevant accumulators. Check the
condition of the diaphragms and defective or brittle ones must be replaced. Do not
use any sharp-edged objects for fitting new diaphragms!
1.3
Check of non-return valve

The non-return valve must also be checked for correct functioning. Therefore, the
complete lubricating quill and accumulator must be removed.
CHECK
If compressed air is blown into X no air must emerge from Y.

If compressed air is blown into Y air must emerge from X.
014.253/06
2.
Removing and fitting

If a non-return valve has to be replaced, remove backing screw 8 together with
filling pin 13.
After fitting the new part tighten the backing screw with 50 Nm and lock it with a
centre punch.
Before removing a cylinder liner 10, the passages for lubricating quills 12 and
protecting bushes 21 must be first disconnected.
Attention! The flange 19 must never be removed before the cylinder cooling water
has been drained.
D
If only the passage for lubricating quill 12 has to be removed, with cylinder liner fitted, then the protecting bush may remain in place.
When refitting the passage for lubricating quill take care that sealing surface
DF between cylinder liner and passage for lubricating quill is absolutely
clean. Sealing surface DF must seal metallically and the use of gaskets is
prohibited!
Remark: The design of the lubricating quills for the upper and the lower row of lubricating grooves is the same.
Non-return valves are only supplied complete with filling pin as replacement parts.
2008
2/ 2
RT-flex96C
21381/A1
Maintenance
Lubricating Quill
Removal and Fitting
with Pulse Jet Lubrication
Tool:
1 Tool box
with fittings for
charging accumulator
1 HP oil pump
1 Hydr. distributor
(with pr. gauge 0...25 bar)
1 Connection nipple (G)
1 HP hose
1.
94720c
1
2
3
4
5
6
7
8
9
10
11
94931
94934h
94934i
94935
Cylinder liner
Lubricating pump
Screw-in union
Union nut
Angle union
Lubricating oil pipe
Supporting ring
Lubricating quill
Nozzle tip
Non-return valve
Housing
12
13, 13a
14
15
16
17
18
19
21, 22
Bush
Flange
Joint
Screw M8x40
Screw M8x100
4/2-way solenoid valve
Sink plunger
Pin (tool)
O-ring
DF Sealing surface
General
If only the lubricating quill must be removed, with cylinder liner in situ, then bush 12,
flanges 13 and 13a may remain in place. Therefore, the cylinder cooling water
must not be drained.
In order to remove cylinder liner 1 or supporting ring however, all lubricating quills
and bushes must be dismantled, whereby the cylinder cooling water must be
drained on the relevant cylinder (see 27081 Removal of cylinder cover).
Remark: For the additional lubrication of exhaust valve spindle see detailed instructions in the Operating Manual 72181.
2.
Removal of the cylinder lubricating oil pipe

Loosen the connection to angle union 5.
Hold the position of the screw-in union 3 with an

open-end spanner while loosening the union nut 4.
Remove lubricating oil pipe 6 and protect it against
damage and dirt.
I
43
6
2
1/ 4
CLU4 / 2012-05
21381/A1
Maintenance
RT-flex96C
Lubricating Quill
2.
Removal and fitting of lubricating quill

Loosen the screw 16.
Remove the housing 11.
Remark: The assembly of nozzle tip / nozzle holder is based on the press fit design. The lubricating quill must be replaced as a whole unit, i.e. nozzle tip 9
with non-return valve 10 inserted and the housing 11.
D
When refitting the lubricating quill, the sealing surface DF must be clean and
undamaged, as it seals metallically. Moreover, the proper seat angles in the
cylinder liner (120_) and on the nozzle tip (114_) differs slightly. Therefore, do
not use any gasket between cylinder liner 1 and nozzle tip 9!
Tighten the oiled screws 15 with a torque of 20 Nm and 16 with 10 Nm.
Fit a new joint 14 as well as O-rings 21 and 22.
I-I
12
7 13a 13
15
16
3
I
II
I
DF
21
14 22
11
II
9
11
WCH00857
2012-05
2/ 4
RT-flex96C
21381/A1
Maintenance
Lubricating Quill
3.
Checking a non-return valve

For judging the proper functioning of the non-return valve an opening pressure test
(opening pressure = 5 bar) must be carried out.
During testing the lubricating quill should be kept in horizontal position and an oil
with a viscosity of either SAE 50 at 40_C (approx. 200 cSt) or SAE 30 at 25_C
(approx. 190 cSt) must be used.
3.1
Test procedure
D
Instead of screw-in union, fit connection nipple 94934i into lubricating quill.
Connect lubricating quill 8 to oil pump 94931 as shown below.

Vent the lubricating quill.
Apply a pressure of 2 bar and increase it in steps of 1 bar until the non-return
valve opens.
Note down the opening pressure.
Remark: The opening (cracking) pressure should be at least 4.25 bar for correct
functioning.
The non-return valve must be replaced in case of:
D
If the non-return valve does not open at 4.25 bar, it does not function properly
or it is damaged.
C
94934i
94931
WCH00859
10
94934h 94935
3/ 4
2012-05
21381/A1
Maintenance
RT-flex96C
Lubricating Quill
4.
Venting of the cylinder lubricating system

After the assembly of the lubricating quills, a function control of the lubricating system must be carried out. Prior to the function control, all single cylinder lubricating
oil pipes 6 must be vented at the connection of the screw-in union 3 and the union
nut 4.
Select the respective cylinder number on the context MANUAL LUBRICATION ON CYLINDER shown on the operator interface or manually operate
the 4/2 way solenoid valve 17 as shown in Fig. D.
Hold the position of the screw-in union 3 with an open-end spanner while loosen the union nut 4. Loosen the union nut 4 only by about 1 to 2 turns.
Push with the pin 19 (diameter 3.5 mm) on top of the sink plunger 18 of the
4/2-way solenoid valve. This must be repeated until the cylinder lubricating oil
is flowing bubble-free out of the loosened connection.
Remark: As described above the lubricating module can also be operated with the
operator interface of the control system. Further information is given in the Operating Manual 72181.
Hold the position of the screw-in union 3 with an open-end spanner while tightening the union nut 4.
D
If all cylinder lubricating oil pipes are vented and afterwards properly tightened
again, actuate the cylinder lubrication module until cylinder oil emerges from
all lubricating points in the bore of the respective cylinder liner. This visual inspection of the lubrication process is carried out through the scavenge ports at
piston underside and the piston is therefore at T.D.C. position.
If there are signs of irregularities with nozzle tips 9 , they must be replaced!
17
18
19
015.438/07
2008 / CLU4
4/ 4
RT-flex96C
21381/A2
Maintenance
Lubricating Quill
Removal and Fitting
with Pulse Feed Lubrication
Tool:
1 Tool box
with fittings for
charging accumulator
1 HP oil pump
1 Hydr. distributor
(with pr. gauge 0...25 bar)
1 HP hose
1.
94720c
94931
94934h
94934i
94935
1
2
3
4
5
6
7
8
9
10, 10a
11
Cylinder liner
Lubricating pump
Accumulator
Supporting ring
Passage for lubricating quill
Bush
Screw-in union
Non-return valve
Filling pin
Flange
Joint
12
13
14
15
16
17
18
19
Screw
Adjustable angle union
Pipe bracket
4/2-way solenoid valve
Sink plunger
Pin (tool)
O-ring
DF Sealing surface
General
If only the lubricating quill (i.e. screw-in union 7, non-return valve 8 and filling pin 9)
must be removed, with cylinder liner in situ, then bush 6, flanges 10 and 10a may
remain in place. Therefore, the cylinder cooling water must not be drained.
In order to remove a cylinder liner 1 or supporting ring 4 however, all lubricating
quills and bushes must be dismantled, whereby the cylinder cooling water
must be drained on the relevant cylinder (see 27081 Removal of cylinder
cover).
Remark: For the additional lubrication of exhaust valve spindle see detailed instructions in the Operating Manual 72181.
12
13
EXHAUST
SIDE
15
3 2
14
1/ 4
017.087/08
CLU4 / 2012-05
21381/A2
Maintenance
RT-flex96C
Lubricating Quill
2.
Removal and fitting of lubricating quill

Loosen lower union nut of adjustable angle union 13 and pipe bracket 14 (Fig.
A). Separate lubricating oil pipe 15 and protect it against any damages and
entering of dirt.
Remove complete lubricating quill, if necessary also passage 5 and bush 6.
D
When refitting the lubricating quill take care that sealing surface DF is absolutely clean, as it seals metallically. Therefore, do not use any gaskets between cylinder liner 1 and passage for lubricating quill 5!
Oil and tighten passage for lubricating quill 5 with a torque of 30 Nm.
(Replace joint 11 and fit new O-rings 19.)
10 10a
7 (AF24)
13
DF
15
WCH00440
2012-05
19
2/ 4
11
12
5 (AF32)
RT-flex96C
21381/A2
Maintenance
Lubricating Quill
3.
Non-return valve
Remark: Always replace a non-return valve completely, i.e. screw-in union 7 with
fitted non-return valve 8 and filling pin 9.
Oil and tighten screw-in union with a torque of 30 Nm.
WCH00441
1 mm
8
9
3.1
Checking a non-return valve

For judging the proper functioning of the non-return valve an opening pressure test
(opening pressure = 5 bar) must be carried out.
During testing the lubricating quill should be kept in horizontal position and an oil
with a viscosity of either SAE 50 at 40_C (approx. 200 cSt) or SAE 30 at 25_C
(approx. 190 cSt) must be used.
3.2
Test procedure
Instead of screw-in union, fit connection nipple 94934i into screw-in union 7.
Connect and vent the lubricating quill as shown below.
Vent the lubricating quill.
Apply a pressure of 2 bar and increase it in steps of 1 bar till the non-return
valve opens.
Note down the opening pressure.
Remark: The opening (cracking) pressure should be at least 4.25 bar for correct
functioning.
With an opening pressure below 4.25 bar the non-return do not function properly or
it is damaged and must be replaced.
D
94934i
WCH00440
001.547/97
94931
94934h 94935
3/ 4
2012-05
21381/A2
Maintenance
RT-flex96C
Lubricating Quill
4.
Venting of the cylinder lubricating system

A function control must be carried out after every assembly of the lubricating quills,
tightening lubricating oil pipes 15 and pipe brackets 14. The lubricating oil pipes
must be vented at angle union 13 and the lower union nut.
Select the respective cylinder number on context MANUAL LUBRICATION
ON CYLINDER shown on the operator interface or manually operate 4/2-way
solenoid valve 16.
Hold the position of the angle union with an open-end spanner while loosening
the lower union nut by about 1 to 2 turns.
Push with pin 18 (diameter 3.5 mm) on top of sink plunger 17 of the 4/2-way
solenoid valve. This must be repeated until the cylinder lubricating oil is flowing bubble-free out of the loosened connection.
Remark: As described above the lubricating module can also be operated with the
operator interface of the control system. Further information and adjustments
about the lubricating pumps are given in the Operating Manual 72181.
Hold the position of the angle union with an open-end spanner while tightening the lower union.
D
If all cylinder lubricating oil pipes are vented and afterwards properly tightened
again, actuate the cylinder lubrication module until cylinder oil emerges from
all lubricating points in the bore of the respective cylinder liner. This visual inspection of the lubrication process is carried out through the scavenge ports at
piston underside and the piston is therefore at T.D.C. position.
TO LUBRICATING
QUILLS
SERVO OIL
16
17
18
015.438/07
2008 / CLU4
4/ 4
RT-flex96C
23031/A1
Maintenance
Piston Rod Gland

Dismantling and Assembling, Measuring the Wear
Tools:
1 Dismantling device
(recommended special tool)
2 Distance holders
1 Clamp ring (2-part)
1 Gauge
2 Spring assembly tools
4 Distance pieces
1 Piston supporting device
94344
94345
94345b
94345c
94345e
94345f
94350
1
2
3
4
5
6
7
7a
8
9
10
11
Housing (2-part)
Scraper ring
Sealing ring
Sealing ring
Ring support
Scraper ring
Locating pin
Locating pin
Tension spring
Tension spring
Screw
Screw
12
13
13a
14
15
16
17
18
19
20
21
22
Cylinder cover stud

Screw
Fitted bolt
Locking plate
Screw
Cylindrical pin
2-part ring
Cylinder jacket
Hinged cover
Piston rod
O-ring
O-ring
Overview
1.
2.
2.1
2.2
2.3
3.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, dismantling and assembling (variant 1) . . . . . . .
Removing a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, dismantling and assembling (variant 2) . . . . . . .
1/7
2/7
2/7
2/7
4/7
6/7
General
The removal of the piston rod gland (hereafter called gland) can be carried out in
two different ways, i.e. removing the gland together with the piston (variant 1) or
removing the gland downwards into the crankcase leaving the piston in situ and
using the dismantling device 94344 (variant 2).
On every piston overhaul, the gland must also be dismantled and inspected. Excessively worn or damaged parts are to be replaced.
It is important that the gland be in perfect condition when assembled. A possible
earlier than planned inspection of the gland with a piston in situ can only be carried
out under difficult conditions and with the help of the dismantling device 94344.
1/ 7
2008
23031/A1
Maintenance
RT-flex96C
Piston Rod Gland: Dismantling and Assembling, Measuring the Wear
2.
Removing, dismantling and assembling (variant 1)

2.1
Removing a gland
For removing the gland, both distance holders

94345 are to be screwed on the foot of piston rod
20 (Fig. A).
17
Unscrew the four outer screws 15 to 2-part ring

17 (Fig. B).
94345
20
Attention! For reasons of safety, the eight inner

screws 10 to 2-part ring 17 are to be loosened and
removed after dismantling the gland (Fig. B).
Remove the gland including the piston (see
34031 Removal of a piston).
12
011.405/04
2.2
Dismantling a gland
Place the piston in piston supporting device 94350. For this 2-part housing 1
of the gland must rest on the two hinged covers 19 of the device.
Loosen screws 10, 11 and remove 2-part ring 17 (Fig. B).
Loosen and remove screws 13 and fitted bolts 13b to 2-part housing.
Push the two gland housing halves away from the piston rod.
Remove all tension springs, scraper rings, sealing rings and ring supports.
On the following parts wear has to be measured (see Fig. D):
Scraper rings
Sealing rings
2008
2 and 6
3 and 4
The admissible wear on the wearing parts is indicated in Clearance Table

03301 Piston rod gland. Parts which are beyond the admissible tolerance
must be replaced.
If necessary remove scraper rings 6 from ring supports 5 and replace them
with new ones.
Defective tension springs 8, 9 and O-rings 21, 22 have to be replaced with

new ones.
2/ 7
RT-flex96C
23031/A1
Maintenance
I-I
II
1
22
10 17
15
16
21
13a 13
20
21
18
FUEL SIDE
II
11
13a
16
17
10
14
15
011.451/04
3/ 7
2008
23031/A1
Maintenance
RT-flex96C
11 mm
94345f
2
3
4
3
4
19 mm
009.655/02
19
94345f
009.654/02
94345b
94350
94345b
11 mm
5
94345f
009.655/02
20
011.468/04
94345
017.874/08
2.3
Assembling a gland
Place the piston in piston supporting device 94350, its hinged covers 19 must
be folded down.
Attach clamp ring (2-part) 94345b resting on the hinged cover to piston
rod.
Place the three parts of a ring support 5 on the clamp ring with scraper rings 6
fitted. Distribute the distances evenly.
Use assembly tool 94345e (see 94035) for fitting tension spring 9.
Place two distance pieces 94345f (11 mm) on ring support 5 and fit another
ring support with scraper ring 6 and tension spring 9 as described above.
D
2008
The height of distance pieces 94345f corresponds to the respective web

height of the ring grooves in 2-part housing 1.
4/ 7
RT-flex96C
23031/A1
Maintenance
D
2
GROOVE a
7a
3
GROOVE b
4
3
4
GROOVE c
GROOVES
di
9
1
011.485/04
18
After assembly of the ring supports for grooves d i (Fig. D), place two distance pieces 94345f (19 mm) on the uppermost ring support 5 and fit sealing
rings 3, 4 and tension spring 8 for groove c.
D
Take care that one segment is always provided with two horizontal locating
pins 7a lying side by side on sealing ring 4. These locating pins must fit into the
corresponding bores in sealing ring 3. Remove possibly existing vertical locating pins 7.
The remaining three segments are provided only with one horizontal locating
pin each.
Place two distance pieces 94345f (19 mm) on the assembled sealing ring 3
and fit again sealing rings 3, 4 and scraper ring 2 with tension spring 8 for
groove b.
D
Proceed in the same way as mentioned above for sealing rings 3 and 4, however, a vertical locating pin 7 in sealing ring 3 must fit into the respective recess
in scraper ring 2.
No vertical locating pin may be fitted in the scraper ring.
Place two distance pieces 94345f (11 mm) on the assembled scraper ring 2
and fit the two uppermost scraper rings 2 with tension springs 8 for groove a.
No vertical locating pin may be fitted in the uppermost scraper ring.
5/ 7
2008
23031/A1
Maintenance
RT-flex96C
E
Remove all distance pieces 94345f and clamp ring
94345b.
CHECK Check the proper position of all rings with gauge
94345c resting on hinged cover 19.
Smear piston rod as well as all rings with bearing
oil.
94350
94345c
19
Push both housing halves 1 on hinged covers 19

over the ring pairs against the piston rod, then
screw them together with screws 13 and fitted
bolts 13b according Fig. B.
Place O-rings 21 and 22.
Place 2-part ring 17 on the housing and locate it by
means of cylindrical pin 16 (Fig. B).
Fit screws 10 and 11 with locking plates 14.
Just before the gland is fitted with the piston, apply
lubricating oil to the respective bores in the cylinder jacket as well as to the gland housing in the region of the O-rings.
20
94345
When fitting the gland into the cylinder jacket distance holders 94345 must be mounted on the piston rod foot.
For fitting the gland in the cylinder jacket see also

34031.
017.875/08
3.
Removing, dismantling and assembling (variant 2)

For removing the gland with piston in situ using dismantling device 94344 (Fig. F)
the following procedure should be observed:
Turn the piston to B.D.C.
Dismantling device 94344 (2-part) as shown in Fig. F is to be set on the stud
nuts of the crosshead/piston rod connection and both halves of the dismantling device are to be screwed together.
Loosen and remove the four outer screws 15 from 2-part ring 17 (Fig. B).
Turn the piston with the mounted dismantling device carefully to T.D.C. until
the 2-part ring is pushed a little upwards (Fig. F).
Loosen and remove the eight inner screws 10 (Fig. B).
2008
6/ 7
RT-flex96C
23031/A1
Maintenance
F
1
94345b
17
18
94344
20
94345b
94344
Clamp 2-part clamp ring 94345b to
piston rod 20 lying on housing 1.
Turn the piston slowly to B.D.C.
again and pay attention that the
gland slides out of the gland bore in
the cylinder jacket without jamming.
2-part ring 17 remains on cylinder
jacket 18.
D
CHECK
I-I
The same procedure as mentioned

in the previous section (variant 1) is
to be applied here for dismantling
and assembling a gland, with the
exception that the dismantling and
assembling is carried out using dismantling device 94344 instead of
piston supporting device 94350.
Attention should be paid that the gland

slides into the bore of the cylinder jacket
without jamming when assembling it
using dismantling device 94344 and the
turning gear.
Fit 2-part ring 17 in T.D.C. (Fig. B)
screw in and tighten screws 10 and
lock these.
94344
Turn the piston to B.D.C. and remove dismantling device 94344.

Subsequently screw in and tighten
screws 15.
011.495/04
7/ 7
2008
RT-flex96C
27081/A1
Maintenance
Cylinder Cover
Removal and Fitting of Cylinder Cover and Water Guide Jacket
Tools:
1
2
3
1
Suspension device
Spec. (nut) eye bolts
Protection caps
Cradle
94265(c)
94265a
94265b
94266
1
2
2a
3
4
5
5a
6
Cylinder cover
Nut
Cylinder cover stud
Cyl. cooling water outlet
Leak oil drain
Exhaust valve cage
Stud to exhaust valve cage
Connection for valve
shank lubrication
7 Hydraulic piping
8 Air inlet for air spring
9 Water guide jacket
10
11
12
13
14
15
16
17
18
Allen screw
Screw M20x200
Platform support
Fixing screw
Plug
Control box
O-ring
O-ring
DB Through hole
RC Eye bolt
Overview
Removal of cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport of cylinder cover (with big crane hook) . . . . . . . .
Transport of cylinder cover (with small crane hook) . . . . . .
Fitting of cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of water guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting of water guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.
2.
3.
4.
5.
6.
1.
1/7
2/7
3/7
4/7
5/7
7/7
Removal of cylinder cover
Drain the cylinder cooling water from the affected

cylinder, i.e. first shut the valves for cylinder cooling
water inlet and outlet at the supporting ring on the
exhaust side and above the cylinder cover respectively.
Open drain cock to the respective cylinder. This

cock is situated on the exhaust side below the cock
for cylinder cooling water inlet.
Then open the vent valve in the cylinder cooling water outlet pipe of the respective cylinder!
Disconnect all the connections to the cylinder cover
and to the exhaust valve as well as the expansion
piece between exhaust valve and exhaust manifold
(see 27511).
16
Remove hydraulic piping 7 as described in 84601.

Remove fuel pressure piping 16 (see 87331).
15
Disconnect plugs 14 from control box 15.

Clean all the thread protrusions on the cylinder cover studs.
14
Loosen the nuts of the cylinder cover studs (see

27082).
011.764/04
1/ 7
2008
27081/A1
Maintenance
RT-flex96C
2.
Transport of cylinder cover (with big crane hook)

Screw spec. eye bolts 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 bolts.
Lift cylinder cover 1 together with water guide jacket 9 and exhaust valve cage
5 by means of the crane (Fig. C).
Remark: Removing and transporting the cylinder cover is the same with exhaust
valve cage 5 in situ or removed from the cylinder cover.
C
94265
94265a
5a
94265b
2a
003.307/00
2008
008.328/01
2/ 7
RT-flex96C
27081/A1
Maintenance
3.
Transport of cylinder cover (with small crane hook)

Screw spec. eye bolts 94265a to suspension device 94265c onto the studs 5a
of the exhaust valve cage. Insert the two hooks of the suspension device into
the spec. eye bolts.
Lift cylinder cover 1 together with water guide jacket 9 and exhaust valve cage
5 by means of the crane (Fig. E).
Remark: Removing and transporting the cylinder cover is the same with exhaust
valve cage 5 in situ or removed from the cylinder cover.
E
94265c
94265a
5a
94265b
2a
012.026/04
3/ 7
2008
27081/A1
Maintenance
RT-flex96C

4.
Fitting of cylinder cover

Before placing the cylinder cover in position the following points must be taken
care of:
D
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 water guide jacket 9 which is screw fastened to the cylinder cover as well as the respective guide surface at the collar of the cylinder
liner must be clean and smeared with bearing oil.
Place new O-rings into the grooves of the cylinder liner and smear these with
bearing oil.
The threads of the cylinder cover studs, nuts and their seating surfaces must
be clean and smeared with Never-Seez NSBT-8.
Place three protection caps 94265b on cylinder cover waisted studs (see Fig.
C and E).
When these conditions are all met, lower the cylinder cover, attached to suspension device 94265 or 94265c, slowly over the cylinder cover studs, whereby a centring pin assures the correct position (see 21242).
Screw all nuts by hand onto the cylinder cover studs, paying attention to easy
turning.
Pre-tension the studs with hydraulic pre-tensioning device 94215 in accordance with 27082.
Reconnect all connections to cylinder cover and exhaust valve.
Finally shut drain and vent cock, and reopen the cocks for cooling water inlet
and outlet.
Remark: Concerning the fitting of the expansion piece between exhaust valve and
exhaust manifold see 27511.
8
1
2
FUEL SIDE
2a
3
7
RC
6
5
5a
4
011.535/04
201007
4/ 7
RT-flex96C
27081/A1
Maintenance
5.
Removal of water guide jacket
5.1
Assembly of the cradle

For the removal or fitting of water guide jacket 9 (Fig. I), cradle 94266 is fastened
with screws 11 to one of platform supports 12, which are also provided for supporting a piston.
Risk of accident! Whenever using the cradle, fasten it to the platform support with
all screws! It also may be never provided as storage place at sea for the cylinder
liner or water guide jacket!
II
ENGINE SIDE
II
11
94266
12
94266
5.2
5
ENGINE SIDE
011.765/04
Placing the cylinder cover

The cylinder cover can be placed on cradle 94266
with exhaust valve in situ.
Turn fixing screws 13 fully back.

1
Place cylinder cover 1 on the cradle.
94266
13
94266
5
1
5/ 7
2008
27081/A1
Maintenance
RT-flex96C
5.3
Removal of water guide jacket

Turn fixing screws 13 till the stop at water guide jacket 9 (Fig. I).
Remove Allen screws 10.
Turn fixing screws 13 equally back till the water guide jacket rests on the holders of the cradle (Fig. K).
Remark: If the water guide jacket should not come loose of the cylinder cover, the
previously removed Allen screws 10 are used as withdrawing screws, which are
turned into tape holes GL.
Lift and remove the cylinder cover with the crane.
Lift and remove the water guide jacket with the crane.
K
1
1
GL
13
10
13
94266
011.767/04
2008
6/ 7
RT-flex96C
27081/A1
Maintenance
6.
Fitting of water guide jacket

Clean all the sealing faces and ring grooves.
Fit new O-rings in the cylinder cover and oil them slightly.
Turn fixing screws 13 fully back.
Place water guide jacket on the cradle.
Lower and align cylinder cover above water guide jacket in such a way that
tape holes GL and through holes DB in water guide jacket 9 are in line.
Remark: In order to facilitate the alignment, two threaded rods (M24 x approx. 300
mm) can be provided in the tape holes GL.
Lower the cylinder cover onto the water guide jacket.
Screw in fixing screws 13 equally till the water guide jacket rests on the cylinder cover (Fig. M).
Screw in and tighten the Allen screws.
L
17
18
13
M
1
GL
9
DB
10
13
94266
011.768/04
7/ 7
2008
RT-flex96C
27082/A1
Maintenance
Cylinder Cover
Loosening and Tensioning of Cylinder Cover Waisted Studs
Tools:
1 Hydr. tensioning device
94215
consisting of:
2 Device halves each with

2 pre-tensioning jacks
8 HP hoses
1 Suspension device
94215a, b
94215c
94215d
1
1
1
2
1
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94932a
94934a
94935
94935a
94942
1.
General
1
2
3
4
5
6
7
8
9
10
Cylinder cover stud

Nut
Vent screw
Piston
Round nut
Screw
Sealing ring
Sealing ring
Cylinder
Disc spring
11 Protection cap
12 Screw M16
MO Emplacement for round
nuts 5 when not in use
RO Emplacement for round
bars RS when not in use
BN Limiting groove
RS Round bar
SA Gap

Should a cylinder cover stud have to be replaced, please observe the indication in
27511.
2.
Placing the pre-tensioning jacks

Clean the threads of all cylinder cover studs 1 and the area around nuts 2.
Mount two device halves of pre-tensioning device 94215 over the cylinder
cover studs according to Fig. B.
Open vent screws 3 (Fig. C) of all pre-tensioning jacks.
Connect the device halves to hydraulic unit 94942, using HP hoses 94935 and
94935a, as well as hydr. distributor 94934a.
Due the force of disc springs 10, pistons 4 are pressed against cylinders 9
(Fig. C)
CHECK
When the pistons are resting on the cylinders there should be little or no clearance
at x.
Remark: For loosening the waisted studs, screw back the round nuts by approx.
1 turns.
For tensioning the waisted studs the round nuts must lie on piston 4.
1/ 4
2010-07
27082/A1
Maintenance
RT-flex96C
3.
Loosening
Place the pre-tensioning jacks as mentioned already. Open vent screws 3 of
the pre-tensioning jacks.
Start up hydraulic unit 94942.
Close vent screws 3 on the jacks as soon as oil flows bubble-free.
Actuate hydraulic unit until a pressure of 1020 bar is indicated on its pressure
gauge and on pressure gauge 94932a.
groove BN (Fig. C).
Turn all nuts 2 upwards till the stop, using round bar RS. Store round bar RS
in emplacement RO while not in use (see Fig. B).
Release pressure to zero.
Disconnect and remove HP hoses 94935a from both device halves.
Unscrew round nuts 5 and remove them together with the pre-tensioning
jacks.
4.
Tensioning
Smear threads of cylinder cover studs 1, nuts 2 and their seating surfaces with
Never-Seez NSBT-8.
CHECK
Tighten all nuts down with round bar RS till fully seated (check with feeler gauge).
Mark position of all nuts, with a line on nuts and cylinder cover, with a felt-tip
pen (this will serve for a later check).
Set-up of the pre-tensioning jacks as mentioned already. Open vent screws 3
of the pre-tensioning jacks.
Start up hydraulic unit 94942.
Shut vent screws 3 on the pre-tensioning jacks as soon as oil flows bubblefree.
Actuate hydraulic unit until a pressure of 1000 bar is indicated on its pressure
gauge and on pressure gauge 94932a.
groove BN (Fig. C).
CHECK
While keeping this pressure constant tighten all nuts 2 with round bar RS till fully
seated on the cylinder cover (check seating with feeler gauge), verify while tightening that all nuts can be turned by about the same angle of 390_.
Where it is found that a nut can be turned considerably less than the others, it must
be assumed that the respective cylinder cover stud has become insufficiently tensioned.
2010-07
2/ 4
RT-flex96C
27082/A1
Maintenance
Possible causes:
Sealing rings 7 and 8 defective (Fig. C).
Piston 4 jams.
Connection piece of HP hoses 94215c leaky or incorrectly connected.
Repeat tensioning procedure after the cylinder cover studs have been loosened again.
When all nuts have been tightened by practically the same angle, release the
oil pressure to zero.
Disconnect and remove HP hoses 94935a from both device halves.
Unscrew round nuts 5 and remove them together with the pre-tensioning
jacks.
CHECK
5.
Verify by the previously applied marks that all nuts have been turned equally by an
angle of about 390_.
Protection upper part of stud and nut

In order to improve the corrosion protection of the cylinder cover stud upper thread,
we strongly advise to mount a protection cap. The protection cap will not only protect the thread at the top of the cylinder cover stud 1 against mechanical damages,
it protects also nut 2. The overall protection cap will also prevent corrosive attack
by any liquid, vapour or other media in the connection area.
The threads of the cylinder cover studs, nuts and their seating surfaces must be
clean and smeared with Never-Seez NSBT-8.
Remark: The new protection cover is easy to be made by the individuals or can
also be bought through the Wrtsil Sales and Spare part channels.
A
12
11
1
2
WCH0069
3/ 4
2010-07
27082/A1
Maintenance
RT-flex96C
94935
94934a
94932a
94935a
94935a
EXHAUST
SIDE
I
94942
I
94215d
94215c
MO
RO
94215c
94215b
94215a
94215b
3 94215a
6
5
RS
BN
10
SA
9
2
1
017.869/08
PRE-TENSIONING JACK
2010-07
PRE-TENSIONING JACK
4/ 4
RT-flex96C
Maintenance
27083/A1
Cylinder Cover
Machining of Sealing Face for Injection Valve
Tools:
1 Overhauling device
1 Ring spanner AF 24
1.
94270
1
2
3
4
5
Cylinder cover
Milling cutter holder
Guide flange
Setscrews
Profiling cutter
6 Centring mandril
7 Screw
* Depository for screw
General
The seat sealing face in the cylinder cover must be clean and undamaged as the
sealing is metallic.
Should any blow-by of combustion gases have been noticed during engine operation, the spring packets with their screws of the injection valve are not, under any
circumstances, to be tightened further as a counter measure.
2.
Machining of sealing face

2
Dirty or slightly damaged sealing faces can be re-conditioned on the spot by using overhauling device 94270.
Carefully insert the profiling cutter, bolted to the milling cutter holder, into the hole in the cylinder cover.
Fasten guide flange 3 with screws 7.
When the tool is being used, the centring mandril on
the profiling cutter on the one hand and the guide
flange on the other, give the tool the necessary stability and direction.
Cutting is done by pressing down lightly with the
hand on the milling cutter holder at the same time as
turning the hexagon evenly with the other hand using the ring spanner.
Try to remove as little material as possible but sufficient, however, to obtain the desired standard for
the seating area.
D
Putting some sticky grease on the profiling cutter

will prevent any foreign matter from entering the
combustion chamber during overhaul.
1/ 1
2008
1
4
5
6
003.512/00
RT-flex96C
27221/A1
Maintenance
Injection Valve
Checking, Dismantling, Assembling and Adjusting
Tools:
1 Protection cap
1 O.M.T. test bench
with O.M.T. Test Bench
94271
94272
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Allen screw
Spring guide
Cup spring (spring packet)
Nozzle holder
Collar nut
Spring tensioner
Nozzle tip
Tappet carrier
Tappet
Retaining nut
Compression spring
Nozzle needle
Nozzle body
Retaining sleeve
Snap ring
16
17
18
19
20
21
22
23
24
25
26
27
Dowel pin
Dowel pin
Holding angle
Support
HP hose
Torque beam
Dowel pin
Spring cage
Circlip
Shim ring
Shim
O-ring
LF Leakage fuel
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Judging an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the opening pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling a spring cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting an injection valve in cylinder cover . . . . . . . . . . . . . . .
Storage and handling of injection valve . . . . . . . . . . . . . . . . . .
1/9
2/9
3/9
4/9
5/9
5/9
7/9
7/9
8/9
8/9
9/9
General
For checking, dismantling, assembling and adjusting the injection valve, test
bench 94272 as well as test & calibration fluid has to be used (e.g. Shell Calibration
Fluid S.9365) complying with the data according to the following table:
Physical characteristics for test & calibration fluid:
Kinematic Viscosity
ASTM D445
at 40 _C
mm2/s
Density at 15 _C
kg/m3
ISO 12185
827
_C
ISO 3016
27
Pour Point
2.6
Remark: Clean diesel oil (gas oil) can be used if no calibration fluid is available.
The use however is not recommended, if the injection valve will be stored and not
directly installed on the engine (corrosion reasons).
On some injection valves the leakage flow amount might be bigger than on others.
In case of the test bench flow is not sufficient to open the nozzle needle, a clean
additive-type crankcase (system) oil of the SAE 30 viscosity grade (for additional
data see 07501 System oil in the Operating Manual) can be used for testing
instead of the above mentioned fluids.
1/ 9
2013-08
27221/A1
Maintenance
RT-flex96C
Injection Valve: Checking, Dismantling, Assembling and Adjusting
2.
Checking an injection valve

Before commissioning the instructions and directions of the test bench manufacturer must be observed.
CHECK
From time to time check the pressure gauges of the test bench with a master pressure gauge and adjust them if necessary.
Remark: The work station must be clean; welding and grinding should not be done
nearby!
Remove combustion residues and clean nozzle tip externally with a brass
wire brush.
Fit injection valve with nozzle tip pointing downwards into holding angle 18 of
test bench 94272 and fasten it with two Allen screws 1 and spring cages 23.
Support 19 must also be fitted for this.
Connect high pressure hose 20 of test bench with fuel inlet of injection valve.
Start test bench following the instructions of the test bench makers.
Bring the injection valve to spray with a few short pump jerks, and then observe at what pressure the injection valve opens, applying slow, equal pump
jerks.
Danger of injuries! Never hold fingers or hands directly before the spray holes of
the nozzle tip!
A
I-I
1
21
23
20
18
18
94272
19
001.437/97
2012-05
2/ 9
011.353/04
RT-flex96C
3.
27221/A1
Maintenance
Judging an injection valve

For correct functioning and for a reuse of an injection valve observe the following
points:
D
Spray pattern: Fuel will spray mainly from the holes in the first level of the
nozzle tip at the specified opening pressure. No fuel should drip from nozzle
tip when injection is finished.
For new injection valves the opening pressure is 375 5 bar.

On used injection valves a pressure reduction of 30 bar may be acceptable.
Should a readjustment of the opening pressure be necessary, see section
Adjusting the opening pressure.
In order to test tightness between the nozzle needle and needle seat, keep the
pressure in the test bench constant at approx. 20 bar below the opening pressure. During a time period of 30 seconds no dripping should occur at the
nozzle tip.
The spray holes of nozzle tip 7 must not be flushed out unduly.
Injection valves which do not spray efficiently must be dismantled as

described in section 4. Often, a thorough cleaning suffices to make them fully
functional.
Remark: Nozzle tips with flushed out spray holes must be replaced by new ones.
Nozzle holder 4 and nozzle body 13 (Fig. E) with poor sealing faces must either be
replaced or reconditioned by the manufacturer or an authorized company.
3/ 9
2013-08
27221/A1
Maintenance
4.
RT-flex96C
Dismantling an injection valve

Screw down the injection valve on holding angle 18 of test bench 94272, as
mentioned, however without support 19.
Loosen collar nut 5 and unscrew spring tensioner 6 until compression spring
11 is fully relaxed (Fig. E).
Turn holding angle with injection valve fitted, so that the nozzle tip points upwards.
Lower torque beam 21 with the socket spanner of test bench 94272 (Fig. B)
over the injection valve.
Note test bench manufacturers application instruction!
Actuate hydraulic loosening (or tightening) device of the test bench to loosen
retaining nut 10, then remove nozzle needle 12, nozzle body 13, retaining
sleeve 14 and nozzle tip 7 (Fig. E).
CHECK
Remove spring tensioner 6 with collar nut 5, compression spring 11 and tappet 9
and inspect their condition.
Remark: If only a nozzle tip 7 has to be replaced, then to this end only snap ring 15
has to be removed, see section 5. All other parts are not to be dismantled.
Never interchange nozzle needle 12 and nozzle body 13! Each nozzle needle belongs to its mated nozzle body into which it has been individually fitted with greatest precision.
B
94272
21
10
18
008.329/01
2008
4/ 9
RT-flex96C
27221/A1
Maintenance
5.
Replacing a nozzle tip

Ensure that always specified nozzle tips are used in accordance with the IMO
technical file of the engine or the shoptest protocol.
If the nozzle tip 7 should be dismantled only, it is sufficient to remove the retaining
sleeve 14.
C
SCREW DRIVER
5.1
16
Removal
Using two screw drivers inserted between both recesses in retaining nut 10, press snap ring 15 out
of the groove in the retaining nut, whereby the retaining sleeve can be withdrawn (Fig. C).
Watch that the snap ring does not jump off unexpectedly.
Remove nozzle tip.
14
15
10
13
5.2
Fitting
For fitting it is advantageous to clamp the injection

valve on its flange into a vice (nozzle body 13 pointing
upwards), and then proceed as follows:
Clean all parts with clean diesel oil or kerosine and
blow them out with compressed air.
Place nozzle tip on the nozzle body whereby the
position is assured by dowel pin 16.
Put retaining sleeve 14 over the nozzle tip, and
press snap ring 15 into the groove of the retaining
nut by means of the screw drivers.
004.072/98
6.
Protecting a nozzle tip

Remark: To protect the nozzle tip integrated in the injection valve against damage, always fit protection cap
94271 for transport, storage, etc. (Fig. D).
94271
004.070/98
5/ 9
2013-08
27221/A1
Maintenance
RT-flex96C
I-I
II - II
6
5
27
INSERT BUSH
WITH SPHERICAL
SEALING SURFACE
x1
1
2
3
23
22
11
8
10
17
12
13
14
15
16
DESIGNATION
OF NOZZLE TIP
MANUFACTRER x IDNO. x
EXECUTION x CHARG. NO.
LF
II
II
2013-08
014.117/06
6/ 9
RT-flex96C
7.
27221/A1
Maintenance
Assembling an injection valve

To assemble an injection valve, follow generally the reverse sequence of the dismantling process, but note also the following points:
To clean injection valve parts, use only clean diesel oil (gas oil) or fresh kerosene, and dry compressed air.
D
The fitting position of nozzle tip 7, nozzle body 13 and nozzle holder 4 is given
by dowel pins 16 and 17 (Fig. E).
Make sure that the sealing faces are in perfect condition and that no lubricant
is applied.
Fit the nozzle tip in accordance with section 5.
D
If tappet 9, compression spring 11 and spring tensioner 6 with collar nut 5 are
already fitted, the spring tensioner must be screwed by approx. one turn only,
in order to prevent the compression spring from being under tension in any
case, otherwise nozzle body 13 does not lie flat on nozzle holder 4 during assembly.
Apply a thin layer of Never-Seez NSBT-8 to the thread and the seating face of
retaining nut 10.
First tighten retaining nut 10 to 100 Nm using the hydraulic tightening (or loosening) device of the test bench 94272 (Fig. B). Starting from this position,
tighten the retaining nut by a further angle of 30_.
CHECK
8.
Repeat the tightening procedure on the initial assembly.
An angle of 30_ corresponds to 20.4 mm on the circumference relating to a nut

diameter of 78 mm.
After assembling the injection valve must be checked and judged according to sections 2 and 3.
Adjusting the opening pressure

Install the injection valve in the test bench as described in section 2.
The opening pressure of the injection valve (see setting table) can be set by
adjusting spring tensioner 6.
For readjusting the opening pressure, compression spring 11 must first be
completely released by means of spring tensioner 6.
Then operate the valve test bench and tighten the spring tensioner simultaneously until the required opening pressure is reached.
Check the injection valve as described in section 2.
After adjusting the opening pressure, tighten collar nut 5.
Remark: An opening pressure of 375 bar corresponds with reference dimension x1 = 49.5 mm.
7/ 9
2010-07
27221/A1
Maintenance
RT-flex96C
9.
Assembling a spring cage
F
24
2
Cup springs 3 are fitted in spring cage 23.
The spring packet consists of three packs composed of three cup springs which are arranged as
shown in Fig. F.
In order to maintain an equal contact force when screwing down the injection valve, distance x must be
adjusted to 1.6 0.1 mm with shims 26 .
25
26
23
011.473/04
10.
Fitting an injection valve in cylinder cover

CHECK
Clean the seating surface of the injection valve in the cylinder cover and check for
damages.
If necessary recondition the seating surface using the special tool supplied with the
tools set (see 27083).
The sealing must be metal-to-metal, i.e. no joint must be put in between.
Place the injection valve carefully in the cylinder cover. Dowel pin 22 assures
the correct position.
FLUSH
1
2
23
3
10.1 Screwing down the injection valve

Apply Never-Seez NSBT-8 to the threads and the
seating surfaces of Allen screws 1.
Fit and equally tighten Allen screws 1 until spring
guides 2 are flush with spring cages 23.
22
011.472/04
2008
8/ 9
RT-flex96C
Maintenance
11.
27221/A1
Storage and handling of injection valve

Store an injection valve in a dry place but not in a place contaminated with exhaust
gases or any other corrosive atmosphere. Keep the injection valve in its original
packing. Handle with care when preparing for use and avoid any hard contact
against other objects.
Attention! Do not open vacuum packed injection valve before the installation on
the engine.
For cleaning use white spirit, e.g. Shellsol TD, Shellsol T or Solvent FP68. Always
wear gloves and safety goggles with closed side frame!
9/ 9
2013
RT-flex96C
27221/A2
Maintenance
Injection Valve
Checking, Dismantling, Assembling and Adjusting
Tools:
1 Protection cap
1 OBEL test bench
1 Adapter piece
with OBEL Test Bench
94271
94272
94272g
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Injection valve
Allen screw
Spring guide
Cup spring (spring packet)
Nozzle holder
Collar nut
Spring tensioner
Nozzle tip
Tappet carrier
Tappet
Retaining nut
Compression spring
Nozzle needle
Nozzle body
Retaining sleeve
16
17
18
19
20
21
22
23
24
25
26
27
28
Snap ring
Dowel pin
Dowel pin
Cylinder cover
Support
HP hose
Receiver
Dowel pin
Spring cage
Circlip
Shim ring
Shim
O-ring
LF Leakage fuel
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Judging an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the opening pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling a spring cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting an injection valve in cylinder cover . . . . . . . . . . . . . . .
Protecting a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage and handling of injection valve . . . . . . . . . . . . . . . . . .
1/8
2/8
3/8
4/8
4/8
6/8
6/8
7/8
8/8
7/8
9/9
General
For checking, dismantling, assembling and adjusting the injection valve, test
bench 94272 as well as test & calibration fluid has to be used (e.g. Shell Calibration
Fluid S.9365) complying with the data according to the following table:
Physical characteristics for test & calibration fluid:
Kinematic Viscosity
ASTM D445
at 40 _C
mm2/s
Density at 15 _C
kg/m3
ISO 12185
827
_C
ISO 3016
27
Pour Point
2.6
Remark: Clean diesel oil (gas oil) can be used if no calibration fluid is available.
The use however is not recommended, if the injection valve will be stored and not
directly installed on the engine (corrosion reasons).
On some injection valves the leakage flow amount might be bigger than on others.
In case of the test bench flow is not sufficient to open the nozzle needle, a clean
additive-type crankcase (system) oil of the SAE 30 viscosity grade (for additional
data see 07501 System oil in the Operating Manual) can be used for testing
instead of the above mentioned fluids.
1/ 8
2013-08
27221/A2
Maintenance
2.
RT-flex96C
Checking an injection valve

Before commissioning the instructions and directions of the test bench manufacturer must be observed.
CHECK
From time to time check the pressure gauges of the test bench with a master pressure gauge and adjust them if necessary.
Remark: The work station must be clean; welding and grinding should not be done
nearby!
Remove combustion residues and clean nozzle tip externally with a brass
wire brush.
Place injection valve 1 with nozzle tip pointing downwards into support 20 of
test bench 94272 and fasten it with two Allen screws 2 and spring cages 24.
Tighten high pressure hose 21 of the test bench with the adapter piece
94272g.
Start the test bench following the proper manufacturers instructions.
Bring the injection valve to spray with a few short pump jerks, and then observe at what pressure the injection valve opens, applying slow, equal pump
jerks.
Danger of injuries! Never hold fingers or hands directly before the spray holes of
the nozzle tip!
A
21
94272g
2
24
1
20
22
94272
2
24
94272g
WCH00862
2012-05
017.086/08
2/ 8
RT-flex96C
3.
27221/A2
Maintenance
Judging an injection valve

For correct functioning and for a reuse of an injection valve observe the following
points:
D
Spray pattern: Fuel will spray mainly from the holes in the first level of the
nozzle tip at the specified opening pressure. No fuel should drip from nozzle
tip when injection is finished.
For new injection valves the opening pressure is 375 5 bar.

On used injection valves a pressure reduction of 30 bar may be acceptable. If
a readjustment of the opening pressure be necessary, see section Adjusting
the opening pressure.
In order to test tightness between the nozzle needle and needle seat, keep the
pressure in the test bench constant at approx. 20 bar below the opening pressure. During a time period of 30 seconds no dripping should occur at the
nozzle tip.
The spray holes of nozzle tip 8 must not be flushed out unduly.
Injection valves which do not spray efficiently must be dismantled as

described in section 4. Often, a thorough cleaning suffices to make them fully
functional.
Remark: Nozzle tips with flushed out spray holes must be replaced by new ones.
Nozzle holder 5 and nozzle body 14 (Fig. B) with poor sealing faces must either be
replaced or reconditioned by the manufacturer or an authorized company.
3/ 8
2013-08
27221/A2
Maintenance
4.
RT-flex96C
Dismantling an injection valve

Remove receiver 22.
Screw down the injection valve on support 20 of test bench 94272, as mentioned, however without connecting HP hose 21 to the injection valve.
Loosen collar nut 6 and unscrew spring tensioner 7 until the compression
spring 12 is completely released (Fig. B).
Turn valve holder through 180_ into vertical position.
Place the special tool of the test bench onto retaining nut 11 and loosen it with
the press of the test bench.
Note test bench manufacturers application instruction!
Remove retaining nut 11, nozzle tip 8, retaining sleeve 15, nozzle body 14 and
nozzle needle 13.
CHECK
Examine all parts for their condition.

Remark: If only a nozzle tip 8 has to be replaced, see section 7.
Never interchange nozzle needle 13 and nozzle body 14! Each nozzle needle
belongs to its mated nozzle body into which it has been individually fitted with
greatest precision.
5.
Assembling an injection valve

To assemble an injection valve, follow generally the reverse sequence of the dismantling process, but note also the following points:
To clean injection valve parts, use only clean diesel oil (gas oil) or fresh kerosene, and dry compressed air.
D
The fitting position of nozzle tip 8, nozzle body 14 and nozzle holder 5 is given
by dowel pins 17 and 18 (Fig. B).
Make sure that the sealing faces are in perfect condition and that no lubricant
is applied.
Fit the nozzle tip in accordance with section 7.
D
If tappet 10, compression spring 12 and spring tensioner 7 with collar nut 6 are
already fitted, the spring tensioner must be screwed by approx. one turn only,
in order to prevent the compression spring from being under tension in any
case, otherwise nozzle body 14 does not lie flat on nozzle holder 5 during assembly.
Apply a layer of Never-Seez NSBT-8 to the thread and the seating surface of
retaining nut 11.
First tighten retaining nut 11 to 100 Nm using a torque wrench. Starting from
this position, tighten the retaining nut by a further angle of 30_ by means of the
hydraulic tightening (or loosening) device of the test bench.
CHECK
2008
Repeat the tightening procedure on the initial assembly.
An angle of 30_ corresponds to 20.4 mm on the circumference relating to a nut

diameter of 78 mm.
After assembling the injection valve must be checked and judged according to sections 2 and 3.
4/ 8
RT-flex96C
27221/A2
Maintenance
I-I
II - II
7
6
28
INSERT BUSH
WITH SPHERICAL
SEALING SURFACE
x1
2
3
4
24
23
12
19
9
10
11
18
13
14
15
16
17
DESIGNATION
OF NOZZLE TIP
MANUFACTRER x IDNO. x
EXECUTION x CHARG. NO.
LF
II
II
014.117/06
5/ 8
2013-08
27221/A2
Maintenance
RT-flex96C
6.
Adjusting the opening pressure

Install the injection valve in the test bench as described in section 2.
The opening pressure of the injection valve (see setting table) can be set by
adjusting spring tensioner 7.
For readjusting the opening pressure, compression spring 12 must first be
completely released by means of spring tensioner 7.
Then operate the valve test bench and tighten the spring tensioner simultaneously until the required opening pressure is reached.
Check the injection valve as described in section 2.
After adjusting the opening pressure, tighten collar nut 6.
Remark: An opening pressure of 375 bar corresponds with reference dimension x1 = 49.5 mm.
7.
Replacing a nozzle tip

Ensure that always specified nozzle tips are used in accordance with the IMO
technical file of the engine or the shoptest protocol.
If the nozzle tip 8 should be dismantled only, it is sufficient to remove the retaining
sleeve 15.
C
7.1
SCREW DRIVER
Using two screw drivers inserted between both recesses in retaining nut 11, press snap ring 16 out of
the groove in the retaining nut, whereby the retaining sleeve can be withdrawn (Fig. C).
Watch that the snap ring does not jump off unexpectedly.
17
Remove nozzle tip.

7.2
15
16
11
Removal
14
Fitting
For fitting it is advantageous to clamp the injection

valve on its flange into a vice (nozzle body 14 pointing
upwards), and then proceed as follows:
Clean all parts with clean diesel oil or kerosine and
blow them out with compressed air.
Place nozzle tip on the nozzle body whereby the
position is assured by dowel pin 17.
Put retaining sleeve 15 over the nozzle tip, and
press snap ring 16 into the groove of the retaining
nut by means of the screw drivers.
5
004.072/98
2010-07
6/ 8
RT-flex96C
27221/A2
Maintenance
8.
Assembling a spring cage
D
25
3
Cup springs 4 are fitted in spring cage 24.
The spring packet consists of three packs composed of three cup springs which are arranged as
shown in Fig. D.
In order to maintain an equal contact force when screwing down the injection valve, distance x must be
adjusted to 1.6 0.1 mm with shims 27 .
26
27
24
011.473/04
9.
Fitting an injection valve in cylinder cover

CHECK
Clean the seating surface of the injection valve in the cylinder cover and check for
damages.
If necessary recondition the seating surface using the special tool supplied with the
tools set (see 27083).
The sealing must be metal-to-metal, i.e. no joint must be put in between.
Place the injection valve carefully in the cylinder cover 19. Dowel pin 23 assures the correct position.
FLUSH
2
3
24
4
10.1 Screwing down the injection valve

Apply Never-Seez NSBT-8 to the threads and the
seating surfaces of Allen screws 2.
Fit and equally tighten Allen screws 2 until spring
guides 3 are flush with spring cages 24.
23
19
011.472/04
7/ 8
2008
27221/A2
Maintenance
RT-flex96C
10.
Protecting a nozzle tip

Remark: To protect the nozzle tip integrated in the injection valve against damage,
always fit protection cap 94271 for transport, storage, etc.
94271
11.
Storage and handling of injection valve

Store an injection valve in a dry place but not in a place contaminated with exhaust
gases or any other corrosive atmosphere. Keep the injection valve in its original
packing. Handle with care when preparing for use and avoid any hard contact
against other objects.
Attention! Do not open vacuum packed injection valve before the installation on
the engine.
For cleaning use white spirit, e.g. Shellsol TD, Shellsol T or Solvent FP68. Always
wear gloves and safety goggles with closed side frame!
2013-08
8/ 8
RT-flex96C
27281/A1
Maintenance
Starting Valve
Removal, Fitting and Dismantling, Grinding-in and Assembling
Tools:
2 Jacking screws
1.
1
2
3
4
5
6
7
8
9
10
11
Nut
Cover
Intermediate ring
Casing
Cylinder cover
Self-locking nut
Piston
Valve spindle
Allen screw
Compression spring
Joint ring
12
13
14
15
16, 17
18
19
Control valve
Connecting pipe
Piston ring
Spindel guide
O-rings
Solenoid
Nut with locking washer
CA Control air pipe

(from starting air pipe)
RC Eye bolt
General
Should functional difficulties occur with the starting valves when starting, or should
a starting air pipe near to the connection become noticeably hotter in operation
than on the neighbouring cylinders, then the starting valve must be dismantled and
reconditioned at the very next opportunity.
If no such difficulties occur it is recommended to dismantle yearly at random one
starting valve for a thorough check and to overhaul the other starting valves in frequencies determined by such checking.
CHECK
2.
Periodical venting of the starting air manifold under higher pressure must be
provided as mentioned in the Operating Manual 03201. In addition, regular
checks must be carried out to make sure, that nut 18 on solenoid 17 is tight (see
also Maintenance Schedule 03801).
Removal from the cylinder cover

Loosen pipes for control air CA.
Loosen and remove all four nuts 1.
Loosen and remove Allen screws 9. Screw jacking screws into the threaded
holes in casing 4 and by tightening them jack the complete starting valve from
the bore in cylinder cover 5.
Reinsert both Allen screws 9 for removing the complete valve.
Suspended by eye bolts RC lift the valve off the cylinder cover.
D
3.
When the removal is carried out with the cylinder cover fitted on the engine,
the vacated opening must be immediately covered by suitable means to prevent the possibility of foreign particles entering the combustion space.
Dismantling a starting valve

D
Lift cover 2 with mounted control valve 12 off casing 4. Take care that during
lifting, the cover does not get jammed, whereby connecting pipe 13 risks being damaged.
Remove intermediate ring 3 from casing 4.

For further dismantling clamp the valve on the milled faces below the valve
spindle head (spanner purchase) in a vice.
1/ 3
2013-08
27281/A1
Maintenance
RT-flex96C
Starting Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling

Loosen self-locking nut 6 with a socket spanner, and remove it.
Pull piston 7 and compression spring 10 from casing 4.
Lift casing up over valve spindle 8.
4.
Grinding-in
D
Slightly damaged seat faces may be ground in (lapped) manually.
Badly worn seat faces must first be machined and then ground in (lapped)
manually.
Remark: The valve spindle has an angle of 61_, however, the valve seat angle
amounts to 60_.
5.
Assembling
Assemble the valve in reverse sequence to the dismantling.
Clean all parts and smear them lightly with oil.
Apply MOLYKOTE paste G to the thread of valve spindle 8, however not in the
area of the locking ring of the self-locking nut 6.
Tighten the not greased, clean self-locking nut with 1215 Nm or by a tightening angle of 50_.
Place new, lightly oiled, O-rings 16 and 17 into the groove in casing 4 and connecting pipe 13 respectively.
CHECK
After completing the assembly (without cover 2) check the easy movement of the
valve spindle by moderately tapping the upper end of the valve spindle several
times with a lead block in an axial direction; the valve spindle must jump every time
back on the seat.
If the valve seat have been ground/machined several times, check the clearance
x (see figure) with a depth gauge from the upper edge of intermediate ring 3 onto
the piston 7.
Clearance x must be minimum 1 mm.
Fit cover 2 and tighten it with Allen screws 9. Take care that when assembling
cover 2, connecting pipe 13 does not interfere.
6.
Fitting in the cylinder cover

Place a new joint ring 11 on the shoulder of the bore in cylinder cover 5.
Smear bore in cylinder cover lightly with oil and fit the assembled starting
valve.
Apply Never-Seez NSBT-8 to the threads of nuts 1, fit and tighten them crosswise through an angle of 85_.
2008
2/ 3
RT-flex96C
27281/A1
Maintenance
Starting Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling
II
I-I
II - II
RC
1
14
14
4
7
III
IV
16
CA
IV
13
10
011.357/04
III
III - III
IV - IV
2
11
9
17
13
17
4
17
18
3/ 3
2013-08
RT-flex96C
27451/A1
Maintenance
Relief Valve for Cylinder Cover

Checking Blow-off Pressure
Tools:
1
1
1
2
1
1.
OBEL test bench

Valve holder
HP oil pump
Hydr. distributors
HP hose
94272
94272c
94931
94934a
94935
1
2
3
4
5
6
7
8
9
Cylinder cover
Relief valve
Indicator valve
Adapter piece
Protection plate
Flange
Adapter
Sleeve
Allen screw
10 Receiver
11 Gasket
12 Gasket
EV Relief valve
MD Metallic sealing
RB Relief bore from
compression chamber
General
Each cylinder cover is provided with an indicator valve combined, depending on
Class requirements, with a relief valve, which is connected by relief bore RB to the
compression chamber. An inadmissible high pressure peak in the compression
chamber opens the valve and the over-pressure is immediately reduced.
A relief valve which has blown off or valves leaking during engine operation
must be replaced at the first opportunity (with engine stopped only).
A relief valve can not be repaired nor adjusted any more after having blownoff!
Relief valves require no maintenance, however they should be checked in general
at every major engine overhaul. Basically leaking or damaged valves should be
returned to the manufacturer for inspection and repair.
BLOW-OFF PRESSURE
STAMPED IN
2
5
12
11
4
12
9
6
7
MD
8
1
RB
017.671/08
1/ 2
2008
27451/A1
Maintenance
RT-flex96C
Relief Valve: Checking Blow-off Pressure
2.
Checking blow-off pressure

For checking relief valve 2 use test bench 94272 and diesel oil or a thin-bodied oil
as test medium.
Remark: Pay attention to the manufacturers detailed instructions and working
specifications of the test bench.
If necessary, a relief valve must be replaced completely and set according to the
following table:
Firing pressure
[bar]
Blow-off pressure
[bar]
140143
200
1441471)
205
148151
210
152155
220
156160
225
1)
Firing pressure range for RTflex96C and RTA96CB engines
B
94935
94934a
94272c
2
10
017.670/08
013.484/05
94931
3.
94272
EV
013.486/05
Fitting the relief valve

Apply Never-Seez NSBT-8 to the thread of relief valve 2 and fit it with new
gasket 10.
Always properly close indicator valve 3 so that no gas escapes and then
screw on its cap.
Remark: If indicator valves leak for a long period the seats will become damaged.
Early replacement of a leaking indicator valve will allow easy repair. All threads and
internal parts must also be smeared with Never-Seez NSBT-8.
2008
2/ 2
RT-flex96C
27511/A1
Maintenance
Exhaust Valve
Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs
Tools:
1
1
1
1
2
1
1
1
2
1
1.
Dismantling tool
Hydr. tensioning device
Valve protector
Suspension device
Lifting lugs
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94008aM100
94252
94262
94265(c)
94811
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
Waisted stud
Nut
Vent screw
Piston
Round nut
Pin
Sealing ring
Sealing ring
9
10
11
12
13
Cylinder
Expansion piece
Protection pipe
Valve cage
Valve spindle
KO Slot
RS Round bar
General
Prior to the removal of an exhaust valve, drain first the cylinder cooling water from
the respective cylinder (see 27081), and close the air inlet to the air spring at the
control air supply.
The exhaust valve can be removed from the cylinder cover or transported as whole
unit (without cylinder cover) with suspension device 94265 or with 94265c for
cranes provided with small hooks (see also 27081).
The valve cage must be suspended as shown in Fig. A.
D
If the exhaust valve is not to be dismantled at site immediately, mount the

valve protector 94262 (Fig. B).
94265(c)
12
13
94262
008.330/01
003.352/00
1/ 6
2012-05
27511/A1
Maintenance
RT-flex96C

2.
Removal
Remove all connected pipes. Removal of hydraulic piping see 84601.
Expansion piece 10 (Fig. C) has to be removed with the aid of lifting lug 94811
and suspension device 94265(c). Therefore, two screws of each suspension
strap have to be screwed into the expansion piece flange. After removing the
connecting screws from the expansion piece flanges the expansion piece can
be taken out in the engine longitudinal direction.
94265(c)
94811
10
10
I
12
I
94811
I-I
94811
003.723/95
11
003.723/95
6
RS
4
7
8
2
9
Clean the threads of waisted studs 1 of the valve

cage as well as the area around nuts 2 (Fig. D).
Place hydr. tensioning device 94252 consisting of
two pre-tensioning jacks on the two waisted studs 1
(Fig. D) which have to be loosened (arrangement
according to Fig. E).
Open vent screw 3 of each pre-tensioning jack.
RS
KO
008.331/01
2008
10
Screw round nuts 5 onto waisted studs 1 until there

is no or very little clearance at x.
Subsequently slacken round nuts by about 1 turns
(for loosening only).
2/ 6
RT-flex96C
27511/A1
Maintenance
94252
94935a
94932a
94934a
94935
94935a
014.774/06
94252
94942
Connect pre-tensioning jacks by HP hoses 94935 and 94935a as well as hydr.

distributor 94934a with hydraulic unit 94942 as shown in Fig. E.
CHECK
Verify the oil level in the hydraulic unit.

Actuate hydraulic unit.
Close vent screws 3 on the pre-tensioning jacks as soon as oil flows bubblefree.
Actuate hydraulic unit till a pressure of 1020 bar is indicated on pressure
gauge 94932a and on the pressure gauge at the hydraulic unit.
D
Attention should be paid to ensure that pins 6 always protrude slightly

compared with pistons 4 on the pre-tensioning jacks!
Turn all nuts 2 upwards till the stop, using round bar RS.
Release pressure to zero at the hydraulic unit.
Disconnect HP hoses to hydr. tensioning device 94252 and remove the latter.
Unscrew round nuts 5 from the waisted studs.
Suspend the hooks of suspension device 94265 (Fig. A) into the eye bolts of
valve gage 12 and pull the complete exhaust valve out of the cylinder cover.
3/ 6
2008
27511/A1
Maintenance
RT-flex96C
3.
Fitting
D
Before fitting the exhaust valve into the cylinder cover, the sealing surfaces
must be checked for cleanliness and possible damage.
Make sure that the soft iron gasket of 2 mm thickness lies flat in its recess in
the cylinder cover.
Fit new O-rings and oil these slightly.

Fit the complete exhaust valve suspended on the suspension device, taking
care not to damage the thread of the waisted studs.
D
The correct position of the exhaust valve cage is determined by the cylindrical
dowel pin set in the cylinder cover.
Clean threads of the waisted studs, nuts and their seating surfaces, and
smear them with Never-Seez NSBT-8.
CHECK
Fit nuts 2 and tighten them firmly with round bar RS till fully seated before mounting the pre-tensioning jacks (check seating with feeler gauge).
Mark position of the nuts on a corner and their position on valve cage 12 with a
felt-tip pen (for later checks).
Place hydr. tensioning device 94252 consisting of two pre-tensioning jacks on
the two waisted studs 1 (Fig. D) which have to be loosened (arrangement
according to Fig. E).
Open vent screw 3 of each pre-tensioning jack.
Screw round nuts 5 onto waisted studs 1 until there is no or very little clearance at x.
Connect the pre-tensioning jacks by HP hoses 94935 and 94935a as well as
hydr. distributor 94934a with hydraulic unit 94942 as shown in Fig. E.
CHECK
Verify the oil level in the hydraulic unit.

Close vent screws 3 on the pre-tensioning jacks as soon as oil flows bubblefree.
Slowly raise the pressure to 1000 bar.
D
CHECK

Keep this pressure constant and tighten nuts 2 with round bar RS till firmly seated
on exhaust valve cage 12 (check seating with a feeler gauge through the slot KO).
After tightening the nuts ascertain that these have been turned by about the same
angle of 230_.
If bigger differences occure the tensioning procedure must be repeated.
Release pressure to zero and remove both pre-tensioning jacks.
Remark: When fitting expansion piece 10 smear its flange surfaces and connecting screws lightly with a heat resisting lubricant. The expansion piece has to be
fitted in such a way that protection pipe 11 of the expansion piece comes to lie in the
flow direction i.e. on the valve cage side, as shown in Fig. C.
2010-07
4/ 6
RT-flex96C
27511/A1
Maintenance
4.
Replacement of waisted studs

When fitting a new waisted stud (in the following text called stud for short) of the
cylinder cover, exhaust valve cage or starting valve, the instructions hereafter
must be strictly observed.
Before fitting the stud, clean and degrease the joint surface respectively sealing
face.
If recommended by the jointing compound manufacturer, apply an adhesive primer in order to improve the adhesion on the joint surface.
Do not apply adhesive primer and any lubricant to the thread!
Screw in the stud right to the bottom and until it rests on its seating surface and
tighten it according to instructions 03522 using always a stud driver or two
counter locked nuts. Tool 94008aM100 must be used for the cylinder cover
stud.
Tools like pipe wrenches or multigrip tongs, etc. which would cause damages to
the shank of the stud must never be used!
Fill the annular space completely up to the rim with jointing compound.
4.1
Studs fitted in cylinder jacket and cylinder cover
F
JOINTING
COMPOUND
ANNULAR
SPACE
SEALING
SURFACE
1
94008aM100
CYLINDER
COVER STUD
WCH00836
003.465/00
5/ 6
2012-05
27511/A1
Maintenance
RT-flex96C
4.2
Recommended jointing compound and adhesive primers

Jointing
compound
Hardener
Adhesive
primer
Elastosil
RT 622 A
RT 622 B
G 790
Silcoset
105 RTV
Manufacturer
Wacker-Chemie Gmbh
Geschftsbereich Silicone
Hanns-Seidel-Platz 4
D-81737 Mnchen
Silcoset
Silcoset Primer AMBERSIL LTD
Curing Agent A
Wylds Rd
Bridgwater
Somerset
TA6 4DD
Uk-Great Britain
Remark: Mixing and applying of the jointing compounds must be done according
to the instruction of the respective manufacturer.
Products of other manufacturers are also allowed when fulfilling the below specification:
2010-07
Containing no acid, e.g. no acetic acid.
Resistant to oil, marine diesel oil, heavy fuel oil and water at a permanent temperature of approximately 100 _C.
Short age hardening time, i.e. at least 24 hours under ISO standard reference
conditions.
Well flowing to properly fill out the annular space, in order to avoid the creation
of any hollow space.
Good adhesion on adhesive-primed metallic surface.
Easy to prepare and combine.
None or only minimal surface shrinkage.
The jointing compound must remain elastic, as a cylinder cover stud may be
removed at any given time.
6/ 6
RT-flex96C
27512/A1
Maintenance
Exhaust Valve
Dismantling and Assembling
Tools:
1
2
2
1
Depth gauge
Retaining screws
Jack screws
Torque wrench
94124
94259
94263
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Valve cage
Lower housing
Screw
Nut
Upper housing
Outside piston
Inside piston
Thrust piece
Valve spindle
Screw plug
Piston guide
Flange
Screw
Measuring cone
Head screw
Valve cotter
Piston
Piston seal ring
Disc spring
Distance ring
Head screw
Guide bush
23
24
25
26
27
28
29
30
31
32
33
34
3544
Vent screw
Valve seat
Rod seal ring
Non-return valve
Bush
Air pipe
Screw
Valve stroke sensor
Screw
Housing
Damper
Shim
O-rings
BO
HH
HU
OB
OB1
Bore
Hydr. HP pipe
Wooden underlay
Oil bore
Oil bath for valve
spindle lubrication
RC Eye bolt
Overview
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling of exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling of exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling of valve drive and blocking exhaust valve . .
1.
2.
3.
4.
RC
1.
1/10
3/10
5/10
9/10
General
There are in minimum two complete exhaust
valves on board, as recommended by the International Association of Classification Societies
(IACS). Therefore, they must be used as a replacement in any case of difficulties appeared
during operation.
4
10
2
3
Defective exhaust valves may, however, only be

repaired or reconditioned by qualified personnel
or a Wrtsil Switzerland Ltd. authorized repair
workshop.
For inspection and overhaul intervals see Maintenance Schedule 03801.
Remark: Pay attention to General Guidelines for
Lifting Tools 00121.
014.570/06
1/ 10
2012-05
27512/A1
Maintenance
RT-flex96C
Exhaust Valve: Dismantling and Assembling
RC
33
35
34
009.716/02
43
7
5
23
13
33
11
BO
12
37
14
15
16
18
38
17
2
3
19
39
21
OB1
20
22
20
25
40
2
1
014.456/06
22
9
41
1
42
24
WCH00438
2012-05
2/ 10
RT-flex96C
27512/A1
Maintenance

2.
Dismantling of exhaust valve
2.1
Dismantling of complete valve drive

Attention! During dismantling and assembling, the activity area has to be clean
and as dust-free as possible (grinding dust etc.), and performing electric welding
must absolutely be omitted near or on the engine.
Place the exhaust valve on wooden underlay HU in vertical position.
Loosen and remove all nuts 4 (Fig. A).
Lift the upper valve drive and remove it using eye bolt RC.
Loosen screws 31 and remove housing 32 with valve stroke sensor 30 (Fig.
H).
Remove O-ring 36.
Loosen and remove all screws 3.
Lift lower housing 2 and remove it.
2.2
Dismantling of valve spindle

Loosen head screws 15 and remove them together with measuring cone 14.
Push piston 17 away from valve cotters 16, then remove the latter.
Withdraw the piston from the valve spindle.
Remove disc springs 19.
Carefully lift valve cage 1 by means of the engine room crane. Ensure that the
valve spindle always stands on the wooden underlay while the valve cage is
sliding out.
9
15
14
16
17
18
38
19
1
HU
014.539/06
3/ 10
2011-05
27512/A1
Maintenance
RT-flex96C
2.3
Removal of guide bush

Undo head screws 21, remove them together with distance ring 20 and rod
seal ring 25.
Screw both jack screws 94263 into the flange of guide bush 22 until the latter
can be lifted off.
CHECK
Check and measure inner diameter of the guide bush according to Clearance
Table 03301 Exhaust Valve.
94263
21
25
20
1
1
22
40
014.540/06
2.4
Fitting of guide bush

Clean the bore in valve cage 1 concerned and guide bush 22.
CHECK
Check oil bores OB in guide bush and valve cage for free passage.
Replace O-ring 40.
Oil guide bush and press it into the valve cage up to the stop using jack screws
94263.
94263
OB
40
1
22
014.540/06
2011-05
4/ 10
RT-flex96C
27512/A1
Maintenance

3.
Assembling of exhaust valve

Assembling is carried out analogously to dismantling but in reverse sequence.
Check dimensions of valve spindle 9 according to Clearance Table 03301 Exhaust Valve.
CHECK
The condition of piston seal ring 18 (Fig. B) is to be examined on every occasion,

at the latest, however, on the occasion of an overhaul of the exhaust valve according to the maintenance schedule. A damaged piston seal ring must be replaced in
any case.
Heat new piston seal rings in boiling water before fitting them. When fitting proceed
with care, to avoid their damage; do not use any sharp edged utensils for assistance.
Check all O-rings of the dismantled parts for damage and replace them if necessary.
Remark: If an exhaust valve is to be fitted with a new seat or spindle, the seats
must be checked according to the instructions given in 27513.
3.1
Fitting of valve spindle

Apply oil to the valve spindle and fit it.
Apply oil to a new rod seal ring 25, fit it with distance ring 20 and tighten the
latter with head screws 21.
Remark: Always fit rod seal ring and distance ring only after fitting the valve
spindle, otherwise the rod seal ring might be damaged.
20
25
21
HU
014.541/06
5/ 10
2010-07
27512/A1
Maintenance
RT-flex96C
3.2
Assembling of valve drive

Push valve spindle 9 against the valve seat and fit disc springs 19 as shown in
(Fig. B).
Fit piston 17, valve cotters 16 and measuring cone 14.
Apply oil to the threads of head screws 15. Fit and tighten them crosswise in
following steps, i.e. with a torque of 20 Nm, 80 Nm and finally up to 250 Nm.
Bring the valve cage to vertical position.
D
In this position fill oil bath OB1 liberally with system oil (see Fig. B).
Fit lower housing 2.

Apply oil to the threads of screws 3. Fit and pre-tighten them crosswise with a
torque of 130 Nm and subsequently by a further angle of 30_.
D
Take care of bush 27 and O-ring 44 when fitting (Fig. J, section I-I).
Fit the upper valve drive and fasten it using nuts 4.
H
33
3.3
Assembling of valve stroke sensor
34
Clean valve stroke sensor, bore and collar in

lower housing as well as transmitter housing.
Apply oil to O-ring 36, valve stroke sensor
30 and insert them carefully into lower housing 2.
Fit transmitter housing 32 and fasten it using
screws 31.
4
15
36
32
30
31
2
3
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2011-05
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RT-flex96C
27512/A1
Maintenance
3.4
Setting of damper
Setting of damper 33 is necessary only after a valve spindle or valve seat has been
replaced, and after one of the valve seating faces has been ground. Setting is to be
carried out, after assembling of the exhaust valve as shown in Fig. I.
3.5
Determining of total thickness h of the shims

Remove damper 33.
Determine with depth gauge 94124 measure H from the top edge of upper
housing 5 to the bottom of the damper bore in inside piston 7; for this the exhaust valve must be closed (check with feeler gauge whether the valve plate
lies against the valve seat without clearance).
D
The total thickness h of shims 34 assigned to measure H is shown in the

following table:
94124
H 0.5
34
5
7
Measure H
0.5 mm
Total
thickness h
222 mm
2 mm
221 mm
3 mm
220 mm
4 mm
219 mm
5 mm
218 mm
6 mm
217 mm
7 mm
216 mm
8 mm
014.543/06
Fit damper 33 and shims 34 with determined total thickness.

Single shim rings of 1 mm are available.
7/ 10
2011-05
27512/A1
Maintenance
RT-flex96C
3.6
Checking vent screw

Remove and check vent screw 23 (detail in Fig. B) for cleanliness, and replace O-ring 43.
3.7
Checking non-return valve

D
In order to remove non-return valve 26 unscrew air pipe 28.
Undo the non-return valve.

CHECK
Check the non-return valve.
I-I
2
27
44
LEAKAGE
OIL
II
I
II
I
26
29
II - II
28
014.544/06
2011-05
8/ 10
RT-flex96C
27512/A1
Maintenance
4.
Dismantling of valve drive and blocking exhaust valve

For dismantling the upper valve drive the operation must be interrupted temporarily. The necessary measures for it are described in Operating Manual 05201 and
must be followed strictly.
4.1
Dismantling of upper valve drive

Drain and dismantle hydr. HP pipe HH to the exhaust valve drive (see
84601).
Remove nuts 4.
Attach the upper part of the valve drive to eye bolt RC (Fig. L) and lift it off.
Cover opening appeared above lower housing 2 to prevent dirt from entering!
L
RC
HH
5
4
2
RC
6
13
7
12
014.546/06
9/ 10
2010-07
27512/A1
Maintenance
RT-flex96C
4.2
94259
Blocking exhaust valve
Unscrew both screw plugs 10 (Fig. A) from

lower housing 2 and screw in retaining
screws 94259 instead.
94259
4.3
Blocked exhaust valve
After screwing in retaining screws 94259 reopen

the shut-off valve to the air spring supply. This
locks valve spindle 9 in OPEN position.
Remark: For operation with a cylinder cut-out
see Operating Manual 05201.
014.547/06a
2011-05
10/ 10
RT-flex96C
27513/A1
Maintenance
Exhaust Valve
Replacing and Grinding the Valve Seat
Tools:
1
1
1
1
Feeler gauge
Valve seat fitting and dismantling device
Gauge
Valve grinding device
94122
94261
94279
94291
1 Valve seat
2 Valve cage
3 O-ring
AF Seating face
HA Hammer
RC Eye bolt
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grinding the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/5
1/5
2/5
3/5
5/5
General
Valve seats of which the seat surfaces are badly damaged, or on which the wear
limit has been reached through frequent grinding, must be replaced.
The most advantageous position for replacing the valve seat is to bring the valve
cage in a vertical position as shown in Fig. A.
Remark: When the valve seat must be removed with the valve cage in the inverted
upside down position, it must be suspended on the engine room crane slightly
above a wooden underlay. Device 94261 can then be attached from below and the
valve seat carefully withdrawn until it drops caused by its own weight (142 kg).
Therefore, the valve seat must be properly secured with additional wooden underlays. The distance to the wooden underlay is to be kept as small as possible to
avoid any accidents or damage.
2.
Removing the valve seat

Fit both pairs of ring halves of the valve seat fitting and dismantling device
94261 into the groove on the circumference of valve cage 2 and valve seat 1
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.
D
Should a valve seat be removed for any reason, it must be reground by means
of valve grinding device 94291 before refitting.
94261
2
008.336/01
1/ 5
201007
27513/A1
Maintenance
RT-flex96C
Exhaust Valve: Replacing and Grinding the Valve Seat
3.
Fitting the valve seat

Place valve cage vertically.
Clean bore as well as seating shoulder at AF meticulously.
Smear the bore into which the valve seat has to fit with oil, or lubricants such
as THREAD GARD, LOCTITE, ANTI-SEIZE COMPOUND etc.
Smear new O-ring 6 of original specification with the same lubricant.
Push valve seat as far as possible into the bore, then mount valve seat fitting
and dismantling device 94261 and by equal tightening of the jack screws
press the valve seat down till fully seated.
CHECK
Through the control openings in the valve seat fitting and dismantling device check
with feeler gauge 94122 all around the circumference that no clearance remains at
AF.
1
94122
94261
2
008.337/01
201007
2/ 5
AF
RT-flex96C
27513/A1
Maintenance
4.
Grinding the valve seat

Grinding in valve seats using the valve spindle with grinding paste must be avoided
as a matter of principle!
Therefore, always use the valve grinding device 94291 for grinding in the valve
seats in the following cases:
When new or reconditioned valve spindles are fitted.
When the seat surface on the valve seat is badly damaged (impacts, corrosion scars).
94291
016.773/08
3/ 5
201007
27513/A1
Maintenance
RT-flex96C

Remark: Regarding the operation of the grinding machine refer to the operating
instructions of the respective manufacturer.
D
The grinding must produce an even and smooth surface.

Valve seat angle = 30_ + 02
CHECK
The grinding allowance on the valve seat is maximum 3 mm. The wear condition
can be checked efficiently with gauge 94279 in combination with feeler gauge
94122. Possible burn scars at the inside of the valve seat must not exceed 15 mm.
The depth of the burn scars can also be verified with the gauge 94279 as shown in
Fig. D.
D
Valve seats which exceed the above mentioned values must be replaced.
94279
003.458/00
max. 15 mm
201007
4/ 5
RT-flex96C
Maintenance
27513/A1
5.
Checking the valve seat
RC HA
CHECK
After grinding it is necessary to check whether the new or

re-ground valve makes correct contact with the valve
seat. For this the spindle head seat face is spread with a
thin coating of blueing paste, then inserted vertically into
the guide bush.
Remark: The angle difference is chosen such that in the
hot operating condition the valves makes contact by
50 100% from the outer edge (Fig. F). 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 gap S on the outer
edge with a feeler gauge (Fig. G).
003.457/00
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%
003.456/00
S = 0.14 0.18 mm
003.455/00
5/ 5
2008
RT-flex96C
Maintenance
27514/A1
Exhaust Valve
Grinding the Seating Surface on the Valve Head
Tools:
1 Feeler gauge
1 Valve grinding device
1 Gauge
1.
94122
94291
94292
General
Grinding in a valve together with its valve seat with grinding paste is not permitted.
Valves which have had the seating surfaces badly damaged by pitting or corrosion
have to be reground by machine. It is strongly recommended that a suitable grinding machine 94291 be made available.
Remark: A valve spindle with missing rotation wing may not be reground. The
wing hub must be shrink-fitted on the valve shaft by heating it to 480 _C. Grinding
may first begin after the whole unit has cooled down.
The machines from the makers HUNGER and CHRIS - MARINE are well proven
for valve grinding and can also be ordered directly from Wrtsil Switzerland Ltd,
Winterthur.
2.
Grinding the seating surface

SEATING SURFACE
ANGLE ON VALVE
a = 30 _
+20
+18
Only as little material as necessary should be

ground off the valve seating surface to provide a
clean and smooth finished 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.
Remark: For the application of the grinding device refer to the operating instructions.
94291
016.744/08
1/ 2
2010-07
27514/A1
Maintenance
RT-flex96C
Exhaust Valve: Grinding the Seating Surface on the Valve Head
CHECK
The wear condition can be checked at any time with gauge 94292 and feeler gauge
94122.
D
Where the precise angle required has been obtained during grinding, a check
with marking blue with the valve on the reground valve seat in the valve cage
will show only a line contact or a very narrow band (extent of contact) starting
from the smaller diameter as shown in Fig. B.
See also remarks in 27513 regarding the valve behaviour at running temperature.
A maximum of 3 mm may be ground off the valve seating surface. Valve

plates, where the seat surface has been ground back by more than 3 mm can
be reconditioned by build-up welding.
On engines with arduous operating conditions, corrosion may form at the

bottom of the valve plate, after a longer operating time. Exhaust valves can be
reconditioned if the loss of material on the valve plate is less than or equal to
12 mm.
Exhaust valves cannot be reconditioned anymore, when the loss of material is
more than 12 mm, but can be kept in operation up to 25 mm loss of material.
Remark: Reconditioning of exhaust valves may, however, only be carried out by a

Wrtsil Switzerland Ltd authorized repair workshop.
max. 3 mm
94292
003.454/00
2012-05
max. 12 mm
2/ 2
003.454/00
RT-flex96C
Maintenance
Group3
Group 3
Crankshaft: Measuring Crank Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31031/A1

Vibration Damper
Taking a Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31301/A1
Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31302/A1
Axial Damper: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31461/A1
Turning Gear: Checking the Toothing and Screwed Connections . . . . . . . . . . . . . . 32061/A1
Crankcase: Utilization of Working Platform and Ladder . . . . . . . . . . . . . . . . . . . . . . 33011/A1
Lower Platform: Platforms and Hatch Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33012/A1
Connecting Rod
Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . 33031/A1
Inspection, Removal and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . 33032/A1
Inspection, Removal and Fitting of Top End Bearing with Piston in Situ . . . . . . 33033/A1
Inspection, Removal and Fitting of Top End Bearing with Piston Removed . . . 33033/A2
Crosshead
Checking the Clearances and Fitting the Guide Shoes . . . . . . . . . . . . . . . . . . . . 33261/A1
Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33262/A1
Piston
Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34032/A1
Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34034/A1
Piston Rings: Checking Wear of Piston Rings and Ring Grooves . . . . . . . . . . . . . . 34251/A1
1/ 3
RTflex96C / MM / 2030-08
RT-flex96C
31031/A1
Maintenance
Crankshaft
Measuring Crank Deflection
Tool:
1 Crankshaft checking equipment

(dial gauge)
1.
94305
1 Flywheel
2 Pinion
General
Regular crankweb deflection measurements according to the intervals defined by
the class rules are sufficient. Detailed alignment measurements might become necessary only in case of abnormalities, like
significant change of crankweb deflection measurement results compared to

the set of previous measurements.
bearing temperature alarms or bearing damage.
after replacing main bearing shells and again after approx. 100 service hours.
in case the ship has touched ground.
In any such cases it is recommended to contact Wrtsil for support.

The checking equipment 94305 is clamped between the crank webs into the provided center punch marks. When turning the crankshaft, the change in distance
between the crank webs can be read from the dial gauge as it indicates any opening or closing up. The smaller the variation the better the alignment of the crankshaft. Thereby, however, the function of the checking equipment, i.e. the sign on
dial gauge + (standard) or must be taken into consideration.
2.
Conditions for measuring

D
Indicator valves must be open.
The ship must be floating freely and lying in the water as horizontal as
possible.
The crankshaft must rest perfectly on all the main bearings.
2.1
1
2
014.254/06
TURNING GEAR
ON FUEL SIDE
Influences on measuring
Engine cold or at service temperature.
The difference in temperature between the lubricating oil

sump tank and the seawater.
Loaded condition of the ship (draught).
Strong sunshine.
It is recommended to include these data in the records.
3.
Measuring procedure
Despite the ordinary rotation direction of the engine, the
crankshaft must always be turned in such a manner that
flywheel 1 and pinion 2 of the turning gear are rotating as
indicated by the arrows.
1/ 3
2013-08
31031/A1
Maintenance
RT-flex96C
3.1
Setting the checking equipment

With the running gear in situ, the crank to be measured has to be turned correspondingly after B.D.C. The checking equipment can now be clamped next to the
connecting rod into the provided center punch marks.
Pretension the dial gauge of checking equipment 94305 and turn the latter
around its own axis for its proper settling.
Dial gauge must not deviate more than 0.01 mm. Set subsequently dial gauge
to zero.
Turn crankshaft by means of turning gear, reading the dial gauge in the shown
crank positions at B.D.C. EXHAUST SIDE T.D.C. FUEL SIDE B.D.C
and noting down the values.
D
The last value at B.D.C. is for checking. With correctly carried out measuring
procedure it should be again nearly zero. If it deviates more than 0.06 mm
from the first reading, then the measuring must be repeated.
VIEW FROM
DRIVING END
COUNTERCLOCKWISE ROTATION
EXHAUST SIDE
T.D.C.
B.D.C.
FUEL SIDE
B.D.C.
CRANK DEFLECTION
SIGN ON DIAL GAUGE
+
94305
OR
APPROX. 18 mm
CENTER PUNCH MARK
FOR DIAL GAUGE 94305
2013-08
2/ 3
RT-flex96C
31031/A1
Maintenance
4.
Judging the measuring
STROKE
C
94305
B.D.C
T.D.C
The difference between the indicated values shows the amount of crank deflection
during one revolution (Fig. B).
Where values are measured which lie above the maximum permissible limits, the
cause has to be found and the necessary remedial measures taken (defective
main bearing, engine stay altered due to hull deformation, loose holding-down
bolts, defective propeller shaft bearings or checking equipment 94305, etc.).
The limits are valid for any condition of ship service after ship delivery, i.e.:
The ships draught and trim are within the limits for normal operation.
The engine is stopped and hot or cold.
In case of measurements at cold engine condition, any tank heating which is

arranged close or below the main engine as well as the pre-heater of the main
lubricating oil separator have to be out of operation at least 8 hours prior to the
measurement.
Normal ship service: Crankweb deflection limits [mm]
Vertical
Cylinder No. 1
(Driving end)
Cylinder No. 2
to penultimate
cylinder
0.76
0.76
0.54
0.54
Horizontal
Last cylinder
(Free end)
1)
2)
0.54
0.54
0.54
0.76
All cylinders
0.25
0.25
1)
For engine without torsional vibration damper or front disc or free end PTO.
2)
For engine with torsional vibration damper or front disc or free end PTO.
Contact Wrtsil Switzerland, if the final measurements exceed the limits given in
the above table.
3/ 3
2013-08
RT-flex96C
31301/A1
Maintenance
Vibration Damper
Taking a Silicone Fluid Sample
1
2
3
4
5
6
1.
Casing trough
Casing cover
Screw plug
O-ring
Sealing ring
Coupling bolts
7 Crankshaft
8 Cap nut
KS Secured by centre punch mark

PB Sample container
General
Viscous vibration dampers manufactured by Hasse & Wrede, Metaldyne International UK, STE Schwingungstechnik and Geislinger can be mounted at the free
end of the crankshaft and in case of RTA engines as well at the free end of the camshaft.
The service life of a vibration damper is largely dependent on the speed range in
which the engine is run. Wear of the inner parts as well as changes in the silicone
oil properties can reduce the effectiveness of the damper. By periodic examination
of the silicone oil the makers of the vibration damper can draw conclusions on its
condition.
The silicone oil must be examined for the first time after about 15 00018 000 operating hours. Future intervals for examinations depend on the result of these first
findings.
Special sample containers PB (Fig. B) can be obtained from the vibration
damper makers.
Remark: Before taking a sample, or before working on a

vibration damper, always follow first the instructions of
the vibration damper manufacturer.
7
3
In casing trough 1 and casing cover 2, two oil sampling

holes are carefully closed and sealed with screw plugs 3.
2
3
3
009.739/02
1/ 4
2010-07
31301/A1
Maintenance
RT-flex96C
2.
Preparation for taking a silicone fluid sample

Remove the casing of the vibration damper.
Turn the crankshaft in such a way that both screw plugs 3 of the vibration
damper are positioned horizontally to each other, whenever possible. If in this
position the screw plugs cannot be loosened , then the vertical position can
also be chosen.
Before removing the screw plug, carefully clean the area around it.
D
Leave the damper in the mentioned position for at least two hours.
(If the oil sample is to be withdrawn from a removed vibration damper the
same conditions apply as regards the positions and the waiting time).
Using a flat caulker, hammer back the squeezed material in the corresponding
slot, which serves as locking means of screw plug 3.
Loosen the screw plug, but do not unscrew it yet, it must still seal.
3.
Taking the sample

CHECK
Prepare sample container PB, i.e. remove both cap nuts 8 and examine the bore
which must be meticulously clean.
Remark: Two different threads are used for the sample bores of the Simpson International and STE vibration dampers. Therefore, the ends of the sample container are provided with different threads.
Remove the previously loosened screw plug 3, and screw in the sample container PB instead.
After fully screwing in the sample container, screw it back by one turn to prevent it from touching the flywheel inside the vibration damper.
Wait until the silicon fluid appears at the open end of the sample container.
Depending on the viscosity of the fluid, this may take some seconds only, or
much longer.
As soon as the silicon fluid flows out of the sample container, close its open
end with the respective cap nut.
Unscrew the sample container from the vibration damper housing (taking care
not to let escape the fluid), then immediately set in screw plug 3 with a new
O-ring 4 or sealing ring 5. (Avoid any leaking of silicon fluid.)
Screw the second cap nut on the sample container and tighten it moderately.
For the different vibration dampers tighten screw plugs 3 as follows:
Metaldyne International with 25 Nm
Hasse & Wrede
with 20 Nm
STE
with 15 Nm (M10) or 45 Nm (M16)
Finally secure the screw plugs with centre punch mark KS (Fig. B).
2008
2/ 4
RT-flex96C
31301/A1
Maintenance
SAMPLE
CONTAINERS
Metaldyne
and STE
8
HASSE & WREDE
3/8BSF (M16)
M10x1
PB
PB
M10x1
5/16BSF (M10)
007.964/97
4
KS
KS
If a sample is not obtained by the method described, proceed as follows:

D
Leave sample container in position.
Remove the opposite screw plug, connect a compressed air supply and apply
about 3.5 bar pressure.
D
Only dried and filtered air may be used (connections and air hose must be
clean, free from any fouling).
As soon as fluid reaches open end of sample container shut off compressed
air supply and then fit one of the two cap nuts 8 to the sampling container.
Disconnect compressed air supply. Remove sample container and fit the
other cap nut 8.
Re-fit the corresponding screw plugs to all withdrawal openings.
Tighten and lock the screw plugs as already mentioned under Taking the
sample.
Remark: The special sample container permits drawing a specific quantity of silicone oil from the damper. The total number of samplings should be limited to 10.
3/ 4
2008
31301/A1
Maintenance
RT-flex96C

The filled sample container has to be labelled and depending on the manufacturer
sent to one of the following addresses for examination:
Hasse & Wrede
Georg-Knorr-Strasse 4
D-12681 Berlin
Germany
Tel: +49 30 93 92 3135
Fax: +49 30 70 09 0835
Remark: Samples taken on dampers manufactured by STE Schwingungstechnik
have to be sent to Hasse & Wrede.
Metaldyne International UK Ltd
131 Parkinson Lane
GB-Halifax HX1 3RD
United Kingdom
Tel: +44 1422 357 234
Fax: +44 1422 354 432
Geislinger GmbH
Hallwanger Landesstrasse 3
A-5300 Hallwang / Salzburg
Austria
Tel: +43 662 66 999 0
Fax: +43 662 66 999 40
The label must contain the following information:
201007
Engine type
Engine No.
Number of operating hours of the vibration damper
Ship name
Shipyard and hull number
Manufacturing serial number of damper (see manufacturing plate or stamped

marks)
Damper location (crankshaft or camshaft)
4/ 4
RT-flex96C
31302/A1
Maintenance
Vibration Damper
Inspection (GEISLINGER Vibration Damper)
1
2
3
4
5
1.
Damper casing
Vent nozzles
Sealing rings
Oil supply piping
Crankshaft
6 Coupling bolt
7 Coupling disc
(crank angle sensor unit)
8 Vibration damper
9 Sealing ring
General
Depending on the design execution of an engine, a vibration damper of GEISLINGER make may be mounted at the free end of the crankshaft.
The service life of a vibration damper depends largely on the speed range in which
the engine is operated. Water, in particular sea-water, in the lubricating oil leads to
increased wear and loss of damping action.
2.
Check
D
The engine filters should regularly be checked for steel or bronze chippings. If
such chippings are found also in the damper housing, the damper supplier is
to be informed accordingly.
Until the reasons for such findings are not clarified and rectified, it is not allowed to
put the damper back into service.
D
Should the oil pressure drop below 1 bar, it may not be corrected by adjustment of the adjustable throttle in the supply piping. Instead, the cause of the
pressure drop must be investigated (defective oil supply piping 4).
Attention! If the oil supply to the damper is interrupted, the engine must be
stopped immediately, otherwise the damper may be seriously damaged. The oil
supply has to be reestablished before restarting the engine.
D
Should damage be noticed on the engine bearings which is due to water contamination of the lubricating oil, then the vibration damper must also be inspected for possible damage at the very earliest opportunity.
To check the inner spring tips and groove flanks the inspection cover on the
face of damper casing 1 (Fig. B) can be removed (with stopped engine). For
wear limits refer to the manual of the damper manufacturer.
Dismantling of a vibration damper should only take place if there is a reasonable suspicion that the damper is damaged or wear rates have exceeded their
limits. In this case contact the damper manufacturer for further instructions.
Attention! Adjustments on the vibration damper may only be carried out by a specialist, with simultaneous torsional vibration measurements.
Prior to removing a vibration damper and balance weight mark their positions with
reference to the crankshaft.
D
For tightening values of coupling bolts 6 see 03521.
Remark: For the test run after the first commissioning, as well as the normal
checking and servicing intervals, refer to the manual of the damper manufacturer.
Contact address for GEISLINGER vibration dampers:
Geislinger GmbH
A-5300 Hallwang / Salzburg
Austria
1/ 2
201007
31302/A1
Maintenance
RT-flex96C
Inspection (GEISLINGER Vibration Damper)
B
8
1
8
6
9
FREE END
OIL SUPPLY
7
011.669/04
2008
2/ 2
RT-flex96C
31461/A1
Maintenance
Axial Damper
Tools:
2 Eye bolts M30
1.
1
2
3
4
5
6
7
8
9
10
11
Upper part of cylinder

Lower part of cylinder
Screw
Screw
Screw
Large seal ring
Small seal ring
Self-locking nut
Allen screw
Throttling valve
Spindle
12
13
14
15
16
17
18
Locking screw
Locking plate
Diaphragms
Oil inlet pipe
Main bearing cover
Crankshaft
Main bearing shell
HZ Lifting tackle
RC Eye bolt
Dismantling
Prior to any overhaul work being started on an axial damper, switch off the bearing
oil pump. Then remove the upper half of the two-piece crankshaft casing at the free
end.
Remove oil inlet pipe 15.
Pull out both taper pins locating the upper and lower part of cylinder 2 and 1
respectively. For this purpose the taper pins have been provided with respective threads.
Loosen and remove all screws 5 and 3 (Fig. A).
Loosen screws 4 to the upper part of cylinder 1 and pull them out as far as
possible.
10
12
15
14
10
11
16
16
5
1
4
6 7
17
18
001.420/97
1/ 3
001.420/97
2008
31461/A1
Maintenance
RT-flex96C
Axial Damper: Dismantling and Assembling
HZ
RC
1
16
001.522/97
17
Screw in two eye bolts RC (Fig. B) into the upper part of cylinder and fit lifting
tackle HZ on the platform support at the free end. Join the eye bolts by steel
ropes and the lifting tackle.
Remark: Pay attention to General Guidelines for Lifting Tools 00121.

Attention! Using lifting tackle carefully raise upper part of cylinder . Make absolutely sure that the upper part of the cylinder slides out of the seal rings 6 and 7
without jamming, as otherwise the seal rings risk being damaged.
For removal of two-part seal rings 6 and 7, loosen first self-locking nuts 8 and
remove Allen screws 9. The sealing rings can then be turned out of their
grooves in the lower part of cylinder 2 without any problems.
9
8
6 (7)
003 718/95
2008
2/ 3
RT-flex96C
Maintenance
31461/A1
Axial Damper: Dismantling and Assembling
2.
Checking the throttling valve

11
12
13
D
10
When overhauling the axial damper check also the

condition of throttling valve 10. The spindle position
has been locked by locking screw 12 and a locking
plate 13.
Changing the position of the throttling valve is forbidden.

D
For pre-setting spindle 11 has to be turned back by

about four turns starting from the closed position.
This adjustment must be verified on the basis of

vibration measurements during sea trial; otherwise
the spindle must be readjusted. The final adjustment has to be engraved in the name plate fitted to
the upper part of cylinder 1.
14
004.156/99
If it becomes necessary to unscrew or replace a spindle for any reason, then the
distance x must be measured first (Fig. D). The spindle has to be adjusted to the
same distance on reassembling.
The spindle must not be turned back by more than 16 turns , that corresponds to a
stroke of x = 48 mm.
D
When the above check brings to light any defect of throttling valve 10 then diaphragms 14 (Fig. A) screwed into the throttling valve must also be checked
for possible damage and replaced if necessary.
Attention! The engine must not be operated with spindle 11 removed or with the
oil supply to the axial damper interrupted!
3.
Assembling
Remark: The seal rings normally have no signs of wear, therefore no dimension
due to wear is indicated. However, worn or damaged seal rings 6 and 7 due to contamination must be replaced. See also 31461 Monitoring system in the Operating Manual.
D
The seal rings are fastened by two Allen screws 9 and self-locking nuts 8. Immediately before fitting the seal rings smear them with clean engine oil.
Newly fitted seal rings must allow radial movement when fitted.
The assembling of the axial damper is done analogously to dismantling but in

reverse sequence. Pay the utmost attention when lowering upper part of cylinder 1 into place, to prevent seal rings 6 and 7 from 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.
Remark: Apply MOLYKOTE and tighten screw 4 between axial damper and bedplate with a tightening angle of 50_ (see also 03521).
3/ 3
201007
RT-flex96C
32061/A1
Maintenance
Turning Gear
Checking the Toothing and Screwed Connections
Tools:
1
1
1
1
1
1
1
1
1
1.
Feeler gauge
Pre-tensioning jack
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
HP hose
94122
94340
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
7
8
Turning gear
Pinion
Toothing of flywheel
Support
Screw
Nut
Spacer ring
Cylinder
9 Piston
10 Vent screw
11 Pin
EV
KO
RS
SA
Relief valve
Slot
Round bar
Gap
General
Before putting the turning gear into operation, the condition of the tooth flanks, i.e.
the lubricant of pinion 2 and toothing of flywheel 3 must always be checked. See
also 07501 in the Operating Manual.
For maintenance of the turning gear the instructions recommended by the
manufacturer must be followed.
The pre-tension of screws 5 for turning gear 1 must be checked in accordance with
Maintenance Schedule 03801.
1
3
2
4
014.254/06
1/ 5
2008
32061/A1
Maintenance
RT-flex96C
Turning Gear: Checking the Toothing and Screwed Connections
2.
Checking the toothing
2.1
Application instruction
The lubricant needs to be spread evenly in a very thin layer over the tooth flanks
of pinion 2 and flywheel 3 in order to prevent it from being thrown off at full engine
speed.
Brand
2.2
Application picture
Remark
1 LE 5182
PYROSHIELD
Apply lubricant in a zigzag line to provide a thin

layer of lubricant over
the entire gear tooth surface.
2 Klberfluid
CF 3 ULTRA
In order to reach a very

thin shiny layer of lubricant, it is recommended
to warm up Klberfluid
to approx. 35 _C in a
small tin which is put into
warm water.
Re-lubrication intervals
According to visual inspection results, when hardly any lubricant is left any more on
the highest loaded tooth flank areas, i.e. before the tooth flanks nearly run dry:
Approximately every 2000 operating hours of the diesel engine, or more frequently, as required.
2.3
Recommended suppliers
2013-08
Lubrication Engineers Inc.

300 Bailey Avenue
Forth Worth, TX
USA
http://www.lelubricants.com/
Email: info@le-inc.com
Klber Lubrication Mnchen KG

Geisenhausenerstrasse 7
81379 Mnchen
Germany
http://www.klueber.com
Email: info@klueber.com
2/ 5
RT-flex96C
32061/A1
Maintenance
3.

Clean threads of screws 5 and seating surfaces around nuts 6. Subsequently
apply MOLYKOTE G paste to the threads.
Place pre-tensioning jack 94340 on screw 5 and screw it down with vent screw
10 open till there is only little or no clearance at x.
Connect pre-tensioning jack with HP oil pump 94931, whereby one side of
connection piece 94934a must be closed with plug piece 94934e.
bubble-free at the vent screw.
Close vent screw, tension the screw with 1000 bar and keep pressure
constant.
D
CHECK

and spacer ring 7.
If any clearance does exist, tighten the nut with round bar RS till it rests firmly
on the spacer ring (check with feeler gauge). Subsequently release the pressure to 0 at the HP oil pump. If no clearance exists, the pressure can immediately be released and the pre-tensioning jack removed.
Check all the screws in this manner and, wherever necessary, tighten the nut.
4
7
KO
RS
94932a
94934a
x
9
94934e
94932
11
012.106/04
10
94935a
3/ 5
94935
EV
94931
2008
32061/A1
Maintenance
RT-flex96C
4.
Loosening the screws

Screw down pre-tensioning jack 94340 as for checking the pre-tension, then
turn back by one turn (gap SA in Fig. C).
Connect pre-tensioning jack to HP oil pump 94931.
Close vent screw and pump till a pressure of 1020 bar has been reached.
D

Turn back nut 6 by one turn, and release the pressure to 0.

Remove the pre-tensioning jack.
4
6
7
SA
RS
94932a
94934a
9
94934e
94932
94935
EV
11
10
94935a
2008
4/ 5
94931
012.107/04
RT-flex96C
32061/A1
Maintenance
5.
Tensioning the screws

Tensioning of all the screws is carried out in two steps as follows:
1st step with 600 bar in the required sequence a f as shown in Fig. D
view II.
2nd step with 1000 bar in the same sequence.
The tensioning procedure is the same as described in section 3.
Apply MOLYKOTE G paste to the screw threads.
I-I
D
I
2
1
5
4
7
6
b e
II
3
I
012.108/04
II
c
f
TENSIONING
SEQUENCE
5/ 5
2008
RT-flex96C
33011/A1
Maintenance
Crankcase
Utilization of Working Platform and Ladder
Tools:
2 Working platforms,
consisting of 3 grids each
2 Working supports
1 Ladder
1.
94142
1
2
3
4
94143
94147
Engine longitudinal beam

Crank web
Step
Strap
General
To avoid accidents, the grids of working platform 94142, working supports 94143
and ladder 94147 should be used for inspections or work in the crankcase. The
grids must always be fitted in such a way that their U-profiles come to lie between
engine longitudinal beam 1 and that the opposite end rests on crank web 2, as
shown in Fig. A.
Working support 94143 can be fitted between the columns at the desired height,
on steps 3. These are safeguarded against falling down by shoving straps 4
against the steps.
Never rotate crankshaft while grids, working supports or the ladder are in position.
I-I
I
3
94143
94143
4
FUEL SIDE
EXHAUST SIDE
94147
94142
94142
1
011.662/04
1/ 1
009.307/01
2008
RT-flex96C
33012/A1
Maintenance
Lower Platform
Platforms and Hatch Covers
1
2
3
4
5
6
7
8
9
10
11
12
1.
Supply unit
Lateral hatch cover
Upper platform
Hatch cover
Hatch cover
Column
Bolting device
Lower platform
Lower platform
Front centre part
Rear centre part
Screw
General
In order to meet the different requirements during removal and fitting of engine
components, the upper and lower platforms as well as the hatch covers can be
opened respectively removed at the (main) lower platform.
Risk of accident! Prior to opening platforms and hatch covers, the access to the
area to be opened must always be barricaded without fail!
All platforms and hatch covers closed:
1
5
4
2
014.140/06
1/ 6
2008
33012/A1
Maintenance
RT-flex96C
Lower Platform: Platforms and Hatch Covers
Hatch cover 5 opened:
014.141/06
Hatch covers 4 and 5 opened:
5
4
014.142/06
2008
2/ 6
RT-flex96C
33012/A1
Maintenance
Lateral hatch cover 2 removed (view I):
014.143/06
Preparation for opening upper platform 3:

Fit RUD-eye bolt RC into upper platform 3.
Hang lifting tackle HZ (lifting capacity 500 kg) into the strap of column 6 and
connect it to RUD-eye bolt RC.
HZ
RC
014.144/06
3/ 6
2008
33012/A1
Maintenance
RT-flex96C
Upper platform 3 opened:

Risk of accident! Secure the upper platform after opening, i.e. bolting device 7
must be fastened to upper platform 3 using screws 12 as shown in the detail below.
6
3
7
12
014.145/06
Lower platform closed:

Remark: To make the lower platform visible, upper platform 3 was blank-arranged in the following figures, however, essentially it remains opened and secured as illustrated in Fig. F.
11 10
014.146/06
2008
4/ 6
RT-flex96C
Maintenance
33012/A1
Preparation for opening lower platforms:

Remove front centre part 10 and rear centre part 11 (see also Fig. G).
10
11
014.147/06
Lower platform 8 removed:
014.148/06
5/ 6
2008
33012/A1
Maintenance
RT-flex96C
Lower platform opened:
8
9
014.149/06
2008
6/ 6
RT-flex96C
33031/A1
Maintenance
Connecting Rod
Loosening and Tensioning the Connecting Rod Studs
Tools:
1
2
2
1
1
1
2
1
Feeler gauge
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94122
94314
94315
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
Connecting rod stud

Nut
Pin
Vent screw
Piston
Cylinder
Sealing ring
8 Bottom end bearing

9 Top end bearing
KO Slot
RS Round bar
SA Gap
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening the stud of bottom end bearing . . . . . . . . . . . . . . .
Tensioning the stud of bottom end bearing . . . . . . . . . . . . . .
Loosening the stud of top end bearing . . . . . . . . . . . . . . . . . .
Tensioning the stud of top end bearing . . . . . . . . . . . . . . . . . .
1/5
2/5
3/5
4/5
5/5
General
For loosening and tensioning clean the threads of connecting rod studs 1 and
the area around nuts 2 and lubricate the threads.
CHECK
Check that the nuts turn freely on the threads.

Always check the oil level before using the hydraulic unit.
Attention! Never turn the crankshaft as long as the pre-tensioning jacks are
mounted on the connecting rod studs!
4
3
5
6
2
RS
SA
KO
011.360/03
011.359/03
PRE-TENSIONING JACK
PRE-TENSIONING JACK
1/ 5
2008
33031/A1
Maintenance
RT-flex96C
2.
Loosening the connecting rod stud of bottom end bearing

Place pre-tensioning jacks 94314 on connecting
rod studs 1 (Fig. B) and completely screw them on
with opened vent screw 4 (Fig. A).
The pre-tensioning jacks are to be loosened by

about turn (gap SA in Fig. A).
94314
Connect the pre-tensioning jacks with hydraulic

unit 94942 as shown in Fig. B.
94935a

1
8
Close vent screws 4 on the pre-tensioning jacks as

soon as oil flows bubble-free.
Actuate hydraulic unit till a pressure of 1020 bar is
indicated on pressure gauge 94932a and on the
pressure gauge at the hydraulic unit.
D
94932a
Attention should be paid to ensure that pins 3 always protrude slightly compared with pistons 5 on
the pre-tensioning jacks!
Turn back nuts 2 by one turn, using round bar RS.
94934a
Release pressure to zero at the hydraulic unit and

then remove pre-tensioning jacks.
94935
008.450/01
94942
2008
2/ 5
RT-flex96C
Maintenance
33031/A1
3.
Tensioning the connecting rod stud of bottom end bearing

D
Consider the previously mentioned directions.
Tighten the nuts first with round bar RS by hand with a smart jerk.
Check whether the nuts rest flush on the connecting rod shank.
CHECK
Equally distribute the clearance between the bearing halves (bearing projection).
Screw pre-tensioning jacks 94314 onto connecting rod studs 1 until these rest
against the connecting rod shank. Moreover, open slightly vent screws 4 so
that pistons 5 can slide back to their initial position, i.e. there is no or little clearance at x (Fig. A).
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. B.
Actuate the hydraulic unit and set pressure to 300 bar (1st step) and keep
pressure constant.
Start up hydraulic unit till bubble-free oil flows out through vent screws 4. Shut
the vent screws.
D

Tighten the nuts with round bar RS and check with the feeler gauge through slot
KO (Fig. A) that no clearance remains between nut and supporting surface.
Check with the feeler gauge that no clearance remains between bearing cover and
connecting rod shank.
(Should clearance remain, loosen the fastening and compare the bearing projection with the nominal value as indicated in 33032).
CHECK
Fig. a
After tensioning to the 1st step mark the position of

the nuts against connecting rod as shown in Fig. a.
Raise the pressure to 1000 bar (2nd step) and keep
constant.
CHECK
y
x
Tighten nuts down and check correct seating with the

feeler gauge.
Check from the markings applied by how much the nuts
were turned after pre-tightening (1st step).
Tightening angle to be about 80_ (Fig. b).
Should considerable differences to these nominal
values be encountered then repeat the tensioning
process.
Fig. b

CHECK
Finally check the vertical bearing clearance (see Clearance Table 03301 Top and bottom end bearings to connecting rod).
98.7700
TIGHTENING ANGLE
3/ 5
2008
33031/A1
Maintenance
RT-flex96C
4.
Loosening the connecting rod stud of top end bearing
Remark: For loosening the studs always follow the sequence shown in Fig. C i.e. a + a and b + b.
I
b
Place pre-tensioning jacks 94315 diagonally on

connecting rod studs 1 (Fig. C) and completely
screw them on with opened vent screw 4 (Fig. A).
The pre-tensioning jacks are to be loosened by

about turn (gap SA in Fig. A).
94315
a
94935a
Connect the pre-tensioning jacks with hydraulic

unit 94942 as shown in Fig. C.

9
Close vent screws 4 on the pre-tensioning jacks as

soon as oil flows bubble-free.
Actuate hydraulic unit till a pressure of 1020 bar is
indicated on pressure gauge 94932a and on the
pressure gauge at the hydraulic unit.
Turn back nuts 2 by one turn, using round bar RS.

94932a
Proceed in the same manner for the second pair of

connecting rod studs.
94934a
94935
003.347/00
94942
2008
4/ 5
RT-flex96C
Maintenance
33031/A1
5.
Tensioning the connecting rod stud of top end bearing

Remark: For tensioning the studs always follow the sequence shown in Fig. C
i.e. a + a and b + b for each step.
Consider the previously mentioned directions.
Tighten the nuts first with round bar RS by hand with a smart jerk.
Check whether the nuts rest flush on the bearing cover.
CHECK
Equally distribute the clearance between the bearing halves (bearing projection).
Screw pre-tensioning jacks 94315 diagonally onto two connecting rod studs 1
until these rest against the bearing cover. Moreover, open slightly vent screws
4 so that pistons 5 can slide back to their initial position, i.e. there is no or little
clearance at x (Fig. A).
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. C.
Start up hydraulic unit till bubble-free oil flows out through vent screws 4. Shut
the vent screws.
Actuate the hydraulic unit and set pressure to 600 bar (1st step) and keep
pressure constant.
Tighten the nuts with round bar RS and check with the feeler gauge through slot
KO (Fig. A) that no clearance remains between nut and supporting surface.
Check with the feeler gauge that no clearance remains between bearing cover and
connecting rod shank.
(Should clearance remain, loosen the fastening and compare the bearing projection with the nominal value as indicated in 33033).
CHECK
Proceed in the same manner for the second pair of

connecting rod studs.
Fig. a
After tensioning to the 1st step mark the position of

the nuts against bearing cover as shown in Fig. a.
Raise the pressure to 1000 bar (2nd step) and keep
constant.
y
CHECK
x
Fig. b
Tighten nuts down and check correct seating with the

feeler gauge.
Check from the markings applied by how much the nuts
were turned after pre-tightening (1st step).
Tightening angle to be about 30_ (Fig. b).
Should considerable differences to these nominal values be encountered then repeat the tensioning process.
remove pre-tensioning jacks.
CHECK
y
Finally check the vertical bearing clearance (see Clearance Table 03301 Top and bottom end bearings to connecting rod).
98.7700
x
TIGHTENING ANGLE
5/ 5
2008
RT-flex96C
33032/A1
Maintenance
Connecting Rod
Inspection, Removal and Fitting of Bottom End Bearing
Tools:
2
2
4
1
1
1
1
2
2
2
2
2
1
1.
Working platforms
Working supports
Retaining pins
Device
Lifting beam
Suspension
Lifting support
Washers
Eye bolts (M64)
Eye bolts (M24)
Ropes with shackles (1060 mm)
Ropes with shackles (1200 mm)
Rope with shackle (1600 mm)
94142
94143
94323a
94326
94334a
94334b
94334c
94334d
94334e
94334f
94334g
94334h
94334i
1
2
3
4
5
6
7
8
9
10
11
12
13
Connecting rod stud

Nut
Crank
Toggle lever
Support
Bearing cover
Connecting rod
Guide way
Tap hole for eye bolt
Bearing shell
Allen screw
Cylindrical pin
Pipe
14
15
16
17
18
19
20
21
Screw
Strap
Handle
Pin
Support
Screw
Bush
Spherical discs
AF Seating surface
H1 ... Lifting tackles
HZ Lifting tackle
Inspection and removal

D
Loosening of connecting rod studs 1 must be carried out according to 33031.
Attention! Never turn the crankshaft as long as the pre-tensioning jacks are
mounted on the connecting rod studs!
1.1
Lowering of bearing cover

Fit an eye bolt 94334f on each side of bearing cover 6 immediately below the
bearing division.
Connect lifting tackles H1 and H2 (lifting capacity 2000 kg each) with the eye
bolts and tighten the ropes.
Remove nuts 2.
Carefully lower the bearing cover while taking

care that the threads of the connecting rod
studs as well as the surface of the crankpin
are not damaged.
H1
Loosen lifting tackle H1 from the eye bolt.

2
1
H2
94334f
6
3
11
10
12
6
014.301/06
1/ 8
1.09
33032/A1
Maintenance
RT-flex96C
1.2
Removal of bearing cover

Fit lifting beam 94334a on the sides of bearing cover 6.
Push suspension 94334b over the movable pipe 13 of the lifting beam.
Fit washers 94334d and lifting support 94334c and fasten them with screws
14 and pipe 13 as shown in view I.
Connect ropes 94334h with suspension 94334b and lifting tackle H1.
Lift bearing cover as shown in Fig. C.
Remove lifting tackle H2.
I
H1
94334h
H2
94334b
94334a
94334d
14
94334h
13
94334b
I
014.303/06
6 94334c
2008
94334c
94334a
2/ 8
RT-flex96C
33032/A1
Maintenance

Turn the crankshaft towards exhaust side by about 70_ after T.D.C.
Lift bearing cover 6 over the crankshaft center.
Fit eye bolt 94334e into the connecting rod head.
Push rope 94334i through eye bolt 94334e and connect it with an additional
lifting tackle H3 (lifting capacity 2000 kg).
Connect first rope 94334i with ropes 94334g, and moreover ropes 94334h
with the shackles of suspension 94334b (Fig. G, view I).
Connect lifting tackle H4 (lifting capacity 2000 kg) with strap 15 and lifting support 94334c.
Tighten lifting tackle H4 and rope 94334i.
Loosen rope 94334h (Fig. F and G, view I).
H3
H1
94334i
H1
94334c
94334e
94334c
94334h
94334g
94334i
15
H4
94334e
15
H4
H3
94334h
94334g
94334b
94334b
014.311/06
014.313/06
REMOVAL OF BEARING COVER

OUTSIDE THE AREA OF SUPPLY UNIT
REMOVAL OF BEARING COVER

BELOW SUPPLY UNIT
3/ 8
2008
33032/A1
Maintenance
RT-flex96C

Remove bearing cover 6 from the crankcase as shown in Fig. F and G.
H3
014.315/06
014.317/06
I
94334g
94334b
94334h
014.320/06
2008
4/ 8
RT-flex96C
33032/A1
Maintenance
1.3
Fitting of retaining pin 94323a

Attention! Always insert four retaining pins 94323a and never move the crosshead in the direction towards them with the turning gear! However, there are only
two retaining pins provided in combination with two roller supports 94331 (see
33033, 33034 and 33262).
Carefully turn crankshaft towards fuel side and position guide shoes 63 mm
above the bores in guide ways 8.
Insert four pins 17, taking care to put seating surface AF of support 18 in horizontal position.
Secure each pin on the back using screw 19 (together with bush 20 and spherical discs 21). Do not tighten screws, but adjust a clearance of 0.1 0.3 mm.
Turn all pins until all seating surfaces AF evenly contact the guide shoes.
Strain the pins by means of screws 19.
GUIDE SHOE
AF
19
63 mm
21
20
19
018.037/09
20
17
18
16
0.10.3 mm
5/ 8
1.09
33032/A1
Maintenance
RT-flex96C
I
018.037/09
1.4
D
HZ
H6
Bearing cover 6 must be lowered (see paragraph 1.1).
Loosen and remove the screws fastening

toggle lever 4 of piston cooling and crosshead lubrication and separate toggle lever
from connecting rod. Suspend toggle lever
with lifting tackle HZ inside the crankcase as
shown in Fig. I.
94323a
Inspection of bearing shell
Turn the crankshaft to T.D.C.
Fit four retaining pins 94323a into the bores

of guide ways 8 (see paragraph 1.3).
Secure the connecting rod with lifting tackle
H6 and rope a (lifting capacity 3000 kg each)
on fuel side.
Carefully turn down the crankshaft to fuel

side, following with the connecting rod bottom by pulling it with the lifting tackle and rope
a just as far as to keep always a distance X
between the connecting rod bearing and the
crank 3.
014.321/06
H7
b
1.5
Removal of bearing shell

Bearing cover 6 may not be in the crankcase
any more (see paragraph 1.2).
a
94326
94142
Turn crank 3 downwards.

Install working platforms 94142.
Attach device 94326 to bearing shell 10 using
four screws.
Connect rope b and lifting tackle H7 (lifting
capacity 500 kg each) with device 94326.
Tighten the rope.
Remove Allen screws 11 (Fig. B) from the
bearing shell.
014.326/06
1.09
6/ 8
RT-flex96C
33032/A1
Maintenance

Lower bearing shell 10 a bit using rope b.
Connect ropes c and d with the corresponding lifting tackle HZ (lifting capacity 500 kg each) and the shackles of device 94326.
Place the bearing shell on working platform 94142 using ropes b, c and d.
After loosening rope c remove the bearing shell from the crankcase as
shown in Fig. L and M.
a
HZ
94326
d
c
94142
94326
a
HZ
c
94142
014.346/06
014.343/06
REMOVAL OF BEARING SHELL

OUTSIDE THE AREA OF SUPPLY UNIT
REMOVAL OF BEARING SHELL

BELOW SUPPLY UNIT
2.
Fitting
The fitting of bearing shell 10 and bearing cover 6 is carried out analogous to removal but in reverse sequence.
D
The running surfaces have to be lavishly smeared with clean bearing oil.
Tensioning of connecting rod studs must be carried out according to 33031.
Attention! Always fit toggle lever 4 in such a way that its curvature stands upwards.
After completing the work all retaining pins 94323a must be removed without fail.
7/ 8
1.09
33032/A1
Maintenance
RT-flex96C
3.
Fitting of a bearing shell

D
For fitting a bearing shell to the bottom end bearing, the surface of the
crankpin must be in perfect condition.
While fitting a bearing shell pay attention to prevent dirt or foreign particles
from entering between the shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be free from any damage. Immediately before inserting the bearing shells they have to be wiped
with a slightly oily hand, so that a trace of oil is on them.
The bearing shell should be placed in the connecting rod head such that it protrudes by the same distance at both ends of the separating face.
This protrusion is a must and under no circumstances may the separating

face of the bearing shell be filed to reduce it!
x2
x1
Protrusion of a new
bottom end bearing shell:
x1 + x2 = approx. 0.56 0.64 mm
008.458/01
Remark: Above measuring checks must be carried out when fitting new bearing
shells. For this the bearing shells are placed in position the bearing cover fitted and
the nuts tightened by hand with a round bar.
Prior to final assembly smear the running surfaces lavishly with clean bearing oil.
Should, however, the engine have to be frequently turned after the fitting of the
bearing, or should a re-start of the engine not be immediately planned, then
instead of bearing oil a mixture of 2/3 steam-engine cylinder oil and 1/3 normal bearing oil should be used. Special oils suited to this purpose are also available from
reliable suppliers.
In order to further reduce the risk of dry running on newly fitted bearing shells, the
latter can be post-lubricated by means of a lubricating pump (see 33033).
1.09
8/ 8
RT-flex96C
33033/A1
Maintenance
Connecting Rod
Inspection, Removal and Fitting of Top End Bearing
Tools:
1
2
2
1
2
2
2
1
Working platform
Retaining pins
Roller supports
Carrying roller
Suspension straps
Wire rope slings with hooks
Eye bolts
Connecting flange
with Piston in Situ

94142
94323a
94331
94332
94333a
94333b
94333c
94336
1
2
3
4
5
6
7
8
9
10
11
12
Crankshaft
Toggle lever
Connecting rod
Guide way
Crosshead pin
Nut
Connecting rod stud
Threaded hole
for eye bolt
Cylindrical pin
Bearing shell
Allen screw
Bearing cover
13
14
15
16
17
18
19
DL
HZ
H1...
OP
RC
Guide shoe
Guide segment
Bolt with nut
Supporting sheet
Piston rod foot
Platform
Oil pressure pipe
Lifting tackle
Lifting tackles
Lubricating pump
Eye bolt
Overview
1.
2.
3.
4.
5.
1.
Inspection of bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal of bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/9
3/9
5/9
7/9
9/9

A
Turn crank of the corresponding cylinder to B.D.C.
HZ
Loosen and remove all nuts 6 of connecting rod studs 7 to top end bearing
as instructed in 33031.
Loosen the screws fastening toggle
lever 2 of the crosshead lubrication
and piston cooling, and separate the
toggle lever from connecting rod 3.
6
94142
Suspend toggle lever with lifting

tackle HZ inside the crankcase.
Remove the working platform from
the crankcase.
3
1
014.367/06
1/ 9
1.09
33033/A1
Maintenance
RT-flex96C
with Piston in Situ
Turn crank to T.D.C.

Fit two retaining pins 94323a into guide ways 4 on exhaust side. Pay attention
to paragraph 1.3 in 33032!
Fix two roller supports 94331 on guide ways 4 on fuel side, using bolts and
nuts 15 belonging to the roller support.
Carrying roller 94332 is to be fitted to the front face of connecting rod 3 on fuel
side, using eye bolt RC (M64) screwed into threaded hole 8 (Fig. G). Thereby, supporting sheet 16 to carrying roller must rest below the connecting rod
head (Fig. B).
Turn crankshaft 1 carefully downwards to exhaust side till the connecting rod
studs are free (i.e. out of bearing cover 12), and guide shoes 13 seat on both
retaining pins 94323a. Otherwise the latter have to be properly ajusted so that
their supports contact the guide shoes.
D
Take care that cylindrical pins 9 and connecting rod studs 7 slide out
through the bores without jamming!
Risk of accident! The piston may not be removed in this position without securing
the bearing cover against falling down.
13
94323a
018.037/09
12
5
9
7
15
13
94323a
RC
16
4
014.368/06
94331
1.09
2/ 9
94332
RT-flex96C
33033/A1
Maintenance
with Piston in Situ
C
Turn the crank to max. 85_ after
T.D.C. as shown in Fig. C.
CHECK
Examine bearing shell.
94331
94142
014.370/06
2.
Mark lateral guide segments 14 (Fig.

G) and remove them.
94331
H2
Remark: The lateral guide segments

must be marked to ensur that they are refitted to the connecting rod head in the
same place!
RC
Sling rope a (lifting capacity 3000

kg) around connecting rod 3.
Connect rope a with lifting tackle H1
(lifting capacity 3000 kg each) and
tighten it till carrying roller 94332 is
lifted slightly from roller support
94331.
H1
3
94332
Remove carrying roller.

Screw eye bolt RC (M64) into the
connecting rod head.
Attach lifting tackle H2, connect rope
b (lifting capacity 4000 kg each) with
eye bolt RC and tighten it.
Remove rope a.
014.375/06
3/ 9
1.09
33033/A1
Maintenance
RT-flex96C
with Piston in Situ
2.1
H3
Removal of bearing shell below

supply unit
Turn the crank to 10_ before B.D.C.

while evenly tightening rope b.
H2
Swing out the connecting rod as

shown in Fig. F.
Fit two eye bolts (M8) each into the
front faces of the bearing shell.
d
Loosen Allen screws 11 (Fig. G).
H4
c
94331
Attach lifting tackle H3 and connect

rope d (lifting capacity 500 kg each)
with the eye bolts fitted in the bearing
shell.
rope c (lifting capacity 500 kg each)
shell.
10
3
Remove the bearing shell from the

connecting rod using ropes c and d.
014.376/06
F
2.2
H3
Removal of bearing shell outside

the area of supply unit
Turn the crank to 10_ before B.D.C.

while evenly tightening rope b.
H2
Swing out the connecting rod as

shown in Fig. F.
H4
Fit two eye bolts (M8) each into the

d

shell.

shell.
10
3
Remove the bearing shell from the

connecting rod using ropes c and d.
014.378/06
1.09
4/ 9
RT-flex96C
33033/A1
Maintenance
with Piston in Situ
G
12
7
11
14
14
14
10
014.379/06
3.
Fitting the bearing shell

The fitting of bearing shell 10 and bearing cover 12 is carried out analogously but in
reverse sequence to the removal, whereby the following points require special
attention:
D
CHECK
Lateral guide segments 14 (Fig. G) must be refitted to connecting rod head in

the same place as before!
Check whether the surface of the crosshead pin is in perfect condition before fitting
the bearing shell.
D
from entering between the shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be free from any damage. Immediately before inserting the bearing shell they have to be wiped with
a slightly oily hand, so that a trace of oil is on them.
The bearing shell should be placed in the connecting rod head such that it protrudes by the same distance at both ends of the separating face (Fig. H).

bearing, or should a restart of the engine not be immediately planned, then instead
of bearing oil a mixture of 2/3 steam-engine cylinder oil and 1/3 normal bearing oil
should be used. Special oils suited to this purpose are also available from reliable
suppliers.
D
The tensioning of the connecting rod studs must be carried out as instructed in
33031.
When fitting the bearing shell, as well as the crosshead pin, pay attention not
to damage the white metal of the two guide segments 14 (Fig. G).
Retaining pins 94323a, roller supports 94331 and carrying roller 94332 must be
removed immediately after completing the work.
5/ 9
2008
33033/A1
Maintenance
RT-flex96C
with Piston in Situ
H
3.1
x1
12
Fitting a new top end bearing shell
Proceed as described in section 3, however protrusion x1 + x2 must be measured prior to tension connecting rod studs 7.
x2
3.1.2 Measuring the protrusion

Hand-tighten nuts 6 (Fig. G) with a round bar and
measure the protrusion (of a new bearing shell):
x1 + x2 = approx. 0.64 0.72 mm
004.148/99
3.2
Post lubrication of connecting rod bearing

In order to further reduce the risk of dry running on newly fitted bearing shells, a
connecting flange 94336 can be fitted after removing the oil pressure pipe DL to
the crosshead bearing as shown in Fig. I. The connecting flange has to be connected via an oil pressure hose to a lubricating pump OP.
The pump has to be filled with the mentioned oil mixture (steam-engine cylinder oil)
or special oil. The lubricating pump 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 DL must be refitted. The remainder of the above mentioned special oil or oil mixture may remain in the engine oil system.
DL
2
EXHAUST SIDE
94336
OP
014.395/06
2008
6/ 9
RT-flex96C
33033/A1
Maintenance
4.
with Piston in Situ
K
I
94333c
94333b
94333a
RC
12
17
012.131/04
L
Turn crank to B.D.C.
Loosen and remove all nuts 6 (Fig. A) to connecting
rod studs 7 (see 33031).
RC
12
Remove the nuts for the connection of crosshead

pin 5 and piston rod foot 17 (see also 34031).
Screw down both suspension straps 94333a (Fig.
K) onto the piston rod foot.
Fit two eye bolts 94333c to the underside of the cylinder jacket.
Turn crank of the corresponding cylinder towards
T.D.C. till both wire rope slings 94333b can be attached to the eye bolts and the two suspension
straps.
014.380/06
Attention: Turn the crankshaft slowly towards B.D.C.

(Fig. L). Piston rod foot must slide out through the
waisted studs in crosshead pin 5 without jamming.
Screw eye bolts RC (M24) into bearing cover 12.
7/ 9
2008
33033/A1
Maintenance
RT-flex96C
4.1
with Piston in Situ
Removal of bearing cover below supply unit

Attach lifting tackles HZ and connect ropes a and b (lifting capacity 1000 kg
each) with eye bolt RC and then lift up bearing cover 12.
Attach lifting tackle H5 and connect rope c (lifting capacity 1000 kg each) with
the bearing cover as shown in Fig. M.
Remove rope b.
Lift out the bearing cover by means of ropes a, c and d as shown in Fig. N.
D
After opening platform 18, the bearing cover can further be transported by
means of spur-geared chain block 19 (see also 33012).
Protect the crosshead pin against dirt and damage.
19
HZ
H5
H5
a
2
18
3
1
d
12
014.392/06
014.391/06
2008
RC
12
8/ 9
RT-flex96C
33033/A1
Maintenance
4.2
with Piston in Situ
Removal of bearing cover outside the area of supply unit

the bearing cover as shown in Fig. O.
Remove rope b.
Lift out the bearing cover by means of ropes a, c and d as shown in Fig. P.
HZ
H5
H5
a
RC
12
d
5
3
1
014.394/06
014.393/06
5.
Fitting the bearing cover

The fitting of bearing cover 12 is carried out analogously but in reverse sequence
to the removal, whereby the following points require special attention:
Before fitting smear the running surfaces lavishly with clean bearing oil.
Tightening of nuts 6 (Fig. G), see 33031.
Tightening of the nuts for the connection of crosshead pin 5 and piston rod foot
17, see 34031.
9/ 9
2008
RT-flex96C
33033/A2
Maintenance
Connecting Rod
Tools:
1
4
1
2
1
1
with Piston Removed

Working platform
Retaining pins
Lifting plate
Eye bolts
Holder
Connecting flange
94142
94323a
94324
94334e
94335
94336
1
2
3
4
5
6
7
8
9
10
11
Crankshaft
Toggle lever
Connecting rod
Guide way
Crosshead pin
Nut
Connecting rod stud
Cylindrical pin
Bearing shell
Allen screw
Bearing cover
12
13
14
15
16
17
DL
HZ
H1...
OP
Guide shoe
Guide segment
Waisted stud
Nut
Platform
Oil pressure pipe
Lifting tackle
Lifting tackles
Lubricating pump
Overview
1.
2.
3.
4.
5.
1.
Inspection of bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal of bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/8
3/8
5/8
7/8
8/8

A
Loosen and remove all nuts 6 (Fig.
G) of connecting rod studs 7 to top
end bearing as instructed in 33031.
Screw in eye bolts 94334e on either
side of the connecting rod head.
H1
H2
94334e
94334e
94142
Connect lifting tackles H1 and H2 (lifting capacity 4000 kg each) with eye
bolts and column straps.
014.433/06
1/ 8
1.09
33033/A2
Maintenance
RT-flex96C
with Piston Removed
Fasten lifting plate 94324 with nuts 15

of waisted studs 14 to crosshead pin
5.
Put holder 94335 over waisted studs
and fasten it to bearing cover 11.
94324
II
14 94335
15
11
II
94324
014.434/06
12
94323a
018.037/09
Connect a lifting tackle with 10 000 kg

lifting capacity to lifting plate 94324
and engine crane.
H1
Risk of accident! For safety reasons the

crosshead shall not be lifted directly with
the engine crane, but with the lifting tackle
connected between!
H2
Lift crosshead and position guide

shoes 63 mm above the bores provided for retaining pins in the guide
ways.
Fit four retaining pins 94323a into
guide ways 4. Pay attention to paragraph 1.3 in 33032!
Put crosshead onto retaining pins.
014.435/06
1.09
2/ 8
RT-flex96C
33033/A2
Maintenance
2.
with Piston Removed
D
HZ
2

G) and remove them.
H2
Attention: The lateral guide segments

must be marked to ensure that they are refitted to the connecting rod head in the
same place!
By means of lifting tackles H1 and H2
(Fig. C) swing connecting rod to fuel
side ensuring that it can not tilting
back to exhaust side.
Remove lifting tackle H1 and swing
connecting rod in that position as
shown in Fig. D.
014.436/06
E
2.1
Removal of bearing shell below

supply unit
Fit two eye bolts M8 each into the

H3

Place lifting tackle H3 and connect
shell.
d
H4
c

shell.
Lift the bearing shell out of the crankcase using ropes c, d and lifting
tackle H4.
014.437/06
3/ 8
1.09
33033/A2
Maintenance
RT-flex96C
with Piston Removed
F
2.2
Removal of bearing shell outside

the area of supply unit
Fit two eye bolts M8 each into the

H3
H4

shell.
d
c

shell.
Lift the bearing shell out of the crankcase using ropes c, d and lifting
tackle H4.
014.438/06
G
11
6
7
13
13
10
13
9
001.688/97
1.09
4/ 8
RT-flex96C
Maintenance
3.
33033/A2
with Piston Removed
Fitting the bearing shell

The fitting of bearing shell 9 and bearing cover 11 is carried out analogously but in
attention:
D
CHECK
Lateral guide segments 13 (Fig. G) must be refitted to connecting rod head in

the same place as before!
Check whether the surface of the crosshead pin is in perfect condition before fitting
the bearing shell.
D
from entering between the shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be free from any damage. Immediately before inserting the bearing shell they have to be wiped with
a slightly oily hand, so that a trace of oil is on them.
The bearing shell should be placed in the connecting rod head such that it protrudes by the same distance at both ends of the separating face (Fig. H).

bearing, or should a restart of the engine not be immediately planned, then instead
of bearing oil a mixture of 2/3 steam-engine cylinder oil and 1/3 normal bearing oil
should be used. Special oils suited to this purpose are also available from reliable
suppliers.
D
The tensioning of the connecting rod studs must be carried out as instructed in
33031.
When fitting the bearing shell, as well as the crosshead pin, pay attention not
to damage the white metal of the two guide segments 13 (Fig. G).
5/ 8
2008
33033/A2
Maintenance
RT-flex96C
with Piston Removed
H
3.1
x1
11
Fitting a new top end bearing shell
Proceed as described in section 3, however protrusion x1 + x2 must be measured prior to tension connecting rod studs 7.
x2
3.1.2 Measuring the protrusion

Hand-tighten nuts 6 (Fig. G) with a round bar and
measure the protrusion (of a new bearing shell):
x1 + x2 = approx. 0.64 0.72 mm
004.148/99
3.2
Post lubrication of connecting rod bearing

In order to further reduce the risk of dry running on newly fitted bearing shells, a
connecting flange 94336 can be fitted after removing the oil pressure pipe DL to
the crosshead bearing as shown in Fig. I. The connecting flange has to be connected via an oil pressure hose to a lubricating pump OP.
The pump has to be filled with the mentioned oil mixture (steam-engine cylinder oil)
or special oil. The lubricating pump 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 DL must be refitted. The remainder of the above mentioned special oil or oil mixture may remain in the engine oil system.
DL
2
EXHAUST SIDE
94336
OP
014.395/06
2008
6/ 8
RT-flex96C
33033/A2
Maintenance
4.
with Piston Removed

Turn crank to B.D.C.
Loosen and remove all nuts 6 (Fig. G) of connecting rod studs 7 to top end
bearing as instructed in 33031.
4.1
Removal of bearing cover below supply unit

each) with eye bolt RC and then lift bearing cover 11.
the bearing cover as shown in Fig. K.
Remove rope b.
Lift out the bearing cover by means of ropes a, c and d as shown in Fig. L.
After opening platform 16, the bearing cover can further be transported by
means of spur-geared chain block 17 (see also 33012).
17
HZ
H5
a
H5
b
c
RC
11
2
5
16
3
1
d
11
014.441/06
014.442/06
7/ 8
2008
33033/A2
Maintenance
RT-flex96C
4.2
with Piston Removed
Removal of bearing cover outside the area of supply unit

the bearing cover as shown in Fig. M.
Remove rope b.
Lift out the bearing cover by means of ropes a, c and d as shown in Fig. N.
HZ
H5
H5
RC
11
5
3
1
11
014.443/06
5.
014.444/06
Fitting the bearing cover

The fitting of bearing cover 11 is carried out analogously but in reverse sequence to
the removal, whereby the following points require special attention:
2008
Before fitting smear the running surfaces lavishly with clean bearing oil.
Tightening of nuts 6 (Fig. G), see 33031.
8/ 8
RT-flex96C
33034/A1
Maintenance
Connecting Rod
Removal and Fitting
Tools:
1
2
1
2
1
1.
Working platform
Retaining pins
Lifting device
Roller supports
Carrying roller
94142
94323a
94330
94331
94332
1
2
3
4
5
6
7
8
9
10
Crankshaft
Toggle lever
Connecting rod
Support
Guide way
Crosshead pin
Bearing cover
Guide shoe
Nut
Guide segment
11
12
13
14
15
Waisted stud
Suspension beam
Upper platform
Lower platform
HZ Lifting tackle
H1... Lifting tackles
RC Eye bolt
General
A connecting rod can be removed from or fitted to the engine without removing the
piston and crosshead pin.
D
The bearing cover for the bottom end bearing must be removed (see 33032).
Risk of accident! Should the piston have been removed prior to the removal of the
connecting rod then lifting plate 94324 for the crosshead pin (see 33262) must be
installed or bearing cover 7 secured by steel ropes. In this way the bearing cover of
the top end bearing is prevented from turning around and dropping down after lowering the connecting rod.
2.
Removal
HZ
Loosen and remove all nuts 9 of connecting rod studs 7 to top end bearing
as instructed in 33031.


94142

B) and then remove them.
Remark: The lateral guide segments
must be marked to ensur that they are refitted in the same place!
3
1
Remove the working platform.

Turn crank to T.D.C.
014.414/06
1/ 8
1.09
33034/A1
Maintenance
RT-flex96C
Connecting Rod: Removal and Fitting
7
9
11
10
10
10
3
014.379/06
Fit two retaining pins 94323a (pay attention to paragraph 1.3 in 33032) and
roller supports 94331, as well as carrying roller 94332 in the same manner as
described for Inspection, Removing and Fitting of Top End Bearing 33033.
Turn crankshaft carefully max. 85_ after T.D.C. towards exhaust side (Fig.
C). Follow instructions in 33033.
Attach lifting tackle H1 and rope a (lifting capacity 3000 kg each) and sling the
latter around the connecting rod (Fig. C).
Tighten rope a till the carrying roller is slightly lifted off the roller support.
Dismantle carrying roller 94332.
Attach lifting tackle H2 and rope b (lifting capacity 4000 kg each), screwing
eye bolt RC into the connecting rod head. Tighten rope b and remove rope
a.
Lower the connecting rod head till column opening, using rope b (Fig. D).
D
Be careful that crosshead pin 6 is not damaged!
D
7
6
8
94331
HZ
b
94323a
2
RC
H1
94332
014.416/06
014.415/06
1.09
2/ 8
RT-flex96C
33034/A1
Maintenance
Fit lifting device 94330 as shown in

view I.
Attach lifting tackle H3 and rope c
(lifting capacity 3000 kg each), connect it to the lifting device and tighten
it.
H4
Attach lifting tackle H4, sling rope d

(lifting capacity 4000 kg each) around
the connecting rod and tighten it.
Remove rope b.
H3
94330
014.417/06
H4
Attach lifting tackle H5 and rope e

(lifting capacity 4000 kg each) and
connect it to lifting device 94330.
H5
Carefully separate the bearing part

from the crankpin by slackening rope
c while lifting the connecting rod with
rope e.
Remove rope c.
RC
H3
Remove eye bolt RC.
94330
014.418/06
3/ 8
1.09
33034/A1
Maintenance
RT-flex96C
G
Attach lifting tackle HZ (lifting capacity 3000 kg) and connect it to lifting
device 94330.
HZ
014.420/06
H
2.1
Removal of connecting rod

outside the area of supply unit
Pull connecting rod head through the

column door by means of lifting tackle
HZ while following up with ropes e
and d.
H4
H6
Screw eye bolt into the connecting

rod head.
12
d
Attach lifting tackle H6 (lifting capacity

4000 kg) to the outer hole on suspension beam 12, connect it to eye bolt
RC and then tighten it.
RC
HZ
Remove rope d and lifting tackle

HZ.
014.421/06
1.09
4/ 8
RT-flex96C
33034/A1
Maintenance
H5
H7 H6
PROTECTION
12

4000 kg) to the inner hole on suspension beam 12 and connect it to lifting
device 94330.
D
Be careful that crosshead pin 6 is not

damaged!
Pull the connecting rod out from the

crankcase by means of lifting tackles
H6, H7 and rope e.
014.422/06
K
Remove rope e.
H5
Attach spur-geared chain block 13

(lifting capacity 6000 kg), connect it to
eye bolt RC and tighten it.
Remove lifting tackle HZ.
H7 H6
13
RC
014.423/06
5/ 8
1.09
33034/A1
Maintenance
RT-flex96C
L
Move connecting rod 3 in such a position that it can be taken over by spurgeared chain block 13.
13
3
014.424/06
M
2.2
H5
14
Removal of connecting rod below

supply unit
Pull connecting rod head through the

column door by means of lifting tackle
HZ while following up with ropes e
and d.
Screw eye bolt RC into the connecting rod head.
12
H6
15
d
RC

4000 kg) to the outer hole on the suspension beam 12, connect it to eye
bolt RC and tighten it.
HZ
Remove rope d and lifting tackle

HZ.
Open upper and lower platforms 14
and 15 (see 33012).
014.425/06
1.09
6/ 8
RT-flex96C
33034/A1
Maintenance
N
4000 kg) to the inner hole on suspension beam 12 and connect it to lifting
device 94330.
13
H5
f
PROTECTION
H7
12
15
H6
RC
Be careful that crosshead pin 6 is not

damaged!
Pull the connecting rod out from the

crankcase by means of lifting tackles
H6, H7 and rope e.
Swing lower platform 15 slightly up.
94330
Connect rope f with spur-geared

chain block 13 (lifting capacity 6000
kg each) and eye bolt RC.
014.430/06
O
Remove rope e.
H5
014.431/06
7/ 8
1.09
33034/A1
Maintenance
RT-flex96C
P
Move connecting rod 3 in such a position that it can be taken over by spurgeared chain block 13.
13
014.432/06
3.
Fitting
Fitting the connecting rod is carried out analogously to the removal but in reverse
sequence, whereby attention must be paid to instructions 33031 to 33033.
For the assembly bearings and bearing pins must be in perfect condition. They
must be smeared lavishly with fresh bearing oil.
Remark: When fitting the crosshead pin, pay attention not to damage the two
guide segments 10 to the crosshead pin (Fig. B) if they are already fitted. The two
white metal lined guide segments are fitted to the front sides of the connecting rod
head.
After completing the work retaining pins 94323a, roller support 94331 and carrying
roller 94332 must be removed immediately.
1.09
8/ 8
RT-flex96C
33261/A1
Maintenance
Crosshead
Checking the Clearances and Fitting the Guide Shoes
Tools:
1
1
1
1
1
1
1
1
1
1
1
1.
Feeler gauge
HYTORC torque machine
Reaction arm
Socket wrench insert
HP hose
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
94238
94339
94339a
94339b
94339c
94931
94932
94932a
94934a
94934e
94935
1
2
3
4
5
Crosshead pin
Guide shoe
Retaining cover
Guide way in engine column
Top end bearing
of connecting rod
6
7
8
9
Guide rail
Middle part
Screw
Screw
EV Relief valve
General
On the occasion of an overhaul or when a crosshead has been removed, the opportunity should be taken to measure the various running clearances and to
compare them with the values found in the Clearance Table 03301 Crosshead
Guide, so that possible wear may be discovered.
A
4
2
4
2
7
3
4
3
9
6
4
FUEL SIDE
1/ 4
4
000.784/99
2008
33261/A1
Maintenance
RT-flex96C

2.
Checking the clearances

Clearance
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 1 is valid over the whole guide way length and
is measured according to the position as shown in Fig. B.
Clearance
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 guide shoe 2 or middle part
7 and not onto crosshead pin 1.
Clearance
Lateral clearance between middle part and

crosshead pin:
Push the corresponding middle part to the stop of retaining
cover 3 in the above mentioned position of the crosshead.
Clearance
Radial clearance between crosshead pin and

middle part:
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 middle part have to be measured with micrometers.
90 BEFORE OR
AFTER T.D.C.
013.784/06
2008
2/ 4
RT-flex96C
33261/A1
Maintenance
3.
Removal and assembly of a guide shoe

For dismantling as well as for assembling guide shoe 2 to middle part 7, use HYTORC torque machine 94339, reaction arm 94339a, socket wrench insert 94339b,
and HP hose 94339c to loosen or tighten screws 9 (Fig. C).
Connect the HYTORC torque machine to HP hose 94339c, hydr. distributor
94934a, and to HP hose 94935 with HP oil pump 94931.
Seal the free connection at hydr. distributor 94934a by means of plug piece
94934e.
In order to loosen screws 9 arrange reaction arm 94339a as shown in Fig. C
(LOOSENING).
Close relief valve EV at the HP oil pump and actuate the latter until screw 9 is
completely loose.
Remark: When using the HYTORC torque machine, observe also the instructions
of the manufacturer.
Loosen all screws 9 in the manner described above, then remove screws 8.
Dismantle guide shoe 2.
94339
2 9
94339b
TIGHTENING
94339
94339a
001.509/97
94339c
94339a
LOOSENING
94339c
94932a
94934e
94932
94934a
94935
001.509/97
001.509/97
94931 EV
3/ 4
2008
33261/A1
Maintenance
RT-flex96C

For fitting the guide shoe, use the tools in the same manner as for dismantling,
however, arrange reaction arm 94339a for TIGHTENING screws 9 as shown in
Fig. C.
Remark: Attention must be paid when mounting guide shoe 2 onto middle part 7
so that the middle part bears the guide shoe with no clearance whatsoever. For
this purpose, screws 8 are first to be tightened slightly. Then screws 9 are to be
tightened slightly by hand and subsequently tightened and secured with 2000 Nm
(approx. 600 bar when using HYTORC torque machine) or to an angle of 30_.
Tighten and secure screws 8.
CHECK
Check with feeler gauge 94238 that there is no clearance between the surfaces of
guide shoe 2 and middle part 7.
D
2008
Guide rails 6 are screwed on fuel side only!
4/ 4
RT-flex96C
33262/A1
Maintenance
Crosshead
Removal and Fitting of a Crosshead Pin
Tools:
1
2
1
2
2
2
1.
Working platform
Retaining pins
Lifting plate
Holders
Guide pieces
Roller supports
94142
94323a
94324
94325
94325a
94331
1
2
3
4
5
6
7
8
9
10
Crosshead pin
Guide shoe
Retaining cover
Screw
Guide way
Guide rail
Middle part
Screw
Crank
Neighbouring cylinder
11
12
13
14
15
Suspension girder
Support
Upper platform
Lower platform
HZ Lifting tackle
RC Eye bolt
General
If a crosshead pin has to be removed, the piston of the cylinder concerned must
first be pulled out (see 34031).
In addition, the covers for top & bottom end bearings and the connecting rod must
be removed from the crankcase. Follow the instructions in 33032 to 33034.
2.
Preparation
A
D
94323a
94331
Turn crankshaft to such a position, that crank

9 of the neighbouring cylinder stands at 90_
or at 270_ after T.D.C. respectively. The correct crank position (ideal position) of the
neighbouring cylinder 10 is shown in the table
Fig. B. This ideal position of the crank is important to ensure the accessibility for the removal of the respective crosshead pin 1.
Remark: Always start the removal of the guide

shoes 2 and middle parts 7 on the corresponding
side of the neighbouring cylinder.
94142
Lift the crosshead pin slightly with the engine

crane and remove roller supports 94331 and
retaining pins 94323a (pay attention to paragraph 1.3 in 33032) used for the removal of
the connecting rod (Fig. A).
014.180/06
1/ 7
1.09
33262/A1
Maintenance
RT-flex96C
Table with ideal crank positions of neighbouring cylinders:
B
CRANK ANGLE
7 Cyl.
ENGINE
6 Cyl.
NEIGHBOURING CYL.
AFTER T.D.C.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
1
2
3
4
5
6
2
1
2
3
4
5
270_
90_
90_
270_
90_
90_
1
2
3
4
5
6
7
2
1
2
5
4
5
6
270_
90_
90_
90_
270_
90_
90_
8 Cyl.
CRANK ANGLE
9 Cyl.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
1
2
3
4
5
6
7
8
2
1
2
5
6
5
6
7
270_
90_
90_
90_
90_
270_
90_
90_
1
2
3
4
5
6
7
8
9
2
3
4
3
4
5
8
9
8
90_
90_
270_
90_
90_
90_
90_
90_
270_
10 Cyl.
CRANK ANGLE
CRANK ANGLE
11 Cyl.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
1
2
3
4
5
6
7
8
9
10
2
1
2
3
4
5
6
7
8
9
270_
90_
90_
90_
90_
90_
90_
90_
90_
90_
CRANK ANGLE
2
1
2
3
6
7
8
9
8
9
10
270_
90_
90_
90_
90_
90_
90_
270_
90_
90_
90_
CRANK ANGLE
1
2
3
4
5
6
7
8
9
10
11
14 Cyl.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
ENGINE
NEIGHBOURING CYL.
AFTER T.D.C.
1
2
3
4
5
6
7
8
9
10
11
12
2
1
2
3
4
5
8
7
8
11
10
11
270_
90_
90_
90_
90_
90_
270_
90_
90_
270_
90_
90_
1
2
3
4
5
6
7
8
9
10
11
12
13
14
2
1
2
5
4
7
6
9
8
9
12
13
12
13
90_
270_
270_
270_
90_
270_
90_
90_
90_
270_
270_
90_
270_
270_
12 Cyl.
2008
CRANK ANGLE
2/ 7
CRANK ANGLE
RT-flex96C
33262/A1
Maintenance
3.
Removal
3.1
Removal of guide shoes

Lower the crosshead pin to the position shown in figure below with the engine
crane.
Remove guide rails 6 (Fig. F).
Fit guide pieces 94325a, which are used for deviating ropes a and b, into
both guide ways 5 on exhaust and fuel sides (Fig. C).
Screw an eye bolt RC into each end of guide shoes 2.
Place lifting tackles HZ (lifting capacity 1000 kg each).
Guide ropes a and b (lifting capacity 1000 kg each) through the eye pieces
of guide pieces 94325a and connect them to eye bolts RC (view I-I).
Tighten both ropes.
Loosen the screwed connections of guide shoes 2 to middle parts 7 (Fig. C)
as described in 33261 Removal and assembly of a guide shoe. Remove the
screws concerned.
I-I
b
HZ
94325a
94324
RC
94325a
RC
2
7
2
9
1
HZ
HZ
5
10
014.511/06
3/ 7
2008
33262/A1
Maintenance
RT-flex96C

Lift the crosshead pin carefully with the engine crane until both guide shoes 2
are no longer in gear (Fig. D and E).
Place lifting tackle H1 (lifting capacity 1000 kg) on suspension girder 11 of the
corresponding support 12 and then remove the guide shoes from the crankcase together with ropes a and b.
The removing process for the two other guide shoes is the same as described
above.
11
12
REMOVAL OUTSIDE OF
AREA OF SUPPLY UNIT
REMOVAL BELOW
SUPPLY UNIT
H1
12
b
11
H1
014.515/06
014.516/06
F
5
5
2
7
4
2
5
8
6
5
014.517/06
FUEL SIDE
2008
4/ 7
RT-flex96C
33262/A1
Maintenance
3.2
Removal of middle pieces

Lower crosshead pin 1 till screws 4 to retaining cover 3 are accessible from
the neighbouring cylinder.
Remove guide pieces 94325a from guide ways 5 and fit holders 94325
instead (Fig. G).
Place lifting tackles HZ (lifting capacity 1000 kg) on the holders.
Connect ropes c and d (lifting capacity 1000 kg each) to lifting tackles HZ
and the holders, and tighten them.
Loosen screws 4 and remove the retaining cover (38 kg).
Using the engine crane, draw the crosshead pin out of the bearing of middle
part 7 in longitudinal direction of the engine.
Remove the middle part.
The dismantling process for middle part 7 on the opposite side of neighbouring cylinder 10 is the same as described above. However, shift the crosshead
pin as near as possible to the neighbouring cylinder, gaining thereby better
access for dismantling retaining cover 3.
G
I
5 94325
4
3
10
014.518/06
5/ 7
2008
33262/A1
Maintenance
RT-flex96C
3.3
Removal of crosshead pin

After dismantling the middle parts, revolve the crosshead pin by 90 around its
own axis.
Place lifting tackles HZ and connect ropes e and f (lifting capacity 5000 kg
each) to lifting plate 94324, and tighten them.
Disconnect the engine crane.
Move the crosshead pin to fuel side (Fig. H and I) by means of ropes e and
f. Subsequently remove rope f.
Place lifting tackle H2 (lifting capacity 5000 kg) on suspension girder 11 of the
corresponding support 12 and connect it to lifting plate 94324 (Fig. H and I).
Remove the crosshead pin from the crankcase by means of lifting tackle H2
and rope e.
Remark: After opening upper and lower platforms 13 resp. 14 (see 33012), the
crosshead pin can be lifted up by means of spur-geared chain block 15 (Fig. K).
Attention! When removing and fitting a crosshead pin it is absolutely necessary to
protect it from being damaged.
H
REMOVAL OUTSIDE OF
AREA OF SUPPLY UNIT
REMOVAL BELOW
SUPPLY UNIT
15
HZ
11
H2
12
13
12
e
f
1
11
H2
014.519/06
2008
e
f
94324
H2
14
014.521/06
6/ 7
014.522/06
RT-flex96C
Maintenance
33262/A1
4.
Fitting
Fitting procedure is analogous to the removal, but in reverse sequence.
D
Fit only crosshead pins which have a perfect, undamaged running surface.
Before fitting the crosshead pin clean all guide and bearing surfaces carefully
and smear them lavishly with bearing oil.
Lock screws 4 to retaining covers 3.
Attention! Always fit toggle lever to crosshead lubrication and piston cooling in
such a way that its curvature stands upwards.
CHECK
After completing the work check that all tools and foreign bodies are removed from
the crankcase, and that all the screwed fastenings are tightened to specification
and locked accordingly.
Check crosshead clearances according to Clearance Table 03301 Crosshead
Guide.
Check with lubricating oil pump running that crosshead and connecting rod bottom
end bearings are lavishly supplied with oil.
7/ 7
2008
RT-flex96C
34031/A1
Maintenance
Piston
Removal and Fitting
Tools:
1
2
1
2
2
1
2
1
1
1
1
1
1
2
1
Piston ring expander

Suspension device
Distance plates
Distance plates
Insertion funnel
Distance holders
Cover plate
Tap
Piston supporting device
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94338
94340
94341(a)
94341c
94341d
94342a(b)
94345
94345d
94348
94350
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
Piston rod
Crosshead pin
Waisted stud
Nut
Vent screw
Pin
Piston
Platform support
Support
Hinged cover
Piston rod gland
12
13
14
15
16
Screw connection
Centring pin
Compression shim
Cylinder liner
Slotted countersunkhead screw
17 Protection
KO Slot
RS Round bar
SA Gap
Overview
1.
2.
3.
4.
5.
6.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening the waisted studs of piston foot fastening . . . . .
Tensioning the waisted studs of piston foot fastening . . . .
Removal of piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/8
1/8
3/8
4/8
7/8
8/8
General
D
21243 Removing wear ridge in cylinder liner at every piston removal.
27081 Removal of cylinder cover and draining cylinder cooling water.
The piston may not be transported with built-on piston rod gland (gland for short).
Attention! The supporting device 94350 can be used for piston overhauling
work at calm sea only, however, in no case this may serve as storage place
during the voyage!
Moreover, always bear in mind, that the passage between engine and supporting
device is limited (e.g. as possible escape route) on the platform.
2.
Loosening the waisted studs of piston foot fastening

Turn piston to B.D.C.
Clean the threads of waisted studs 3 and the area around nuts 4 (Fig. A).
Place both pre-tensioning jacks 94340 crosswise on the waisted studs to be
loosened, and completely screw them on (arrangement according to Fig. A)
with opened vent screw 5 (Fig. B).
Pre-tensioning jacks are to be loosened by approx. turn (gap SA in Fig.
B).
Connect pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. A.
1/ 8
2011-05
34031/A1
Maintenance
RT-flex96C
Piston: Removal and Fitting
CHECK
Check oil level in the hydraulic unit.

Start up the hydraulic unit and at the same time open vent screws 5 of pre-tensioning jacks 94340 till oil flows out bubble-free. Close the vent screws.
At a pressure of 1020 bar unscrew nuts 4 by one turn with round bar RS.
D

Release pressure to zero at the hydraulic unit and then remove pre-tensioning
jacks and the nuts.
D
The same procedure is to be applied for loosening the other two waisted
studs.
94340
13
94340
3
4
14
94935a
94932a
94934a
94942
94935
94935a
008.480/01
2008
2/ 8
RT-flex96C
34031/A1
Maintenance

3.
Tensioning the waisted studs of piston foot fastening
B
Clean the threads of waisted studs 3
and the area around nuts 4 (Fig. A).
PRE-TENSIONING JACK PLACED FOR

TENSIONING
LOOSENING
Apply oil to the threads of the waisted

studs and screw on the nuts.
5
Tighten the nuts with round bar RS

(Fig. B) by hand.
6
7
CHECK
Mark position of nuts to seating surface with a felt tipped pen (Fig. a).
Completely screw the pre-tensioning

jacks diagonally onto waisted studs 3
(Fig. A). Moreover, vent screws 5
are to be opened slightly so that pistons 7 can slide back to their initial
position i.e. there is no or very little
clearance at x (Fig. B).
4
RS
KO
Using a feeler gauge, check whether the

nuts rest flush on the piston foot.
SA
012.167/04
Connect pre-tensioning jacks to hydraulic unit 94942 as shown in Fig.

A.
Start up the hydraulic unit till bubble-free oil flows
out through vent screws 5. Shut the vent screws.
Fig. a
Slowly raise the pressure to 600 bar (1st step).

D
Keep the pressure of 600 bar constant and tighten

nuts 4 with round bar RS till firmly seated.

then screw the pre-tensioning jacks onto the other
two waisted studs. These are to be tensioned in the
same sequence as described above.
x
Fig. b
Subsequently the waisted studs are to be tensioned

again diagonally with 1000 bar (2nd step).
CHECK
After tightening nuts 4 check:
their seatings with a feeler gauge through slot KO

whether these have been turned by about the
same angle, i.e. approx. 60_ compared with the
marks previously made (Fig. b).
3/ 8
2008
98.7700
TIGHTENING
ANGLE
34031/A1
Maintenance
RT-flex96C
4.
Removal of piston
4.1
Adjusting suspension device to crane hook

Distance x must be adjusted so that an axial clearance of 25 mm results between the relevant crane hook and distance plates 94341c.
Therefore loosen slotted countersunk-head screws 16 and remove them with distance plates 94341c and 94341d.
Subsequently distance plates 94341d have to be machined to the determined
thickness and then refitted with distance plates 94341c.
94341c
94341d
II
II
x
II - II
014.686/06
94341
16
4.2
Removal of protection at rail unit

Remove protections 17 before placing piston supporting device due to the verry
close spaces.
WCH00439
FREE
END
17
2011-05
4/ 8
RT-flex96C
34031/A1
Maintenance
4.3
Removal of piston
Remark: Loosen and remove all screws for the screwing gland / cylinder jacket
(see 23031).
Remove antipolishing ring as described in 21242.
Screw fasten both distance holders 94345 to the piston foot (Fig. E).
Turn crank to T.D.C. whereby the gland is pushed out of its seating in the cylinder jacket by distance holders 94345 (Fig. F).
Use tap 94348 to clean threaded holes of combustion residue in the piston
crown.
Mount suspension device 94341(a) to the piston crown.
D
Before pulling the piston out, the crosshead pin and the top end bearing must
be protected, so that entry of dirt into the top end bearing is absolutely prevented.
94341(a)
FUEL
SIDE
94341(a)
94350
11
8
11
94345
94345
017.876/08
5/ 8
2011-05
34031/A1
Maintenance
RT-flex96C
Fasten piston supporting device 94350 to platform supports 8 designed for

this on the cylinder cover platform (Fig. F and G).
Pull piston by crane out of cylinder liner.
Loosen screw connection 12 and push supports 9 of piston supporting device
completely outwards and turn up hinged covers 10.
Remark: Take care of the main lubricating pipe and therefore rotate the piston by
90_.
Lower piston on crane into the supporting device until the piston foot protrudes below the supporting device.
Turn the two hinged covers 10 down and lower the piston until gland 11 rests
on the two hinged covers. Push the two supports 9 together and firmly tighten
screwed connection 12.
Lower piston further till the piston rod head rests on support 9.
Attention! To prevent having a fall place cover plate 94345d over the gland bore in
the cylinder jacket and fasten it provisionally with several screws.
9
12
11
10
94350
8
017.877/08
2011-05
6/ 8
RT-flex96C
Maintenance
34031/A1
5.
Fitting the piston

Prior to fitting the piston, the following works must be carried out:
Remove piston rings with ring expander 94338 (see 34251) and clean piston
exterior thoroughly. (Use no tool which could scratch or otherwise damage the
surface!).
CHECK
Determine the height of the piston ring grooves (see Clearance Table 03301
Piston and piston rings).
Clean piston rings and measure them.
Remarks: For refitting of used and new piston rings, follow strictly instructions in
34251.
CHECK
When refitting used piston rings be sure to fit them in the same grooves
as before.
Fit the piston rings in such a manner that their marking TOP is on top.
Check the piston top surface (see 34034).

Measure bore of cylinder liner (see 21241) and carry out any needed reconditioning to lubricating grooves and scavenge ports (see 21243).
Actuate the cylinder lubrication of the respective cylinder until oil flows from all
the lubricating points.
D
Gland and both distance holders 94345 must be mounted on the piston rod
(see 23031).
Suspension device 94341(a) must be fastened to the top of the piston crown.
Remarks: 2-part insertion funnel 94342b has the advantage that a half can be removed, if required.
H
94342a(b)
Insertion funnel 94342a(b) for the piston rings must

be placed on cylinder liner 15 and fitted as shown in
Fig. H.
Smear piston rings, piston skirt, piston rod and running surface in cylinder liner lavishly with bearing oil.
15
003.351/00
7/ 8
2011-05
34031/A1
Maintenance
RT-flex96C
5.1
Fitting
Slightly lift piston by crane. Loosen screw connection 12 of supports 9 (Fig. G) and push both supports outwards. Then lift the piston including gland
11 so far that the two hinged covers 10 can be
turned up.
94342a(b)
Lift piston out of supporting device, bring it above

cylinder liner and lower it slowly into it (Fig. I).
D
When the piston is lowered into the cylinder liner

until the lowest piston ring is at the upper level of
the insertion funnel, arrange the piston rings so
that their gaps alternate by 180_ to each other.
See instructions in 34251.
Slowly lower the piston further till its piston rod foot
has arrived just above the crosshead pin. While
one person directs the further lowering of the piston from the top, another directs the piston rod
progress from the engine interior and how it must
be turned to guide the piston rod foot, without jamming, into the centring pins 13 (Fig. A) in the
crosshead pin.
94345
Slacken the crane rope a bit and remove the suspension device.
Turn piston to B.D.C. and direct the insertion of the
gland into its seating bore in the cylinder jacket
(see 23031).
Loosen and remove both distance holders from
the piston foot.
Firmly tighten all screws fastening the gland housing.
014.039/06
Tension the waisted studs for the piston foot fastening as described above.
Remark: Refit antipolishing ring as described in
21242 and reinstall protections 17.
6.
Leak test
A leak test must be carried out after every fitting of a piston in the cylinder. For this,
start the bearing lubrication pump and set the bearing lubricating pressure. Check
through the scavenge space on the fuel side in the cylinder jacket (piston underside) whether cylinder liner running surface and piston rod remain dry.
Any increase in the dirty oil level in the scavenge air space may be caused by a
faulty O-ring in the piston.
2011-05
8/ 8
RT-flex96C
Maintenance
34032/A1
Piston
Changing the Compression Shims
Tools:
4 Supports
2 Eye bolts
1.
94347
1 Ring, 2-part
2 Piston rod
3 Piston rod foot
4 Crosshead pin
5 Piston
6 Compression shim
Fitting and removing compression shim
5
94347
I
1
Loosen the nuts of the waisted studs for the screwing of piston rod foot 3 and crosshead pin 4, as described in 34031.
Open the door to the piston underside of the corresponding cylinder on fuel side.
Fasten four supports 94347 to the 2-part ring 1 of
the gland housing as shown in the figure.
CHECK
Turn the piston downwards until it rests fully on the four

supports.
Carefully turn crank forward and take care that the two
centring pins in crosshead pin 4 do not jam in the piston
rod foot.
Loosen the two screws fastening compression
shim 6 and remove them.
Remove the compression shim with the aid of the
two eye bolts.
2
3
For fitting the new compression shim proceed in reverse sequence to the removal.
Remark: Please note the correlation between setting

screw ST on measuring gauge 94225 (see 21241)
and the mean thickness of built-in compression shims.
008.533/01
I-I
94347
1
008.534/01
1/ 1
2008
RT-flex96C
34033/A1
Maintenance
Piston
Tools:
1
4
1
2
2
1
1
1
2
4
1
1
Suspension device
Piston supporting device
Jacking screws
Jacking screws
Hydr. distributor
Connection block
HP hose
HP hoses
HP hoses
Hydraulic unit
Torque wrench
94341(a)
94346
94350
94363
94364
94934a
94934c
94935
94935a
94935b
94942
1
2
2a
3
4
5
6
7
8
9
10
11
12
Piston crown
Spraying plate with oil pipe
Nozzle to spraying plate
Vent screw
Piston
Cylinder
Nut
Waisted stud
Piston rod
Piston skirt
Rubbing ring
Centring pin
Elastic screw
13
14
15
16
17
18
Locating pin
Locating pin
Waisted screw
O-ring
O-ring
O-ring
BN
EV
KO
RS
SA
Limiting groove
Relief valve
Slot
Round bar
Gap
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening the waisted studs of piston crown . . . . . . . . . . . .
Tensioning the waisted studs of piston crown . . . . . . . . . . .
Dismantling of a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling of a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/6
2/6
3/6
4/6
6/6
General
Should the dismantling of a piston become necessary (cleaning the cooling chamber, reconditioning the ring grooves etc.), then this can be carried out as described
below. For this purpose the piston is to be placed in the piston supporting device
94350 according to 34031.
Attention! When dismantling or assembling a piston take particular care that the
nozzles to spraying plate 2a are not damaged.
1/ 6
2008
34033/A1
Maintenance
RT-flex96C
Piston: Dismantling and Assembling
2.
Loosening the waisted studs of piston crown
A
Clean the threads of waisted studs 7 and the
area around nuts 6.
94346
3
Place the four pre-tensioning jacks 94346

crosswise on the waisted studs as shown in
Fig. C, and completely screw them on with
opened vent screws 3 till there is a clearance
at x of approx. 1 mm (Fig. B).
The pre-tensioning jacks are to be loosened

by approx. turn (gap SA in Fig. B).
Connect all pre-tensioning jacks to hydraulic
unit 94942 as shown in Fig. A.
Start up hydraulic unit.
Close vent screws 3 of the pre-tensioning
jacks as soon as oil flows out bubble-free.
Operate the hydraulic unit till a pressure of
about 1030 bar is reached.
Unscrew nuts 6 by one turn (Fig. B).
Pistons 4 of the pre-tensioning jacks must never
exceed the red limiting grooves BN (Fig. B).
Release pressure to zero.
Remove pre-tensioning jacks.
Always the same procedure is to be applied
crosswise according to the sequence in Fig.
C for loosening the remaining waisted studs.
I-I
94934c
94935b
94346
94935a
94932a
94934a
017.878/08
94935
2008
2/ 6
94942
RT-flex96C
34033/A1
Maintenance

3.
Tensioning the waisted studs of piston crown

PRE-TENSIONING JACK PLACED FOR
TENSIONING
LOOSENING
Clean the threads of waisted studs 7

and the area around nuts 6 (Fig. A).
3
Apply oil to the threads of waisted

studs and screw on the nuts.
Tighten the nuts with round bar RS
(Fig. B) by hand.
BN
x
CHECK
4
Mark position of nuts to seating surface with a felt tipped pen (Fig. a).
Place the four pre-tensioning jacks

94346 crosswise on the waisted
studs as shown in Fig. C, and completely screw them on with opened
vent screws 3 till there is a clearance
at x of approx. 1 mm.
RS
KO
Using a feeler gauge, check whether the

nuts rest without clearance.
SA
Connect the pre-tensioning jacks to

the hydraulic unit 94942 as shown in
Fig. A.
KO
Start up hydraulic unit.

Close vent screws 3 of the pre-tensioning jacks as
soon as oil flows out bubble-free.
TENSIONING
SEQUENCE
Operate the hydraulic unit till a pressure of 1000 bar

is reached.
Pistons 4 of the pre-tensioning jacks must never exceed
the red limiting grooves BN (Fig. B).
Fig. a
Keep the pressure of 1000 bar constant and tighten

nuts 6 with round bar RS till firmly seated.
CHECK
Fig. b
After tensioning the nuts check their seatings with a

feeler gauge through slot KO.
Always the same procedure is to be applied crosswise according to the sequence in Fig. C for tensioning the remaining waisted studs.
y
x
Remove pre-tensioning jacks.
y
CHECK
TIGHTENING
ANGLE
After tensioning the nuts check if these have been

turned by about the same angle, i.e. approx. 115_
compared with the marks previously made (Fig. b).
011.675/04
3/ 6
2008
34033/A1
Maintenance
RT-flex96C
4.
Dismantling of a piston
Insert both jacking screws 94363 into the two opposite bores for centring pins
11 in the piston rod head (Fig. G), and drive them in till they press against the
centring pins (Fig. E).
Equally tighten the two jacking screws in small steps, till the piston crown is
separated from the piston rod.
Lift piston crown 1 by crane and take particular care not to damage nozzles 2a
of spraying plate 2.
Remove both jacking screws from piston rod head.
Following the removal of piston crown separate piston skirt 9 from piston rod 8 as
described below:
Loosen and remove both elastic screws 12 (Fig. G).
Using two jacking screws 94364 (Fig. F) the piston skirt can be separated
from the piston rod.
D
While raising the piston skirt pay attention that locating pin 13 does not jam.
For the removal of spraying plate with oil pipe 2 (Fig. G)

loosen and remove first waisted screws 15 with locking
plates. The spraying plate with oil pipe can then be pulled
as a complete unit from piston rod 8.
94341(a)
1
Attention! Do not damage nozzles to spraying plate 2a!
2a
8
SEPARATING OF
PISTON CROWN
SEPARATING OF
PISTON SKIRT
1
2
94364
2
11
8
94363
017.879/08
2008
4/ 6
RT-flex96C
34033/A1
Maintenance
I-I
II - II
V
1
2a
IV
15
II
II
16
13
9
10
17
14
V
IV
I
FUEL SIDE
6
7
IV - IV
1
8
11
9
8
17
V
III
1
12
III
8
6
7
014.274/06
5/ 6
2008
34033/A1
Maintenance
RT-flex96C
5.
Assembling of a piston
For assembling the piston the following points must be observed:
CHECK
Damaged spraying nozzles 2a may under no circumstances be reused. New

ones must be fitted with liquid securing agent LOCTITE No. 0648.
Whenever possible always use new O-rings, they must conform in dimensions and quality to our specifications (see 03701).
All cylindrical guide portions and O-rings must be smeared with oil before
the assembly.
No additional lubricant must be applied to the threads of waisted screws 15.
Pre-tighten waisted screws 15 with 60 Nm using a torque wrench, subsequently

tighten to an angle of 40_ and finally secure them with locking plates.
D
Attention must be paid to locating pin 13 when assembling piston skirt 9 with
piston rod 8.
Insert and tighten both elastic screws 12.
201007
For the assembly of piston crown 1 with piston rod 8 make sure that the two
centring pins 11 (Fig. G), serving also as guides, mate with the corresponding bores in the piston skirt 9 and the piston rod.
Tension waisted studs 7 according to section 3.
6/ 6
RT-flex96C
Maintenance
34034/A1
Piston
Checking Piston Top Surface
Tools:
1 Feeler gauge
1 Template
1 Template
94122
94366
94366a
CHECK
Every time a piston is pulled the piston top surface contour must be checked with
the checking template 94366 and with feeler gauge 94122. The template is placed
on the topmost piston ring and rotated around the piston axis (see Fig. A).
D
Where burn scars are only slight it is sufficient to grind them over and to
smooth sharp-edged zones with emery cloth. Where, however, burn scars exceed x = 10 mm the original material thickness must be restored by surface
welding. This entails the removal of the piston crown.
Before re-starting the engine, the reason for such heavy burns should be established. The causes must be remedied.
Causes of heavy burn scars may be:
A
94366
Poor combustion
Worn nozzles
Heavy local carbon deposits on top of the piston

crown etc.
PISTON RING
003.321/00
The template 94366a should be used if the shape of

the crown top of a piston in situ has to be checked.
As shown in Fig. B, the template is to be pushed
through one of the scavenge ports of the cylinder liner and placed on top of the piston crown.
94366a
003.321/00
1/ 1
2008
RT-flex96C
34251/A1
Maintenance
Piston Rings
Checking Wear of Piston Rings and Ring Grooves
Tools:
Key to Illustration:
1 Inside micrometer
1 Feeler gauge
1 Piston ring tensioning device
94101
94122
94338
1 Equipment case
with instruments for
measuring chrome layers
1 Micrometer (030 mm)
1 Calliper gauge
94356
1
2
3
4
Piston ring
Cylinder liner
Piston head
Claw
94357
Overview
1.
2.
3.
4.
5.
6.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determine wear rate of piston rings . . . . . . . . . . . . . . . . . . . . .
Measuring piston ring grooves . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage and handling of piston rings . . . . . . . . . . . . . . . . . . . .
1/7
1/7
4/7
6/7
7/7
7/7
General
For judging and evaluating the condition of cylinder liner, piston and piston rings
the following guidelines serve for a condition-based Maintenance for piston and
cylinder liner overhaul.
Wear rates strongly depend on operational factors, such as fuel in use, engine load
profile, ambient conditions etc.
By visual inspections, critical conditions of cylinder liners and piston rings can be
detected at an early stage. Further information to monitor the cylinder liner and piston ring conditions are given in the Operating Manual 07501 Lubricating Oils.
The information regarding measuring piston ring grooves helps to define if the
wear on piston ring grooves is within the given limits or if the piston head must be
reconditioned. For the maximum wear data see Clearance Table 03301 Piston
and Piston Rings.
2.
Determine wear rate of piston rings

Measure the thickness of the chrome-ceramic coating of the piston rings as scheduled in 03801 to determine the wear rate and the remaining life time of the piston
rings.
Remark: See suppliers operation manual for the usage of layer measurement tool
94356.
1/ 7
2013-08
34251/A1
Maintenance
RT-flex96C
Piston: Checking Wear of Piston Rings and Ring Grooves
2.1
Measure coating thickness with piston in situ (through scavenge ports)

Before each measurement the layer measurement tool 94356 must be calibrated.
Use the delivered calibration foils and the bare top flank of a spare top piston ring
as base material for proper setting.
Clean piston ring running surface at reachable measuring points P1 to P9.
Press the sensor of the layer measurement tool against the piston ring surface
at middle of ring height.
Measure the layer thickness and note the output value.
MEASURING POINTS
ON PISTON RING
RECOMMENDED
MINIMUM
P9
1
P1
P9
P1
94356
P7
P3
2
P5
WCH01145
2.2
P5
Wear rate
The chrome-ceramic coating is a lifetime coating. However, the actual wear depends on operating conditions. When during a piston underside inspection a piston ring with a partially worn chrome-ceramic coating is found, we recommend
overhauling the unit at next opportunity (Fig. B).
With regular done measuring you can determine the specific wear rate for each
piston ring.
The piston rings can still be used, if the remaining chrome-ceramic coating is
above the following limits:
Uppermost piston ring a > 0.05 mm
Lower piston rings b and c > 0.02 mm
Below those minimal coating thicknesses, a piston ring replacement must be

planned.
PARTIALLY WORN CC-COATING
2013-08
2/ 7
RT-flex96C
34251/A1
Maintenance
2.3
Lifetime calculation
Calculate the wear rate and the remaining lifetime of a piston ring.
Use the formula below to calculate the wear rate:
WR = (D1D2) x 1000
T2T1
WR = Wear rate [mm/1000 h]
T2 = Actual running hours [h]
T1 = Running hours at previous measurement [h]
D2 = Actual coating thickness [mm]
D1 = Coating thickness at previous measurement [mm]
Example for wear rate calculation:
D1
D2
T1
T2
WR
0.382
0.367
0 (new)
1500
0.01
0.351
0.340
3500
5000
0.0073
Use the formula below to calculate the remaining piston ring lifetime according to
the latest condition setting:
LT =
(D2 Dmin) x 1000

WR
LT = Remaining lifetime [h]

D2 = Actual coating thickness [mm]
Dmin = Minimal coating thickness [mm] (see chapter 2.2)
WR = Calculated wear rate [mm/1000 h]
Example for remaining lifetime calculation:
D1
D2
Dmin
T1
T2
WR
LT
0.382
0.367
0.05
0 (new)
1500
0.01
31700
0.351
0.340
0.05
3500
5000
0.007333
39545
3/ 7
2013-08
34251/A1
Maintenance
RT-flex96C
3.
Measuring piston ring grooves

CHECK
3.1
Check all dimensions and record them (see Clearance Table 03301 Piston and
piston rings). These records are important for later evaluation of the running gear.
They should encompass all dimensions, the date of overhaul and operating hours
of the various components and of the engine itself.
Measurement with piston in situ (through scavenge ports)

The measurement of the piston ring clearance has to be carried out at two to four
free positions around the complete circumference of the piston head. The number
of measurement points depends on the accessibility.
Make sure that feeler gauge 94122 is pushed into the piston ring groove until it
touches the inner diameter of the groove, i.e. at point A. If there is a wear step on
the chromium layer, the feeler gauge can be pushed only to that point (C3).
Remark: Also consider the deposits in the piston ring groove and/or on the piston
ring top face.
Move piston 3 down (C1) by means of the turning gear.
Make sure that the total clearance is measured:
First measure the clearance x1at point A.
Afterwards repeat the measurement at the same circumferential position and
measure the clearance x2.
The sum of both values will give the total piston ring clearance.
Remark: The reason for this split measuring principle is that the piston rings might
be in a tilted position and thus not fully pushed-up and tight to the upper face of the
piston ring groove (C2).
The maximum clearance is at point A. For the maximum wear data see Clearance
Table 03301 Piston and Piston Rings.
If the clearance at point A exceeds the permitted value, the piston rings have to be
replaced and the piston head has to be reconditioned.
For reconditioning of piston crowns please contact your nearest Wrtsil Service
Center.
PISTON MOVED
DOWN (C1)
1
3
3
1
x1
3
1
(C2)
x2
A
94122
WCH02244
WEAR STEP ON
CHROMIUM LAYER (C3)
POSSIBLE WEAR
SHAPE ON GROOVE
1
3
2013-08
WCH02244
4/ 7
RT-flex96C
34251/A1
Maintenance

3.2
Measurement with piston removed from cylinder liner

The measurement of the piston ring clearance has to be carried out on at least four
positions around the complete circumference of the piston head.
Remove the piston rings as described in section 4.
Clean the piston ring grooves.
Measuring method with calliper gauge:
Measure the groove height with calliper gauge 94357 at point A and B.
WCH02244
94357
POSSIBLE WEAR
SHAPE ON GROOVE
Measuring method with a piece of a piston ring:
Measure the thickness of piece of a piston ring (1).
Place piece of piston ring into the piston ring groove.
Measure gap x2 between the face of piston ring and groove with feeler gauge
94122.
Evaluate the piston ring clearance with the following data:
CL = GH RT (mm)
CL =
CLearance
GH =
Measured piston ring Groove Height (mm)
RT =
Nominal piston Ring Thickness (mm)
x2
E
3
(1)
94122
WCH02244
If the clearance at point A and/or B exceeds the permitted value, the piston head
has to be reconditioned. For the maximum wear data see Clearance Table 03301
Piston and Piston Rings.
A piston head with clearances close to the maximum value may not be further used
as the expected remaining lifetime is too short.
5/ 7
2013-08
34251/A1
Maintenance
RT-flex96C
4.
Removing piston rings

For removing piston rings, always use the corresponding tensioning device with its
specially designed claw 4 preventing the coating from being chipped off at the ring
ends:
To prevent deformation it is of the utmost importance not to open the rings
more than absolutely necessary, i.e. allowing removal over the piston
crown.
Thoroughly clean piston, piston rings and piston ring grooves.
D
Take care not to damage the chromed surfaces.
1
4
94338
017.681/08
2013-08
6/ 7
RT-flex96C
34251/A1
Maintenance
4.
Fitting piston rings

D
When reusing piston rings, only rings in perfect condition may be fitted, however in the same position and groove as removed.
Always fit piston ring with the marking TOP upwards

(when the piston is assembled the piston rings must be turned such that the
ring gaps are staggered by 180_).
The chromium plating thickness of a new CC coated piston ring should be

measured and recorded to monitor the wear rate over time.
Remark: New piston rings have to be run-in according to the relevant indications in
the Operating Manual 04101.
D
Ring type
Uppermost piston ring a
1 x SCP1CC 20
Coating / material
Application
chrome-ceramic
coated
for new and fully

honed cylinder liners
as well as for used
cylinder liners in good
conditions
chrome-ceramic
coated
for new and fully

honed cylinder liners
as well as for used
cylinder liners in good
conditions
1 x GTP1CC 20 (GasTight) 1
Piston rings b d
3 x SCP2CC 20
3 x SCP2CC20 1
1
Additional execution
I-I
G
TOP
5.
CHROMIUM
PLATING
CHROMIUM
PLATING
CHROMIUM
PLATING
CHROMIUM
PLATING
r2
r2
TOP
I
r2
r2
GasTight
003.831/96
Storage and handling of piston rings

Store the piston rings in a dry place and lay them horizontally on a flat surface,
keeping them in their original packing. Handle with care when preparing for use
and avoid any hard contact against other objects.
7/ 7
2013-08
RT-flex96C
Maintenance

Group4
Group 4
Driving Wheels
Checking the Running and Backlash Clearances and Condition of Teeth . . . . 41031/A1
Removal and Fitting of Intermediate Wheel (610, 12 & 14 Cyl. Engines) . . . 41032/A1
Removal and Fitting of Intermediate Wheel (11 Cylinder Engines) . . . . . . . . . . 41032/A2
Replacing the Gear Wheel on Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41033/A1
Replacing the Gear Wheel on Crankshaft (Single Wall Column) . . . . . . . . . . . . 41033/A2
Shut-off Valve for Starting Air: Cleaning and Function Check . . . . . . . . . . . . . . . . . 43251/A1
1/ 2
RT-flex96C
41031/A1
Maintenance
Driving Wheels
Checking the Running and Backlash Clearances and Condition of Teeth
Tools:
1
1
1
1
1.
Feeler gauge
Micrometer
Dial gauge
Lead wire 1.5 mm
94122
06 Tooth profile
a, b, c Lead wires
TF Driving flanks
General
Gear wheels of new engines have to be checked visually during the running-in period after about 12 operating hours. The same applies to old engines which have
been equipped with new gear wheels.
2.
Check
Rotate crankshaft with the turning gear until all the teeth have been inspected.
Check with running lubricating oil pump, whether all the spray nozzles are delivering oil freely.
Check whether all the screws are correctly locked, and whether any irregularities can be detected.
After the running-in period check the gear wheels periodically every three
months in the manner described above. Should in this time faults appear, then
these can in certain cases be remedied by an experienced engineer.
3.
Should noises be heard in the region of the gear train, search for its cause.
Replace defective gear wheels as soon as ever possible, to prevent damage
to the mating gear wheels.
When the gear wheels have run well for an initial running period of 60008000
hours the above-mentioned inspection may be carried out annually.
For the checking of clearances and tooth impressions the tie rods and the
waisted studs of the main bearings must be tightened.
Checking the gear tooth backlash

Information concerning the gear tooth backlash values can be found in the table of
clearances (see 03301). The backlash can be determined in several ways. Depending on the possibilities, the following methods of measurement can be used:
3.1
With feeler gauge 94122

Measure the gap between the teeth flanks by using different thicknesses of feelers. Repeat the measurement at a minimum of four points on the circumference of
the gear wheel.
3.2
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 turned in such a way that the tooth profile of one tooth
moves from one side to the other. When using this method of measuring care must
be taken since the drive wheel must not be allowed to turn.
1/ 2
2008
41031/A1
Maintenance
RT-flex96C
Checking the Running and Backlash Clearances as well as Condition of the Teeth
15 mm
=
=
15 mm
3.3
a1
a3
b1
Use a fresh piece of lead wire Pb 99.9 fine of

1.5 mm diameter for each measurement.
b3
Always use lead wires of the same diameter

and quality.
Place lead wire pieces a, b, c of about 200 mm

length around the tooth profile and attach
them with scotch tape (see Fig. A and B).
b
c
Number the tooth profiles in accordance with

Fig. B.
000.653/93
Measuring tooth backlash with lead wire
Turn the lead wires only once through the

teeth meshing.
LEAD WIRE 1.5 mm
Lead wire c (Fig. A) serves to verify total

tooth backlash f (Fig. C).
With lead wires a and b (Fig. A) the tooth
profile parallelity is checked.
Total tooth backlash f (Fig. C) composes of

f1 and f2 (thickness of lead wire):
f = f1 + f2
Obliquity Df is calculated from the difference

in thickness of the squashed lead wires along
driving flanks TF (Fig. A):
Df = a1 b1 or a3 b3 etc.
The admissible deviation of tooth profile parallelity amounts to max. 0.2o/oo across the
width of the tooth.
B
0
1
2
3
4
6
...
...
...
000.653/93
4.
To enable judging the running performance of

the gear train after re-commissioning, three
teeth each of the gear wheels are smeared
with a thin coat of oil resisting marking blue
(ink) equally spread. This check is necessary
in order to verify the mating appearance of the
teeth.
One brand of oil resisting marking blue is, for
example, Dykem Layout Red Dx-296.
f1
f2
Checking the running performance
TF
000.653/93
2008
2/ 2
RT-flex96C
41032/A1
Maintenance
Driving Wheels
Removal and Fitting of Intermediate Wheel
Tools:
1 Feeler gauge
6 Adjusting devices
Withdrawing device
for taper pins
610, 12 and 14 Cyl. Engines

94122
94410
1
2
3
4
5
6
7
8
9
9a
10
11
Intermediate wheel
Cover
Cover
Pipe bend
Support
Waisted screw
Cover
Screw plug for taper pin
Screw plug
Taper pin
Bearing
12
13
14
15
16
17
18
19
20
Bearing journal
Locking strap
Double column
Wheel hub
Gear rim
Self-locking nut
Strap
Suspension beam
HZ Lifting tackle
Overview
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of intermediate wheel . . . . . . . . . . . . . . . . . . . . . . .
Replacement of a gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.
2.
3.
4.
5.
1.
1/6
2/6
4/6
5/6
6/6
General
The turning gear must be engaged.
Risk of accident! Precautions must be taken that, while removal work is in progress, the running gear can on no account be put into motion.
014.066/06
1/ 6
2008
41032/A1
Maintenance
RT-flex96C
2.
Removal
B
6 and 7 cylinder engines:
Fasten lifting tackle HZ to pipe bend
4 and connect it to cover 3.
Fasten lifting tackle H1 (lifting capacity 4000 kg) to strap 19 and connect it
to cover 3.
Loosen and remove the cover.
I
HZ
3
H1
H1
19
4
HZ
014.069/06
C
810, 12 and 14 cylinder engines:
Fasten lifting tackle HZ to support 5
and connect it to cover 3.
Fasten lifting tackle H1 (lifting capacity 4000 kg) to suspension beam 20
and connect it to cover 3.
I
HZ
H1
20
H1
HZ
014.068/06
2008
2/ 6
RT-flex96C
41032/A1
Maintenance
D
Remove lubricating oil pipes 17 to intermediate wheel 1, where necessary.
Fasten lifting tackle H2 (lifting capacity 4000
kg) to cover 2.
Connect one rope a (lifting capacity 4000
kg) with intermediate wheel and lifting tackle
H2.
2
a
Pull wire rope a taut.

Loosen and remove waisted screws 7 on
both sides of taper pins 10.
H2
Remove screw plugs 9 (Fig. E) and then

loosen taper pins 10 for the bearing location
using a withdrawing device.
Loosen remaining waisted screws (Fig. E) of
the intermediate wheel and remove them together with cover 8.
012.183/04
II - II
16
15
11 13
II
17
14
7
8
001.639/97
III
III
II
9a
III - III
12
9a
7
8
9
10
012.185/04
001.639/97
3/ 6
2008
41032/A1
Maintenance
RT-flex96C
Lower intermediate wheel 1 completely onto

the gear wheel on crankshaft 6 by means of
rope a, and turn it out to exhaust side while
following up with rope b.
When the intermediate wheel is in position as
shown in Fig. F, attach it to lifting tackle H3
and rope b as well as to lifting tackle H1 and
rope c (ropes and lifting tackles with lifting
capacity 4000 kg).
Remove rope a.
H2
b
H1
H3
Lift the intermediate wheel out of the double

column with ropes b and c.
D
After having removed locking straps 13 with

screws and locking plates, bearings 11 can
be pulled off bearing journal 12 (Fig. E).
6
012.184/04
3.
Fitting
Fitting the intermediate wheel is carried out analogously to the removal but in
reverse sequence, whereby attention must be paid as follows:
Remark: When fitting bearings 11 they must first be lavishly smeared with bearing
oil. Both bearings are basically equal, they may, however, only be refitted in their
original place, as their position has been dowelled with taper pins 10 when building
the engine.
D
Fit intermediate wheel so that marking DRIVING END appears when viewed
from the driving end of the engine.
Intermediate wheel may be fitted arbitrarily with respect to the tooth position.
Before the final assembly of the intermediate wheel, apply a non-hardening

sealing compound on the joint face of covers 8; afterwards fit it with three
waisted screws 7 (lubricated with MOLYKOTE G paste) on double column 14.
Tighten the waisted screws only as much as bearings 11 can still be moved.
Align the bearings so that the bores of the pinholes in the double column correspond exactly with those in the bearings.
Drive home the taper pins to both of the bearings, using a copper rod and a
hammer.
2008
4/ 6
RT-flex96C
41032/A1
Maintenance
Screw in the remaining waisted screws and tighten them all slightly and
evenly by hand with a wrench.
In this position mark the screws with a line and tighten them crosswise until an
angle of 50 is obtained.
CHECK
As a safeguard check the tooth backlash between the gear wheels (see also Clearance Table 03301 Driving Wheels for Supply Unit).
Fit screw plugs 9 with LOCTITE No. 0222 and screw them in till the stop at the
taper pins.
Lock all waisted screws 7 in pairs with locking wire.
4.
Adjustment of intermediate wheel

Should it be necessary to replace one bearing 11, the opposite bearing must be
replaced at the same time, as new bearings are always manufactured in pairs.
When fitting them an exact adjustment of the intermediate wheel is essential.
For a new adjustment of the intermediate wheel, adjusting devices 94410
must be used as shown in Fig. G.
D
CHECK
After a new adjustment of the intermediate wheel the tooth backlash (see Clearance Table 03301 Driving Wheels for Supply Unit), as well as the tooth flank contact pattern have to be checked (see 41031).
If a new adjustment of the bearings is required, the pin holes pre-bored in the
column must be used.
II - II
14
14
I
II
I
8
94410
II
11
94410
012.186/04
5/ 6
001.639/97
2008
41032/A1
Maintenance
5.
RT-flex96C
Replacement of a gear rim

D
The replacement of a damaged 2-part gear wheel may only be done in exchange for a complete gear wheel i.e. gear rim 16 must be screw fastened to
wheel hub 15 and the bearing journal fitted.
This is necessary as the final machining of the gear teeth has been carried out
in this mounted condition at the makers works and guarantees the required
perfect true running of the complete gear wheel.
For this reason a split design gear wheel may only be installed if the final
machining of the teeth had been carried out with assembled hub / gear
rim.
After the final machining of the teeth the gear rim may not be separated from the
wheel hub.
D
Should the damage be limited to the toothing (gear rim), then the hub may be
reused, provided a new rim, on which the teeth are not finish-machined, is
fitted to the hub, screw-fastened and dowelled. Then its teeth can be finishmachined.
Apply LOCTITE 262 and then tighten self-locking nuts 18 until an angle of 80_
is obtained.
16
18
15
012.185/04
2008
6/ 6
RT-flex96C
41032/A2
Maintenance
Driving Wheels
Tools:
1 Feeler gauge
6 Adjusting devices
1 Suspension device
Withdrawing device
for taper pins
11 Cylinder Engines
94122
94410
94411
1
2
3
4
5
6
7
8
9
9a
10
11
Intermediate wheel
Cover
Cover
Pipe bend
Support
Waisted screw
Cover
Screw plug for taper pin
Screw plug
Taper pin
Bearing
12
13
14
15
16
17
18
19
20
Bearing journal
Locking strap
Double column
Wheel hub
Gear rim
Self-locking nut
Strap
Strap
HZ Lifting tackle
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of the intermediate wheel . . . . . . . . . . . . . . . . . . .
Replacement of a gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/6
2/6
4/6
5/6
6/6
General
D
Risk of accident! Precautions must be taken that, while removal work is in progress, the running gear can on no account be put into motion.
6
014.078/06
1/ 6
2008
41032/A2
Maintenance
RT-flex96C
2.
11 Cylinder Engines
Removal
Fasten lifting tackle HZ to pipe bend 4 and
connect it to cover 3.

kg) to strap 19 and connect it to cover 3.
Remove lubricating oil pipes 17 to intermediate wheel 1, where necessary.
kg) to cover 2.
Connect one rope a (lifting capacity 4000 kg)

with intermediate wheel and lifting tackle H2.
Pull wire rope a taut.
H2
19
H1
3
HZ
I
4
HZ
014.079/06
II - II
16
Loosen and remove waisted screws 7 on

both sides of taper pins 10.
Remove screw plugs 9 (Fig. C) and then
loosen taper pins 10 for the bearing location
using a withdrawing device.
15
11 13
14
Loosen remaining waisted screws (Fig. C)

of the intermediate wheel and remove them
together with cover 8.
17
III - III
II
7
8
9a
9a
10
12
001.639/97
III
001.639/97
III
II
012.185/04
2008
2/ 6
RT-flex96C
41032/A2
Maintenance
11 Cylinder Engines
D
Lower intermediate wheel 1 completely onto
the gear wheel on crankshaft 6 by means of
rope a, and turn it out to exhaust side while
following up with rope b.
kg) to cover 2.
Connect rope b (lifting capacity 4000 kg)
with intermediate wheel and lifting tackle H3.
Remove rope a.
H2
b a
H3
1
6
014.086/06
E
Fit suspension device 94411 to the intermediate wheel as shown in view I.
kg) to straps 20 and connect it to the suspension device.
Lift the intermediate wheel out of the double
column with rope b and lifting tackle H4.
I
b
20
H4
H4
H3
1
6
94411
014.080/06
3/ 6
2008
41032/A2
Maintenance
RT-flex96C
11 Cylinder Engines
F
Connect lifting tackle H1 and rope d (lifting
capacity 4000 kg each) with intermediate
wheel 2.
Pull out the intermediate wheel by means of
lifting tackle H4 and rope d and then remove
lifting tackle H4.
D
After having removed locking straps 13 with

screws and locking plates, bearings 11 can
be pulled off bearing journal 12 (Fig. C).
H4
H1
d
014.081/06
3.
Fitting
Fitting the intermediate wheel is carried out analogously to the removal but in
reverse sequence, whereby attention must be paid as follows:
Remark: When fitting bearings 11 they must first be lavishly smeared with bearing
oil. Both bearings are basically equal, they may, however, only be refitted in their
original place, as their position has been dowelled with taper pins 10 when building
the engine.
D
Fit intermediate wheel so that marking DRIVING END appears when viewed
from the driving end of the engine.
Intermediate wheel may be fitted arbitrarily with respect to the tooth position.
Before the final assembly of the intermediate wheel, apply a non-hardening

sealing compound on the joint face of covers 8; afterwards fit it with three
waisted screws 7 (lubricated with MOLYKOTE G paste) on double column 14.
Tighten the waisted screws only as much as bearings 11 can still be moved.
Align the bearings so that the bores of the pinholes in the double column correspond exactly with those in the bearings.
Drive home the taper pins to both of the bearings, using a copper rod and a
hammer.
2008
4/ 6
RT-flex96C
41032/A2
Maintenance
11 Cylinder Engines
Screw in the remaining waisted screws and tighten them all slightly and
evenly by hand with a wrench.
In this position mark the screws with a line and tighten them crosswise until an
angle of 50 is obtained.
CHECK
As a safeguard check the tooth backlash between the gear wheels (see also Clearance Table 03301 Driving Wheels for Supply Unit).
Fit screw plugs 9 with LOCTITE No. 0222 and screw them in till the stop at the
taper pins.
Lock all waisted screws 7 in pairs with locking wire.
4.
Adjustment of the intermediate wheel

Should it be necessary to replace one bearing 11, the opposite bearing must be
replaced at the same time, as new bearings are always manufactured in pairs.
When fitting them an exact adjustment of the intermediate wheel is essential.
For a new adjustment of the intermediate wheel, adjusting devices 94410
must be used as shown in Fig. G.
D
CHECK
After a new adjustment of the intermediate wheel the tooth backlash (see Clearance Table 03301 Driving Wheels for Supply Unit), as well as the tooth flank contact pattern have to be checked (see 41031).
If a new adjustment of the bearings is required, the pin holes pre-bored in the
column must be used.
II - II
14
14
I
II
I
8
94410
II
11
94410
012.186/04
5/ 6
001.639/97
2008
41032/A2
Maintenance
RT-flex96C
5.
11 Cylinder Engines
Replacement of a gear rim

D
The replacement of a damaged 2-part gear wheel may only be done in exchange for a complete gear wheel i.e. gear rim 16 must be screw fastened to
wheel hub 15 and the bearing journal fitted.
This is necessary as the final machining of the gear teeth has been carried out
in this mounted condition at the makers works and guarantees the required
perfect true running of the complete gear wheel.
For this reason a split design gear wheel may only be installed if the final
machining of the teeth had been carried out with assembled hub / gear
rim.
After the final machining of the teeth the gear rim may not be separated from the
wheel hub.
D
Should the damage be limited to the toothing (gear rim), then the hub may be
reused, provided a new rim, on which the teeth are not finish-machined, is
fitted to the hub, screw-fastened and dowelled. Then its teeth can be finishmachined.
Apply LOCTITE 262 and then tighten self-locking nuts 18 until an angle of 80_
is obtained.
16
18
15
012.185/04
2008
6/ 6
RT-flex96C
41033/A1
Maintenance
Driving Wheels
Replacing the Gear Wheel on Crankshaft
Tools:
1 Feeler gauge
1 Hydraulic tightening device
consisting of:
1 Clamping fork with extension
1 Impact ring spanner
1 Forked piece
1 Hydraulic ram
1 Retaining wrench
1 HP oil pump
1 Pressure gauge
1 Pressure gauge
1 Hydr. distributor
1 Plug piece
1 HP hose
1 HP hose
94122
94412
94412a
94412b
94412c
94412d
94412e
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
Gear wheel
Crankshaft flange
Waisted stud
Castle nut
Base
Flange screw
7
8
9
10
Distance sleeve
Self-locking nut
Dowel pin
Column
EV Relief valve
Overview
1.
2.
3.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/7
Preparing the assembly of the gear wheel . . . . . . . . . . . . . . . 2/7
Assembly of the gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/7
6
1
4
5
3
9
5
4
001.173/97
1/ 7
2008
41033/A1
Maintenance
RT-flex96C
Replacing the Gear Wheel on the Crankshaft
1.
General
Usually, the gear wheel on the crankshaft (from now on referred to as gear wheel)
is executed in one part and fitted as such on the crankshaft. If a damaged gear
wheel in the engine is to be replaced, it must be separated into two halves for dismantling. In order to avoid damages, especially to the crankshaft, please obtain the necessary instructions and recommendations for executing such dismantling work from the engine supplier or from Wrtsil Switzerland Ltd.
For dismantling as well as for assembling a new gear wheel, dismount the intermediate wheel (41032) to the supply unit drive.
The spare gear wheel is designed in two parts and must be fitted as described below.
Remark: When ordering a two-part spare wheel, please indicate the engine type,
the engine No., as well as the engine supplier. This data is necessary because the
centring diameter of the crankshaft is registered for mounting the gear wheel, and
the center hole of the two-part spare wheel is manufactured according to these dimensions.
2.
Preparing the assembly of the gear wheel

DRIVING END
CHECK
DEGREASE
The undersize of center hole d (Fig. A) on two-part

gear wheel 1 with regard to the corresponding centring
diameter of the crankshaft has to be checked and recorded beforehand. For measuring, the crankshaft, the
gear wheel, and the measuring instrument must have
the same temperature.
The undersize of the center hole with respect to the centring diameter must be 0.050.14 mm.
D
If the undersize is not within the mentioned tolerance, the gear wheel must not be assembled, but
the center hole of the gear wheel has to be given an
appropriate aftertreatment (remachine / possibly
bore and flame-spray, and machine to obtain the
correct diameter).
Check whether there is a mark on crankshaft flange

2 for fitting the gear wheel. For the assembly, the
gear wheel partition must coincide with this mark.
The designation DRIVING END, which is located on
the front of the gear wheel, must be on the side of
the flywheel!
2/ 7
1
000.697/98
DRIVING END
MIDDLE OF ENGINE
DEGREASE
1
000 697/98
2008
RT-flex96C
41033/A1
Maintenance

D
Before assembling, the centring diameter of the crankshaft flange as well as

the centre hole of the gear wheel with the corresponding flange faces must be
well cleaned and degreased (Fig. B). Do not use neither oil nor MOLYKOTE.
All surfaces must be in faultless condition.
Remark: The assembly of the gear wheel must be carried out carefully, since relatively small faults could have a negative influence on the operating performance of
all gear wheels of the drive.
3.
Assembly of the gear wheel

The connection consists of four waisted studs 3, each of them comprising two
castle nuts 4 and bases 5 (Fig. C).
C
4
MOLYKOTE
LOCTITE 262
DEGREASE
SPLINT PIN
Before assembling the gear wheel halves, fit two

waisted studs crosswise into each half.
5
3
Fasten a base 5 and a castle nut 4 on either side

of each waisted stud.
The projection X of the waisted stud with respect
to the castle nut must be 4 mm.
Before fitting the castle nut, degrease the thread

and apply LOCTITE 262 to it.
1
5
In addition, secure the castle nut with a split pin to

prevent it from slipping when tightening the waisted studs afterwards.
Wait one or two days before tightening the waisted

studs in order to ensure thorough curing of the
LOCTITE.
001.168/97
Remark: The castle nut secured with LOCTITE and a

split pin must be fitted in such a way that the waisted stud
can be tensioned together with the castle nut opposite,
as shown in Fig. I and K.
3.1
Turn the crankshaft so that the mark on the crankshaft flange is approximately horizontal with regard to the crankshaft centre line.
D
6
1
3
001.167/97
Work sequence
Put one gear wheel half with two pre-assembled

waisted studs 3 on the centring diameter of the
crankshaft flange in such a way that the joint face
of the gear wheel coincides with the mark on the
crankshaft flange. The designation DRIVING END
located on the front of the gear wheel must be on
the side of the flywheel.
Insert flange screws 6 (Fig. D) each in the centre
and at both ends of the gear wheel half and tighten
them temporarily.
3/ 7
2008
41033/A1
Maintenance
RT-flex96C
E
3
Turn the gear wheel half to the bottom (Fig. E) and

place the second gear wheel half, which is also provided with two pre-assembled waisted studs 3, on
the top (Fig. G).
001.167/97
Check the correct diameter tolerance by measuring

the size of the gap between both gear wheel halves.
For that the gap must be closed on the opposite side
(Fig. F).
GAP 0
F
CHECK
After measuring, align the gaps between the wheel

halves and slightly tighten castle nuts 4 of waisted
studs 3 (Fig. C).
001.166/97
Also insert a flange screw 6 in the centre of upper

gear wheel half and tighten it temporarily (Fig. G).
6
1
6
001.166/97
Remove flange screws 6 from each end of the lower

gear wheel half so that there are now only two flange
screws 6, each of them tightened temporarily in the
centres of the upper and the lower gear wheel half
(Fig. H).
CHECK There must be no clearance on the seating surfaces between the gear wheel and the crankshaft flange check!
001.166/97
2008
Gap j must be 0.16 mm0.44 mm. If the dimension is

not within the mentioned tolerance, the gear wheel must
not be assembled, but the center hole has to be given an
appropriate re-machining (see Preparing the assembly
of the gear wheel).
For fitting the four remaining castle nuts 4 belonging

to waisted studs 3 (Fig. C), apply MOLYKOTE
paste to the threads and the seating surfaces. Tighten only the castle nuts treated with MOLYKOTE
paste. Use retaining wrench 94412e (Fig. K) for
holding up the castle nuts opposite which have already been fitted and secured with LOCTITE and a
split pin.
Tighten the four castle nuts 4 of waisted studs 3
crosswise by means of hydraulic tightening device
94412 (Fig. I and K), measuring and recording the
length of the waisted studs beforehand.
4/ 7
RT-flex96C
Maintenance
41033/A1

Fit the clamping fork with extension 94412a as shown in Fig. I and K, and
connect hydraulic ram 94412d to forked piece 94412c and impact ring spanner 94412b.
For tightening, connect the hydraulic ram together with both HP hoses
94935a and 94935 and hydr. distributor 94934a to HP oil pump 94931, plugging one of the openings at the connection piece with plug piece 94934e (Fig.
K).
Close relief valve EV on the HP oil pump and actuate the HP oil pump.
CHECK
The waisted studs are correctly pretensioned if an extension of L 1.75 0.08

mm is measured.
Check: there must be no gap in the gear wheel partition.
If the split pin for securing the castle nut cannot be fitted, turn the castle nut
only so far as to allow the split pin to be fitted.
After the check mentioned above has been carried out, dismantle both flange
screws 6 which have been temporarily fitted beforehand (Fig. H).
Degrease the threads of all flange screws 6 and their self-locking nuts 8 and then
apply LOCTITE 262 to them; do not use MOLYKOTE!
Fit all flange screws 6 with distance sleeves 7 and self-locking nuts 8 (Fig. I).
Afterwards, tighten them crosswise and evenly distributed over the circumference with an angle of 80_.
CHECK
After fitting the gear wheel on the crankshaft and assembling the intermediate
wheel, check the correct positioning of the driving wheels (see 41032).
Check all driving wheels as specified in 41031 after assembling them.
5/ 7
2008
41033/A1
Maintenance
RT-flex96C
10
94412a
94412d
94412b
94412c
000.696/98
2008
6/ 7
RT-flex96C
41033/A1
Maintenance
10
I-I
94412a
1
3
94412d
94935a
94412e 4 2
LOCTITE 262
MOLYKOTE
I
94932a
94934e
94934a
94935
012.093/04
94932
7/ 7
EV
94931
2008
RT-flex96C
41033/A2
Maintenance
Driving Wheels
Replacing the Gear Wheel on Crankshaft
Single Wall Column
Tools:
1 Feeler gauge
1 Hydraulic tightening device
94122
94412
consisting of:
1
1
1
1
1
1
1
1
1
1
1
1
1
Impact ring spanner

Forked piece
Hydraulic ram
Retaining wrench
Extension
Retaining device
HP oil pump
Pressure gauge
Pressure gauge
Hydr. distributor
Plug piece
HP hose
HP hose
94412b
94412c
94412d
94412e
94412f
94412g
94931
94932
94932a
94934a
94934e
94935
94935a
1
2
3
4
5
6
7
Gear wheel
Crankshaft flange
Waisted stud
Castle nut
Base
Flange screw
Distance sleeve
8
9
10
11
Self-locking nut
Dowel pin
Column
Screw
EV Relief valve
Overview
1.
2.
3.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/7
Preparing the assembly of the gear wheel . . . . . . . . . . . . . . . 2/7
Assembly of the gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/7
6
1
4
5
3
9
5
4
001.173/97
1/ 7
2008
41033/A2
Maintenance
1.
RT-flex96C
Single Wall Column
General
Usually, the gear wheel on the crankshaft (from now on referred to as gear wheel)
is executed in one part and fitted as such on the crankshaft. If a damaged gear
wheel in the engine is to be replaced, it must be separated into two halves for dismantling. In order to avoid damages, especially to the crankshaft, please obtain the necessary instructions and recommendations for executing such dismantling work from the engine supplier or from Wrtsil Switzerland Ltd.
For dismantling as well as for assembling a new gear wheel, dismount the intermediate wheel (41032) to the supply unit drive.
The spare gear wheel is designed in two parts and must be fitted as described below.
Remark: When ordering a two-part spare wheel, please indicate the engine type,
the engine No., as well as the engine supplier. This data is necessary because the
centring diameter of the crankshaft is registered for mounting the gear wheel, and
the center hole of the two-part spare wheel is manufactured according to these dimensions.
2.
Preparing the assembly of the gear wheel

DRIVING END
CHECK
DEGREASE
The undersize of center hole d (Fig. A) on two-part

gear wheel 1 with regard to the corresponding centring
diameter of the crankshaft has to be checked and recorded beforehand. For measuring, the crankshaft, the
gear wheel, and the measuring instrument must have
the same temperature.
The undersize of the center hole with respect to the centring diameter must be 0.050.14 mm.
D
If the undersize is not within the mentioned tolerance, the gear wheel must not be assembled, but
the center hole of the gear wheel has to be given an
appropriate aftertreatment (remachine / possibly
bore and flame-spray, and machine to obtain the
correct diameter).
Check whether there is a mark on crankshaft flange

2 for fitting the gear wheel. For the assembly, the
gear wheel partition must coincide with this mark.
The designation DRIVING END, which is located on
the front of the gear wheel, must be on the side of
the flywheel!
2/ 7
1
000.697/98
DRIVING END
MIDDLE OF ENGINE
DEGREASE
1
000.697/98
2008
RT-flex96C
41033/A2
Maintenance

D
Single Wall Column
Before assembling, the centring diameter of the crankshaft flange as well as

the centre hole of the gear wheel with the corresponding flange faces must be
well cleaned and degreased (Fig. B). Do not use neither oil nor MOLYKOTE.
All surfaces must be in faultless condition.
Remark: The assembly of the gear wheel must be carried out carefully, since relatively small faults could have a negative influence on the operating performance of
all gear wheels of the drive.
3.
Assembly of the gear wheel

The connection consists of four waisted studs 3, each of them comprising two
castle nuts 4 and bases 5 (Fig. C).
C
4
MOLYKOTE
LOCTITE 262
DEGREASE
SPLINT PIN
Before assembling the gear wheel halves, fit two

waisted studs crosswise into each half.
5
3
Fasten a base 5 and a castle nut 4 on either side

of each waisted stud.
The projection X of the waisted stud with respect
to the castle nut must be 4 mm.
Before fitting the castle nut, degrease the thread

and apply LOCTITE 262 to it.
1
5
In addition, secure the castle nut with a split pin to

prevent it from slipping when tightening the waisted studs afterwards.
Wait one or two days before tightening the waisted

studs in order to ensure thorough curing of the
LOCTITE.
001.168/97
Remark: The castle nut secured with LOCTITE and a

split pin must be fitted in such a way that the waisted stud
can be tensioned together with the castle nut opposite,
as shown in Fig. I and K.
3.1
Turn the crankshaft so that the mark on the crankshaft flange is approximately horizontal with regard to the crankshaft centre line.
D
6
1
3
001.167/97
Work sequence
Put one gear wheel half with two pre-assembled

waisted studs 3 on the centring diameter of the
crankshaft flange in such a way that the joint face
of the gear wheel coincides with the mark on the
crankshaft flange. The designation DRIVING END
located on the front of the gear wheel must be on
the side of the flywheel.
Insert flange screws 6 (Fig. D) each in the centre
and at both ends of the gear wheel half and tighten
them temporarily.
3/ 7
2008
41033/A2
Maintenance
RT-flex96C
Single Wall Column
E
3
Turn the gear wheel half to the bottom (Fig. E) and

place the second gear wheel half, which is also provided with two pre-assembled waisted studs 3, on
the top (Fig. G).
001.167/97
Check the correct diameter tolerance by measuring

the size of the gap between both gear wheel halves.
For that the gap must be closed on the opposite side
(Fig. F).
GAP 0
F
CHECK
After measuring, align the gaps between the wheel

halves and slightly tighten castle nuts 4 of waisted
studs 3 (Fig. C).
001.166/97
Also insert a flange screw 6 in the centre of upper

gear wheel half and tighten it temporarily (Fig. G).
6
1
6
001.166/97
Remove flange screws 6 from each end of the lower

gear wheel half so that there are now only two flange
screws 6, each of them tightened temporarily in the
centres of the upper and the lower gear wheel half
(Fig. H).
CHECK There must be no clearance on the seating surfaces between the gear wheel and the crankshaft flange check!
001.166/97
2008
Gap j must be 0.16 mm0.44 mm. If the dimension is

not within the mentioned tolerance, the gear wheel must
not be assembled, but the center hole has to be given an
appropriate re-machining (see Preparing the assembly
of the gear wheel).
For fitting the four remaining castle nuts 4 belonging

to waisted studs 3 (Fig. C), apply MOLYKOTE
paste G to the threads and the seating surfaces.
Tighten only the castle nuts treated with MOLYKOTE paste G. Use retaining wrench 94412e (Fig. K)
for holding up the castle nuts opposite which have already been fitted and secured with LOCTITE and a
split pin.
Tighten the four castle nuts 4 of waisted studs 3
crosswise by means of hydraulic tightening device
94412 (Fig. I and K ), measuring and recording the
length of the waisted studs beforehand.
4/ 7
RT-flex96C
Maintenance
41033/A2
Single Wall Column
Fasten retaining device 94412g to the column using screws 11 as shown in

Fig. K.
Fit extension 94412f as shown in Fig. I and K, and connect hydraulic ram
94412d to forked piece 94412c and impact ring spanner 94412b.
For tightening, connect the hydraulic ram together with both HP hoses
94935a and 94935 and hydr. distributor 94934a to HP oil pump 94931, plugging one of the openings at the connection piece with plug piece 94934e.
Close relief valve EV and actuate the HP oil pump.
CHECK
The waisted studs are correctly pretensioned if an extension of L 1.75 0.08

mm is measured.
Check: there must be no gap in the gear wheel partition.
If the split pin for securing the castle nut cannot be fitted, turn the castle nut
only so far as to allow the split pin to be fitted.
After the check mentioned above has been carried out, dismantle both flange
screws 6 which have been temporarily fitted beforehand (Fig. H).
Degrease the threads of all flange screws 6 and their self-locking nuts 8 and then
apply LOCTITE 262 to them; do not use MOLYKOTE!
Fit all flange screws 6 with distance sleeves 7 and self-locking nuts 8 (Fig. I).
Afterwards, tighten them crosswise and evenly distributed over the circumference with an angle of 80_.
CHECK
After fitting the gear wheel on the crankshaft and assembling the intermediate
wheel, check the correct positioning of the driving wheels (see 41032).
Check all driving wheels as specified in 41031 after assembling them.
5/ 7
2008
41033/A2
Maintenance
RT-flex96C
Single Wall Column
II - II
I
I
94412g
94412g
94412f
94412d
94412c
94412b
015.091/07
2008
6/ 7
RT-flex96C
41033/A2
Maintenance
Single Wall Column
I-I
II
94412g
94412f
11
III
94935a
94412c
MOLYKOTE
LOCTITE 262
III - III
1
3
1
94932a
III
94934e
94934a
94412e
4 2
94935
II
94932 EV 94931
7/ 7
2008
RT-flex96C
43251/A1
Maintenance
Shut-off Valve for Starting Air

Cleaning and Function Check
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1.
Valve seat
Cover
Spring
Valve
Valve seat
Valve guide
Spring
Valve body
Control valve
Piston seal ring
Piston
Valve
Screw plug
Spring
Screw plug
Liner bush
Screw
18
19
20
21
22
23
24
Spindle
Spindle guide
Handwheel
Locking lever
Common start valve
O-ring
O-ring
DT* To instrument panel and

pressure transmitter PT4301C
EB Equalizing bore
EV* To venting valve 2.21
SL* Control air
TV* To (drain and) test valve 2.06
* See Control Diagram 40032
in the Operating Manual
General
The shut-off valve must be dismantled, cleaned and inspected according to Maintenance Schedule 03801.
Remark: To avoid accumulation of water in the main starting air piping open for a
short time water drain pipe on the main starting air piping after each starting operation.
Risk of accident! Before starting work on the shut-off valve for starting air it is essential to manually close the stop valves on the starting air receivers.
The venting valve 2.21 to connection EV as well as the valve 2.27 must be open
for venting and draining the main starting air piping on the engine (see Control Diagram 40032 in the Operating Manual).
2.
Dismantling and assembly
2.1
Dismantling
If the valve seat 1 is to be grind in, first loosen the screws to cover 2.
Withdraw spring 3 together with valve 4 and spindle 18 as an unit.
Unscrew spindle guide 19 and remove the valve from the spindle.
If valve seat 5 of the non-return valve is to be grind in, then the shut-off valve
must be completely dismantled.
After dismantling valve guide 6 and spring 7 remove valve body 8 of the nonreturn valve.
D
When the above mentioned items are being checked, control valve 9 has also
to be dismantled and cleaned.
1/ 4
2006
43251/A1
Maintenance
RT-flex96C
Shut-off Valve for Starting Air: Cleaning and Function Check
2.2
Assembly
Before reassembling all items replace corroded springs by new ones.
Replace damaged or much worn piston seal ring 10.
Check equalizing bores EB for free passage.
Before reassembling spindle 18, the threads in valve 4 and spindle guide 19
are to be thoroughly degreased and then smeared with LOCTITE. Insert the
spindle and fully tighten the spindle guide.
For the assembly smear all the parts lightly with MOLYKOTE paste.
Check to ascertain that clearance S between piston 11 and valve 12 of control
valve 9 amounts to about 1 mm.
CHECK
24 6
17
7
8
13
5
1
EB
S1
DT
EV
19
10
4
16
23
14
12
TV
2
SL
15
9
11
21
22
019.238/10
18
20
011.670/04
201007
2/ 4
RT-flex96C
Maintenance
43251/A1
3.
Function check
After completing the assembly carry out a function check, for which the following
precautions have to be taken:
3.1
3.2
Initial position
D
The stop valves of the starting air receivers must still be closed.
Screw plug 13 of the shut-off valve has to be removed.
Shut-off valve for starting air is in position CLOSED (closed by hand).
Venting valve 2.21 to connection EV must be closed.
The engine has to be completely assembled, ready to start and the turning gear must be in the disengaged position.
The area of flywheel, propeller shaft and propeller must be free of persons or
objects.
During the functional check the reversing must remain in position STOP and
START may not be actuated under any circumstances.
Tightness
Close venting valve 2.27 in the main starting pipe.
Open the stop valve of a starting air receiver slowly.
CHECK
3.3
Check whether the automatic shut-off valve is airtight, i.e. verify that no air escapes
from the bore of screw plug 14.
Manual opening
Open the shut-off valve slowly with the help of handwheel 20 till locking lever
21 is in the position OPENED (by hand). The discharging air at the bore for
screw plug 13 indicates that valve 4 of the shut-off valve and valve body 8 of
the non-return valve are open.
Risk of accident! Great care must be taken for this operation. To prevent accidents from compressed air suddenly escaping out of the bore for screw plug 13 a
sufficient distance has to be kept.
3.4
Automatic closing
Turn handwheel 20 to position CLOSED till locking lever 21 engages in position AUTOMATIC.
In this position the shut-off valve should, through the spring resistance, be automatically closed. No more air should come out at the bore for screw plug 13.
In this position the valve closes positively only if there is a clearance S1 (in
new condition min. 2 mm max. 5 mm) between spindle 18 and spindle guide
19.
3/ 4
2006
43251/A1
Maintenance
RT-flex96C
CHECK
3.5
By turning the spindle carefully to position OPENED, the contact with spindle guide
19 can be felt. The clearance S1 can thus be determined externally and it shall be
min. 2 mm corresponding to 1/3 turn of the spindle.
D
Should virtually no clearance exist after frequent reconditioning of valve seat

and valve, these parts have to be replaced during the next overhaul.
Locking lever 21 is in position AUTOMATIC.
By opening test valve 2.06, which is fitted in piping TV, the same effect is obtained as when actuating control valve 9.
Upon opening test valve 2.06 the shut-off valve opens automatically. The air
now escaping at the bore for screw plug 13 indicates that valve 4 of the shutoff valve and valve body 8 of the non-return valve have opened.
Automatic opening
Risk of accident! Great care must be taken for this operation. To prevent accidents from compressed air suddenly escaping out of the bore for screw plug 13 a
sufficient distance has to be kept to the shut-off valve.
D
After shutting test valve 2.06 no air must escape from bore for screw plug 13.
After completing these checks fit and tighten screw plug 13, and close the
shut-off valve with handwheel 20 to position CLOSED (by hand).
2006
4/ 4
RT-flex96C
Maintenance

Group5
Group 5
Supply Unit
Removal and Fitting of Dynex Servo Oil Pump and Servo Oil Pump Drive . . . 55521/A2
Removal and Fitting of Camshaft and Bearing Shells . . . . . . . . . . . . . . . . . . . . . 55522/A1
Removal and Fitting of Gear Wheel on Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 55523/A1
Removing and Fitting the Fuel Cams with Conical Bushes . . . . . . . . . . . . . . . . 55523/A2
Removal and Fitting of Intermediate Wheel to Camshaft . . . . . . . . . . . . . . . . . . 55524/A1
Lubrication of Supply Unit During Maintenance Works (Dynex SOP) . . . . . . . 55525/A1
Fuel pump
Removal of a Jammed Pump Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55562/A1
Injection Control Unit: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55641/A1
Pressure Reducing Valve 8.111: Checking the Gas Pre-charge Pressure . . . . . 56101/A1
Exhaust Valve Drive: Removal, Fitting, Dismantling and Assembling . . . . . . . . . . . 56121/A1
Regulating Linkage: Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58011/A1
1/ 5
RTflex96C / MM / 2012-05
RT-flex96C
55521/A2
Maintenance
Supply Unit
Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive
Tools:
1 Device
1 Lifting plate
1.
Dynex Pumps
94561
94435
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Servo oil pump

Flange
Screw
Pump support
Snap ring
Pinion
Shaft
Gear wheel
Intermediate wheel
Bearing bush
Housing
Spray nozzle
Spray nozzle
Screw
Screw
Cover
Guide bush
Stop rod
19
20
21
22
23
24
25
26
27
28
29
30
3133
Foot
Guide
Flange
Screw
Flange
Screw
Wing nut
Shut-off valve
Collector block
Screw
Drain screw
Screw
O-ring
HZ Lifting tackle
MA Mark
RC Eye bolt
General
Concerning the maintenance of the servo oil pump observe the instructions from
the manufacturer. The servo oil pump drive must be checked in accordance with
the Maintenance Schedule 03801 Supply Unit.
2.
Removal of servo oil pump

Stop the engine.
Shut stop valve before automatic filter

(see 55511 in the Operating Manual).
Remove the casing as far as necessary.
Disconnect the electrical connections
from servo oil pump 1 to be removed.
Open drain screw 29 (Fig. I).
19
Remove the corresponding pipings.

Close shut-off valves 26 to collector
block 27 (Fig. I).
Connect servo oil pump 1 (227 kg) with
the lifting plate 94435, loosen and remove it in horizontal direction.
94435
014.464/06
1/ 5
2008
55521/A2
Maintenance
RT-flex96C
10
11
10 5
Dynex Pumps
MA
2.1
Removal of pinion
2
3
Device 94561 is used for removing pinion 6

as shown in Fig. F and its application is
illustrated in Fig. C to F.
Loosen and remove flange 2 (30 kg).
Remark: Please note there are also supply

units without flange 2.
33
Withdraw and remove shaft 7.

Remove screws 3 and fit threaded rods
M16 instead.
Withdraw pump support 4 from housing
11 using two screws 3 and then remove
the pump support.
014.465/06
RC
Fit guide bush 17 as shown in Fig. C.
Fit eye bolts RC.
17
014.465/06
Turn stop rod 18 till its foot 19 pointing

vertically downwards.
Turn guide 20 till its mark TOP pointing
upwards.
Insert stop rod as shown in Fig. D.
I-I
18
11
18
014.465/06
19
20
20
014.474/06
2008
2/ 5
RT-flex96C
55521/A2
Maintenance
Dynex Pumps
Turn stop rod 18 till its mark TOP pointing upwards (view I).
Fasten flanges 23 to flange 21 by means of screws 24.
Push flange 21 (mark TOP pointing upwards) over stop rod 18 to guide bush
17 and fasten it by means of screws 22.
Fit and tighten wing nut 25 to the stop rod.
Connect lifting tackle HZ with eye bolt RC and remove pinion 6 (see Fig. F).
11
RC
22
I
I
25
23
24
21
014.473/06
18
17
014.475/06
HZ
F
RC
94561
014.467/06
3/ 5
2008
55521/A2
Maintenance
RT-flex96C
3.
Dynex Pumps
Spray nozzles
Two spray nozzles 12 are provided for each pinion; they are located in such a manner that oil is sprayed between pinion 6 and gear wheel 8.
The tap holes in the housing of the supply unit are properly arranged ensuring correct fitting of the spray nozzles.
The spray nozzles can be removed each time the engine and the lubricating pump
are stopped.
3.1
Removal of spray nozzles
CHECK
Spray nozzle 12 can be removed after loosening screw 14.
Spray nozzle 13 for intermediate wheel 9 can only be unscrewed after removal of cover 16 (Fig. H).
For the removal of cover 16 see 55522.
Check spray nozzles for free passage.
G
I
I-I
12
32
12
31
23
14
6
8
12
014.468/06
2008
4/ 5
RT-flex96C
55521/A2
Maintenance
Dynex Pumps
I-I
16
13 15
4.
014.470/06
Fitting
I
Fitting is carried out analogously to the removal but in reverse sequence, whereby attention
must be paid to the following:
27
26
29
1
30
O-rings 31 and 32 of spray nozzles 12

must be replaced.
Screws 15 for fastening spray nozzles 13

(Fig. H) must be secured with LOCTITE
0243.
O-rings 33 in pump support 4 and flange 2

must be replaced by new ones.
Remark: Bores for bearing bushes 10 in housing 11 and pump support 4 are machined together and marked accordingly. Therefore,
never interchange the pump supports and take
special care of marks MA on assembly!
D
CHECK
During fitting the clearances are to be determined in accordance with Clearance Table
03301 Supply Unit.
Open shut-off valves 26 and tighten their
spindles with 200 Nm.
014.472/06
Apply oil to screws 30 and tighten them

with a torque of 600 Nm.
5/ 5
2008
RT-flex96C
55522/A1
Maintenance
Supply Unit
Removal and Fitting of Camshaft and Bearing Shells
Tools:
Devices
94430
(depending on number of cylinders)
1
1
1
1
1
1
1
1
1
1
2
2
1
2
2
2
1
1
1
1
1
2
1
Lifting support
Lifting support
Lifting support
Lifting plate
Fork lever consisting of:
Face plate
Rocker arm
Nut
Bolt
Web
Sleeves
Socket wrench
Round bars
Supports
Tension nuts
Assembly template
Pipe
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94553
94553a
94553b
94553c
94554
94554a
94554b
94554c
94554d
94554e
94557
94558
94559
94560
94566
94566a
94567
94567a
94932
94934a
94935
94935a
94942
1
2
3
4
5
6, 6a
7, 7a
8
9
10
11
12
13
14
15
16
17
17a
Servo oil pump

Cover
Fuel pump
Cover
Cover
Waisted bolt
Nut
Vent screw
Cylinder
Piston
Housing
Bearing cover
Dowel pin
Camshaft
Thrust bearing ring half
Screw
Lower bearing shell
Upper bearing shell
18
19
20
21, 21a
22
23
24
25
26
BN
BO
HK
HZ
H1...
SA
Gear wheel
Push rod
Nut
Bolt
Guide
Dowel pin
Flange
Distance plate
O-ring
Limiting groove
Bore
Wooden wedge
Lifting tackle
Lifting tackle
Gap
Overview
1.
2.
3.
4.
1.
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/16
Removal of camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . 5/16
Removal of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/16
Fitting of bearings and camshaft . . . . . . . . . . . . . . . . . . . . . . 13/16
Preparation
Stop the engine and main lubricating pump.
Remove the casing plates from servo oil pumps.
Cut out fuel pumps 3 (Fig. A or D) by means of devices 94430 (see 55562 in
the Operating Manual).
Remove servo oil pumps 1 which are placed in front of camshaft wheel and
the corresponding pinions (see 55521).
1/ 16
2008
55522/A1
Maintenance
RT-flex96C
Supply Unit: Removal and Fitting of Camshaft and Bearing Shells
A
1.1
Removal of covers
1.1.1 Removal of cover 4
Remove cover 2.
Connect lifting tackle HZ with lifting

support 94553 as shown in Fig. B.
Fasten lifting support 94553 or 94553
with lifting plate 94553c to cover 4.
Remove cover 4.
5
011.824/04
I
94553
HZ
HZ
94553
4
810 CYL. ENGINES
I
94553
94553c
4
017.865/08
011.829/04
1114 CYL. ENGINES
2008
2/ 16
RT-flex96C
55522/A1
Maintenance
1.1.2 Removal of cover 5

Connect lifting tackle HZ with lifting support 94553a as shown in Fig. C.
Fasten lifting support 94553a to cover 5.
Remove cover 5.
Connect the lifting support with lifting tackle H1 for the further transport of the
cover.
H1
HZ
HZ
94553a
II - II
I
94553a
II
I
24
5
5
014.092/06
011.836/04
3/ 16
II
2008
55522/A1
Maintenance
RT-flex96C
D
1.2
Removal of cover 5
(6 and 7 Cyl. engines)
Remove cover 2.
Install flange 24 to lifting support

94553b.
1
Connect lifting tackle HZ with lifting

support 94553b as shown in Fig. E.
Fasten lifting support 94553b to cover 5.
Remove cover 5.
Connect the lifting support with lifting
tackle H1 for the further transport of the
cover.
2
014.091/06
E
HZ
I
H1
5
94553b
24
94553b
I
5
2008
014.094/06
014.093/06
4/ 16
RT-flex96C
55522/A1
Maintenance
2.
Removal of bearing shells
2.1
Loosening and removal of waisted bolts 6

Remark: Always two waisted bolts can be loosened at the same time.
Clean the threads of waisted bolts 6 and the area around nuts 7 and oil the
threads.
Put sleeves 94558 over the nuts.
With vent screws 8 open, screw pre-tensioning jacks 94557 on waisted bolts 6
till they seat on the sleeves and there is little or no clearance at x.
Then unscrew the pre-tensioning jacks by 1 turns (gap SA in Fig. F).
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. F.
Actuate hydraulic unit, and close vent screws as soon as oil flows bubble-free.
Operate hydraulic unit till a pressure of approx. 1020 bar is reached.
Pistons 10 of the pre-tensioning jacks must never exceed the red limiting grooves
BN.
Turn back nuts 7 with round bar 94560 till they are almost touching the pistons
Release pressure to zero and remove the pre-tensioning jacks and sleeves.
Remove the nuts and waisted bolts.
94932
94935a
94557
10
94935a
94934a
13
BN
11
SA
14
94558
94935
6
7
94560
11
94942
011.837/04
5/ 16
2008
55522/A1
Maintenance
RT-flex96C
2.2
Loosening of waisted bolts 6a

With vent screws 8 open, screw pre-tensioning jacks 94557 on waisted bolts
6a till they seat on bearing cover 12 and there is little or no clearance at x (Fig.
G).
D
Till the removal of pre-tensioning jacks the further procedure is the same as
described in paragraph 2.1.
Nuts 7a are turned out with socket wrench 94559 as shown in Fig. H.
Remark: For safety reasons do not unscrew nuts 7a before the corresponding
bearing cover will be removed!
10
12
13
8 BN SA
13
7a
6a
94557
94935a
94932
94934a
94559 12
011.861/04
94935
I-I
94942
7a
2008
6/ 16
94560
RT-flex96C
55522/A1
Maintenance
2.3
Numbering of bearings
Bearing No. 1 is designed as thrust bearing.
Remark: All bearing covers 12 are machined together with housing 11, therefore
never interchange them! They must be marked accordingly before their removal.
12
11
12
7/ 16
2008
55522/A1
Maintenance
RT-flex96C
2.4

Start with the removal of bearing No. 1 (Fig. I). The other bearing covers may be
removed after the respective bearing shells have been removed and support
94566 has been installed.
2.4.1 Removal of bearing covers

(8 to14 Cyl. engines)
HZ
Fasten lifting support 94553 to bearing

cover 12.
D
94553
For bearing covers 12 the removal procedure is the same as described for
cover 4 in paragraph 1.1.1.
II
94553
13
23
II
12
011.854/04
2.4.2 Removal of bearing covers

(6 and 7 Cyl. engines)
HZ
Install distance plate 25 to lifting support 94553b.
H1
Fasten lifting support to bearing cover.

D
94553b
For bearing covers 12 the removal procedure is the same as described for
cover 5 in paragraph 1.2.
II
94553b
13
II
23
25
12
014.095/06
2008
014.106/06
8/ 16
RT-flex96C
55522/A1
Maintenance
M
2.4.3 Removal of bearing shell No. 1
Move camshaft 14 till there is a clearance on
both sides of thrust bearing ring halves 15.
Push thrust bearing ring halves out and remove them.
I
18
11
4
18
14
15
15
17a
14
2.4.4 Turning out the bearing shells

Loosen screw 16 so far till web 94554e is fastened only.
Push fork lever 94554 over waisted bolt 6a and fasten it with nut 94554c as
shown in Fig. N.
I-I
94554
94554b
16
94554e
94554c
011.855/04
94554a 6a
I
9/ 16
94554d
2008
55522/A1
Maintenance
RT-flex96C
O
Place assembly template 94567 on lower
bearing shell 17, so that its pin fits into the corresponding bore of the bearing shell.
14
Put pipe 94567a on the assembly template

and pull it in arrow direction, push camshaft
14 up by tightening screw 16 till the bearing
shells can be turned at the same time.
17a
17
94567
Turn lower bearing shell 17 upwards as far as

possible.
94567a
16
P
Insert pipe 94567a into the other pin and turn
lower bearing shell upwards till assembly
template stops at housing 11.
11
Remove assembly template.
94567
94567a
Q
Turn screw 16 out of gear with face plate
94554a, lift and remove rocker arm 94554b.
Remove lower bearing shell.
17a
Remark: Lower bearing shells 17 which are

reused must be marked properly with the
bearing number and LOWER in order to fit
these in the same place as before.
Remove face plate 94554a.
16
94554e
2008
94554b
94555a
011.858/04
10/ 16
RT-flex96C
55522/A1
Maintenance
3.
Removal of camshaft
Push support 94566 over waisted bolt 6a and fasten it with tension nut 94566a
as shown in Fig. R.
Attention! Heads of bolts 21 and 21a must point towards the free end when fitting
support 94566 as shown in Fig. R.
By means of turning nut 20, extend push rod 19 till it touches camshaft 14.
I-I
14
19
21a
21
20
94566a
94566
6a
S
Screw the bearing cover and bearing shell
down to bearing No. 3 as described in paragraph 2.4.4.
Fit support 94566 and extend push rod 19
as described for Fig. R.
4
Remove the bearing covers and lower bearing shells 17 from the remaining bearings.
011.864/04
11/ 16
2008
55522/A1
Maintenance
RT-flex96C
94430
Equally retract push rods 19 till camshaft 14

is seated horizontally on supports 94566.
Take care that rear bearing shells do not fall
out.
Secure the camshaft with wooden wedge
HK.
14
19
94566
HK
Pull out bolt 21 and lift push rod 19 together

with guide 22.
Reinsert the bolt and put the guide on it as
shown in Fig. U.
Remove the push rod from the guide.
22
21
19
HK
011.865/04
2008
12/ 16
RT-flex96C
55522/A1
Maintenance
V
Pull out bolt 21a. Lift and remove
guide 22.
94430
Reinsert the bolt.

Remove wooden wedge HK (Fig. U)
and roll camshaft 14 till the stop.
Upper bearing shells 17a can now be
removed.
17a
Remark: Upper bearing shells 17a which

are reused must be marked properly with
the bearing number in order to fit these in
the same place as before.
22
21a
011.868/04
4.
Fitting of bearings and camshaft

The fitting of bearings and camshaft is carried out analogously but in reverse sequence to the removal, whereby the following points require special attention:
The camshaft can be installed in every position, however:
all parts to be fitted must be clean and undamaged!
for the assembly smear bearing shells, thrust bearing ring halves and camshaft with oil.
take care of the designations of reused bearing shells.
fit bearing shells, so that their bores provided for dowel pins 23 in the bearing
covers point to the same side (Fig. K or L).
Align bearing shells laterally and their mating surfaces with housing 11.
fit lower bearing shell 17 laterally aligned with upper bearing shell 17a.
take care of the bearing cover numberings and meshing of dowel pins 13 and
23 (Fig. K).
apply oil to the threads of nuts 7, 7a and tighten nuts 7a with socket wrench
94559 till there is no clearance at y (Fig. W).
13/ 16
2008
55522/A1
Maintenance
RT-flex96C
4.1
Tensioning of waisted bolts 6a

6a till they seat on the sleeves and there is little or no clearance at x.
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. W.
Operate hydraulic unit till a pressure of 1000 bar is reached.
BN.
Keep pressure constant and tighten nuts 7a with round bar 94560 till firmly
seated.
Release pressure to zero and remove the pre-tensioning jacks.
10
X
x
12
BN
7a
6a
7a
94557
94559
y
94935a
94934a
011.867/04
94935
I-I
94942
7a
2008
14/ 16
94560
RT-flex96C
55522/A1
Maintenance
4.2
Tensioning of waisted bolts 6

Clean and oil the threads of waisted bolts 6.
Fit and tighten the waisted bolts.
Clean the area around nuts 7.
Screw on and tighten the nuts by hand with round bar 94560.
With vent screws 8 open, screw pre-tensioning jacks 94557 on waisted bolts 6
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. Y.
Operate the hydraulic unit till a pressure of 1000 bar is reached.
BN.
Keep pressure constant and tighten nuts 7 with round bar 94560 till firmly
seated.
Y
94932
94935a
94557
10
94935a
94934a
13
BN
11
14
94558
6
94935
7
94560
11
011.866/04
94942
15/ 16
2008
55522/A1
Maintenance
RT-flex96C
4.3
Final assembly
CHECK
Determine radial and axial clearances, see clearance table 03301 Supply Unit.
Put O-ring 26 in cover 5 (Fig. C).
Apply sealing compound to sealing faces of covers 4, 5 and fit the latter.
Fit servo oil pumps (see 55521).
Install all pipings.
Cut in the fuel pumps and remove tools 94430 (see 55562 in the Operating
Manual).
CHECK
After assembly, turn the engine and check if lubricating oil is supplied to all lubricating points and bearings with the oil pump in operation!
Attention! Prior to commissioning or after maintenance works and exchange of
Bosch servo oil pumps, they must be filled up with system oil (see 55521 Fitting).
2008
16/ 16
RT-flex96C
55523/A1
Maintenance
Supply Unit
Removal and Fitting of Gear Wheel on Camshaft
Tools:
2
2
1
1
1
2
1
2
1
1.
Sleeves
Round bar
Pressure gauge
Hydr. distributor
Connecting elements
HP hose
HP hoses
Hydraulic unit
94557
94558
94560
94932(a)
94934a
94934d
94935
94935a
94942
1
2
3
4
5
6
7
8
9
Camshaft
Fuel cam
Nut
Vent screw
Cylinder
Piston
Shaft
Gear wheel
Camshaft wheel
10 Waisted bolt
11 Withdrawing screw
BN
HU
HZ
RS
SA
Limiting groove
Wooden underlay
Lifting tackle
Round bar
Gap
Removing the camshaft wheel

Prior to dismantling camshaft wheel 9, waisted bolts 10 must be loosened and
shaft 7 with gear wheel 8 removed.
1/ 5
2008
55523/A1
Maintenance
RT-flex96C
1.1
Loosening the waisted bolts

Clean the threads of waisted bolts 10 and the areas around nuts 3 and oil the
threads.
Unscrew the pre-tensioning jacks by 1 turns (gap SA in Fig. A).
Connect the pre-tensioning jacks to hydraulic unit 94942.
Operate the hydraulic unit till a pressure of approx. 1030 bar is reached.
groove BN.
Turn back nuts 3 with round bar 94560 till they are almost touching the pistons
A
x
4
94558
10
1
BN SA
94557
94934d
2008
10
94560
94932a
94942
014.229/06
94935a
94935
2/ 5
94934a
RT-flex96C
55523/A1
Maintenance
1.2
Removing the camshaft wheel

Connect shaft 7 and camshaft wheel 9 with the crane and lifting tackle HZ .
Remove nuts 3.
Turn withdrawing screws 11 (M16) into the flange of camshaft 1 in order to
loosen and separate the camshaft wheel.
Carry away the whole unit (consisting of camshaft wheel 9, shaft 7 and gear
wheel 8) by means of the crane.
B
I
HZ
11
012.211/04
10 3
11
Hold camshaft wheel 9 with two nuts 3 (Fig. B) provisionally on the shaft 7.
Place the unit on wooden underlays HU.
11
Remove nuts 3.
Turn withdrawing screws 11 (M16) into the flange of

shaft 7 in order to loosen and separate the camshaft
wheel.
HU
Lift and move the camshaft wheel away.
3/ 5
2008
55523/A1
Maintenance
RT-flex96C
2.
Fitting the camshaft wheel

D
Waisted bolt 10 itself has to be tightened with a torque of 140 Nm providing oil
on its thread.
Lower camshaft wheel 9 over the flange of shaft 7.

Clean and oil the threads of waisted bolts 10.
Equally press camshaft wheel into the flange of shaft 7 by means of spacers
13 and nuts 3.
Hang the unit consisting of camshaft wheel, shaft and gear wheel 8 on the
crane as shown in Fig. B.
Remove the spacers and nuts.
Fit the unit onto the camshaft and tighten it with nuts 3.
10
3
13
8
HU
2008
4/ 5
RT-flex96C
55523/A1
Maintenance
2.1
Tensioning the waisted bolts

Clean the areas around nuts 3.
10 till they seat on the sleeves and there is little or no clearance at x.
Connect the pre-tensioning jacks to hydraulic unit 94942.
Operate the hydraulic unit till a pressure of 1000 bar is reached.
groove BN.
Keep pressure constant and tighten nuts 3 with round bar 94560 till firmly
seated.
E
x
4
94558
10
1
BN
94557
94934d
10
94560
94932a
94942
014.264/06
94935a
94935
5/ 5
94934a
2008
RT-flex96C
55523/A2
Maintenance
Supply Unit
Removing and Fitting the Fuel Cams with Conical Bushes
Tools:
1 Hydr. jacking tool
1 Adapter piece
Cam adjusting gear
94424
94426a
94562
consisting of:
1
1
1
1
1
1
1
1
1
1
2
1
1
Angle rail
Guide tube
Positioning unit
Distance holder
Distance holder
Distance holder
HP oil pump
Pressure gauge
Hydr. distributor
Plug piece
HP hoses
HP hose
Hydraulic unit
94562a
94562e
94562f
94563
94563a
94563b
94931
94932(a)
94934a
94934e
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Camshaft
Fuel cam
Washer
Fitted bolt
Camshaft wheel
Screw M8x20
Conical bush
Screw
Vent screw
Ring piece
Piston supporting plate
Piston
Shaft
Driving wheel for servo oil pumps
EV Relief valve
GL Taphole
Overview
1.
2.
3.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/10
Removing the 2-part fuel cam . . . . . . . . . . . . . . . . . . . . . . . . . . 2/10
Fitting the 2-part fuel cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/10
General
The following instructions apply to supply units which are providing 2-part fuel
cams, i.e. with conical bushes (bush for short).
The camshaft must be removed from the supply unit for removing and fitting the
fuel cams and gear wheels on the camshaft (see 55522). To be able to work appropriately, it is recommended to put the camshaft on suitable pedestals.
Prior to fitting the fuel cams, it must be ensured that the fuel cams, bushes and
camshaft are absolutely clean and in perfect condition.
HP oil pump 94931 and hydraulic unit 94942 have to be filled with engine oil having
a viscosity of SAE30 to SAE40 before starting them up. In exceptional cases hydraulic unit 94942 may be filled with cylinder lubricating oil.
1/ 10
2008
55523/A2
Maintenance
RT-flex96C
Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
2.
Removing the fuel cam

Screw adapter piece 94426 into fuel cam 2 to be removed and connect it to
hydraulic unit 94942.
Push hydr. jacking tool 94424 on fuel cam and fasten it using six screws 8
(evenly tighten screws slightly by hand only).
Connect the hydr. jacking tool to HP oil pump 94931, however one side of
hydr. distributor 94934a must be plugged with plug piece 94934e.
Close relief valve EV and open vent screw 9.
Actuate HP oil pump 94931 and close the vent screw as soon as oil flows
bubble-free, and continue pumping till all pistons 12 are drawn out.
Evenly tighten screws 8.
Danger of accident! The following order of actuating HP oil pump and hydraulic
unit must be followed!
The oil pressure in the hydr. jacking tool 94424 may not exceed 250 bar.
Actuate HP oil pump 94931 till the pressure in the hydr. jacking tool reaches
approx. 90 bar.
Actuate hydraulic unit 94942 till oil is squeezing out on the whole circumference between bush 7 and fuel cam 2. While keeping the hydraulic unit running, the oil pressure in the hydr. jacking tool may slowly be reduced with relief
valve EV at HP oil pump 94931, whereupon the fuel cam will loosen.
Dismantle all tools and remove bush and fuel cam.
A
12
11 2
10
94424
94426a
94935
94935a
94932
94934a
94942
94931
2008
EV
94932a
94934e
94935
2/ 10
RT-flex96C
55523/A2
Maintenance
3.
Fitting the fuel cam
3.1
Numbering, distances and positioning angle of fuel cam

D
The numbering starts with fuel cam No. 1 , which is next to the camshaft
wheel 5.
Setting the distances of the fuel cams to each other is carried out with the aid
of distance holders 94563, 94563a and 94563b.
Distance x1 = 365 0.1 mm
Setting the positioning angles of the fuel cams to each other is carried out with
the aid of cam adjusting gear 94562, i.e. angle rail 94562a, guide tube 94562e
and positioning unit 94562f.
The appropriate tool is delivered for each engine.
The positioning angles of the fuel cams to the camshaft wheel is undefined.
All fuel cams are identical.
Remark: A fuel cam 2 and its bush 7 (Fig. A) form one unit and must not be interchanged! If necessary, both parts must therefore be replaced at the same time;
moreover they are only supplied together.
6 and 7 CYLINDERS
94563a
94564
94563
94562
GL
1
5
x2
x1
3/ 10
2008
55523/A2
Maintenance
RT-flex96C
8 to 10 CYLINDERS
94563b
94564
94563a
94563
94562
x1
x2
x3
11 to 14 CYLINDERS
1
94563a
94563b 94563a
x2
3
2
94563
94564 94562
2008
x3
x2
x1
4/ 10
RT-flex96C
55523/A2
Maintenance
3.2
Fitting the fuel cam No. 1

Put distance holder 94563 onto the camshaft and push it against the camshaft
flange.
Push fuel cam 2 together with bush 7 onto the oiled camshaft till the bush rests
on the distance holder.
Push hydr. jacking tool 94424 on bush 7 and fasten it to the fuel cam using six
screws 8 (evenly tighten screws slightly by hand only).
Open vent screw 9 and relief valve EV.
Tighten screws 8 evenly by hand till ring piece 10 rests on piston supporting
plate 11.
Close relief valve EV.
Screw adapter piece 94426a into fuel cam 2 and connect it to hydraulic unit
94942.
E
I
12
11 2 94563
10
94424
94426a
94935
94935a
94932
94934a
94942
94931
EV
94932a
94934e
94935
5/ 10
2008
55523/A2
Maintenance
RT-flex96C
Actuate HP oil pump 94931 till oil flows bubble-free at vent screw 9; then close
the latter.
Actuate hydraulic unit 94942, and when oil is squeezing out on the whole circumference between bush 7 and fuel cam 2, operate also the HP oil pump.
Pull the fuel cam onto the bush by means of the HP oil pump while keeping the
hydraulic unit running. During this process pay attention that oil is continuously squeezing out between bush and fuel cam.
Attention! The oil pressure in hydr. jacking tool 94424 may not exceed 250 bar.
When fuel cam 2, is flush with piston supporting plate 11, release the pressure
to zero at the hydraulic unit and approx. 30 seconds later also at the HP oil
pump.
Remove all tools.
Remark: Mark camshaft together with bush and fuel cam by means of a nonwashable colour in order to ascertain a possible deviation of the marks, i.e. twisting
of the parts.
F
14
11 2
I
94424
94563
94426a
94935
94935a
94932
94934a
94942
94931
2008
EV
94932a
94934e
94935
6/ 10
RT-flex96C
55523/A2
Maintenance
;
3.3
Fitting the fuel cams for 6 and 7 cylinders
3.3.1 Preparation
Fasten angle rail 94562a with fitted bolts 4 and washer 3; and guide tube
94562e at 25 mark with screws 8 to fuel cam No. 1 .
Push bush 7 together with fuel cam No. 2 onto the oiled camshaft.
Fit positioning unit 94562f with its shaft 13 into one of the three tapholes on the
relevant side of fuel cam No. 2 .
Put distance holder 94563a onto the camshaft and push it against fuel cam
No. 1 .
Push and turn the bush with fuel cam so that shaft 13 meshes in guide tube
94562e.
I-I
G
4
94424
94563a 94562
III
94563a
94426
14
2
8
94562a
III
3, 4
x1
III - III
SEE ALSO FIG. I AND K
x3
x2
017.855/08
94562f
13
94562e
94562a
Push bush 7 together with fuel cam 2 till the bush rests on distance holder
94563a (Fig. G).
Push hydr. jacking tool 94424 on bush 7 and fasten it to the fuel cam using six
screws 8 (evenly tighten screws slightly by hand only).
Open vent screw 9 and relief valve EV.
Tighten screws 8 evenly by hand till ring piece 10 rests on piston supporting
plate 11.
Screw adapter piece 94426a into fuel cam 2 and connect it to hydraulic unit
94942 as shown in Fig. E.
7/ 10
2008
55523/A2
Maintenance
RT-flex96C
3.3.2 Fitting the fuel cam

Actuate HP oil pump 94931 till oil flows bubble-free at vent screw 9; then close
the latter.
Actuate hydraulic unit 94942, and when oil is squeezing out on the whole circumference between bush 7 and fuel cam 2, operate also the HP oil pump.
Pull the fuel cam onto the bush by means of the HP oil pump while keeping the
hydraulic unit running. During this process pay attention that oil is continuously squeezing out between bush and fuel cam.
Attention! The oil pressure in hydr. jacking tool 94424 may not exceed 250 bar.
When fuel cam 2 is flush with piston supporting plate 11, release the pressure
to zero at the hydraulic unit and approx. 30 seconds later also at the HP oil
pump.
Remove shaft 13 from positioning unit 94562f and subsequently remove the
angle rail.
Remove all remaining tools.
Remark: Mark camshaft together with bush and fuel cam by means of a nonwashable colour in order to ascertain a possible deviation of the marks, i.e. twisting
of the parts.
H
BEFORE DRAWING UP
AFTER DRAWING UP
2
94424
8
94563a
10 12
2008
11
8/ 10
RT-flex96C
55523/A2
Maintenance
3.4
Fitting the fuel cams for 8 to 10 cylinders

The preparation and fitting procedures are the same as described in paragraphs 3.3.1 and 3.3.2, however, angel rail 94562a with an angle of 15_ or 20_
must be fastened to, and the corresponding distance holders 94563b must be
pushed against the relevant fuel cam.
I
94563b
94562
II
II
I-I
II - II
III
III
8
94562a
94563a
94562a
III
III
3, 4
3, 4
94563b
9/ 10
2008
55523/A2
Maintenance
RT-flex96C
3.5
Fitting the fuel cams for 11 to 14 cylinders

The preparation and fitting procedures are the same as described in paragraphs 3.3.1 and 3.3.2, however, angle rail of 20_ and 40_ must be fastened
to, and the corresponding distance holders must be pushed against the relevant fuel cam.
K
94563a
94562
II
II
II
II
I
I-I
II-II
3, 4
94563b
94563a
III
8
94562a
8
III
III
3, 4
III
2008
10/ 10
RT-flex96C
55524/A1
Maintenance
Supply Unit
Removal and Fitting of Intermediate Wheel to Camshaft
Tools:
1
2
1
1
1
2
2
1
8
1
1
1
1
1
2
1
Feeler gauge
Assembly template
Pipe
Rail
Screws
Washers
Carriage
Screws
Support (left)
Support (right)
Pressure gauge
Hydr. distributor
HP hose
HP hoses
Hydraulic unit
94122
94556
94567
94567a
94571
94571a
94571b
94571c
94571d
94571e
94571f
94932a
94934a
94935
94935a
94942
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Intermediate wheel
Housing
Intermediate shaft
Cover
Screw plug
Screw
Spray nozzle
Housing
Screw
Bush
Screw
Securing bolt
Waisted bolt
Nut
Vent screw
Cylinder
Piston
18
19
20
21
21a
22
23
24
25
Pin
Bearing cover
Jack
Lower bearing shell
Upper bearing shell
Locating pin
Locating pin
Thrust bearing ring halves
Bearing pin
AF
BO
HU
RC
RS
SA
ZA
Seating face
Bore
Wooden underlay
Eye bolt M10
Round bar
Gap
Pin
Overview
1.
2.
3.
4.
5.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/10
Removal of housing with intermediate wheel . . . . . . . . . . . . 2/10
Removal of bearing shell and intermediate wheel . . . . . . . 7/10
Fitting bearing shell and intermediate wheel . . . . . . . . . . . . 8/10
Fitting housing with intermediate wheel . . . . . . . . . . . . . . . 10/10
General
Removing intermediate wheel 1 is only possible after the camshaft has been removed too (see 55522).
The intermediate wheel must be removed together with its housing from the supply
unit.
011.926/04
1/ 10
2013-05
55524/A1
Maintenance
RT-flex96C
Supply Unit: Removal and Fitting of Intermediate Wheel to Camshaft
2.
Removal of housing with intermediate wheel

Remove the cover 4 and the screw plugs 5 (Fig. B).
Loosen the screws 6 and remove the nozzle 7 (Fig. C).
Connect the rail 94571 to ropes a, b and the lifting tackles. Rope b is guided
through the opening, which appears after the cover 4 is removed.
C
b
2
94571
I
6
2013-05
014.571/06a
2/ 10
RT-flex96C
55524/A1
Maintenance

Instead of screw plugs 5 (Fig. B), put the screws 94571a and washers
94571b into the housing 8 and attach them to rail 94571.
Remove rope a and b.
Attach the carriage 94571c to the rail 94571 as shown in Fig. D.
Move the carriage 94571c along the rail 94571 into the tightening position
(Fig. D and E).
Risk of accident! Make sure that the bolt 12 is installed in the rail.
D
b
a
I-I
94571a
I-I
12
94571b
8
94571
94571d
94571c
2
Use the screws 94571d to hold the

carriage 94571c sufficiently in position
on the housing 2 (see Fig. E). Do not
tighten the screws too much.
Remove the screws 9 and the bushes

10.
Loosen the screws 11.
I
10
9
11
I
014.572/06a
3/ 10
2013-05
55524/A1
Maintenance
RT-flex96C
94571f
94571e
014.571/06a
Use the bolts from the supply unit cover to attach the supports 94571f and
94571e to the supply unit (Fig. F).
Fully tighten the screws 94571d on the carriage 94571c to lift up the intermediate wheel and the housing (Fig. G).
I-I
I-I
I
94571d
94571
94571c
1
2013-05
4/ 10
RT-flex96C
55524/A1
Maintenance

Pull the housing 2 and the intermediate wheel 1 back until the securing bolt 12
as shown in Fig. H.
Connect the rope c (lifting capacity 3000 kg) through the holes in the housing
2 and intermediate wheel 1 with the lifting tackle and tighten rope.
Loosen the securing bolt 12, then remove the housing and the intermediate
wheel and place them on wooden underlays HU as shown in Fig. I.
Remark: Wooden underlays HU must be high enough so that a jack can be underlaid afterward as shown in Fig. L.
H
c
12
2
014.573/06a
5/ 10
2013-05
55524/A1
Maintenance
RT-flex96C
2.3
Loosening waisted bolts

13 until they seat on bearing cover 19 and there is little or no clearance at x.
Unscrew the pre-tensioning jacks by turns (gap SA in Fig. I).
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. I.
Operate hydraulic unit until a pressure of approx. 1030 bar is reached.
D

Turn back nuts 14 with round bar RS until they are almost touching the pistons of the pre-tensioning jacks.
Release pressure to zero and remove the pre-tensioning jacks and nuts.
18 15
x
94932a
94934a
17
16
13
RS
14
19
SA
94935a
94556
94935
HU
94942
011.936/04
2008
6/ 10
RT-flex96C
55524/A1
Maintenance
K
RC
19
23
3.
22
Remark: All bearing covers 19 are machined

together with housing 2, therefore never interchange them! They must be marked accordingly before their removal.
Fit eye bolt RC into bearing cover 19, lift
and remove the latter by means of the
crane.
BEARING DIVISION
L
94567a
94567
In order to be able to remove bearing shells 21

and 21a, jack 20 with a protection (Al or Cu
plate) is used to lift intermediate wheel 1 as
shown in Fig. L.
21
25
Lift intermediate wheel as much as necessary until a clearance of approx. 0.10 mm

around bearing pin 25 can be measured
with feeler gauge 94122.
2
21a
Place assembly template 94567 on upper

bearing shell 21a, so that its pin ZA fits
into the corresponding bore of the bearing
shell.
Insert pipe 94567a into the other pin and
turn assembly template in arrow direction
until it stops at housing 2.
20
PROTECTION
Remove assembly template and upper

bearing shell.
Lift and remove the intermediate wheel.
011.937/04
ZA
7/ 10
2008
55524/A1
Maintenance
RT-flex96C
Dismantle thrust bearing ring halves 24.

Remove lower bearing shells 21 and mark
them.
011.938/04
24
4.
BO
21
AF
Fitting bearing shell and intermediate wheel

The fitting of bearing shells intermediate shaft is carried out analogously but in
attention:
D
All parts to be fitted must be clean and undamaged!
For the assembly smear bearing shells and thrust bearing ring halves with oil.
Take care of the designations of reused bearing shells.
Fit bearing shells, so that their bores BO provided for locating pins 22 in the
bearing covers (Fig. L) point to the same side (Fig. M).
Moreover align bearing shells laterally (they must not protrude in any case!)
with seating faces AF of thrust bearing ring halves 24.
Take care of the designations and meshing of locating pins 22 and 23 when
fitting the bearing covers.
Apply oil to the threads of nuts 14 and tighten them with round bar RS until
there is no clearance at y (Fig. N).
D
CHECK
2008
Carry out tensioning of waisted bolts 13 as described in paragraph 4.1.
After tensioning of waisted bolts determine radial and axial clearances, see clearance table 03301 Supply Unit.
8/ 10
RT-flex96C
55524/A1
Maintenance
4.1
Tensioning waisted bolts

13 until they seat on bearing cover 19 and there is little or no clearance at x.
Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. N.
Operate hydraulic unit until a pressure of approx. 1000 bar is reached.
D

Keep pressure constant and tighten nuts 14 with round bar RS until firmly
seated.
CHECK
Using feeler gauge inserted through slot KO (Fig. N), check whether the nuts rest
on bearing cover without any clearance.
Release pressure to zero and remove the pre-tensioning jacks.
18 15
N
94932a
94934a
17
16
13
RS
14
19
KO
94935a
949556
14
94935
HU
94942
011.939/04
9/ 10
2008
55524/A1
Maintenance
RT-flex96C
5.
Fitting housing with intermediate wheel

The fitting of housing with intermediate wheel is carried out analogously but in
reverse sequence to the removal.
Fastening housing 2 to housing 8 is carried out as follows:
Apply oil to the threads of screws 9 and 11.
Fit screws 9 and bush 10.
Tighten screws 9 until housing 2 seats on housing 8.
Fit and tighten screws 11 with a torque of 170 Nm using a torque wrench.
Lightly tighten screws 9 manually in small steps using a wrench. Starting from
this position, tighten the screws by a further angle of 47_.
CHECK
Check tooth backlash, see clearance table 03301 Driving Wheels for Supply
Unit.
Remove all tools.
8
10
9
11
6
7
I
014.574/06a
5.1
Fitting spray nozzle

CHECK
Check spray nozzle 7 for free passage!

D
2013-05
Screws 6 must be secured with LOCTITE 0243!
10/ 10
RT-flex96C
Supply Unit
Lubrication of Supply Unit During Maintenance Works
Tools:
Lubricating device
Filling device A
Filling device B
Filling device C
Flexible hose
Cross union
Holder
1.
55525/A1
Maintenance
Dynex Servo Oil Pumps
94844
94844a
94844b
94844c
94844d
94844e
94844f
1
2
2a
3
4a
4b
4c
Ball valve
Blind flange
Flange
Oil pipe
Lubrication bore
Lubrication bore
Lubrication bore
5 Hose clamp
6 Warning plate
7 Flange
General
Lubricating device 94844 has been provided to prevent bearing bushes of the servo oil pump drive from being damaged (dry running) due to turning the engine during overhaul works.
For this additional lubrication of the supply unit, system oil (bearing oil) is used (see
Operating Manual 07501).
Remark: Clean surroundings of the flanges which are opened up and take care
that no dirt or any kind of debris are entering to the supply unit.
2.
Application of lubricating device

Make sure that the ball valve 1 is closed.
If it is not already done, exchange blind flange 2 for new flange 2a (flange with
G1/2 thread).
Remove oil pipes 3 from the lubrication bores 4a/4b/4c.
Check that the filling device 94844a is installed correct (no contact with flange
7) into the lubrication bore 4a. Between the upper flange of the filling device
94844a and the surface of the supply unit should be a gap of 4mm to ensure
that the filling device does not touch the bottom of the lubrication bore. Check
that the filling devices 94844b / 94844c are installed correct into the lubrication bores 4b/4c. Between the upper flange of the filling device 94844b should
be a gap of 2mm to ensure that the filling device does not touch the bottom of
the lubrication bore. The flange 94844c on the surface ot the supply unit has
no clearance.
After install filling devices 94844a / 94844b / 94844c into the lubrication bores
4a/4b/4c tighten the four screws by hand (50 Nm).
Install the lubrication device 94844 with the cross union 94844e, the flexible
hoses 94844d and connect the hoses to the straight unions of the cross union
94844e and the filling devices 94844a / 94844b / 94844c, tighten the hose
clamps 5.
During lubrication time, remove inspection covers to check if the lubrication oil
is going through all bores and reaches the bearings.
Remark: Before operating the turning gear, carefully read and follow the remarks
mentioned on the warning plate 6.
Attention! Before taking the engine into operation, rebuild the supply unit in reverse sequence.
1/ 2
2013-05
55525/A1
Maintenance
RT-flex96C
Lubrication of Supply Unit During Maintenance Works
Dynex Servo Oil Pumps
A
94844f
6
94844
94844d
3
1
2
2a
94844e
3
94844a
94844b
94844c
94844a 94844b
94844c
4a
4c
4b
94844a
94844b
4mm
2013-05 / Dynex
5
2mm
2/ 2
RT-flex96C
55561/A3
Maintenance
Fuel Pump
Tool:
1
1
1
1
1
2-part clamping ring

Fitting & dismantling device
Lifting tool
Spacer
Fitting & dismantling device
1
2
4
4
2
1
2
2
1
Oil trough
Limiters
Screws
Screws
Screws
Assembly tool
Guide screws
Steel wires
Assembling device
1
1
2
1
4
1
1
1
2
1
Tool half
Tool half
Flat bars
Metal sheet
Screws
Mandrel
Mandrel
Impact wrench
Extensions
Socket spanner insert
Lifting tackles
94550
94551
94552
94555
94592
consisting of:
94592a
94592b
94592c
94592d
94592e
94581
94581a
94581b
94593
consisting of:
94593a
94593b
94593c
94593d
94593e
94597
94597a
94598
94598a
94598b
H1...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Interm. fuel accumulator

Fuel pipe
Screw
Pump cover
Upper housing
Lower housing
Guide piston
Roller
Guide pin
Roller pin
Circlip
Pressure disc
Bush
Rod seal ring
Thrust piece
Circlip
Retaining ring
Connection pin (M22x1.5)
Adapter piece
Allen screw
Lower spring carrier
Pump plunger
Pump cylinder
Compression spring
Guide pin
Regulating sleeve
Upper spring carrier
Screw
29
30
31
32
33
34
35
36
37
38, 38a
39
40
41
42
43
44, 44a
45
46
47
48
49
50
5157
58
DP
DS
GS
RC
Intermediate flange
Regulating (toothed) rack
Circlip
Ring
Head screw
Valve block
Valve body (NRV)
Compression spring
Retaining screw
Fluted seal rings
Intermediate disc
Circlip
Bush
Spindle
Rod seal ring
Seals
Oil inlet pipe
Oil drain pipe
Screw plug
Orifice
Cover
Locating pin
O-rings
Screw
Depository
Pressure piece
Handle screw
Eye bolt
Overview
1.
2.
3.
4.
5.
6.
7.
1.
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/20
Removal of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/20
Dismantling of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/20
Assembling of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/20
Fitting of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19/20
Oil flow check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20/20
Preserving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20/20
Preparation
Stop the engine and switch off the fuel supply pump and lubricating oil pump.
Close the shut-off valves to fuel inlet and outlet pipes (see 80191 in the Operating Manual).
Remove casings as far as necessary and the fuel inlet and outlet pipes.
Remove the fuel pressure piping (see 87521).
Switch of power supply to the actuators and disconnect the connecting element between regulating rack 30 and the regulating linkage (see 58011).
Remove oil inlet pipe 45 and oil drain pipe 46 from upprt housing 5.
Turn the engine till roller 8 rests on the cam base circle (Fig. O).
1/ 20
V4 / 2011-02
55561/A3
Maintenance
RT-flex96C
Fuel Pump: Dismantling and Assembling
B
58
1
2
58
94552
4
30
017.706/08
012.387/04
2.
Removal of a fuel pump

Fit lifting tool 94552 onto pump cover 4.
Remove all screws 3.
Using a jacking screw M16, lift fuel pump till locating pin is no longer meshing.
2.1
Fitting assembly tool

Insert guide screws 94581a into the corresponding bores of assembly tool
94581 and secure them by means of steel wires 94581b.
Align assembly tool to the height of the tapholes in the fuel pump housing provided for guide screws 94581a.
Extract steel wires 94581b.
Drive guide screws into the tapholes till the stop.
94552
94581a
94581
94581b
94581a
013.905/06
201007
2/ 20
RT-flex96C
55561/A3
Maintenance
E
H2
2.2
Removal from suply unit
Connect lifting tackle H1 with lifting lug a and

lifting tool 94552.
H1
Connect lifting tackle H2 with lifting lug b and

assembly tool 94581.
D
94552
94581
BANK B
For the removal of the fuel pumps of BANK B,

the tools are used as drawn with interrupted
lines, however only lifting lugs d and e are
necessary.
012.389/04
Carefully pull the fuel pump out of the supply

unit housing by means of lifting tackles H1 and
H2.
Remove lifting tackle H1 from lifting tool
94552 and then lift the fuel pump as high as
possible with lifting tackle H2.
F
H2
H2
H1
94552
3/ 20
2008
55561/A3
Maintenance
RT-flex96C
H
H2
Connect lifting tackle H1 with the short lever

of assembly tool 94581.
Connect lifting tackle H3 with lifting lug c and

the long lever of the assembly tool.
H1
H3
94581
012.390/04
Move the fuel pump towards lifting tackle H3

as far as possible by means of lifting tackles
H1, H2 and H3.
Disconnect lifting tackle H2 from the long lever and connect it with the short lever of the
assembly tool.
I
H2
H2
H1
H3
2008
4/ 20
RT-flex96C
55561/A3
Maintenance
K
H2
H1
Move the fuel pump by means of lifting

tackles H1, H2 and H3, i.e. till it hangs as
shown in Fig. K with the short lever of assembly tool 94581 now in vertical position.
H3
Remove lifting tackles H1 and H3.
94581
012.391/04
Connect lifting tackle H4 with lifting lug e and

the long lever of the assembly tool.
Move the fuel pump over the supply unit by
means of lifting tackles H2 and H4 as shown in
Fig. M.
M
b
e
H4
H2
H4
5/ 20
H2
2008
55561/A3
Maintenance
RT-flex96C

3.
Dismantling of a fuel pump

Attention! During dismantling and assembling the fuel pumps, the activity area
has to be clean and as dust-free as possible (grinding dust etc.), and performing
electric welding must absolutely be omitted near or on the engine.
Fasten fitting and dismantling device 94592 to the upper platform using
screws 94592e , and place oil trough 94592a underneath on the bottom plate.
Carefully lift and remove the fuel pump (395 kg) from the fuel pump unit, and
cover the latter immediately.
Fit fuel pump into fitting and dismantling device 94592 using screws 94592c.
For safety reasons always provide limiters 94592b on both sides of the
device and consider unbalanced conditions during removal procedures!
N
94592c
DP (94592c)
45
46
94592b
94592
DP (94592e)
94592a
94592e
017.706/08
N1
201007 / V4
N2
6/ 20
RT-flex96C
55561/A3
Maintenance
I-I
33
4
STAMP AREA FOR:
VERSION
MANUFACTURER
DATA
SERIAL NO.
STAMP AREA FOR:
VERSION
MANUFACTURER
DATA
SERIAL NO.
PLUNGER
23
22
52
37, 38
25
27
26
24
16 54
44, 55
15
19
53
44a, 56
47, 38a
14, 56
48
17 18
51
41
21
7
9
12
10
11
13
019.325/10
7/ 20
V4 / 2012-05
55561/A3
Maintenance
RT-flex96C
P
3.1
94551
Removal of guide pin
Risk of accident! Guide pin 9 must only be removed with fitting & dismantling device 94551!
7
8
Turn the fuel pump till roller 8 points upwards.

Mount fitting & dismantling device, and press
guide piston 7 inwards by turning the spindle
of the device till guide pin 9 allows to be withdrawn by means of handle screw GS (M10).
9
GS
013.909/06
R
3.2
RC
Removal of guide piston
Screw eye bolt RC (M16) into the hexagon of

tool 94551.
42
Turn back spindle 42.
94551
Loosen equally Allen screws 20 and remove

them.
Carefully lift now lower housing 6 together
with guide piston 7, lower spring carrier 21
and pump plunger 22 by means of eye bolt
RC.
7
6
21
Remove compression spring 24.
20
24
22
014.873/06a
201007 / V4
8/ 20
RT-flex96C
Maintenance
55561/A3
S
Push pump plunger 22 out from lower spring carrier
21.
Store pump plunger in a manner not to damage it.
Remove circlip 16 and push retaining ring 17 downwards.
Unscrew connection pins 18 with O-rings 54 by
means of an Allen wrench AF10, and remove lower
spring carrier.
18
54
17
16
21
22
T
13
RC
50
12
Screw two eye bolts RC (M10) into guide piston 7,

and withdraw the latter from the housing.
11
10
3.3
Removal of roller
Remove circlip 11.
Press out roller pin 10, and remove roller 8 together

with its shrunken bush 13 and pressure discs 12.
Remark: If necessary, the roller and roller pin must be replaced as a unit only.
15
9/ 20
V4 / 201007
55561/A3
Maintenance
RT-flex96C
30
3.4
Removal of regulating rack
Unscrew all screws 28 and remove cover 49.

Remove circlip 31 and ring 32.
Remove intermediate flange 29, and push out regulating rack 30.
I-I
29
28 30
49
32
019/236/10
57
31
43
V
33
36
35
34
23
3.5
Removal of pump cylinder
Turn fuel pump till pump cover 4 points upwards.
39
40
52
Unscrew head screws 33 crosswise in equal steps.
37, 38
Remove retaining screw 37 and pump cylinder 23.
Remark: Pump cylinder and pump plunger form a single

unit and must not be interchanged.
Therefore, they are not delivered separately.
Remove pump cover 4, valve block 34, valve body

35 and compression spring 36 (valve block and
valve body are marked together).
For removing intermediate disc 39 loosen circlip 40.
Withdraw adapter pieces 19 from upper housing 5

(Fig. O).
201007 / V4
10/ 20
RT-flex96C
55561/A3
Maintenance
3.6
Removal of non-return valve

By means of 2-part clamping ring 94550 and the four screws M10x60 valve
block 34 can be withdrawn from pump cover 4.
Remove circlip 40 with a snap ring tong.
Remark: The non-return valve must be replaced as a unit only, i.e. valve block 34,
valve body 35, compression spring 36 and intermediate piece 39.
M10x60
94550
STROKE
3 0.3 mm
34
94550
52
36, 35
40
39
019.235/10
11/ 20
V4 / 201007
55561/A3
Maintenance
RT-flex96C
4.
Assembling of a fuel pump
4.1
Preparation
Clean all parts and check their condition.
Damaged parts must be replaced.
Replace all O-rings, piston and rod seal rings.
Check the lubricating oil bores in the housings and in pump cylinder 23 for free
passage using compressed air.
X
4.2
23
Fitting the pump cylinder
Place upper housing 5 in vertical position on fitting

and dismantling device 94592.
37, 38
Carefully fit pump cylinder 23, aligning the groove in

the pump cylinder precisely with the bore provided
in the upper housing for retaining screw 37.
Screw in and tighten the retaining screw together

with its fluted seal ring 38.
Remark: There must be a clearance between retaining
screw 37 and the groove base!
Oil and insert adapter pieces 19 with their O-rings
53 into upper housing 5 (Fig. O).
4.3
Fitting the non-return valve and pump cover

Remark: Thoroughly check the sealing surfaces for cleanness when fitting the
valve block and the pump cover (Fig. V).
Fit valve block 34 with the mounted and oiled O-rings 52 in upper housing 5 by
means of a nylon hammer. Then insert the oiled valve body 35 verifying its free
movement and place compression spring 36.
Fit intermediate disc 39 with circlip 40 into the pump cover.
Fit pump cover 4 paying attention not to damage the compression spring.
CHECK
Check that the compression spring fits properly into the hole in the intermediate
disc by using a flashlight (see arrow in Fig. V).
Apply Never-Seez NSBT-8 to the threads and head seating surfaces of the
head screws 33 (M27), and tighten them crosswise in three steps with 100,
300 and finally to a torque of 480 Nm. Recheck all head screws 33, i.e. by applying the corresponding torque again!
201007 / V4
12/ 20
RT-flex96C
Maintenance
55561/A3
RC
4.4
10
8
Assembling the guide piston
Clean and oil all bores and parts.

Press thrust piece 15 into guide piston 7.
Fit roller 8 with its shrunken bush 13, pressure disc

12 and roller pin 10 in guide piston 7.
Pay attention to the position of locating pin 50 and
secure roller pin by means of circlip 11 (Fig. T).
44a
4.5
Checking axial clearance of pump piston
Suspend guide piston on eye bolt RC (M10).
21
x
15
44
22
Fit pump plunger 22 in lower spring carrier 21 with

inserted seals 44 and 44a (for their fitting see paragraph 4.10).
Push lower spring carrier together with pump plunger over guide piston 7. Press lower spring carrier by
hand against thrust piece 15, checking whether
there results a clearance of x = 0.120.24 mm.
Remove lower spring carrier and pump plunger.
4.6
Fitting the regulating rack

Turn fuel pump in device 94592 till the pump cover points downwards.
Fit regulating rack 30 according to Fig. U.
CHECK
Check regulating rack for easy movement.

Place rod seal ring 43 and O-ring 57 in both intermediate flanges 29.
Push the intermediate flanges onto regulating rack and screw them up with
upper housing.
Fit rings 32 and circlips 31.
4.7
51
26
27
5
25
Fitting the regulating sleeve
Bring regulating rack 30 to the position shown in Fig.

Z, and place spacer 94555.
Fit guide pin 25.
Fit regulating sleeve 26 in the upper housing, the
toothed rim turned to the bottom and the groove of
12 mm width being flush with guide pin 25.
Fit upper spring carrier 27.
CHECK
30 94555
Remark: The regulating sleeve can only be fitted in

one position: guide pin in upper housing and groove
in regulating bush which is 12 mm wide must correspond. Only in this position, the correct assembly of
the regulating sleeve is possible. Before fitting the
regulating sleeve, the toothed rack has to be positioned with the spacer.
012.413/06a
Remove spacer 94555 and check that the regulating

rack moves freely over the entire regulating travel.
13/ 20
V4 / 201007
55561/A3
Maintenance
RT-flex96C
A1
4.8
CHECK
27
30
25
26
Press upper spring carrier 27 against upper housing

5, checking whether regulating sleeve 26 can be
moved axially (clearance x = 0.50.7 mm).
26
Checking axial clearance of regulating sleeve
013.919/06a
4.9
Fitting the spring carrier

Insert O-ring 51 and fit compression spring 36.
Place tool halves 94593a, 94593b and flat bars 94593c.
Tighten screws 94593e till the tool halves rest on upper housing 5.
B1
94593e
94593e
I-I
C1
94593a
94593a
24
51
5
I
94593b
013.920/06
2008
013.921/06
14/ 20
RT-flex96C
55561/A3
Maintenance
D1
21
Remark: Figures D1, E1, H1 and I1 are drawn
with former lower spring carrier and connection pin.
17
16
The assembling procedure is the same, however,

with the exception of the connection pins, which are
screwed into the lower spring carrier.
22
Oil pump plunger 22, sliding carefully into pump cylinder 23 and rest it on tool halves.
Guide retaining ring 17 and circlip 16 over lower
spring carrier 21 and push them onto the pump
plunger.
013.922/06
E1
94593d
17
16
Install metal sheet 94593d on the tool halves and

place circlip 16 and retaining ring 17.
013.923/06
15/ 20
201007
55561/A3
Maintenance
RT-flex96C

4.10 Fitting rod seal ring 14 and seals 44, 44a
Insert O-rings 55 and 56 into the corresponding grooves of lower spring carrier 21 and lower housing 6.
Deform rod seal ring 14 and seals 44 and 44a kidney-shaped, insert them
into the grooves concerned and pay attention to their fitting positions as
shown below.
Press the seal into the groove in direction of the arrows.
Press mandrel 94597 ( 70 mm) by means of a handle screw M16 through
lower spring carrier 21 and bush 41, calibrating the seal after fitting.
Same procedure is to be applied analogously, but with mandrel 94597a ( 40
mm) by means of a handle screw M10 in the upper groove of the lower spring
carrier.
F1
21
55
09.276/10
15 44
6
56
14
21
56
7 44a
7
016.860/08
G1
I
94597
21, 6
55, 56
44, 44a
6
41
017.738/08
201007 / V4
016.860/08
16/ 20
RT-flex96C
Maintenance
55561/A3
H1
4.11 Final assembly
Oil guide piston 7 and fit it into lower housing 6.
42
Install fitting & dismantling device 94551 on the lower housing.
94551
Turn back spindle 42.

Lower down carefully lower housing together with
guide piston into lower spring carrier 21 and insert/fit
connection pins 18 with O-rings 54 (crosswise
tighten connection pins (M22x1.5_V4) in four steps
with a final torque of 80 Nm).
Push up retaining ring 17 and fit circlip 16.
Turn pump plunger 22 till both drivers fit into the recesses of tool halves 94593a and 94593b.
Loosen equally screws 94593e and remove the tool
halves.
Remark: When loosening screws 94593e, make sure
that the pump plunger is not pushed up too!
17 18
21
94593a
16
54
22
94593e
17/ 20
201007
55561/A3
Maintenance
RT-flex96C
I1
Lower down carefully lower housing 6 together with
guide piston 7, ensuring that the drivers of pump
plunger 22 fit into the slot (guide) of regulating
sleeve 26.
Should this not be possible, the regulating sleeve
must be properly turned by means of regulating rack
30.
94551
Fit the lower housing to the upper housing with the

two Allen screws 20 (Fig. R).
Preload compression spring 24 with fitting & dismantling device 94551 till guide pin 9 can be inserted into the lower housing and guide piston with
handle screw GS.
Should this not be possible, the groove in the guide
piston must be aligned turning pressure piece DS
in the required direction.
21
Press the pump plunger into T.D.C. using fitting &

dismantling device 94551 as shown in Fig. K1, and
check regulating rack 30 for easy movement.
Release fitting & dismantling device and remove it.

51
22
26
J1
K1
30
DS
9
GS
013.929/06
013.928/06
2008
18/ 20
RT-flex96C
Maintenance
55561/A3
5.
Fitting of a fuel pump

Turn the engine till the cam belonging to the fuel pump concerned is on the
base circle (Fig. Q).
CHECK
Check whether the seating surfaces as well as the guide parts of the supply unit
housing and the fuel pump itself are in a faultless condition.
Fit remaining O-rings 45.
Oil the guide parts and fit the fuel pump, taking care of the locating pin and the
regulating shaft (do not use any jointing agent).
Fit screws 3 with oiled threads and head seating surfaces.
Tighten screws 3 to an angle of 64 using socket spanner insert 94598b, extensions 94598a and pneum. impact wrench 94598.
CHECK
Check the setting of the regulating linkage (see 58011).

Fit all pipings. Apply Never-Seez NSBT-8 to threads and head seating surfaces of screws 58 (Fig. A) and tighten them crosswise in equal steps with a
total value of 70 Nm.
When putting the fuel pump into operation, watch for possible leakages or abnormal temperature rise. Fit the casing when everything is in order.
L1
94598
94598a
94598b
3
013.930/06
19/ 20
2008
55561/A3
Maintenance
RT-flex96C

6.
Oil flow check

The oil flow at all fuel pumps must be checked after a fuel pump or plunger exchange in order to ensure a proper lubrication via orifice 48 to lower housing 6 and
guide piston 7.
D Engine at standstill and lubricating oil pump switched off.
Remove oil drain pipe 46 from all fuel pumps.
Switch on the lubricating pump.
Turn the turning gear in AHEAD direction.
Check the oil flow from the oil drain pipe.
If no oil is flowing out of a certain oil drain pipe, the respective fuel pump must
be separately checked:
Turn the crankshaft until roller 8 of the respective fuel pump is on the cam
peak. If after one minute no oil flow is noticed, it might be an indication that
the oil supply is blocked by foreign particles.
Cut off the fuel pump according to the Operating Manual 55562 and replace or remedy the fuel pump at the next opportunity.
M1
48
46
45
7
OIL
FLOW
7.
Preserving
If a fuel pump has to be stored over a long period of time, the spaces carrying fuel
oil must be filled with Vaseline oil and plugged with plastic stoppers.
Furthermore, oil the fuel pump and protect it against humidity and soiling by wrapping it suitably.
Always store fuel pumps in upright position!
2011-02
20/ 20
RT-flex96C
55562/A1
Maintenance
Fuel Pump
Removal of a Jammed Pump Plunger
Tool:
1
1
1
1
2
1
1
1
Jack
Short tappet
Long tappet
Piston reset tool
Screws
HP oil pump
Pressure gauge
HP hose
1.
94595
94595b
94595c
94595d
94595e
94931
94932
94935
1
2
3
4
5
6
7
8
Upper housing
Lower housing
Pump plunger
Pump cylinder
Guide pin
Compression spring
Allen screw
Screw
9
10
11
12
13
14
Nut
Head screw (12xM27)
Piston
Vent screw
Spindle
Indicator
EV Relief valve
Preparatory works
Dismantle the fuel pump as far as possible (see 55561).
Check whether piston 11 is in the top position. If necessary push it fully back by
means of piston reset tool 94595d.
Insert short tappet 94595b.
Fasten jack 94595 onto upper housing 1 with head screws 10.
Remove first screw 8. Insert first screw 94595e and screw together with nut 9,
however keeping a clearance of 10 25 mm.
Remove second screw 8 from opposite side. Insert second screw 94595e and
screw together with nut 9, however keeping a clearance of 10 25 mm.
Remove both Allen screws 7.
I-I
11
10
94595
II
II
94595b
I
8
94595
1
1
2
11
94595d
13
9
94595e
014.181/06
WCH00075
7
2
x = 10 25 mm
II - II
1/ 3
201007
55562/A1
Maintenance
RT-flex96C
Fuel Pump: Removal of a Jammed Pump Plunger
2.
Jacking-out procedure
Connect jack 94595 with HP oil pump 94931.
Shut relief valve EV and actuate HP oil pump till oil flows bubble-free at vent
screw 12.
Close the vent screw.
Attention! Take care during the jacking-out procedure that nuts 9 show always a
clearance of 10 25 mm, readjust repeatedly if required (Fig. A section II-II).
Press carefully till pump plunger 3 is jacked out by the spring force or till indicator 14 shows the stroke end, i.e. the indicator is flush with the housing.
D
If the pump plunger can now be taken out, remove jack 94595 and short tappet 94595b. Push the piston fully back by means of piston reset tool 94595d.
In case the pump plunger is still not loose, proceed as described in the following paragraph Jacking-out 2nd stage.
Jacking-out 1 st stage with short tappet 94595b:
12
94595
11
94595d
14
94595b
FLUSH
13
94932
WCH00075
94935
201007
2/ 3
EV
94931
RT-flex96C
55562/A1
Maintenance
Fuel Pump: Removal of a Jammed Pump Plunger

Insert long tappet 94595c and fasten jack 94595 again onto upper housing 1
with head screws 10.
Reconnect jack 94595 with HP oil pump 94931.
Shut relief valve EV and actuate HP oil pump till oil flows bubble-free at vent
screw 12.
Close the vent screw.
Press carefully till pump plunger 3 is jacked out by the spring force or till indicator 14 shows the stroke end, i.e. the indicator is flush with the housing.
Remove jack 94595 and long tappet 94595c. Push the piston fully back by
means of piston reset tool 94595d.
Jacking-out 2 nd stage with long tappet 94595c:
12
10
94595
94595c
14
1
FLUSH
94932
WCH00075
EV
94935
3/ 3
94931
201007
RT-flex96C
55641/A1
Maintenance

Removal and Fitting
Tools:
1 Lifting plate
2 Withdrawing tools
1 Tightening device
1.
94584
94589
94874
1
2
3
4
5
6
7
7a
8
9
10
Hose line
Hose line
Fuel leakage return
Fuel rail
Connection piece
Screw
Screw
Pre-control valve
Screw
Intermediate plate
11
12
13
14
15
16
17
18
19
20
21
Lip seal
Position sensor
Countersunk screw
Nipple
Filter holder
Connecting nipple
Dowel pin
O-ring
O-ring
Oil filter
Circlip
General
When working on an injection control unit in principle the engine has to be stopped
and the fuel booster and bearing oil pumps switched off.
If it is necessary to replace an injection control unit, the engine must operate for a
minimum of 1.5 hours with marine diesel oil (MDO). For more data see Operation
Manual 02701.
Attention! There must be no pressure in fuel rail 4.
The corresponding drain (screws) valves must be opened as described in 05101
of the Operating Manual. Follow the detailed instructions without fail!
Maintenance on the injection control unit can be done only by the manufacturer as
a matter of principle. However, if troubles have been detected on the injection control unit during operation, it must be replaced by a revised unit, following the instruction below.
Remark: No maintenance work is provided for pre-control valve 8. If necessary it
must be replaced as a whole unit!
2.
Removal
A
3
5
7a
7
14
Loosen hose lines 1, 2 and unscrew

nipple 14 (the nipple is screwed into
the spare injection control unit).
Remove screws 7 and 7a.
011.730/04
Remove fuel pressure pipings according to 87331 and unscrew connection pieces 5 from injection control unit 6 as shown in Fig. D (the
connection pieces are screwed into
the spare injection control unit).
1/ 4
2012-11
55641/A1
Maintenance
RT-flex96C
Injection Control Unit: Removal and Fitting

Fasten lifting plate 94584 onto injection control unit 6.
Remove cable plugs from pre-control valves 8 and position sensor 12.
Loosen screws 9 and remove them together with pre-control valves (Fig. B).
Lift up the injection control unit.
Remark: Immediately cover the appearing opening in fuel rail 4 to prevent dirt from
entering in any circumstance!
Lip seal 11 (Fig. C) can be removed (if necessary) with one of withdrawing
tools 94589.
2.1
Cleaning the filter

Loosen connecting nipple 16, remove filter holder 15 and clean oil filter 20.
Remark: Maintain the flow direction when refitting or replacing the oil filter. Moreover, the three oil filters must be secured by means of circlip 21.
Apply oil to the filter holder 15 and tighten it with a torque of 120 Nm.
Apply Never-Seez NSBT-8 to the threads of connecting nipple and tighten it
with 350 Nm.
B
3
94584
12
4
9
8
011.954/04
2008
2/ 4
RT-flex96C
55641/A1
Maintenance
3.
Fitting
Insert lip seal 11.
Lower injection control unit 6 carefully onto the fuel rail and remove the lifting
plate.
Apply Never-Seez NSBT-8 to the threads of screws 7 and 7a (Fig. A).
First tighten screws 7a crosswise with a torque of 110 Nm and subsequently
screws 7.
Replace O-rings 18, if necessary.
Apply Never-Seez NSBT-8 to screws 9 and fasten pre-control valve 8 to injection control unit 6 with them.
Tighten screws 9 with a torque of 2.5 Nm.
15
21
16
20
FLOW
DIRECTION
II
11
4
17
II
13
18
10
9
014.279/06
3/ 4
201007
55641/A1
Maintenance
RT-flex96C

Apply Never-Seez NSBT-8 to the threads of connection pieces 5.
Insert new O-rings 19 and fit the connection pieces.
Fasten tightening device 94874 with its screws to the connecting piece.
Apply torque wrench on the hexagon of the device and tighten the connecting
piece with a torque of 700 Nm.
Install hose lines and pipings.
D
For fitting the fuel pressure pipings see 87331.
For restarting the injection see instructions 05101 in the Operating Manual!
I-I
94874
19
6
014.280/06
2008
4/ 4
RT-flex96C
56101/A1
Maintenance
Pressure Reducing Valve 8.111

Checking the Gas Pre-charge Pressure
Tool:
1 Case
94720c
consisting of:
measurement set complete

for checking / refilling of
hydraulic accumulator
1.
1
2
3
4, 4a
5
Hydraulic accumulator
Protection cap
Pressure reducing valve
Hose (1m, 4 m)
Control unit with
valves A, B and C
7 Pressure gauge 060 bar
8 Valve block
9
10
11
12
13
14
15

Pressure transmitter
Cable socket
Pressure gauge
Screw plug
Stop valve
Nitrogen bottle
Checking the gas pre-charge pressure

Once filled with gas, the hydraulic accumulator is largely maintenance-free, however in order to ensure a trouble-free service, maintenance works must be carried
out according to the manufacturers detailed operating instructions of the Cylinder
Lubricating System. Checks and maintenance are only to be carried out, when
the engine is at standstill.
The same measurement set 94720c must always be used to refill the accumulator
as provided for checking the gas pre-charge pressure on the lubricating pumps
hydraulic actuators (see also 72181).
CHECK
Check the filling pressure at least once in the first week after start-up of the accumulator. If no loss of gas is observed, recheck after three months. If there is still no
change in pressure, an annual check might be sufficient, however, it is recommended to continue carrying out checks every three months.
Attention! Ensure that servo oil supply is shut off before starting accumulator
pressure checking and charging. Also no residual oil pressure in valve block must
be visible on pressure gauge 12 (PI2041L) of pressure reducing valve 8.111.
1.1
1.2
Preparation
Stop servo oil supply.
Close stop valve 14 between rail unit and pressure reducing valve (Fig. C).
Drain servo oil system by means of screw plug 13.

Screw plug 13 must remain open during entire checking / refilling procedure.
Remove protection cap 2 from accumulator 1.
Checking procedure
Close the three valves A, B and C on control unit 5.
Connect accumulator 1 to control unit 5 using short hose 4.
Open valve A and read pressure from gauge 7.
Required gas pressure: min. 20 bar / max. 25 bar.
If gas pre-charge pressure is ok:
Close valve A and drain remaining pressure in control unit by opening valve B.
Disconnect short hose from accumulator.
Refit protection cap.
Remark: During every check a small amount of gas may be lost to the atmosphere. Therefore, make sure a gas bottle is available before a pressure check is
made in order to refill possible loss.
If gas pre-charge pressure is not ok:
Refill the accumulator.
1/ 4
2012
56101/A1
Maintenance
RT-flex96C
Pressure Reducing Valve: Checking the Gas Pre-charge Pressure
2.
Refilling the accumulator

Measurement set 94720c must always be used to refill the accumulator.
The hydraulic accumulator may only be filled with super-clean, class 4.0 nitrogen,
99.99 % N2 by volume.
Remark: Check and refill the accumulators of the pressure reducing valves
(8.111 & 2) at free end and driving end at the same time on engines with 8 to 12
and 14 cylinders.
2.1
Refilling procedure
Fit pressure reducing valve 3 to nitrogen bottle 15 and adjust the pressure to
approx. 30 bar.
Close the three valves A, B and C on control unit 5.
Connect pressure reducing valve with long hose 4a to the right side (C), and
accumulator with short hose 4 to the left side (A) of control unit.
Slowly open valve C and refill accumulator to the required pressure of 25 bar.
Close valves A and C and drain remaining pressure in control unit by opening
valve B.
Disconnect hoses 4, 4a and refit all protection caps.
2.2
After checking or refilling procedure

Reopen stop valve 14 between rail unit and pressure reducing valve valve
(Fig. C).
Close screw plug 13.
After pressure checking and refilling the accumulator, ensure to run the servo oil
supply and vent air from the system before putting the pulse lubricating system into
operation (see Operating Manual 72181).
2012
2/ 4
RT-flex96C
56101/A1
Maintenance
Case with measurement set 94720c for CLU4 and PRV 8.111:
Case 94720c
4, 4a
Arrangement of equipment:
B
PI2041L
12
13
7
A
C
15
8
1
4a
WCH00703
3/ 4
2012
56101/A1
Maintenance
RT-flex96C
Pressure reducing valve 8.111:
C
14 (4.305)
9
PRESSURE REDUCING
UNIT
1, 2
10, 11
FREE
END
SERVO OIL PIPE TO

LUBRICATING PUMPS
WCH00853
Details of servo oil rail 4.11 > pressure reducing valve 8.111 > lubricating pump 8.06:
8.06
RAIL UNIT
4.11
PI2041L
8.111
13
DRAWN FROM CONTROL

DIAGRAM 40032
WCH00861
WCH00852
2012
4/ 4
RT-flex96C
56121/A1
Maintenance
Exhaust Valve Drive

Removal, Fitting, Dismantling and Assembling
1
2
3
4
5
6
7
8
8a
9
10
11
12
13
14
15
16
17
18
1.
Housing (partition device)

3/2-way valve
Pre-control valve
Connecting piece
Screw
Nut
Servo oil rail
Elastic bolt
Nut
Elastic bolt
Screw
Stud
Screw
Cover
Piston
Spring housing
Spring guide
Compression spring
Spring carrier
19
20
21
22
23
24
25
26
27
28
29
30
31
32
3340
Slide rod
Lower cover
Piston
Screw plug
Filter holder
Filter
Circlip
Closing piece
Gasket
Screw
Non-return valve
Nipple
Screw
Screw
O-rings
KO Slot
OE Oil inlet
General
When working on the exhaust valve drive in principle the engine has to be stopped
and the bearing oil pump switched off.
Attention! Pipings for servo and control oil must be pressureless.
Follow the instruction in 05201 of the Operating Manual without fail!
2.
Removal
For the removal of the exhaust valve

drive, first remove hydraulic piping from
exhaust valve drive (see 84601).
2
1
Remove piping.
Remove pre-control valve 3.

Loosen screws 5.
10
5
6
4
7
Loosen nut 6.
8a
Remove connecting piece 4 from servo

oil rail 7.
Loosen nuts 8a and lift the complete exhaust valve drive by means of the board
crane.
8
9
Remark: Immediately cover the appearing

opening to prevent dirt from entering in any
circumstance!
WCH00088
1/ 4
201007
56121/A1
Maintenance
RT-flex96C
Exhaust Valve Drive: Removal, Fitting, Dismantling and Assembling
3.
Fitting
It is recommended to pre-assemble the exhaust valve drive outside the rail unit.
The work station must be clean; welding and grinding should not be done nearby!
Remark: All screw and nut threads must be oiled, and all O-rings must be replaced
by new ones.
Place connecting piece 4 with O-ring 38 (Fig. B, view II) over the studs taking
care of the dowel pins and screw it down by hand, using nuts 6.
CHECK
Make sure that the connecting piece has metallic contact with the servo oil rail.
Place housing 1 together with 3/2-way valve 2 on servo oil rail 7.
Drag housing with 3/2-way valve by hand against connecting piece and tighten the four screws 5 by hand.
Loosen screws 10 slightly. Take care of O-ring 34.
Crosswise tighten connecting piece to the servo oil rail by means of nuts 6 with
a torque of 60 Nm.
Crosswise tighten connecting piece to 3/2-way valve by means of screws 5
D
Tighten elastic bolts 8 with a torque of 20 Nm (no additional lubricant required

on threads).
Pre-tighten the housing to the support by means of nuts 8a with a torque of

100 Nm (1st step).
Tighten elastic bolts 9 with a torque of 270 Nm.
Final tighten the housing to the support by means of nuts 8a with a torque of
300 Nm (2nd step).
Re-tighten screws 10 with a torque of 350 Nm.
Fit pre-control valve 3 with screws 28 (Fig. D) and tighten them with a torque
of 2.5 Nm.
Insert gasket 27, place cover 13 and fasten it equally with screws 12.
D
4.
For fitting the hydraulic piping to the exhaust valve drive see 84601.
Cleaning the filter

Loosen screw plug 22, remove filter holder 23 and clean oil filter 24.
Remark: Maintain the flow direction when refitting or replacing the oil filter. Moreover, the three oil filters must be secured by means of circlip 25.
Apply oil to filter holder 23 and tighten it with a torque of 120 Nm.
201007
2/ 4
RT-flex96C
56121/A1
Maintenance
13
30
1
10
I
4
II
11
II
38
7
KO
4
011.827/04
5.
Removal and fitting of non-return valve
30
5.1
13
Removal
Screw off nipple 30.

Unscrew non-return valve 29.
OE
5.2
Fitting
Check non-return valve.

Oil the non-return valve, fit and tighten
it with a torque of 60 Nm.
Screw nipple 30 sleeve into cover 13.
014.239/06
29
3/ 4
201007
56121/A1
Maintenance
RT-flex96C
6.
Removal and fitting of 3/2-way valve

The complete 3/2-way valve 2 can only be removed after the removal of the exhaust valve drive according to section 2.
The movable parts can be removed and fitted after removing spring housing 15.
Refitting the complete 3/2-way valve must always be carried out according to
section 3.
7.
Removal and fitting of piston

Remove cover 13 and withdraw piston 14 using a threaded rod M12.
After fitting piston 14, insert gasket 27, place cover 13 and tighten the latter
equally with screws 12.
I-I
26
3
28
10
37
31
15
16
17
18
33
12
13
19
36
25
22
34
39
40
74 mm
27
14
21
32
23
24
35 20
WCH00090
FLOW
DIRECTION
201007
4/ 4
RT-flex96C
58011/A1
Maintenance
Regulating Linkage
Adjusting
1
2
3
4
5
6
7
8
9
10
1.
Fuel pump
Actuator
Forked lever
Torsion spring
Pin
Adjusting screw
Limit lever
DU bush
Regulating (toothed) rack
Stop ring
11
12
13ae
14a, b
15
16
17
18
19
Flange
Holder
Connecting rods
Stop screws
Actuator lever
Actuator shaft
Regulating shaft
Intermediate wheel
Pointer
General
After overhauling the linkage or the fuel pumps, as well as after fitting a new fuel
pump or a new actuator, the setting of the linkage must be checked and, if necessary, adjusted.
A
Attention! The power to the actuators 2
must be interrupted first, before they are
disconnected from the regulating linkage
(see 93621 in the Operating Manual).
1
2
012.431/04
2.
Adjusting of regulating linkage
I-I
2.1
3
8
17
Pre-adjusting of forked levers
Adjust clearance x = 8 mm between

all limit levers 7 and forked levers 3
by means of adjusting screws 6.
011.776/04
1/ 4
2008
58011/A1
Maintenance
RT-flex96C
Regulating Linkage: Adjusting
2.2
Adjustment of mechanical minimum maximum limiters on actuator

The connecting rods (Fig. E) must not be connected with actuator levers 15.
2.2.1 Adjustment of mechanical minimum limiter

Turn back all stop screws 14a.
Rotate actuator shaft 16 in counter-clockwise direction till the stop inside the
actuator.
In this position push the actuator lever onto the actuator shaft and place it at
the corresponding stop screw 14a as near as possible.
Screw in stop screw 14a till it rests on actuator lever. Then turn stop screw by
one further turn.
Secure stop screws with lock nuts.
C
15
14a 16
14b
012.439/04
2.2.2 Adjustment of mechanical maximum limiter

Turn back all stop screws 14b.
Rotate actuator shaft 16 in clockwise direction till the stop inside the actuator.
In this position push the actuator lever onto the actuator shaft and place it at
the corresponding stop screw 14b as near as possible.
Screw in stop screw 14b till it rests on actuator lever. Then turn stop screw by
one further turn.
Secure stop screws with lock nuts.
2008
2/ 4
RT-flex96C
58011/A1
Maintenance
2.3
Fitting of connecting rods

Adjust the length of connecting rods 13e (Fig. E) to x = 151.1 mm and connect them with levers 11.
(there are connecting rods 13e for 11 and 12 cylinder engines only)
Install connecting rods 13ad as shown in Fig. D and E.
13e 19
19
13b
2
13a
13d
13c
19
13e
012.401/04
19
E
I-I
13b
13a
15
13d
13c
17
11
13e
13e
18
11
012.402/04
3/ 4
2008
58011/A1
Maintenance
RT-flex96C

2.4
Adjustment of connecting rods

Set all actuator levers to the mechanical minimum limiters (Pos. 0) as shown
in Fig. F.
Set pointers 19 to Pos. 0 by means of adjusting the length of the corresponding connecting rods 13ad.
13b
13a
13d
13c
012.403/04
2.5
Adjustment of fuel pumps

Set regulating linkage to Pos. 5.
Fit toothed racks 9 and holders 12 with forked levers 3 (Fig. G).
Adjust the toothed racks to dimension x = 48 mm by means of adjusting
screws 6. Always screw in one adjusting screw while unscrewing the other by
the same amount.
D
The admissible deviation between the individual fuel pumps is 0.1 mm.
If there are no pointers or incorrectly set ones fitted on the regulating shaft, an
easy alternative adjustment (cross check) can be carried out. I.e. a distance of
approx. 5 mm must result between pump housing and stop ring 10 with actuator shaft at pos. 0.
Rotate the actuator shafts while checking whether the fuel regulating linkages are
freely moveable over the whole regulating range.
Stop rings 10 must not touch the fuel pump housing in any of the end positions. A
possible correction can be carried out by adjusting screws 6.
CHECK
10
x
9
10
12
I
3
19
13e
012.432/04
2008
4/ 4
RT-flex96C
Maintenance
Group6
Group 6
Checking the Air Flaps and Cleaning the Scavenge Air Receiver . . . . . . . . . . . . . . 64201/A1
Auxiliary Blower: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65451/A1
Scavenge Air Cooler

Removal, Fitting of Cooler Element & Cooler Pre-stage . . . . . . . . . . . . . . . . . . . 66061/A1
Removal, Fitting of Cooler Element & Cooler Pre-stage (Engine with Rail) . . . 66061/A2
Water Separator: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67081/A1
Scavenge Air Waste Gate: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . 67351/A1
1/ 4
RT-flex96C
64201/A1
Maintenance
Scavenge Air Receiver

Checking the Air Flaps and Cleaning the Scavenge Air Receiver
1
2
3
4
5
6
7
8
1.
Scavenge air receiver

Suction space
Air flap
Door
Auxiliary blower
Cover
Cover
Screw
9
10
11
12, 12a
13
14
15
Screw
Locking plate
Distance ring
Stop plate
Pin
Drain
Relief valve
General
Depending on number of cylinders air flaps are arranged either as shown in Fig. B
or Fig C or there are both arrangements fitted in the same engine.
2.
Inspection of air flaps

CHECK
In the course of periodic cleaning of the scavenge air receiver, air flaps 3 (Fig. B
and C) must be checked for damage, movability and fouling.
To check air flaps in scavenge air receiver 1, the two doors 4 arranged at the
end are to be opened and locked with pins 13 on the inner sides (Fig. A view
II).
To check upper air flaps, cover 7 must be opened and locked with one of
screws 8 (Fig. C view V).
To check air flaps for auxiliary blowers 5, the cover 6 on suction space 2 is to
be opened (Fig. B).
A
5
II
I
II
1
13
011.956/04
1/ 4
2012-05
64201/A1
Maintenance
RT-flex96C
3.
Removal and fitting of air flaps

D
For the removal of several air flaps, first screws 9 and their locking plates 10 as
well as stop plates 12 and 12a must be removed as shown in Fig. C. Subsequently the air flaps can be removed as single unit.
The fitting procedure is analogously to the removal, but in reverse sequence.

CHECK
Check that the air flaps are freely moveable in fitted condition.
3
II
10
II
3
III
IV
III
12
11 12
9
10
IV
011.957/04
2012-05
2/ 4
RT-flex96C
64201/A1
Maintenance
II
III
III
13
II
I
IV
V
12a
8
3
12
I-I
1
IV
VI
VI
12
3
VII
10
12
11
12
VII
011.958/04
3/ 4
2008
64201/A1
Maintenance
RT-flex96C
4.
Cleaning the scavenge air receiver

Cleaning and checking of the scavenge air receiver must always be carried out
after a piston overhaul. The inside of the scavenge air receiver has to be cleaned at
regular intervals.
CHECK
At this opportunity check whether drains 14 are not clogged, so that their function is
assured during operation (Fig. D).
During a major overhaul relief valve 15 must be checked. The valve is set to an
opening pressure of 4.1 $ 0.2 bar (relative).
Remark: Do not open the relief valve with disc springs! In case of any damages or
malfunctions please contact the manufacturer or Wrtsil Switzerland Ltd.
15
1
14
011.959/04
14
RELIEF VALVE WITH
COMPRESSION SPRING
RELIEF VALVE WITH
178 mm
DISC SPRINGS
50 mm
MAX. STROKE
011 960/04
2012-05
4/ 4
RT-flex96C
65451/A1
Maintenance
Auxiliary Blower
Maintenance
Tools:
1 Spur-geared chain block
94650
94651
1
2
3
4
5
6
7
8
consisting of:
1 Trolley
2 Centring studs
1.
94651c
94652
Electric motor
Motor plate
Spiral casing
Impeller
Support
Shim
Screw
Screw
9 Screw
10 Longitudinal beam
11 Exhaust manifold
BC Board crane
LA Strap
General
Remark: Auxiliary blowers which are out of service for a longer period should be
started up for a short time twice a month. Where this is not feasible, the impeller
should be turned by hand by several turns. This is necessary to protect the bearings from corrosion damage.
2.
Support of electric motor

Support 5 is used for electric motor 1.
Level differences are compensated with fitted shims 6. The shims have to be
marked prior to dismantling!
3.
Removal
Separate electrical leads from electric motor 1.
Remove screws 8.
On 10 and 12 cylinder engines support 5 is welded on the receiver, therefore,
screws 9 must be removed.
A
3
1
6
8
011.699/04
1/ 3
2012-05
65451/A1
Maintenance
RT-flex96C
Auxiliary Blower: Maintenance

Install trolley 94651c and spur-geared chain block 94650 on longitudinal
beam10.
Attach electric motor to spur-geared chain block 94650.
Unscrew two screws 7 facing each other, then screw in two centring studs
94652 instead.
Unscrew the remaining screws 7 of the motor plate.
Separate the motor plate 2 from the spiral casing with two jacking screws.
Extract electric motor with plate and impeller 4 from spiral casing in horizontal
direction.
I
BC
11
LA
When removing take care not to damage the

impeller.
By means of a second chain block fastened to

strap LA of exhaust manifold 11, the entire
unit can be moved, and subsequently be removed with board crane BC.
10
94651c
94650
94652
011.701/04
1
2012-05
2 4 94652
2/ 3
RT-flex96C
Maintenance
65451/A1
Auxiliary Blower: Maintenance
4.
Dismantling
For dismantling works and maintenance of the auxiliary blower please comply with
the instructions of the manufacturer.
The impeller is statically and dynamically balanced, and therefore must in no way
suffer damage. The impeller must be rebalanced in case of any damaged or replaced parts turning together with the motor shaft.
5.
Fitting
Fit both centring studs 94652.
With the aid of trolley 94651c and spur-geared chain block 94650 fit electric
motor 1 including impeller 4 into spiral casing 3 and firmly tighten screws 7
crosswise.
Remove centring stud and replace it by screws.
Connect electric motor to mains and check direction of rotation.
3/ 3
2012-05
RT-flex96C
66061/A1
Maintenance
Scavenge Air Cooler

Removal and Fitting of Cooler Element and Cooler Pre-stage
Tools:
1
1
1
1
1
1
1
4
1
1
1
1
1
1
*
Lifting device
Lifting device
Extension
Extension
Roller plate
Support
Beam
Swivel lugs
Wire rope sling*
Wire rope sling*
Wire rope sling*
Wire rope sling*
Wire rope sling*
Wire rope sling*
94660
94660a
94660b
94660c
94662
94663
94664
94665
94666
94666a
94666b
94666c
94666d
94666e
1
2
3
4
5
6
7
8
9
10
11
12
13
Butterfly valve
Cooling water inlet pipe
Cooling water outlet pipe
Drain pipe
Vent pipe
Connecting bend
Screw
Cover
Screw
Connection chamber
Receiver
Swivel lug
14
15
16
17
18
19
20
Cooler pre-stage
Main cooler
Screw
Rail
Roller
Plate
Plate
AH
DF
HZ
RC
ST
Stop lever
Sealing surface
Lifting tackle
Eye bolt
Set screw
(hereafter called rope)
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/18
Preliminary works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/18
Removal of cooler element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/18
Transport of cooler element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/18
Separating of cooler elements . . . . . . . . . . . . . . . . . . . . . . . . . 9/18
Assembly of cooler elements . . . . . . . . . . . . . . . . . . . . . . . . . . 9/18
Fitting of cooler element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/18
Removal of cooler pre-stage . . . . . . . . . . . . . . . . . . . . . . . . . . 12/18
Fitting of cooler pre-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/18
General
Risk of accident! Either only the cooler pre-stage alone or the cooler element
(consisting of main cooler and cooler pre-stage) may be removed.
Depending on the manner in which the cooler element or the cooler pre-stage are
carried away (upwards or downwards) after their removal, parts concerned must
be removed from the upper or lower platform (Fig. K). Therefore, always block or
cover the relevant openings for reason of safety!
1/ 18
2008
66061/A1
Maintenance
RT-flex96C
Scavenge Air Cooler: Removal and Fitting of Cooler Element and Cooler Pre-stage
2.
Preliminary works
Stop the cooling water pump. Close butterfly valves 1 and drain coolers.
Remove drain and vent pipes 4 and 5.
Remove cooling water inlet and outlet pipes 2 and 3 above butterfly valve 1 of
the element to be dismantled.
Remove connecting bend 6 for the removal of cooler pre-stage 14.
14
5
I
3
2
I
I-I
5
6
4
1
011.870/04
2008
2/ 18
RT-flex96C
66061/A1
Maintenance
3.
Removal of cooler element

Connect cover 8 (392 kg) to a lifting tackle.
Loosen screws 7 and remove the cover.
Loosen screws 9 at the whole circumference on connection side.
Separate the cooler element from receiver 11 using jacking screws M20.
II
11
7
9
10
II
14
011.872/04
3/ 18
2008
66061/A1
Maintenance
RT-flex96C
Remove plate 20 from roller plate 94662 (Fig. T).
Fasten roller plate with their screws to connection chamber 10 as shown in
Fig. C (view I).
Connect rope 94666b with eye bolts of the roller plate.
Connect rope 94666c with eye bolts RC (M20) fitted into the opposite side.
Connect ropes 94666b with 94666e.
Connect ropes 94666e with 94666c to lifting tackle HZ.
Press cooler element slightly upwards with set screws ST.
II
11
94666b 94666e
HZ
94666c
RC
ST
18
10
94662
17
ST
AH
II
011.873/04
94666b 94666e a b HZ 94666c
2008
4/ 18
RT-flex96C
66061/A1
Maintenance
Pull out the cooler element till the minimum length of lifting tackle HZ is
reached. Subsequently remove rope 94666e (Fig. C) and connect 94666b
directly to lifting tackle HZ.
Pull out the cooler element till stop a.
Place beam 94664 over cooler pre-stage 14.
Fasten lifting devices 94660 and 94660a to main cooler 15 as shown in Fig.
D.
Risk of accident! Swivel lugs 12 to the lifting devices must be hand-screwed using an open end wrench.
II
HZ
94666
94666a
94664
14
15
94660
94660a
a 94666b
HZ 94666c
II
SHIP SIDE
II
13
Connect rope 94666 with spur-geared chain

block 13 (lifting capacity 5000 kg) and lifting
device 94660a.
Hang lifting tackle HZ (lifting capacity 3000
kg) on the lifting lug of rope 94666.
94666a
94666
94660a
12
94660
Connect rope 94666a with lifting tackle HZ

and lifting device 94660.
Tighten ropes 94666 and 94666a.
Remove beam 94664.
12
013.876/06
5/ 18
2008
66061/A1
Maintenance
RT-flex96C
Pull stop lever AH of roller plate 94662 upwards and draw the cooler element
till stop b. Follow up with spur-geared chain block 13 maintaining the ropes
tight at the same time.
Remove ropes 94666b with 94666c, lifting tackle HZ and roller plate 94662.
Lift cooler element slightly upwards with spur-geared chain block (Fig. F).
I
AH
I
013.877/06
b 94666b HZ 94666c
SHIP SIDE
F
13
013.878/06
2008
6/ 18
RT-flex96C
66061/A1
Maintenance
HZ
Turn the cooler element into vertical position

by means of lifting tackle HZ as shown in
Fig. G to I.
In this position the cooler element can be
moved up or downwards and subsequently
returned into horizontal position (Fig. K).
013.879/06
H
SHIP SIDE
K
13
013.880/06
013.882/06
013.881/06
7/ 18
2008
66061/A1
Maintenance
RT-flex96C
4.
Transport of cooler element
L
Place cooler element on the lower platform.
Loosen lifting gear 94660 from the cooler element and extend it by means of tools 94660b
and 94660c.
Refasten the extended lifting gear to the cooler element.
Transport the cooling element along the engine till it can be further handled by the crane.
013.883/06
94660b
94660c
Turn the cooler element into vertical position

as shown in Fig. M. Then connect it to the
crane, lift and carry the cooler element away.
013.884/06
2008
8/ 18
RT-flex96C
66061/A1
Maintenance
5.
Separating of cooler element

Suspend cooler element on the crane as shown in Fig. M and loosen screws
16 (plates 19 remain on main cooler 15).
Put down cooler element and secure it against falling down.
Remove connecting bends 6.
Remove lifting devices 94660 and 94660a.
Connect cooler pre-stage to the crane, lift and place it in horizontal direction.
Connect swivel lugs to the crane, lift and carry the cooler pre-stage away (Fig.
O).
N
I
16
16
14
15
19
013.885/06
I
94665
I
014.031/06
DF
6.
Assembly of cooler element

Assembly of the cooler element is carried out analogously to removal but in reverse sequence.
Thereby a high-temperature and non-hardening jointing compound must be applied to sealing surfaces DF (Fig. O).
9/ 18
2008
66061/A1
Maintenance
RT-flex96C
7.
Fitting of cooler element

Clean sealing surfaces DF of the cooler element and receiver (Fig. N).
Move the cooler element to the mounting place as shown in Fig. F to M for
the removal but in reverse sequence, and adjust it to the mounting height.
Fit roller plate 94662 and eye bolt RC.
D
Take care that the roller plate rests on stop b as shown in Fig. M.
Fasten support 94663 to the platform.

Connect rope 94666c with eye bolts RC.
Connect rope 94666e with support 94663.
Connect ropes 94666e with 94666c to lifting tackle HZ.
Remark: The fitting procedure of the cooler element is same on the opposite side,
however, rope 94666d is used instead of 94666e (Fig. P).
94663
94666e
HZ
94666c
RC
HZ
ST
94666d
94663
94662
18
17
b
94666e
HZ
94663
013.886/06
2008
10/ 18
RT-flex96C
66061/A1
Maintenance
Pull the cooler element into the receiver by approx. 110 mm.
Place beam 94664 over the cooler element and then remove all lifting tools.
Apply a high-temperature and non-hardening jointing compound to sealing
surfaces DF.
Remove beam 94664.
approx. 110 mm
ST
013.887/06
94666e
94666c
94664
DF
R
Pull the cooler element into the receiver till the
minimum length of lifting tackle HZ is
reached. Subsequently connect rope 94666e
and lifting tackle HZ directly to rope 94666c
as shown in Fig. R.
Pull the cooler element fully into the receiver.
Remove all tools and fasten the cooler element to the receiver.
Clean sealing surfaces DF of cover 8 and receiver (Fig. B) and apply a high-temperature
and non-hardening jointing compound.
Fit the cover.
Install all pipings and parts concerned to the
upper or lower platform.
011.910/04
HZ 94666c
CHECK
11/ 18
Vent cooler element and finally carry out a

leak test.
2008
66061/A1
Maintenance
RT-flex96C
8.
Removal of cooler pre-stage

D
Pay attention to sections 1 & 2 General information and Preliminary works.
Remove connecting bend 6.

Loosen screws 9 in the area of cooler pre-stage 14.
Loosen screws 16 (as described for separating the cooler element, Fig. N ).
Separate the cooler pre-stage from receiver 11 using jacking screws M20.
II
11
7
9
10
II
14
011.872/04
2008
12/ 18
RT-flex96C
66061/A1
Maintenance
Fasten roller plate 94662 with corresponding plate 20 to the flanges for connecting bends 6 of cooler pre-stage 14.
Connect rope 94666e with eye bolt of the plate.
Connect rope 94666b with eye bolts RC fitted into the opposite side.
Connect ropes 94666e with 94666b to lifting tackle HZ.
Press cooler pre-stage slightly upwards with set screws ST.
II
14
94662 94666e
HZ 94666b
RC
I
I-I
20
ST
94662
18
17
II
011.918/04
94666e
13/ 18
HZ 94666b
RC
2008
66061/A1
Maintenance
RT-flex96C
Pull out cooler pre-stage 14 till stop a.
Place beam 94664 over the cooler pre-stage.
Fasten swivel lugs 94665 to cooler pre-stage on both sides (see also Fig. N).
Connect rope 94666 and spur-geared chain block 13 with swivel lugs on engine side.
Hang lifting tackle HZ (lifting capacity 750 kg) on the lifting lug of rope 94666.
Connect rope 94666a with lifting tackle HZ and swivel lugs on ship side.
Tighten ropes 94666 and 94666a.
Remove beam 94664.
I
HZ
94666
94666a
94664
94665
14
94666b
a 94666e
HZ
I
SHIP SIDE
13
HZ
94666
94666a
94664
94665
94662
011.919/04
2008
14/ 18
RT-flex96C
66061/A1
Maintenance
Pull out the cooler pre-stage till the minimum length of lifting tackle HZ is
reached. Subsequently remove rope 94666e (Fig. U) and connect roller support 94662 directly to lifting tackle HZ.
Pull stop lever AH of roller plate 94662 upwards and draw the cooler prestage till stop b. Follow up with spur-geared chain block 13 maintaining ropes
94666 and 94666a tight at the same time.
Remove rope 94666b, lifting tackle HZ and roller plate 94662.
V
13
I
AH
94666
94666a
I
b
94662
SHIP SIDE
HZ 94666b
13
Lift cooler pre-stage slightly upwards with
spur-geared chain block.
Turn the cooler pre-stage into vertical position by means of lifting tackle HZ.
In this position the cooler pre-stage can be
moved up or downwards and subsequently
returned into horizontal position.
HZ
011.920/04
15/ 18
2008
66061/A1
Maintenance
RT-flex96C
9.
Fitting of cooler pre-stage

Clean sealing surfaces DF of the cooler pre-stage and receiver.
Carry the cooler element to mounting position analogously to removal but in
reverse sequence (Fig. W), and place it on the correct mounting height (Fig.
G to K).
Connect rope 94666c with two eye bolts RC fitted into the cooler pre-stage.
Fasten support 94663 to the platform.
Connect rope 94666e with support 94663.
Connect ropes 94666e with 94666c to lifting tackle HZ providing a protection
between rope 94666e and main cooler.
Remark: The fitting procedure of the cooler pre-stage is same on the opposite
side, however, rope 94666d is used instead of 94666e (Fig. X).
X
I
PROTECTION
94663
94666e
94666c
RC 14 DF
94666d
I
94666e
HZ
94663
011.921/04
2008
16/ 18
RT-flex96C
66061/A1
Maintenance
Fit roller plate 94662.
D
Take care that the roller plate rests on stop b as shown in view I.
Y
I
94662
DF
94666c
Pull the cooler pre-stage into the receiver by approx. 110 mm.
Place beam 94664 over the cooler pre-stage and then remove all lifting tools
(ropes 94666, 94666a, lifting tackle HZ and swivel lugs 94665).
Remove the beam.
surfaces DF.
Press cooler pre-stage slightly upwards to the correct height with set screws
ST (Fig. T).
Pull the cooler pre-stage into the receiver till the minimum length of lifting
tackle HZ is reached.
Z
HZ
94666
94666a
approx. 110
mm
011.922/04
94664
17/ 18
2008
66061/A1
Maintenance
RT-flex96C
Remove 94666e (Fig. Y) and subsequently connect lifting tackle HZ directly
to support 94663 and rope 94666c as shown in Fig. A1.
Pull the cooler pre-stage fully into the receiver.
Remove all tools and fasten the cooler pre-stage to the receiver.
Fit cooler pre-stage 14 and plates 19 using screws 16 (Fig. N).
Clean sealing surfaces DF of cover 8 and receiver (Fig. B) and apply a hightemperature and non-hardening jointing compound.
Fit the cover.
Install all pipings and parts concerned to the upper or lower platform.
CHECK
Vent cooler element and finally carry out a leak test.
A1
011.923/04
94663
2008
HZ
18/ 18
94663c
RT-flex96C
66061/A2
Maintenance
Scavenge Air Cooler

Removal and Fitting of Main Cooler and Cooler Pre-stage
Tools:
2
1
1
1
1
1
2
1
4
4
1
1
1
1
*
Lifting devices
Extension
Roller plate
Support
Support
Support
Supports
Catwalk
Swivel lugs
Discs
Wire rope sling*
Wire rope sling*
Wire rope sling*
Wire rope sling*
Engine with Rail
94660d
94661
94662
94663a
94663e
94663d
94663f
94664a
94665b
94665c
94666f
94666g
94666h
94666i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Butterfly valve
Cooling water inlet pipe
Cooling water outlet pipe
Drain pipe
Vent pipe
Connecting bend
Screw
Cover
Screw
Connection chamber
Receiver
Screw
Cooler pre-stage
Main cooler
Screw
Rail
Roller
Plate
Plate
Bottom plate
Support
Plate
24
25
26
27
28
29
30
31
32, 32a
33
34
35
36
37
Screw
Roller
Screw
Double spring clip
Bolt
Lower stay
Bolt
Upper stay
Bolt
Threaded rod
Roller support
Bolt
Roller
Swivel lug
AH
DF
HU
HZ
H1
RC
ST
Stop lever
Sealing surface
Wooden underlay
Lifting tackle
Lifting tackle
Eye bolt
Set screw
Overview
1.
2.
3.
4.
5.
6.
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/18
Preliminary works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/18
Removal of cooler pre-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/18
Fitting of cooler pre-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/18
Removal of main cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/18
Fitting of main cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/18
General
Risk of accident! Cooler pre-stage and main cooler may be removed only one by
one. To prevent having a fall, immediately close the openings off after removing
bottom plates!
For every removal and fitting of a cooler, supports 22 (Fig. C) must always be provided and may be removed again only after completion of the works.
1/ 18
2008
66061/A2
Maintenance
RT-flex96C
SAC: Removal and Fitting of Main Cooler and Cooler Pre-stage
2.
Engine with Rail
Preliminary works
Stop the cooling water pump. Close butterfly valves 1 and drain coolers.
Remove drain and vent pipes 4 and 5.
Remove cooling water inlet and outlet pipes 2 and 3 above butterfly valve 1 of
the cooler to be dismantled.
Remove connecting bend 6 for the removal of cooler pre-stage 14 and main
cooler 15.
Remark: Depending on the situation, the corresponding pipings must also be removed from the opposite scavenge air cooler.
14
5
6
4
I
3
2
I
I-I
5
6
14
15
011.870/04
2008
2/ 18
RT-flex96C
66061/A2
Maintenance
3.
Engine with Rail
Removal of cooler pre-stage
III
Loosen screws 9 in the area of the cooler prestage.
II
Loosen all screws 16 and remove plates 19.

Separate cooler pre-stage 14 from receiver
11 using jacking screws M20.
III
II
11
7
8
14
10
III - III
16
19
15
013.948/06
3/ 18
2008
66061/A2
Maintenance
RT-flex96C
3.1
Engine with Rail
Pulling out the cooler pre-stage

Fasten roller plate 94662 with corresponding plate 20 to the flanges for connecting bends 6 of cooler pre-stage 14.
Connect rope 94666g with eye bolt of plate 20.
Fit eye bolt RC on the opposite side.
Connect rope 94666g to lifting tackle HZ and eye bolt RC.
Press cooler pre-stage slightly upwards with set screws ST.
II
22
14
94662
94666g
HZ RC
I-I
20
94662
ST
18
17
II
013.951/06
2008
94666g
4/ 18
HZ RC
RT-flex96C
66061/A2
Maintenance
Engine with Rail
Pull out the cooler pre-stage till stop a.

Remark: If the cooler pre-stage does not touch stop a although lifting tackle HZ
has reached its maximum length, rope 94666g must be removed and the lifting
tackle has to be connected directly to roller support 94662. Subsequently the cooler pre-stage can be pulled out till stop a.
Fasten support 94663f to main cooler 15.
Place catwalk 94664a over cooler pre-stage 14.
Fasten swivel lugs 94665b together with their discs 94665c on both sides of
the cooler pre-stage.
94664a
I
AH
I
013.952/06
15
94663f
HZ
11
94665b
Hoist stop lever AH of roller plate 94662 and pull out the cooler pre-stage till
stop b.
Remark: If the cooler pre-stage does not touch stop b although lifting tackle HZ
has reached its minimum length, rope 94666h must be connected directly to swivel
lugs 94665b and the lifting tackle as shown in Fig. E. Subsequently the cooler prestage can be pulled out till stop b.
Remove the lifting tackle, rope and catwalk.
013.955/06
94665b 94666h
5/ 18
94664a b
HZ
2008
66061/A2
Maintenance
RT-flex96C
Engine with Rail
Connect spur-geared chain blocks 13 (lifting capacity 3000 kg each) to swivel

lugs 94665b and tighten them.
Remove supports 94663f and roller plate 94662.
13
013.957/06
94663f
G
3.2
94662
Lowering the cooler pre-stage
Remove the corresponding bottom plates

and supports.
Loosen and put bottom plate 21 aside.
21
14
Turn cooler pre-stage 14 into vertical position

by means of the spur-geared chain blocks as
shown in Fig. G to K.
013.958/06
013.959/06
2008
013.960/05
6/ 18
RT-flex96C
66061/A2
Maintenance
Engine with Rail
013.961/06
L
Turn cooler pre-stage 14 into horizontal position by means of the spur-geared chain
blocks as shown in Fig. L and M.
013.962/06
013.963/06
14
7/ 18
2008
66061/A2
Maintenance
RT-flex96C
4.
Engine with Rail
Fitting of cooler pre-stage

Clean sealing surfaces DF of the cooler pre-stage and receiver.
Carry cooler pre-stage to mounting position analogously to removal but in reverse sequence and place it on the correct mounting height (Fig. G to M and
Fig. F).
Fix supports 94663f and roller support 94662.
Fasten support 94663e onto the platform.
Connect rope 94666i with two eye bolts RC fitted into the cooler pre-stage.
Connect lifting tackle HZ to support 94663e.
Connect ropes 94666f with 94666i to lifting tackle HZ.
Place catwalk 94664a over the cooler pre-stage, disconnect spur-geared
chain blocks 13 and remove swivel lugs 94665b with their discs.
Remove the catwalk again.
Remark: The fitting procedure of the cooler pre-stage is same on the opposite
side, however, rope 94666g and support 94663d are used instead of 94666i and
94663e.
N
94663f
94663e
HZ
94666f
94666i RC
13
94664a
DF
94665b
94662
94666g
94663d
013.964/06

surfaces DF.
Adjust the cooler pre-stage slightly to the correct height with set screws ST
(Fig. D).
Pull the cooler pre-stage into the receiver till the minimum length of lifting
tackle HZ is reached.
2008
8/ 18
RT-flex96C
66061/A2
Maintenance
Engine with Rail
Remove rope 94666f (Fig. N) and connect lifting tackle HZ to rope 94666i as
shown in Fig. O.
Pull out cooler pre-stage 14 till stop b and remove support 94663f.
013.965/06
HZ
94666i
94663f
Pull the cooler pre-stage fully into the receiver (Fig. P).
Remove all tools and fasten the cooler pre-stage to the receiver.
Fit cooler pre-stage 14 and plates 19 using screws 16 (Fig. B).
Clean sealing surfaces DF of cover 8 and receiver (Fig. B) and apply a hightemperature and non-hardening jointing compound.
Fit the cover.
Install all pipings and platform parts.
CHECK
Vent cooler element and finally carry out a leak test.
013.966/06
9/ 18
2008
66061/A2
Maintenance
RT-flex96C
5.
Engine with Rail
Removal of main cooler

D
Pay attention to section 1 General information and carry out the works as described under sections 2 & 3 Preliminary works and Removal of cooler prestage.
Loosen screws 9 at the whole circumference on connection side.

Separate main cooler 15 from receiver 11 using jacking screws M20.
Q
I
11
9
10
15
013.967/06
Remove plate 20 from roller plate 94662 (Fig. C).

Fasten roller plate to connection chamber 10 using the proper screws as
shown in Fig. R view I).
Press main cooler slightly upwards with set screws ST.
Fasten extension 94661 to the main cooler (see also paragraph 5.2).
R
I
ST
18
17
013.968/06
94661
2008
94662 10
10/ 18
RT-flex96C
66061/A2
Maintenance
Engine with Rail
S
5.1
Fastening the extension
It is advantageous to install extension 94661 in individual steps:
24
23
5.1.1 Step 1
Withdraw double spring clip 27 and remove
pin 28 with roller 25.
013.969/06
26
15
26
Fasten plates 23 to main cooler 15 using

screws 24.
25
Press main cooler upwards with screws 26, fit

roller with pin and secure them by means of
double spring clip.
Turn screws 26 back.
25
27
28
5.1.2 Step 2
Connect lower stays 29 with plates 23 by
means of bolts 30 resp. 32.
Secure the bolts by means of double spring

clips.
32
23
31
Adjust distances x = 12 mm.

Remark: The max. permissible distance must not
exceed x1 = 118 mm.
29
30
I
x1
33
013.970/06
11/ 18
2008
66061/A2
Maintenance
RT-flex96C
Engine with Rail
5.1.3 Step 3
Connect lower stays 29 with roller support 34
by means of bolts 35.
31
Connect lower stays 29 with upper stays 31

by means of bolts 32a.
Secure all bolts by means of double spring
clips.
013.971/06
32a
35 29
5.2
34
Pulling out the main cooler

Connect rope 94666i with eye bolts RC of roller plate 94662.
Fit eye bolts RC on the opposite side and connect them with lifting tackle HZ.
Connect rope 94666i to lifting tackle HZ.
94661
94662
94666i
HZ RC
013.972/06
94661
2008
94666i
12/ 18
RT-flex96C
66061/A2
Maintenance
Engine with Rail
Pull out the main cooler till extension 94661 is situated in the receiver.
Press main cooler slightly upwards by turning threaded rod 33 (Fig. T view I).
Pull out the main cooler till the minimum length of lifting tackle HZ is reached.
Place catwalk 94664a over the main cooler.
Fasten both lifting devices 94660d to the main cooler.
D
Make sure that the swivel lugs 37 are screwed in at the top of the lifting devices.
Fit eye bolt RC on the opposite side and connect it to lifting tackle H1.
Connect rope 94666h to the swivel lugs and lifting tackle H1.
Tighten lifting tackle H1.
Remove lifting tackle HZ and rope 94666i.
W
I
37
94664a
94666h
H1
RC
94660d
94660d
013.973/06
94660d
94666i
HZ
13/ 18
2008
66061/A2
Maintenance
RT-flex96C
Engine with Rail
Hoist stop lever AH of roller plate 94662 (Fig. D view I) and pull out the main
cooler till stop b.
Remove rope 94666h and lifting tackle H1.
94666h
H1
013.974/06
Screw swivel lugs 37 into the lifting device 94660d on that side pointing to the
engine, and these on the opposite side in the middle of the lifting device (Fig.
Y view I).
Connect and tighten spur-geared chain blocks 13 to the swivel lugs of the lifting devices.
Remove extension 94661 and roller plate 94662.
13
37
37
013.975/06
94661
94662
2008
14/ 18
RT-flex96C
66061/A2
Maintenance
Engine with Rail
Z
13
5.3
013.976/06
Lowering the main cooler
Turn the main cooler into vertical position by

means of the spur-geared chain blocks 13 as
shown in Fig. Z to C1.
A1
013.977/06
C1
B1
013.979/06
013.978/06
15/ 18
2008
66061/A2
Maintenance
RT-flex96C
Engine with Rail
D1
Turn the main cooler into horizontal position
by means of the spur-geared chain blocks 13
and place it on wooden underlays HU as
shown in Fig. D1 to F1.
F1
013.980/06
13
E1
013.981/06
HU
013.982/06
2008
16/ 18
RT-flex96C
66061/A2
Maintenance
6.
Engine with Rail
Fitting of main cooler

Clean sealing surfaces DF of the main cooler and receiver.
Move the main cooler to the mounting place as shown in Fig. Z to F1 for the
removal but in reverse sequence, and adjust it to the mounting height.
Fit roller plate 94662 and extension 94661 as described in paragraph 5.2.
D
Make sure that the roller plate rests on stop b as shown in Fig. G1.
Fasten support 94663a to the main cooler.

Fasten support 94663e to the platform.
Connect rope 94666f with support 94663a.
Connect lifting tackle HZ to rope 94666f and support 94663e.
Place catwalk 94664a over main cooler 15 and install lifting devices 94660d.
Remove the catwalk.
Remark: The fitting procedure of the main cooler is same on the opposite side,
however, rope 94666g and support 94663d are used instead of 94666f and
94663e.
G1
13
94664a
DF
94663e
HZ
94666f
94661
94660d
ST
94666g
94663d
94662
94663a
I
17
013.987/06
17/ 18
2008
66061/A2
Maintenance
RT-flex96C
Engine with Rail
Pull the main cooler fully into the receiver till stop a.
D
Take care that the main cooler does not jam during fitting.
Remark: If the main cooler rests on stop a, rollers 25 should be in the receiver,
otherwise the main cooler must be further pulled in correspondingly.
Lift roller 36 of extension 94661 slightly off the receiver 11 by turning threaded
rod 33.
Pull the main cooler into the receiver till the minimum length of lifting tackle
HZ is reached. Subsequently connect rope 94666f and lifting tackle HZ directly to support 94663a.
H1
94662
94666f
013.988/06
I1
11 36
33
94663a
25
Pull the main cooler fully into the receiver.

Press main cooler upwards with screws 26 in
order to remove rollers 25 (see also paragraph 5.1, Fig. S).
Lower main cooler again, remove all tools
and finally fasten main cooler to the receiver.
Remark: If the works have been completed, refit
all screws into the individual tools which were
used for removal and fitting of the coolers.
013.989/06
2008
18/ 18
RT-flex96C
67081/A1
Maintenance
Water Separator
Removal and Fitting of Water Separator
Tools:
1
1
1
1
1
*
1.
Carriage
Pulley device
Support
Lifting device
Wire rope sling*
94667
94668
94669
94672
94673
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Door
Pin
Cover
Cover
Receiver
Platform support
Platform support
Screw
Intermediate ring
Plate
Plate
Rail
Screw
Screw with washer
15
16
17
18
19
20
21
AC
HZ
KO
RC
TU
Water separator
Rail
Lock screw
Drain pipe
O-ring (round rubber ring)
O-ring (round rubber ring)
Chamfer
Lifting tackle
Slot
Eye bolt
Door opening
Preparation
Loosen doors 1, open up and lock it on the inside with pin 2.
Attach lifting tackle HZ (carrying capacity 1000 kg) to the lug on the platform
support (Fig. A and F).
Remove platform supports 6, 7 and the corresponding bottom plates which
hinder the removal of the water separator.
Attention! To prevent having a fall, immediately close the openings off after removing the bottom plates!
HZ
I
6
2 1
1
011.966/04
1/ 8
2008
67081/A1
Maintenance
RT-flex96C
II
II
5
TU
III
III
1.1
Removal of sealing elements (variant 1)
The sealing elements consist of plates 10 and 11, rail 12,

O-rings 20 and 21.
Loosen and remove covers 3 (87 kg) and 4 (21 kg).
Loosen screws 13 and remove rail 12 and O-ring 21.
Loosen screws 14.
Remove plate 11.
Remark: Plates 11 and rails 12 must be removed from
both ends of water separator 15.
Enter through door opening TU (view II) into receiver 5 and remove plates 10.
Carefully draw O-ring out, if possible starting at the

end, otherwise remove it after removal of the water
separator.
012.559/04
IV
IV
15
11
14
III - III
15
11
14
10
13
12
20
AC
13
012.560/04
2008
21 12
IV
KO
2/ 8
SILICONE
RT-flex96C
67081/A1
Maintenance
1.2
Removal of sealing elements (variant 2)

Instead of O-ring 21 (variant 1) silicone is used for sealing, therefore rail 12 with
screws 13 are not provided.
Removal of the remaining elements are the same as described in paragraph 1.1.
V-V
III - III
V
15
11
14
10
20
15
SILICONE
012.561/04
2.
Fitting the sealing elements (variants 1 and 2)

For both variants the assembly takes place analogously but in reverse sequence
to the removal, whereby the following points require special attention:
2.1
O-rings 20 and 21 must be replaced depending on their conditions. The old

silicone must be removed carefully.
Both edges must be filled with silicone before fitting O-ring 21, which should
protrude on both sides.
Variant 1 (Fig. B, view III, section IV)

CHECK
When fitting plate 10 take into consideration that its longitudinal chamfer AC
presses O-ring 20 against the water separator.
D
2.2
After placing O-ring 21 on rail 12, the latter is bolted with plate 11.
The O-ring is pressed against receiver 5 by means of an appropriate blunt tool
through slot KO.
Variant 2 (Fig. B view III, section V)

D
First fill up the gap between receiver 5 and water separator 15 on both ends
with silicone. Subsequently fit O-ring 21 and the remaining sealing elements.
3/ 8
2008
67081/A1
Maintenance
RT-flex96C
2.
Removal
Loosen screws 8 and remove them together with intermediate ring 9.
Put carriage 94667 on rail 16 and fasten it to water separator 15.
5
94667
15
16
15
012.562/04
19
2008
4/ 8
RT-flex96C
67081/A1
Maintenance

Fasten support 94669 to receiver 4.
Fit a lock screw 18 each into stop b on both rails 16 (view I).
Risk of accident! Both lock screws must be provided without fail to prevent the
water separator 15 from being pulled out over support 94669!
Remark: When removing the opposite water separator, lock screws 18 must be
fitted into stops a, and support 94669 has to be fastened directly below the water
separator to be removed.
Fit eye bolt RC on the opposite side.
Connect lifting tackle HZ to eye bolt RC and carriage 94667 (Fig. E).
Pull out the water separator till it stops at the lock screws.
Remove lifting tackle HZ.
94667
15
94669
18
16
94667
011.968/04
16
18
b 94667
RC
HZ
15
94669
5/ 8
2008
67081/A1
Maintenance
RT-flex96C

Fasten lifting device 94672 to water separator 15.
Connect lifting tackle HZ to lifting device and lift water separator slightly.
Remove carriage 94667.
Lift water separator.
HZ
15
94672
94667
G
17
HZ
Connect spur-geared chain block 17 to lifting

device 94672.
94672
For carrying away the water separator, move

it into the required position using spur-geared
chain block and lifting device.
15
011.969/04
2008
6/ 8
RT-flex96C
67081/A1
Maintenance
3.
Fitting
CHECK
Prior to fitting the water separator, check drain pipes 19 (Fig. C) for free passage.
Move the water separator to the mounting place as shown in Fig. F and E for
the removal but in reverse sequence, and adjust it to the mounting height.
Mount support 94669 and carriage 94667.
Fit a lock screw 18 each into stop b on both rails 16 (view I).
Carefully lower water separator onto rails 16 and support 94669 as shown in
Fig. H.
D
Pay attention that carriage 94667 is placed in its proper position!
Remark: When fitting the opposite water separator, lock screws 18 must be fitted
into stops a, and support 94669 has to be fastened directly below the water separator to be fitted (Fig. E).
Remove lifting device 94672 and disconnect lifting tackle HZ from carriage
94667.
I
94667
18
16
HZ
94672
18
b 94667
011.970/04
94669
7/ 8
2008
67081/A1
Maintenance
RT-flex96C

Fasten pulley device 94668 to receiver 5.
Attach lifting tackle HZ to eye bolt RC.
Fasten rope 94673 to carriage 94667 and connect it with lifting tackle HZ via
pulley device as shown in Fig. I.
Pull water separator into the receiver and align it to the fitting position.
Fit and tighten screws 8 together with intermediate rings 9 (Fig. C).
Reinstall all sealing elements according to section 2.
Remove all tools.
Fit covers 3 and 4 (Fig. B).
Close and tighten up doors 1.
Reinstall platform.
94668
94673
18
94667
HZ
RC
011.971/04
2008
8/ 8
RT-flex96C
67351/A1
Maintenance
Scavenge Air Waste Gate

1
2
3
4
5
Housing
Cover
Piston
Adjusting screw
(stroke limitation)
6 Seal (1 mm thickness)
1.
7
8
9
10
11
12
13
Lock nut
Screw
Guide ring
Piston seal ring
Compression spring
Solenoid valve
Silencer
Dismantling, function check

A function check must be carried out half-yearly on the running engine (see also
Operating Manual 67351). If a malfunction in the waste gate valve occurs it must
be overhauled according to the following instructions at the first opportunity:
Attention! Adjusting screw 5 must not be readjusted!
Loosen screw 8 for cover 2. Specially long screws are fitted for releasing the
spring 11.
Dismantle piston 3. Clean piston and housing 1.
Check piston seal ring 10, guide ring 9 and replace them if necessary.
After reassembling smear piston lightly with oil and check its easy movement
in the housing.
2.
Assembling
Assembling is carried out analogously to dismantling but in reverse sequence.
Attention! Should seal 6 need to be replaced, attention must be paid to ensure
that a seal of the same thickness (1 mm) is refitted.
Before assembling smear all moving parts lightly with clean oil.
Remark: The retaining pressure is adjusted with pressure reducing valve 4.
10
11
6
12
2
7
5
8
13
1
014.132/06
014.131/06
1/ 1
2008
RT-flex96C
Maintenance
Group7
Group 7
Lubrication Pump CLU4: Checking the Gas Pre-charge Pressure . . . . . . . . . . . . . 72181/A1
1/ 5
Pulse / RTflex96C / MM /2010
RT-flex96C
72181/A1
Maintenance
Lubricating Pump CLU4

Checking / Refilling the Gas Pre-charge Pressure
Tool:
1 Case
94720c
consisting of:

1.
1
2
3
4
5
6
7
8
Hydraulic accumulator
Protection cap
Hose (1 m)
Hose (4m)
Control unit with valves A,B,C
Pressure gauge 0...60 bar
Lubricating pump (CLU4)
9
10
11
12
13
14
15
Lubricating oil inlet

Servo oil outlet
Measuring connection M16
Screw plug
Vent plug (Zyl. Lubr. oil)
Nitrogen bottle
Vent plug (servo oil)
Checking / refilling the gas pre-charge pressure

Once filled with gas, the hydraulic accumulator is largely maintenance-free, however in order to ensure a trouble-free service, maintenance works must be carried
out according to the manufacturers detailed operating instructions of the Cylinder
Lubricating System. Checks and maintenance are only to be carried out, when
the engine is at standstill. Furthermore see also Operating Manual 72181.
CHECK
Check the pre-charge pressure directly after the installation of a new accumulator,
then at least once in the first week after start-up. Afterwards, check the pre-charge
pressure every three months.
Attention! Ensure that servo oil supply is shut off before starting accumulator
pressure checking and charging. Also no residual oil pressure in the servo oil supply line must be visible on pressure gauge PI2041L of pressure reducing valve
8.111.
1.1
Preparation before checking / refilling

Before starting any maintenance work, ensure that the servo oil supply unit is
switched off and the servo oil pressure is completely released.
In any case, when the accumulator has been removed the lubricating pump has to
be vented, see paragraph 2.2 Venting the lubricating pump.
Stop servo oil supply.
Close the stop valve 4.305 on servo oil rail 4.11 (Fig. D).
Drain the servo oil system at screw plug 12 of pressure reducing valve 8.111
(Fig. E).
Remark: Screw plug 12 must remain open during the entire checking / refilling
procedure.
1.2
Tools for pre-charge pressure checking / filling

For checking / filling the pre-charge pressure of the accumulator always use
the measurement set case 94720c!
1/ 5
CLU4 / 2011-07
72181/A1
Maintenance
RT-flex96C
Lubricating Pump CLU4: Checking / Refilling the Gas Pre-charge Pressure
1.3
Checking the pre-charge pressure on a new-type accumulator

For the below work procedure, the accumulator does not have to be disconnected
from the lubricating pump.
Remark: During every check a small amount of gas may be lost to atmosphere.
Therefore, in order to make up possible losses make sure a nitrogen bottle is available before a pre-charge pressure check is made.
Procedure for checking / refilling the gas pre-charge pressure:
Close the three valves A, B and C on control unit 6 (Fig. A).
Connect accumulator 1 to valve A using hose 4.
Open valve A and read the pressure on gauge 7.
Required pre-charge pressure: min. 20 bar / max 25 bar.
If pre-charge pressure is within the given limit, close valve A and vent remaining pressure in the control unit by opening valve B. Disconnect hose 4 from the
accumulator and refit protection cap 2.
If it is required to refill the accumulator, please continue to next point.
Remark: The accumulator may only be filled with super-clean, Class 4.0 nitrogen,
99.99% N2 by volume.
Connect pressure reducing valve 3 to nitrogen bottle 14 (Fig. B).
Connect pressure reducing valve to control unit 6 at valve C using hose 5 and
adjust the outlet pressure to approx. 30 bar.
Close the three valves A, B and C on the control unit.
Slowly open valve C and refill accumulator to the required pressure of 25 bar.
Close valves A and C and vent the remaining pressure in the control unit by
opening valve B.
Disconnect hoses 4 and 5, remove the tools and refit all protection caps.
2011-07 / CLU4
2/ 5
RT-flex96C
72181/A1
Maintenance
2.
Final assembly
2.1
After checking / refilling procedure

Reopen stop valve 4.305 on servo oil rail 4.11 (Fig. D).
Close screw plug 12 of pressure reducing valve 8.11 (Fig. E).
After checking the pressure and refilling the accumulator, ensure to run the servo
oil supply system and vent air from the system before putting the pulse lubricating
system into operation.
2.2
Venting the lubricating pump

The lubricating pump has to be vented after refitting the accumulator.
The lubricating pump contains two vent plugs (Fig. C):
Vent plug 13 for the cylinder lubricating oil.
Vent plug 15 for the servo oil.
Required equipment:
Oil collection tray.
Cloth to wipe up escaping oil.
Venting the cylinder lubricating oil:

Place an oil collection tray beneath the lubricating pump.
Loosen vent plug 13 for the cylinder lubricating oil. For this, turn the plug
counter-clockwise a maximum of three turns.
Wait until bubble-free oil escapes at the vent plug.
Tighten the vent plug again.
Venting the servo oil:
Attention! The servo oil system is under high pressure. Oil may spurt out when the
screws are loosened. Do not loosen the vent plug more than three turns. Wear
safety goggles!
Proceed as follows to vent the servo oil section of the lubricating pump:
Place an oil collection tray beneath the lubricating pump.
Operate the lubricating system via manual lubrication or intermediate lubrication operation (for additional details see also the Operating Manual 72181).
This is only possible after the servo oil priming pressure has been achieved by
starting the servo oil pumps.
Loosen vent plug 15 for the servo oil. For this, turn the plug counter-clockwise
a maximum of three turns.
Wait until bubble-free oil escapes at the vent plug.
Tighten the vent plug again.
3/ 5
CLU4 / 2011-07
72181/A1
Maintenance
RT-flex96C
Case with measurement set 94720c:
Case 94720c
4, 5
Arrangement of equipment:
14
2011-07 / CLU4
4/ 5
RT-flex96C
72181/A1
Maintenance
Lubricating pump (CLU4):

TO LUBRICATING
QUILLS
13
15
9
10
SERVO
OIL
1
2
11
015.438/07
Details of servo oil rail 4.11 > pressure reducing valve 8.111 > lubricating pump 8.06:
8.06
RAIL UNIT
4.11
PI2041L
8.111
12
DRAWN FROM CONTROL

DIAGRAM 40032
WCH00861
PRESSURE REDUCING
UNIT
5/ 5
WCH00852
CLU4 / 2012-05
RT-flex96C
Maintenance
Piping
Group8
Group 8
Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81351/A1
Servo Oil Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . 84471/A1
Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding . . . . 84601/A1

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

Checking and Setting of Relief Valve with O.M.T. Test Bench . . . . . . . . . . . . . . 87501/A1
Checking and Setting of Relief Valve with OBEL Test Bench . . . . . . . . . . . . . . . 87501/A2
Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling . . . . 87502/A1
Fuel Pressure Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . 87521/A1
1/ 1
RTflex96C / MM / 2011-03
RT-flex96C
81351/A1
Maintenance
Exhaust Waste Gate (Low-Load Tuning)
1.
General
The Low-Load Tuning concept is based on the combination of a specifically designed turbocharging system setup and appropriately adjusted engine parameters related to fuel injection and exhaust valve control. This allows enhancing the
performance of engines while operating at low part loads, in particular in the range
up to 70% load, by realizing considerably reduced fuel consumption as well as lower thermal load and thus improved engine reliability.
2.
Maintenance
D
Butterfly valve 1 does not require special maintenenace. For a general inspection however, the instructions of the valve manufacturer must be followed.
To carry out a function check see 81351 in the Operating Manual and Maintenance Schedule 03801.
11
10
4
9
2
8
12
6
7
2
3
WCH00395
WCH00349
1
2
3
4
5
6
Butterfly valve
Control actuator (one or two)
Feedback sensor ZS5372C
Orifice
Solenoid valve ZV7076C
Control air supply
7
8
9
10
11
12
1/ 1
Air spring air pipe

Control air pipe
Exhaust gas turbocharger
Exhaust manifold
Exhaust by-pass line
Cardan rod
2011-03
RT-flex96C
84471/A1
Maintenance
Servo Oil Piping

Removing, Fitting and Regrinding
Tools:
1 Tool box with

grinding machine
1.
94835
1
2
3
4
5
6,a,b
7
8
9
10
11
12
13
14,a,b
15
Servo oil piping

Servo oil piping
Leakage oil piping
Shut-off valve
Shut-off valve
Screw
Flange
Screw
Clamp piece
Shim
Protective shell
Claw
Thrust ring
Drain screw
Non-return valve
16
17
18
19
20
21
22
23
24
25
26
Screwed sleeve
Valve block
Intermediate piece
Shim
Shim
Connecting piece
Back-up ring
O-ring
O-ring
O-ring
O-ring
DF Sealing face
Removal
1.1
Preparatory works
Remove the casing where necessary.

Close shut-off valves 4 and 5 for the relevant
servo oil piping.
19
7
14a
6
1
Open drain screw 14.

Remark: The spindles of the closed shut-off
valves must be tightened with 200 Nm.
1.2
Removal of servo oil piping 1
Open drain screws 14a.

Loosen screws 6.
Push flanges 7 back till they are no more engaged, so that servo oil piping 1 can be removed.
D
3
The ends of the servo oil piping must be protected from any damages.
5
14
I-I
10
11
9
8
014.447/06
1/ 4
2008
84471/A1
Maintenance
RT-flex96C
Servo Oil Piping: Removing, Fitting and Regrinding
1.3
Removal of servo oil piping 2

Open drain screws 14b.
Loosen screws 6a and push flanges 7 back till they are no more engaged.
Mark shims 10 together with clamp pieces 9 (Fig. A).
Hold servo oil piping (65 kg) by means of a lifting tackle.
Loosen and remove screws 8 (Fig. A).
Remove clamp pieces with protective shims 11 and shims 10 (Fig. A view
I-I).
Mark shims 19 and 20 together with connecting piece 21.
Loosen screws 6b and push flange 7 back.
Remove servo oil piping 2.
B
I
7
6a
1
2
I
17
14b
7
6a
II
IV
014.448/06
III
II
III-III
2
19
22 23
21
IV
22
23
20
III
6b
2008
14b
2/ 4
18
RT-flex96C
84471/A1
Maintenance
2.
Fitting
x = 10 mm
2.1
24
Checking the claw position
Before fitting the servo oil piping check

whether its claws 12 are screwed on properly
as shown in Fig. C, i.e. the servo oil piping
must protrude by x = 10 mm compared to the
claw.
12
7
13
1, 2
Measure x can be adjusted by turning the

claw using an open-end wrench.
Remark: On newer engines claw 12 and thrust

ring 13 are provided in one piece.
25
014.449/06
2.2
Fitting the servo oil pipings

Fitting is carried out analogously to the removal but in reverse sequence, whereby
the following points require special attention:
Fitting position of new back-up rings 22 (Fig. B views IV and V).
All shims must be fitted in the same place as before.
Oil the threads of screws 6, a, b and tighten them crosswise with a torque of
170 Nm.
When fitting clamp pieces 9 tighten their screws 8 after all servo oil pipings
have been tightened!
Close all drain screws.
After refitting the servo oil pipings open shut-off valves 4 and 5, and tighten
their spindles with 200 Nm.
3/ 4
2008
84471/A1
Maintenance
RT-flex96C
3.
Non-return valve
If a non-return valve 15 has been removed from valve block 17, O-rings 26 must be
replaced by new ones.
The proper flow direction must be maintained when refitting the non-return valve.
Apply LOCTITE 0222 to the screwed sleeve 16 and tighten it with a torque of
80 Nm.
17
26
16
15
FLOW
DIRECTION
4.
014.450/06
Regrinding the sealing faces DF
E
DF
D
Tool 94835 must be used according to the

manufacturers detailed instructions for regrinding sealing face DF.
Unscrew corresponding claw 11 (Fig. B).

To prevent grinding compound from entering
the servo oil piping, plug its openings with a
piece of cloth.
1, 2
After grinding thoroughly clean the servo oil

piping.
014.936/06
2008
4/ 4
RT-flex96C
84601/A1
Maintenance
Hydraulic Piping for Exhaust Valve Drive

Tools:
1 Tool box with

grinding machine
1.
94835
1
2
3
4
5
6
7
8, 8a
9
10
Hydraulic piping
Stop valve
Drain screw
Pilot valve
Partition device
Screw
Screw
Housing
Sealing ring
Metallic hose
11
12
13
14
15
16
17
18
Screw
Holder
Screw
Gasket
Clamping flange
Clamping flange
Waisted screw
O-ring
DF Sealing face
Removal
When working on a hydraulic piping 1 the engine has to be stopped, and it is essential that instructions 05201 Exchange of a defective hydraulic piping in the Operating Manual be strictly followed.
CHECK
Before beginning dismantling works recheck whether stop valve 2 of the oil inlet
pipe is closed and drain screw 3 is removed.
17
16
15
8a
12
13
14
x
015.860/07
II
6
3
4
8
5
II
2
011.782/04
1/ 3
2008
84601/A1
Maintenance
RT-flex96C
Hydraulic Piping: Removing, Fitting and Regrinding

Loosen and remove the longitudinal fastening of holder 12.
Loosen screws 6 and undo screws 7.
Turn housing 8a back by 23 turns, draw hydraulic piping 1 axially back and
move it to the side.
Connect the hydraulic piping to the crane, undo screws 6 and remove the hydraulic piping.
D
Pay attention not to damage sealing faces DF when removing the hydraulic
piping.
All openings must be closed off immediately after removing the connections.
II
1
18 9
8a
6
8
11
011.783/04
2.
11
18
10
Fitting
CHECK
Check before assembly whether the inside of the hydraulic piping, sealing faces
DF of the piping ends, the seating surfaces of sealing rings 9 are clean and undamaged, and whether O-rings 18 (gaskets 14 if necessary) are in good condition.
D
Fitting together should be carried out axially, i.e. the objects to be connected
must not be moved closer together laterally, in order to avoid any damaging
of sealing faces DF.
Housing 8 or 8a (Fig. B) should be screwed on hydraulic piping 1 in such a

manner that after tightening screw 6 or 7 clearance x is about 3 mm.
Fasten holder 12 in longitudinal direction without stresses, i.e. providing the

corresponding shims.
Remark: If the hydraulic piping has been separated, the following must be additionally observed:
2008
Clean hydraulic piping and clamping flanges 15, 16 and fix them in such a
manner that clearance x is about 8 mm equally distributed after tightening
waisted screws 17.
Oil the threads and apply a torque of 70 Nm to the waisted screws and retighten these after 1000 operating hours.
After assembly open stop valve 2, fit and tighten drain screw 3.
2/ 3
RT-flex96C
84601/A1
Maintenance
Hydraulic Piping: Removing, Fitting and Regrinding
3.
Regrinding the sealing faces DF
C
DF
D
Tool 94835 must be used according to the

manufacturers detailed instructions for regrinding sealing face DF.
Screw off housing 8, 8a concerned (Fig. B).

To prevent grinding compound from entering
the hydraulic piping, plug its openings with a
piece of cloth.
After grinding thoroughly clean the hydraulic

piping.
014.936/06
3/ 3
2008
RT-flex96C
87331/A1
Maintenance

Removing, Fitting and Regrinding of Sealing Faces
Tools:
1 Regrinding device
94870
1
2
3
4
5
6
7
8
9
10
consisting of:
1
1
1
1
Screw-on sleeve
Grinding tool
Lock nut
Template
94870a
94870b
94870c
94870d
1 Torque wrench
1.
Cylinder cover
Injection valve
Fuel pressure pipe
Claw
Head screw
Flange
Thrust ring
Connection piece
Drain screw
11
12
13
14
15
1618
Pipe bracket
Holder
Angle steel
Pipe clip
Screw with nut & washer
O-rings
DF Sealing face
EC Emry cloth
HD Hand drill
Removal
When working on a fuel pressure pipe the engine has to be stopped, and it is essential that instructions 05101 in the Operating Manual be strictly followed.
Attention! Fuel leakage pipes are under pressure. Before removing them, they
must be depressurized by means of drain valve 3.65 (see 80191 Fuel leakage
system in the Operating Manual).
Loosen screws 15, remove pipe clips from pipe bracket 11 or angle steel 13.
Remove screws 6 from flange 7 on injection valve 2 and ICU 4.
Pay attention not to damage sealing faces DF when removing the fuel pressure pipes.
All connections must be closed off immediately and sealing faces DF must be
protected after removing fuel pressure pipes.
I
14,15
11
12
2
1
3
II
I
II
I
14,15
13
WCH00078
I
1/ 4
2011-03
87331/A1
Maintenance
RT-flex96C
Fuel Pressure Piping: Removing, Fitting and Regrinding of Sealing Faces
2.
Fitting
Fitting procedure is analogous to the removal but in reverse sequence.
Before fitting fuel pressure pipe 3 check whether its claws 5 are screwed on properly, i.e. the fuel pressure pipe must protrude by x = 11 mm compared to the claw
as shown in Fig. C.
CHECK
Measurement x can be adjusted by turning the claw using an open end spanner.
Fit fuel pressure pipe and fasten it as stress-free as possible.
Apply Never-Seez NSBT-8 to threads of screws 6 and tighten them crosswise
D
Connection piece 9 is smeared with Never-Seez NSBT-8 and thightened with

a torque of 700 Nm).
Retighten the holder and pipe clips according to 03801.
II - II
B
x
16
6
7
8
5
17
2
WCH00078
I-I
DF
16
6
8
7
10
5
17
9
18
4
011.815/04
DF
2010-07
2/ 4
RT-flex96C
Maintenance
87331/A1
3.
Regrinding of sealing faces DF
3.1
With regrinding device 94870

In order to achieve a clean and smooth sealing face the following regrinding process is recommended. For deep notches > 0.1 mm choose emery cloth of medium
to coarse grade. Once the deep notches have been ground off, use a fine or ultra
fine emery cloth.
D
Place template 94870d on the back of emery cloth
EC .
94870d
Trace inner contour using a pointed pencil or a ball

pen.
Cut out precisely the traced contour.
EC
016.738/08
E
Shape the cut cloth in a manner to obtain a cone with
the grained face being turned inward.
94870b
Place the emery cloth in the cone of the grinding tool

94870b and fix it by means of its countersunk screw.
GRAINED FACE
TIGHTENED
CONDITION
016.738/08
3/ 4
2008
87331/A1
Maintenance
RT-flex96C
F
1.
Remove claw 5 (Fig. C).
2.
Fix fuel pressure pipe 3, e.g. in a vice.

016.739/08
Screw on counter nut 94870c until it reaches the

thread end of the fuel pressure pipe.
Turn screw-on sleeve 94870a up to the counter nut.
94870c
94870a
Lock the screw-on sleeve with the counter nut.
G
Clamp grinding tool 94870b in hand drill HD.
Slide grinding tool into the screw-on sleeve
until it slightly touches the fuel pressure pipe.
016.739/08
94870b
Let the grinding tool rotate with a max. speed

of 1500 rpm and grind for 3 to 5 seconds.
HD
Withdraw the grinding tool from the screw-on sleeve

and blow out both parts with pressurized air.
DF
Verify the surface quality of sealing face DF and if

necessary repeat the regrinding process using a
fresh emery cloth EC.
Remark: In case of big notches the tube has to be shortened in order to restitute a clearance of x = min. 0.5 mm
between the countersunk screw and the end face.
016.739/08
Remove counter nut and screw-on sleeve.

After grinding thoroughly clean the fuel pressure
pipe.
2008
4/ 4
RT-flex96C
87331/A2
Maintenance

Removing, Fitting and Regrinding of Spherical Sealing Faces
Tools:
1 Regrinding device
1.
94872
1
2
3
4
5
6
7
8
9
10
Cylinder cover
Injection valve
Fuel pressure pipe
Claw
Head screw
Flange
Thrust ring
Connection piece
Drain screw
11
12
13
14
15
1618
Pipe bracket
Holder
Angle steel
Pipe clip
Screw with nut & washer
O-rings
DF Sealing face
EC Emry cloth
HD Hand drill
Removal
When working on a fuel pressure pipe the engine has to be stopped, and it is essential that instructions 05101 in the Operating Manual be strictly followed.
Attention! Fuel leakage pipes are under pressure. Before removing them, they
must be depressurized by means of drain valve 3.65 (see 80191 Fuel leakage
system in the Operating Manual).
Loosen screws 15, remove pipe clips from pipe bracket 11 or angle steel 13.
Remove screws 6 from flange 7 on injection valve 2 and ICU 4.
Pay attention not to damage sealing faces DF when removing the fuel pressure pipes.
All connections must be closed off immediately and sealing faces DF must be
protected after removing fuel pressure pipes.
I
14,15
11
12
2
1
3
II
I
II
I
14,15
13
WCH00078
I
1/ 3
2011
87331/A2
Maintenance
RT-flex96C
Fuel Pressure Piping: Removing, Fitting and Regrinding of Spherical Sealing Faces
2.
Fitting
Fitting procedure is analogous to the removal but in reverse sequence.
CHECK
Before fitting fuel pressure pipe 3 check whether its claws 5 are screwed on properly, i.e. the fuel pressure pipe must protrude by x = 6 mm compared to the claw as
shown in Fig. C.
Measurement x can be adjusted by turning the claw using an open end spanner.
Fit fuel pressure pipe and fasten it as stress-free as possible.
Apply Never-Seez NSBT-8 to threads of screws 6 and tighten them crosswise
D
Connection piece 9 is smeared with Never-Seez NSBT-8 and thightened with

a torque of 700 Nm).
Retighten the holder and pipe clips according to 03801.
II - II
16
7
8
6
7
8
5
17
2
DF
I-I
3
16
6
8
10
9
18
5
17
9
WCH00372
DF
2011
2/ 3
RT-flex96C
Maintenance
87331/A2
Fuel Pressure Piping: Removing, Fitting and Regrinding of Spherical Sealing Faces
3.
94872
To prevent any traces of grinding compound from

entering the bores of the fuel pressure pipe, plug the
same with a piece of cloth.
Place regrinding device 94872 on sealing face DF.
DF
First rough-grind the sealing faces with grinding

compound No. 200, then finish-grind them with
grinding compound No. 500.
piping.
3
WCH00373
3/ 3
2011
RT-flex96C
87501/A1
Maintenance

Checking and Setting of Relief Valve
Tools:
1 O.M.T. test bench

1 Slide gauge
94272
1
2
3
4
5
6
7
8
9
10
11
Valve housing
Valve needle
Ball
Spring carrier
Disc spring (11 pieces)
Stop ring
Distance ring
Seating washer
Snap ring
Screw plug
Fuel overpressure
safety valve 3.52
12
12a
13
14
15
Flushing valve
Spindle
Adapter (test head)
Back-up ring
O-ring
AB Drain bore
EV Relief valve
MK Marking 3 mm
A
Y
10
OPENING PRESSURE STAMPED IN
3
4
015.499/07
AB
1.
7 15 14 MK 5
General
CHECK
Before dismantling a relief valve for overhaul (grinding in of the valve needle), distance X must be measured and recorded as X. For this purpose, distance ring 4
must be pressed against stop ring 3 by screw plug 10.
After grinding valve needle 2 into the seat of valve housing 1, thoroughly clean
all parts, lightly oil valve needle 2 and apply MOLYKOTE paste G to parts 6, 7,
9 and 11.
D
During assembly, care must be taken that disc springs 6 are correctly positioned (Fig. A).
Not yet fit distance ring 4.

Tighten screw plug until distance X is about the same as before dismantling.
For testing and setting the relief valve, use test bench 94272 (Fig. B).
1/ 2
2008
87501/A1
Maintenance
RT-flex96C
Intermediate Fuel Accumulator: Checking and Setting of Relief Valve

2.
Setting the opening pressure

Place the relief valve (without joint) into adapter 13 of test bench 94272 and
tighten it.
D
Pay attention to the manufacturers detailed instructions, in particular

prior to commissioning and for the operation of the test bench.
Open flushing valve 12 a little by spindle 12a at adapter 13. Operate the test
bench pump until pressure chambers are filled and diesel oil escapes bubblefree. Close spindle 12a.
Increase the pressure on the test bench and observe at what value the relief
valve opens. Correct opening pressure = 1250 bar.
Set required pressure by adjusting screw plug 10. Measure distance X and
note it as X1 (Fig. A).
Reduce height Y of the distance ring by the difference between distances X1
and X.
Reassemble relief valve with distance ring 4 and tighten screw plug until it is
fully down on distance ring.
CHECK
Recheck the opening pressure on the completely assembled relief valve.
13
94272
11
12a
12
13
000.931/94
000.930/94
3.

Apply Never-Seez NSBT-8 to thread GW (Fig. A).
Screw the relief valve into the intermediate fuel accumulator and tighten it with
a torque of 300 Nm.
2008
2/ 2
RT-flex96C
87501/A2
Maintenance

Checking of Relief Valve
Tools:
1
1
1
2
2
1.
OBEL test bench

Valve holder
HP oil pump
Hydr. distributors
HP hoses
94272
94272a
94931
94934a
94935
1
2
3
4
5
6
7
8
9
10
Valve housing
Valve needle
Ball
Spring carrier
Disc spring (11 pieces)
Stop ring
Distance ring
Seating washer
Snap ring
Screw plug
11 Fuel overpressure
safety valve 3.52
12 Receiver
13 Back-up ring
14 O-ring
AB Drain bore
EV Relief valve
MK Marking 3 mm
General
A relief valve normally requires no maintenance, however the opening pressure
and the tightness should be checked according to Maintenance Schedule 03801.
Leaky or faulty valves have to be returned to the manufacturer or to a Wrtsil
Switzerland Ltd. authorized repair workshop for inspection and repair.
The opening pressure of the relief valve must be approved by IACS (International
Association of Classification Societies) and recorded on the Inspection Report.
Remark: To identify the new fuel overpressure safety valve (relief valve) 11, two
bores MK on one face have been provided as a marking.
AF80
AF41
OPENING PRESSURE
STAMPED IN
3
4
015.499/07
AB
2
6
2.
7 14 13 MK 5
8 9 10
Checking
In order to properly loosen the relief valve from the fuel accumulator, a spanner
AF80 must be used and placed on housing 1!
Test bench 94272 as well as test & calibration fluid has to be used (e.g. Shell Calibration Fluid S.9365) complying with the data according to the following table:
2.1
Physical characteristics for test & calibration fluid

Kinematic Viscosity
at 40 _C
Density at 15 _C
kg/m3
ISO 12185
827
_C
ISO 3016
27
Pour Point
ASTM D445
mm2/s
1/ 2
2.6
201007
87501/A2
Maintenance
RT-flex96C
Checking of Relief Valve

Remark: Pay attention to the manufacturers detailed instructions and working
specifications of the test bench.
Fit relief valve 11 into the valve holder and tighten it.
Connect valve holder 94272a to HP oil pump 94931 (or hydraulic unit 94942).
2.2
Checking the sealing pressure

Increase the pressure by means of HP oil pump to 1150 bar and keep pressure constant during one minute.
D
2.3
No leakage is allowed!
Checking the opening pressure

Increase the pressure by means of HP oil pump and observe at what value the
relief valve opens.
Correct opening pressure = 1250 bar
D
+ 100
50
Confirm the opening pressure two times again.
94934a
94935
94272a
11
12
013.484/05
94931
EV
94272
94934a
013.486/05
3.

Apply Never-Seez NSBT-8 to the thread of valve housing 1.
Screw the relief valve into the intermediate fuel accumulator and tighten it with
a torque of 300 Nm by means of a spanner with AF41.
201007
2/ 2
RT-flex96C
87502/A1
Maintenance
Fuel Pressure Control Valve

Removal, Fitting, Dismantling and Assembling
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1.
Fuel pressure control valve

Piston
Valve tip
Valve seat
Oil pressure regulating valve
Compression spring
Compression spring
Knurled screw
Adjusting disc
Housing
Cover
Cover
Filter
Union
15
16
17
18
19
20
21
22
23...25

Flange
Screw M16x200
Locating pin
Intermediate ring
Connection piece
Solenoid valve
Allen screw M6x55
O-rings
BA Fuel outlet
BE Fuel inlet
OE Oil inlet pipe
General
To avoid any risk of failures related to the fuel pressure control valve (PCV),
Wrtsil recommends only performing the below mentioned maintenance. PCV
maintenance onboard is limited to:
Replacement of the complete PCV
Replacement of the 3/2-way solenoid valve
Replacement or cleaning of the control oil inlet filter
Remark: In case the PCV was replaced on a previous occasion, Wrtsil offers a
new or remanufactured PCV which will be equipped and set according to the latest
technical specification with the correct pressure adjustment.
For detailed maintenance intervals of the PCV refer to the Maintenance Schedule
03801.
The engine has to be stopped when working on a PCV and the instructions 05151
in the Operating Manual must be strictly followed.
1 21
WCH00845
1/ 3
2012-05
87502/A1
Maintenance
RT-flex96C
Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling
2.
Removal of fuel pressure control valve

Remove all pipings from fuel pressure control valve 1.
Connect the PCV (45 kg) to the crane by means of a manual ratchet.
Loosen screws 17 and move the PCV in arrow direction, taking care that intermediate ring 19 and connection piece 20 do not fall down.
3.
Fitting the fuel pressure control valve

Bring the PCV in fitting position at the fuel rail by means of a manual ratchet.
Apply Never-Seez NSBT-8 to the screw threads 17.
Place new O-rings 23 and 24 into the grooves of intermediate ring 19.
Fit the intermediate ring over locating pin 18 and insert connection piece 20.
Fasten the PCV to flange 16 with screws 17 and tighten them crosswise with a
torque of 190 Nm.
I
1
18 19 20
16
17
15
WCH00845
2012-05
23
24
2/ 3
16
RT-flex96C
87502/A1
Maintenance
Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling
4.
Cleaning the filter

Remove oil inlet pipe OE and union 14.
Loosen filter 13 and clean it. If necessary replace it.
Oil the filter, screw it into cover 12 and apply a torque of 10 Nm.
14
12 13
8
9
OE
7
6
11
3
4
25 21 22
10
5
BE
WCH00763
BA
OIL
FUEL OIL
5.
Storage on board
The spare parts must be carefully protected against corrosion.
D
The PCV has to be free from any dirt, oil and grease.
Apply coating liquids (e.g. Tectil 506, ISOTEC 337 or similar) on the surfaces
to be preserved.
All blind holes and tapped holes must be plugged.
Especially consignments transported overseas must be well protected against adverse climatic conditions (intense cold, rain, high humidity, etc.) and kept in a
closed box.
3/ 3
2012-05
RT-flex96C
87521/A1
Maintenance

Tools:
2 Regrinding devices
94870
consisting of:
1
1
1
1
Screw-on sleeve
Grinding tool
Lock nut
Template
94870e
94870f
94870g
94870h
1
1
1
1
Screw-on sleeve
Grinding tool
Lock nut
Template
94870i
94870j
94870k
94870l
1 Turnbuckle
1.
1
2
3
4
5
6
7
8
9,a,b
10,a
11
12

Stop valve
Stop valve
Heating pipe
Pipe bracket
Screw
Flange
Screw
Intermediate piece
13
14
15
16
17
18
19
2022
Claw
Thrust ring
Drain screw
Valve block
Screwed sleeve
Non-return valve
Fuel pressure pipe
O-rings
DF Sealing face
94873
Removal
3
1.1
Preparation to removal
Close steam supply to heating pipes 4 on

plant side.
Remove casings where necessary.

Close respective stop valves 2 and 3.
5
Remark: The spindles of closed stop valves 2 and

3 must be tightened with 100 Nm.
Open corresponding drain screws 15 (Fig. B

view III).
4
II
8
7
I
1
19
011.799/04
1/ 6
2010-07
87521/A1
Maintenance
RT-flex96C
Fuel Pressure Piping: Removing, Fitting and Regrinding

1.2
Removal of fuel pressure pipings 6 and 7

D
If a fuel pressure piping 6 must be removed, first dismantle the corresponding

fuel pressure piping 7.
The sealing faces DF at the pipe ends must be protected from any possible
damages.
1.2.1 Removal of fuel pressure piping 7

Loosen corresponding heating pipe 4.
Undo screws 9 and push flanges 10a back till they do not mesh any more.
Pull fuel pressure piping 7 away and remove it from intermediate fuel accumulator 1.
1.2.2 Removal of fuel pressure piping 6
Undo screws 9a and push flange 10 back.
Undo screws 11 and remove them together with intermediate piece 12.
Undo screws 9b and remove fuel pressure piping 6.
B
I
10
15
9b
4
5
II
6
9a
10
II
11
III
15
12
10a
9
4
III
9
011.801/04
2008
2/ 6
10a 15
RT-flex96C
87521/A1
Maintenance
C
1.3
Removal of fuel pressure piping 5
Place turnbuckle 94873 between fuel pressure piping 5 as shown in Fig. C.

Remark: Tension turnbuckle 94873, so that it
does not fall down.
10
Undo screws 9b and push flange 10 back till it

does not mesh any more.
9b
4
Remove fuel pressure piping 5.

D
94873
approx. 383 mm
The sealing faces DF at the pipe ends must

be protected from any possible damages.
011.810/04
Fitting
X = 16.5mm
2.
21
Fitting procedure is analogous to the removal but

in reverse sequence.
CHECK
13
Measurement x can be adjusted by turning the

claw using an open end spanner.
14
Remark: For fitting fuel pressure piping 5 must be

expanded to approx. 383 mm with turnbuckle
94873 as shown in Fig. C.
10
Apply Never-Seez NSBT-8 to threads of

screws 9, a, b and tighten them crosswise
20
Close all drain screws.
5, 6, 7
After refitting the fuel pressure piping open

stop valves 2 and 3 and tighten their spindles
with 100 Nm.
014.493/06
Before fitting fuel pressure pipings 5, 6 or 7, check

whether their claws 13 are screwed on properly,
i.e. fuel pressure pipe must protrude by x = 16.5
mm compared to the claw, as shown in Fig. D.
3/ 6
2008
87521/A1
Maintenance
RT-flex96C
3.
Non-return valve
If a non-return valve 18 has been removed from valve block 16, O-rings 22 must be
replaced by new ones.
The proper flow direction (see arrow engraved in valve block) must be maintained
when refitting the non-return valve.
Apply LOCTITE 0222 to screwed sleeve 17 and tighten it with 80 Nm.
I-I
16
014.451/06
FLOW
DIRECTION
22
18
4.
17
Fuel pressure pipe

For regrinding sealing faces DF on fuel pressure pipe 19, the same instruction
applies as mentioned under paragraph 5.1. Please consider the special left-hand
thread M36x2 LH and therefore use tools 94870i, 94870j, 94870k and 94870l.
A defective fuel pressure pipe must always be replaced completely.
CHECK
Before fitting fuel pressure pipe, check whether their claws are screwed on properly, i.e. fuel pressure pipe 19 must protrude by x = 13.4 mm compared to the claw.
19
WCH00084
2010-07
4/ 6
RT-flex96C
Maintenance
87521/A1
5.
5.1
With regrinding device 94870

In order to achieve a clean and smooth sealing face the following regrinding process is recommended. For deep notches > 0.1 mm choose emery cloth of medium
to coarse grade. Once the deep notches have been ground off, use a fine or ultra
fine emery cloth.
G
Place template 94870h(I) on the back of emery cloth
EC .
94870h(I)
Trace inner contour using a pointed pencil or a ball

pen.
Cut out precisely the traced contour.
EC
016.738/08
H
Shape the cut cloth in a manner to obtain a cone with
the grained face being turned inward.
94870f(j)
GRAINED FACE
Place the emery cloth in the cone of the grinding tool

94870f(j) and fix it by means of its countersunk
screw.
TIGHTENED
CONDITION
016.738/08
5/ 6
2010-07
87521/A1
Maintenance
RT-flex96C
Remove claw 13 (Fig. D).

1.
Fix fuel pressure piping 5, 6, 7 or 19, e.g. in a vice.
2.
Screw on counter nut 94870g(k) until it reaches the

thread end of the .
016.739/08
5,6,7,19 94870g(k)
Turn screw-on sleeve 94870e(i) up to the counter

nut.
Lock the screw-on sleeve with the counter nut.
94870e(i)
J
Clamp grinding tool 94870f(j) in hand drill
HD.
Slide grinding tool into the screw-on sleeve
until it slightly touches the fuel pressure
piping.
016.739/08
94870f(j)
HD
Let the grinding tool rotate with a max. speed

of 1500 rpm and grind for 3 to 5 seconds.
Withdraw the grinding tool from the screw-on sleeve

and blow out both parts with pressurized air.
DF
Verify the surface quality of sealing face DF and if

necessary repeat the regrinding process using a
fresh emery cloth EC.
Remark: In case of big notches the tube has to be shortened in order to restitute a clearance of x = min. 0.5 mm
between the countersunk screw and the end face.
016.739/08
Remove counter nut and screw-on sleeve.

piping.
2010-07
6/ 6
RT-flex96C
Maintenance
Group9
Group 9
Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting . . . . . . . . . . . . . 92231/A1

Tools: Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94031/A1
Hydraulic Jacks and Pumps: Arrangement and Application . . . . . . . . . . . . . . . . . . . 94032/A1

Storing, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94033/A1
General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94034/A1
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94035/A1

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 01 53
Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 54 58
Special Tools Obtainable on Loan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 59 62
1/ 22
RTflex96C / MM / 2013-02
RT-flex96C
92231/A1
Maintenance
Crank Angle Sensor Unit

Dismantling, Assembling and Adjusting
Tools:
1 Feeler gauge
1 Hook spanner
1 Hook spanner
94122
94924
94925
1
2
3
4
5
6
7
8
9
10
11
12
13
13a
14
15(a)
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32(a)
33
34
35
36
Protection hood
Covering cap
Screw
Nut
Shaft
Crank angle sensor (CAS)
Holder
Screw
Toothed belt
Protection plate
Screw with locking plate
Angle holder
Outer shaft encoder
Inner shaft encoder
Bearing housing
Screw
Washer
Locking plate
Gear wheel
Gear wheel
Waisted screw
Packing ring
Adjusting disc
Locking plate
Shaft nut
Locking plate
Shaft nut
Circlip
Retaining ring
Sealing ring
Distance ring
Ball bearing
Distance ring
Distance sleeve
Disc spring
Circlip
37
38
39
40
41
42
43
44
45
46
47
48
48a
49
50
51
52
53
54
55
56
57
58
59
60
Disc
Key
Packing ring
Locating pin
Inspection cover
Compression spring
Lever
Throttle
Housing
Screw
Screw
Locking plate
Connecting unit
Locating pin
Coupling disc
Spring tensioner
Adjusting screw
Clamp screw w. tab washer
Distance piece
Locating pin
Spring balance
O-ring
GL
KD
KK
MB
MK
OE
SU
SH
SK
SR
Tap hole
Cable clamp
Terminal box
Magnetic base with dial gauge
Mark
Oil inlet
Collar
Protective sleeve
Sensor cable
Protective pipe
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Removal of shaft encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/22

Shaft encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/22
Fitting the shaft encoder and the toothed belt . . . . . . . . . . . 3/22
Removal of crank angle sensor drive . . . . . . . . . . . . . . . . . . . 8/22
Dismantling the crank angle sensor drive . . . . . . . . . . . . . . . 9/22
Assembling the crank angle sensor drive . . . . . . . . . . . . . . 11/22
Fitting the crank angle sensor drive . . . . . . . . . . . . . . . . . . . 14/22
Removal and fitting of compression spring . . . . . . . . . . . . 15/22
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18/22
Replacement of toothed belt or CAS drive . . . . . . . . . . . . . 22/22
1/ 22
2012-05
92231/A1
Maintenance
RT-flex96C
Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting
1.
Removal of shaft encoder

FREE END
1.1
Preparation
Pull out plug of sensor cable SK at terminal

box KK (Fig. A).
KK
SK
Unscrew protection hood 1 and remove it together with covering cap 2.
SR
OE
Unscrew cable clamps KD as well as protective sleeve SH and withdraw sensor cable
from protective pipes SR.
2
1
1.2
Outer shaft encoder
Loosen screws 3 and remove them together

with protection plates 10.
Loosen screws 11 and remove them together
with angle holder 12.
Loosen screws 15, 15a and remove outer
shaft encoder 13 together with toothed belt 9.
008.724/00
II - II
I
I-I
1 14 11
CLEARANCE
11 12 10
II
2
5 4
008.725/00
13
13a SH
II
2008
008.758/00
15a 15
2/ 22
KD SK
RT-flex96C
92231/A1
Maintenance
1.3
Inner shaft encoder

Removing the inner shaft encoder 13a is only possible after the toothed belt of the
outer shaft encoder 13 has been removed according to paragraph 1.2.
Removal of the inner shaft encoder 13a is carried out analogously to the outer one.
13
13a
008.727/00
008.726/00
SK
2.
Shaft encoder
Shaft encoders are only supplied complete. The crank angle sensor 6 is fastened
to the holder 7 and set by the manufacturer.
Attention! Never loosen screw 8!
008.728/00
3.
Fitting the shaft encoder
3.1
Inner shaft encoder
19
008.728/00
Turn crankshaft to T.D.C. of Cyl. No.1.

Mount shaft encoder 13a (Fig. D and F) on the guide plate of bearing housing 14 with screws 15, washers 16 and locking plates 17. Do not tighten
screws 15. Apply MOLYKOTE paste G to the threads and head seatings.
CHECK
Slide shaft encoder along the guide plate to check that the shaft encoder is moving
freely.
Push shaft encoder inwards.
3/ 22
2012-05
92231/A1
Maintenance
RT-flex96C
3.2
Fitting the toothed belt

Only the new belt version (black colour) must be installed.
Connect gear wheels 19 and 18 with toothed belt 9, paying attention to their
marks MK which must coincide according to Fig. G (zero position).
Push shaft encoder outwards till the toothed belt is lightly tensioned and
meshing properly with the gear wheels. Lightly tighten screws 15. Recheck
marks MK.
Fit screws 15a, washers 16 and locking plates 17. Apply MOLYKOTE paste G
to the threads and head seatings.
Align toothed belt exactly in running direction.
Attach spring balance 59 to the shaft encoder and slightly preload it according
to Fig. F.
Loosen all screws 15 and 15a, paying attention that the shaft encoder can still
move freely.
Tension toothed belt with 30 N indicated on spring balance, and fixate shaft
encoder with screws 15 and 15a.
Remark: Pull the spring balance exactly in tensioning direction, keeping the friction between the holder guide and screw surfaces as small as possible.
15
15a
13a
MK
59
SK
58
008.729/00
2012-05
4/ 22
17
16
15a
008.730/00
RT-flex96C
92231/A1
Maintenance

In order to align toothed belt 9 on its running track, turn the crankshaft one to
two revolutions with the turning gear.
Recheck belt tension according to Fig. G and H as well as marks MK. Repeat tensioning procedure if belt slackened after crankshaft has been turned
or if marks MK are not matching.
Adjust and bend the long lugs of locking plates 17 according to Fig. G.
Tighten all screws 15 and 15a with a torque of 16 Nm and lock them.
Attention! Always use new locking plates, bending them once only!
TOOTHED BELT
TENSIONED
G
9
18
15
TOOTHED BELT
LOOSE
H
I
15a 17
19
T.D.C. 1
T.D.C. 1
008.731/00
008.732/00
MK
16
17
008.731/00
15a
MK
3.3
Outer shaft encoder
Fitting the outer shaft encoder 13 is carried out analogously to the inner one.
Attention! When fitting shaft encoders, toothed belts
or crank angle sensor drive (section 7) always pay
attention to the following points:
58
SK
Crankshaft at T.D.C. of Cyl. No.1.
Bore for locating pin 58 of the crank angle sensor

drive pointing downwards as shown in Fig. I.
Mark MK (T.D.C. 1) of gear wheel 18 pointing upwards as shown in Fig. G and all other marks
aligned according to Fig. I.
008.733/01
5/ 22
2008
92231/A1
Maintenance
RT-flex96C
3.4
Final works
Fit angle holder 12 using screws 11 with their locking plates. Subsequently
install protection plates 10 in such a way that they contact each other at the
centre without overlapping and touching any moveable parts, using screws 3
with their locking plates.
Tighten and lock screws 3 and 11.
After assembling fit carefully the sensor cables SK. Pay attention to the clearance which must exist between sensor cables and housing (Fig. B, section
II).
Fit protection hood 1 together with covering cap 2.
3.5
Toothed belt change

If there should be changed only one toothed belt, proceed as follows:
Remove protection plate 10 and angle holder 12 (Fig. B).
Remove screws 15a with locking plates and washers.
Remove screws 15, replace locking plates and loosely refit the screws.
Push shaft encoder inwards and replace toothed belt.
D
3.6
For fitting pay attention to paragraphs 3.1 to 3.4.
Rechecking of toothed belt tension

In accordance with Maintenance Schedule 03801 Crank angle sensor unit the
toothed belt tension must be visually rechecked as shown in Fig. G and H, and by
lightly tapping on the toothed belt with a finger.
If necessary or in case of doubt the toothed belt must be retensioned as described
in paragraph 3.2!
Attention! After every loosening of a shaft encoder the toothed belt tension must
be rechecked after about five operating hours!
2008
6/ 22
RT-flex96C
92231/A1
Maintenance
3.7
Adjustment of crank angle offset in WECS

After the mechanical work on the CAS and CAS drive, the crank angle offsets must
be adjusted.
Turn the engine with the turning gear until the flywheel marks show T.D.C. of
Cyl. No.1 = 0.0_.
Marks MK must be aligned as indicated in Fig. J.
T.D.C. of the Cyl. No.1 can be cross checked from the crankcase. But safety
measures must be taken accordingly before opening of the crankcase, see
Warning labels located near the crankcase doors on the engine.
Start the flexView programme and go to the ADJUST card.
With the flywheel position as described above, read the crank angle values
displayed in the fields Crank angle 1/2. If they are different from 0.0_ CA,
enter the displayed values as offset in the fields CA 1/2 Offs.
Remark! For negative deviations, e.g. 359.8 <_, use negative values 0.2 <_.
J
Crank Angle
CA 1/2 Offs.
Crank Angle
0.0 < _
Crank angle 1/2 0.1 < _
0.0 < _
CA 1/2 Offs.
0.1 < _
-0.2 < _
359.8 <_
Crank angle 1/2
0.0 < _
0.0 < _
MK
T.D.C. 1
008.731/00
008.726/00
MK
7/ 22
2012-05
92231/A1
Maintenance
RT-flex96C
4.
Removal of crank angle sensor drive

Preparation according to paragraph 1.1.
Loosen and remove nuts 4.
Attention! When loosening nut 4 hold up shaft 5 by means of an open end spanner AF27!
Remove screws 21 and withdraw the crank angle sensor from the waisted
screw 20 (view II).
Remark: Do not unscrew adjusting disc 23.
I-I
21
22 21
II
5
4 20
23
I
008.735/01
SK
008.734/01
II
008.736/01
2008
8/ 22
RT-flex96C
92231/A1
Maintenance

5.
Dismantling the crank angle sensor drive

Recommendation: To ensure a high availability and quality standard we recommend that a complete crank angle sensor drive according to Fig. K, view II (including shaft encoder Fig. D) always be kept in stock. Maintenance works as described in sections 5 and 6 may be carried out only by qualified manufacturers as a
matter of principle.
Remove shaft encoder according to paragraphs 1.2 and 1.3.
Unbend locking plate 24, loosen and remove shaft nut 25 using hook spanner
94924.
Withdraw gear wheel 18 from the shaft 5.
Remark: If withdrawing by hand is not possible, the gear wheel must be removed
by means of the two tap holes GL and suitable tools, however, without striking and
damaging the toothing.
18
24 25
GL
008.737/01
Remove circlip 28 using a snap ring tong.

Unbend locking plate 26, loosen and remove shaft nut 27 using hook spanner
94925.
Remove shaft 5, however, key 38 remains in situ.
M
26 27 38
28
008.738/01
9/ 22
2008
92231/A1
Maintenance
RT-flex96C
N
14
34
35
Parts to be removed in the following sequence:
Retaining ring 29 (using tap holes GL) together with sealing ring 30 and O-ring 60.
Distance ring 31.
Ball bearing 32, distance ring 33, distance

sleeve 34 and disc springs 35.
Circlip 36.
Disc 37 together with ball bearing 32a.
60
GL
31
29
30
008.739/01
36
2008
37 32a
33 32
10/ 22
RT-flex96C
92231/A1
Maintenance
6.
Assembling the crank angle sensor drive

Clean all parts and check their conditions prior to assembling.
Replace sealing ring 30, ball bearings 32, 32a and O-ring 60 (Fig. N).
6.1
Determining of thickness x of distance ring 33 (Fig. N)

Push ball bearing 32a, distance sleeve 34, ball bearing 32 and distance ring
31 onto the shaft 5 according to Fig. O.
Attention! Big collar SU on inner ring of the ball bearings must point outwards!
Screw shaft nut 27 onto shaft 5 and lightly tighten it by means of hook spanner
94925.
Measure and note down distance a.
SU
SU
38
008.740/01
32a 34
32
31 27
14
Measure and note down distance b in housing 14.
According to the following formula determine thickness
x for distance ring 33 to be fitted:
x = a b 4.2 mm
Tolerance x amounts to " 0.2 mm.
008.741/01
11/ 22
2008
92231/A1
Maintenance
RT-flex96C
6.2
Sub-assembly of bearing housing
Remove the parts which are fitted on shaft 5

as shown in Fig. O.
Oil ball bearing 32a and insert it into housing
14. Pay attention to the fitting position in paragraph 6.1!
Place disc 37 with its smaller seating surface
pointing to the ball bearing and fit circlip 36.
36
37 32a 14
008.742/01
6.3
Completing of the bearing housing

Oil all parts.
Fit shaft 5.
Push distance sleeve 34 onto the shaft.
Fit disc springs 35 according to view I.
Fit distance ring 33 with thickness x determined under paragraph 6.1.
Oil ball bearing 32 and insert it into housing 14. Pay attention to the fitting
position in paragraph 6.1!
Fit retaining ring 29 with new sealing ring 30 and O-ring 60 according to view
II.
Fit distance ring 31.
R
14 34
34
35
35
33
31
14
008.744/01
II
31
30
29
II
14
33 32
008.743/01
2008
12/ 22
008.744/01
60
RT-flex96C
92231/A1
Maintenance
6.4
Tightening the shaft nut

Apply MOLYKOTE paste G to the thread and seating surface of shaft nut 27.
Fit locking plate 26 and screw down shaft nut.
Put torque wrench with socket spanner AF27 on the hexagon of shaft 5 and
tighten the shaft nut with 25 Nm using hook spanner 94925.
Lock shaft nut with locking plate.
Fit circlip 28.
S
26 27
5
28
008.738/01
6.5
Fitting gear wheel 18

Oil bore and push gear wheel 18 onto shaft 5 till the stop.
Apply MOLYKOTE paste G to the thread and seating surface of shaft nut 25.
Fit locking plate 24 and screw down shaft nut 25.
Put torque wrench with socket spanner AF27 on the hexagon of shaft 5 and
tighten the shaft nut with 25 Nm using hook spanner 94924.
14
24 25
58
18
008.737/01
13/ 22
2008
92231/A1
Maintenance
RT-flex96C

6.6
Fitting the shaft encoder

For the purpose of improved accessibility the shaft encoders 13 and 13a may be
fitted onto the bearing housing 14 (Fig. T) outside the engine. For that proceed as
described under paragraphs 3.1 and 3.2 with the difference that shaft 5 must be
turned several times by hand in order to adapt it to its running track.
When fitting the toothed belt pay attention to the important points in paragraph 3.3!
7.
Fitting the crank angle sensor drive

Push crank angle sensor drive with packing ring 22 a little onto waisted screw
20 and turn shaft 5 in such a way that locating pin 40 and the corresponding
bore in the shaft are in line.
Push crank angle sensor drive further till the locating pin fits into the corresponding bore in shaft 5.
Fasten screws 21 with their locking plates.
CHECK
Turn crankshaft to an appropriate position.

Remove inspection cover 41 and check through the opening the fitting positions of:
Compression springs 42, lever 43 and connection according to view I.
Apply MOLYKOTE paste G to the thread and seating surface of nut 4.

Screw nut onto waisted screw 20 and tighten it with a torque of 140 Nm.
Attention! When tightening nut 4 hold up shaft 5 by

means of an open end spanner!
41
Check adjustments according to paragraph 3.3.
CHECK
7.1
39
40
43
Final works
Carry out final works according to paragraphs

3.4 and 9.1.
22
21
I
43
5
40
5 20
4 20
42 58 23
008.745/01
44
NO CLEARANCE
008.734/01
2008
14/ 22
RT-flex96C
92231/A1
Maintenance
8.
Removal and fitting of compression spring
47
46
8.1
Preparation
Remove oil inlet OE (Fig. A).

Dismantle crank angle sensor drive according to
section 4.
Remove screws 47 and housing 46.
20
008.746/01
W
49
Remove screws 48 and connecting unit 49.

Remove screws 44 and withdraw waisted screw 20
from the lever 43.
50
20
I-I
50
43
44
40
43
48a
48
51 48
008.748/01
51
008.747/01
15/ 22
44
2008
92231/A1
Maintenance
RT-flex96C
8.2
Removing the compression spring
Loosen screws 53 and remove them together with

spring tensioner 52.
FITTING
POSITION
Remove and check compression springs.

Remark: When replacing only one compression spring
42, it is recommend to remove also the second spring
tensioner for carrying out further adjustments.
CHECK
Check spring seating surface for wear.
57
42
54
55
55
52
008.749/01
53
8.3
52
51
008.750/01
54
Fitting of the lever

When fitting lever 43 pay attention to its fitting position (Fig. X).
Replace locking plates to screws 57.
Apply MOLYKOTE paste G to threads and seating surfaces of screws 57.
Tighten screws 57 with a torque of 60 Nm and lock them.
8.4
Y
x
Loosen clamp screws 55 of spring tensioner

52 (Fig. X). Replace locking plates. Apply
MOLYKOTE paste G to threads and seating
surfaces of screws 55 and refit them.
Oil and adjust all adjusting screws 54 to
x = 10 " 0.10 mm (Fig. Y).
008.751/01
52
Fitting the compression spring
54
Insert compression springs 42, fit spring tensioner with screws 53 and new locking plates,
applying MOLYKOTE paste G to threads and
seating surfaces.
Tighten screws 53 with a torque of 60 Nm and
lock them.
2008
16/ 22
RT-flex96C
92231/A1
Maintenance
8.5
Adjusting the compression spring

By means of synchronously adjusting screws 54 (i.e. if one of the adjusting
screws is screwed-in by e.g. turn, the opposite one must be screwed-out by
turn) move the relevant compression spring pair 42 until lever 43 shows the
same distance x between the stops on both sides (centering lever).
For measuring use feeler gauge 94122.
Tighten all clamp screws 55 with a torque of 35 Nm and lock them.
50
40
II - II
II
42
008.752/01
II
56
43
55
54
008.749/01
8.6
Fitting the connecting unit (Fig. W)

Fit waisted screw 20 and screw 44 with new locking plates. Tighten and lock
the latter (Fig. U view I).
Remark: Screw 44 must not press against waisted screw 20!
Fit connecting unit 49 and screws 48 together with new locking plates 48a,
applying MOLYKOTE paste G to threads and seating surfaces.
Tighten screws 48 with a torque of 60 Nm and lock them.
CHECK
Locating pin 40 and locating pin 50 must point upwards on Cyl. No.1 at T.D.C. according to Fig. W and Z!
17/ 22
2008
92231/A1
Maintenance
RT-flex96C
8.7
Final fitting the crank angle sensor unit

Fit housing 46 with joint and fasten with screws 47 (Fig. V).
Fitting of the crank angle sensor drive according to section 7.
Carry out final works according to paragraphs 3.4 and 9.1.
9.
Checks
The periodical checks must be carried out according to Maintenance Schedule
03801 Crank angle sensor unit.
9.1
Lubricating oil flow in the crank angle sensor drive

Start main lubricating oil pump and adjust bearing oil pressure.
Remove inspection cover 41.
With correct oil flow at operating temperature an oil spray results according to Fig.
B1. However, the oil outlets should be filled up.
Refit inspection cover 41.
I-I
A1
41
008.753/01
OIL OUTLET
B1
I
008.725/00
008.754/01
OIL SPRAY
2008
18/ 22
RT-flex96C
92231/A1
Maintenance
9.2
Checking the throttle

Before reaching the crank angle sensor unit, the oil flows first through throttle 45,
which reduces the oil quantity and also keeps back larger oil particles.
Checking the throttle is carried out as follows:
Stop main lubricating pump.
Remove oil inlet OE from the throttle.
Unscrew throttle and check its oil spray holes for free passage. Clean if necessary.
Reinstall all parts.
C1
II
II
OE
I
008.755/01
II - II
45
OIL INLET
008.724/00
008.756/01
19/ 22
2008
92231/A1
Maintenance
RT-flex96C
9.3
Checking the shaft eccentricity

The following chekcs and the replacement of CAS parts can only be carried out if
the engine is at standstill.
Ckeck the shaft eccentricity in case of CAS exchange.
It is essential to perform the eccentricity check according to the Maintenance
Schedule 0380-1.
9.4
Eccentricity check
Remove the protection hood 1 of the CAS drive (see Fig.B).
Install the magnetic base with dial gauge MB.
D1
MB
18
Remark! The measuring point must be horizontally adjacent of the gear wheel 18.
Read the deviation on the dial gauge while turning the crankshaft with the
turning gear.
The average shaft eccentricity under normal working and assembly condition
must be less than 0.15 mm.
In case the measured value is out of the stated average eccentricity value, it is recommended to replace the CAS with a new one (see sections 5 and 7). A CAS drive
is available as a standard spare part.
2012
20/ 22
RT-flex96C
92231/A1
Maintenance
9.5
Checking the clearance between shaft and internal bearing of the CAS
In case the CAS is over five years in service or has more than 48 000 operating
hours, it is recommended to check the condition of the CAS before a new belt version is installed. The CAS condition is checked by measuring the clearance between the shaft and internal CAS bearing.
Procedure for measuring the clearance:
Remove the protection hood 1 of the CAS drive (see Fig.B).
Remove the protection plate 10.
After loosening the screws 15a and 15, remove first the toothed belt of the outer CAS and then the toothed belt of the inner CAS.
After removing the toothed belt, tighten the screws 15a and 15 again.
Install the magnetic base with dial gauge MB as shown below.
Push the gear wheel of the CAS to the left and right direction.
The measurements X and Y have to be done in fixed condition of the outer and
inner CAS but without the toothed belts.
Read the deviation on the dial gauge while pushing the gear wheel of the CAS.
The average CAS clearance under normal working and in assembly condition must be less than 0.05 mm.
E1
15a
9.6
15
10
MB
Checking the toothed belt condition

The toothed belt has to be checked every 3000 operating hours for its pre-tension.
In addition a visual inspection of the belt ha to be performed, which means checking for possible cracks and worn-out areas.
Attention! Worn-out toothed belts must be replaced immediately.
21/ 22
2012
92231/A1
Maintenance
RT-flex96C
10.
Replacement of toothed belt or CAS drive
10.1 Replacement of the toothed belt

The new toothed belt version must be used (Fig. E), which can be ordered separately as single part according to the Spare Parts Code Book.
Do not use the old toothed belt anymore.
10.2 Reasons for CAS drive replacement
There are two reasons which require a CAS drive overhaul:
High shaft eccentricity: To verify the eccentricity, see the paragraph 9.3.
Maintenance schedule: Work to be carried out at 48 000 operating hours.
Before carrying out the replacement of a CAS drive which is available as a standard spare part, a new CAS drive must be ordered unless a repair kit is available on
board.
The spare parts order number is to be found in the Spare Parts Code Book, Group
9, Chapter 96011, within item Crank Angle Sensor Unit and named Shaft encoder drive, complete or Shaft encoder, complete (box).
Remark! According to IACS regulations, at least one Shaft Encoder Package box
containing the spring balance is part of the standard spare parts supply per ship.
2012
22/ 22
RT-flex96C
Maintenance
94031/A1
Tools
Explanation
1.
General
The tools required for erection and maintenance of the engine are divided into
three groups as per the following Tool List:
Standard tools
Recommended special tools
Special tools available on loan
When ordering additional tools or replacements, the tool No. as well as the tool
description including engine type must be indicated (see 94035).
Detailed instructions on the arrangement and application, storing, servicing and
maintenance of the hydraulic pre-tensioning jacks are given in 94032 to 94034.
When oil must be added to the hydraulic pumps, the specification regarding oil
quality issued by the pump manufacturers must be followed. Utilize generally an
engine lub. oil having viscosities SAE 30 to SAE 40.
A cylinder lubricating oil also can be used in exceptional cases.
A separate set of tools is issued for certain components from sub-suppliers, which
should also be stored separately from the engine tools.
2.
Standard tools
... are tools and devices required for normal maintenance work on the engine. In
this respect take into consideration that, depending on the design execution of the
engine, certain tools and devices which are mentioned in the above sheets are not
required for specific maintenance work, and are therefore not part of the engine
tools supply.
3.
Recommended special tools

... 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.
4.
Special tools available on loan

... 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.
1/ 1
2008
RT-flex96C
94032/A1
Maintenance
Hydraulic Jacks and Pumps

Arrangement and Application
13 12 11 10
9
3
14
7
1
13 11
10
16 17
13
12
11
10
19
6
18 5
20
18
014.126/06
A = Tensioning / loosening of waisted studs to main bearings, tie rods, valve

cages, top and bottom end bearings to connecting rod; piston foot fastening;
screwed connections to turning gear; waisted bolts to camshaft and gear
wheel bearings, supply unit housing.
B = Tensioning / loosening of waisted studs to cylinder cover.
C = Removing and fitting of main bearing shells, and jacking out of cylinder liners.
1/ 4
2008
94032/A1
Maintenance
RT-flex96C
Hydraulic Jacks and Pumps: Arrangement and Application
13 12 11 10
8
9
14
13 11
F
17 16
14
7
10
13
12
11
10
24 18
20
17 16
20
18 24
19
6
18 5
18
10
22
17
21
18
G
014.127/06
D = Tensioning / loosening of foundation bolts and engine stays.

E = Tightening / loosening of screwing to crosshead middle part, guide shoe.
F = Tightening / loosening of gear wheel on the crankshaft
(only to be applied when replacing a gear wheel on the crankshaft).
G = Tensioning / loosening of waisted bolts to piston crown.
H = Tensioning / loosening of waisted bolts to intermediate gear wheel.
2008
2/ 4
RT-flex96C
94032/A1
Maintenance
I
25
18 20
13 12 1110
18
7
17
18
10
19
5
28
28
14
14
6
13 11
13 12 11 10
23
9
3
14
13
12
11
27
11
26
014.133/06
15
I = Fitting / removing the 2-part fuel cam
K = Repositioning the driving wheel for servo oil pumps
014.138/06
L = Checking / setting the relief valve, and removal of a

jammed fuel pump plunger
M = Set-up of pre-tensioning jacks 94215a (i.e. collecting
the sequeezing oil)
3/ 4
2008
94032/A1
Maintenance
RT-flex96C
Tool
1 Hydraulic jack 1000 kN (100 t)
94936
2 Hydraulic ram 44.8 kN (4.48 t)
94412d
3 HP oil pump 2500 bar
94931
4 Hydraulic unit
94942
5 Hydraulic distributor
94934a
6 Pressure gauge
94932a
7 Plug piece
94934e
8 Pressure gauge
94932
9 Hydraulic distributor
10 Adapter
11 Closing valve
12 Coupling socket
13 Adapter
14 High pressure hose max. 2500 bar
94935
15 Oil drain hose
94935c
16 Adapter
17 Closing valve
18 Coupling socket
19 Safety valve
2008
94935a
94935b
22 Connection block
94934c
23 Connection piece
94426
24 Connecting element
94934d
94424
26 Valve holder
94272a
27 Jack
94595
28 Adapter piece
94426a
4/ 4
RT-flex96C
94033/A1
Maintenance

Storing, Servicing and Maintenance
1.
General
The hydraulic pre-tensioning jacks forming part of the engine tool kit are to be
stored in their tool boxes when not in use, in a clean place, where they are protected from damage (after greasing them and closing the connections with dust
plugs). We recommend to always keep in stock a sufficient number of new O-rings,
back-up rings, piston seal rings and rod seal rings of the specified quality and dimensions.
When fitting new back-up rings, piston seal rings and rod seal rings proceed with
care, to avoid their damage; do not use any sharp edged utensils for assistance.
Heat unslit back-up and sealing rings which are used as piston seal rings in boiling
water before fitting them.
Tool 94114
Double pre-tensioning jack for waisted studs to main bearing
1 Piston
8 Back-up ring
9 O-ring
2 Double cylinder
3
4
5
6
7
Distance sleeve
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
10
11
12
13
14
Sealing
ring
Cover
Nut
Screw
Tension sleeve
Eye bolt
14
11
12
10
6
7
1
2
9
8
13
3
009.318/01
008.308/01
4
5
1/ 9
2008
94033/A1
Maintenance
RT-flex96C
Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance

Tool 94145
Pre-tensioning jacks for foundation bolts and engine stays
Tool 94314
Pre-tensioning jacks for waisted studs to bottom end bearing
Tool 94315
Pre-tensioning jacks for waisted studs to top end bearing and

waisted stud (spindle) 94561d on camshaft
Tool 94340
Pre-tensioning jacks for waisted studs to piston foot fastening

and screwed connections to turning gear
Tool 94556
Pre-tensioning jacks for waisted studs to bearing of intermediate

wheel (supply unit)
1
2
3
4
5
6
7
Piston
Cylinder
Vent screw
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
8
9
10
11
Back-up ring
O-ring
Allen screw
Pin
Sealing ring
5
10
11
6
7
9
8
1
2
003.902/96
2008
2/ 9
RT-flex96C
94033/A1
Maintenance

Tool 94215a, b
1
2
3
4
5
6
7
Pre-tensioning jack for waisted studs to cylinder cover
Piston
Cylinder
Vent screw
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
8
9
10
11
12
Back-up ring
O-ring
Nut
Screw
Disc spring
Sealing ring
11
12
5
10
3
6
9
8
017.025/08
3/ 9
2008
94033/A1
Maintenance
RT-flex96C

Tool 94252
1
2
3
4
5
6
7
Pre-tensioning jacks for waisted studs to exhaust valve

cage
Piston
Cylinder
Vent screw
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
8
9
10
11
Back-up ring
O-ring
Nut
Pin
Sealing ring
10
3
11
6
9
8
003.902/96
2008
4/ 9
RT-flex96C
94033/A1
Maintenance

Tool 94346
1
2
3
4
5
Pre-tensioning jacks for waisted studs of piston crown
Piston
Cylinder
Vent screw
Adapter
Connection piece
6
7
8
9
Back-up ring
O-ring
Back-up ring
O-ring
Sealing ring
Sealing ring
3
4
6
7
2
9
8
012.100/04
5/ 9
2008
94033/A1
Maintenance
RT-flex96C

Tool 94180
1
2
3
4
5
6
7
Pre-tensioning jacks for tie rod
Piston
Cylinder
Vent screw
Adapter
Connection piece
Back-up ring
Sealing ring
O-ring
8
9
10
11
Back-up ring
Sealing ring
O-ring
Nut
Allen screw M10x97
11
10
5
4
3
1
6
7
9
8
012.101/04
2013-02
6/ 9
RT-flex96C
94033/A1
Maintenance

Tool 94557
Pre-tensioning jacks for waisted studs to supply unit

housing and camshaft bearings and gear wheel on
camshaft
1 Piston
2 Cylinder
3 Vent screw
4 Adapter
5 Connection piece
6 Back-up ring
7 O-ring
Sealing
ring
8 Back-up ring
9 O-ring
Sealing ring
5
3
4
1
9
8
012.102/04
7/ 9
2008
94033/A1
Maintenance
RT-flex96C

Hydr. jacking tool for camshaft
Tool 94424
1
2
3
4
5
6
7
Piston supporting plate

Piston
Ring piece
Adapter
Connection piece
Piston seal ring
Sealing ring
O-ring
8
9
10
11
Allen screw
Ball
Screw
Screw plug
9
8
10
I-I
I
I
1
2
11
3
014.578/06
2008
8/ 9
RT-flex96C
94033/A1
Maintenance

Jack for removal of a jammed fuel pump plunger
Tool 94595
1
2
3
4
Piston
Cylinder
Push rod
Vent screw
5
6
7
8
6
5
Adapter
Connection piece
Back-up ring
O-ring
8
7
1
2
3
014.579/06
9/ 9
2008
RT-flex96C
Maintenance
94034/A1

General Application Instructions
1.
General
For distinct screwed connections different designs and sizes of waisted bolts or
waisted studs (bolts/studs) are used, which are pretensioned by hydraulic pre-tensioning jacks. The bolts/studs have threads which extend over the nut. The pretensioning jack is mounted on this thread end.
For each thread of the various bolts/studs a suitable pre-tensioning jack is supplied. Since the bolts/studs are pretensioned with the pre-tensioning jacks, the
nuts are threaded-on only manually until seated.
Prior to the mounting of the pre-tensioning jacks, their threads as well as the
threads of the waisted bolts/studs must be carefully cleaned. The threads must be
undamaged and freely working. Concerning utilization of lubricant for screwing on
nuts the instructions in 03521 must be followed.
Risk of accident! Always use gloves, a face shield and wear safety goggles when
working with hydraulic tools.
2.
Working procedure for loosening

Thread the pre-tensioning jack by hand onto the extending thread end of the
bolts/studs to be loosened until it is landed on the part and the piston on the
cylinder without any clearance. On pre-tensioning jacks with round nuts these
have to be slightly tightened.
D
Then, depending on the design of the pre-tensioning jack, turn it or the round
nut back by about to 4 turns. The clearance thus obtained between pre-tensioning jack and landing face of the part or piston and cylinder is essential,
before starting the pre-tensioning of the bolts/studs. It enables the loosening
of the nut till total relaxation of the bolts/studs in one single working sequence.
Connect the HP oil pump and pre-tensioning jack with the HP hose.
Open the vent screw on top of the pre-tensioning jack a little.
Shut relief valve at the HP oil pump and actuate it. As soon as oil flows out
bubble-free close the vent screw at the pre-tensioning jack.
D
When loosening attention should be paid that the pins of the pre-tensioning
jacks protrude slightly above the upper edges of the pistons (stroke limitation!).
Pre-tensioning jacks providing red limiting grooves on the pistons, the latter
must not exceed the indicated stroke limitation.
Raise the pressure about 2030 bar beyond the nominal pressure (see
03521). The nut is now slack, loosen it with a round bar, while keeping the
pressure constant.
Release the pressure at the HP oil pump and remove the pre-tensioning jack.
1/ 2
2008
94034/A1
Maintenance
RT-flex96C
Hydraulic Pre-tensioning Jacks: General Application Instructions
3.
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 part. The marks are later a reference for judging the correct pre-tensioning.
Thread on by hand the pre-tensioning jack onto the protruding thread end of
the bolts/studs until it is fully seated without any clearance between the jack
and the part or the piston is seated on the cylinder without any clearance. On a
pre-tensioning 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 HP oil pump and pre-tensioning jack by the HP hose.
Open the vent screw on top of the pre-tensioning jack a little.
Shut relief valve at the HP oil pump and actuate it. As soon as oil flows out
bubble-free close the vent screw at the pre-tensioning jack.
D
When tensioning attention should be paid that the pins of the pre-tensioning
jacks protrude slightly above the upper edges of the pistons (stroke limitation!).
Pre-tensioning jacks providing red limiting grooves on the pistons, the latter
must not exceed the indicated stroke limitation.
Raise the pressure with the HP oil pump, in accordance with the indication on
the tightening of important screwed connections (see 03521).
Maintain the oil pressure constant at the adjusted value and use the round bar
to tighten the nut onto its seating surface until firmly seated.
CHECK
Check with the feeler gauge whether actually no clearance remains between nut
and seating.
Check with the referenced markings, whether all the nuts of a screwed connection
have been turned by the same value as mentioned in 03521. If big differences are
noted their causes have to be investigated and the tensioning procedure must be
repeated.
Release the pressure at the HP oil pump and remove the pre-tensioning
jacks.
D
2008
For operation and maintenance of the HP oil pump we also refer to the
manufacturers documentation.
2/ 2
RT-flex96C
Maintenance
94035/A1
Tool List
Standard Tools
94000
9400036
9400041
9400046
9400050
9400055
9400060
Combination wrenches
2 Pieces . . . . AF36
2 Pieces . . . . AF41
2 Pieces . . . . AF46
2 Pieces . . . . AF50
2 Pieces . . . . AF55
2 Pieces . . . . AF60
94001
9400165
9400170
9400175
9400180
9400185
9400195
94001110
Open end wrenches

1 Piece . . . . . AF65
1 Piece . . . . . AF70
1 Piece . . . . . AF75
1 Piece . . . . . AF80
1 Piece . . . . . AF85
1 Piece . . . . . AF95
1 Piece . . . . . AF110
94001a110
Slugging open end wrench

1 Piece . . . . . AF110
000.385/93
000.384/93
93.7463
94002
9400227
9400230
9400232
9400236
9400241
9400246
9400250
9400255
9400260
9400265
9400270
9400275
9400285
9400295
94002110
Ring slugging wrenches

1 Piece . . . . . AF27
1 Piece . . . . . AF30
1 Piece . . . . . AF32
1 Piece . . . . . AF36
1 Piece . . . . . AF41
1 Piece . . . . . AF46
1 Piece . . . . . AF50
1 Piece . . . . . AF55
1 Piece . . . . . AF60
1 Piece . . . . . AF65
1 Piece . . . . . AF70
1 Piece . . . . . AF75
1 Piece . . . . . AF85
1 Piece . . . . . AF95
1 Piece . . . . . AF110
000.382/93
1/ 62
2010-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
94003
940035
940036
940038
9400310
9400312
9400314
9400317
9400319
9400322
9400324
9400327
Allen keys
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
1 Piece . . . . .
94004
9400410
9400412
9400425
Angle screwdrivers
1 Piece . . . . . b =
1 Piece . . . . . b =
1 Piece . . . . . b =
AF5
AF6
AF8
AF10
AF12
AF14
AF17
AF19
AF22
AF24
AF27
000.381/93
10 mm
12 mm
25 mm
b
94005
94005d
94005e
94005f
94005g
94005h
94005i
Rods
for pre-tensioning jacks
3 Pieces . . . . 7 mm
3 Pieces . . . . 7.5 mm
3 Pieces . . . . 9 mm
3 Pieces . . . . 15 mm
3 Pieces . . . . 20 mm
3 Pieces . . . . 33 mm
94006
9400611
9400612
9400614
9400617
9400619
9400622
9400627
Socket head keys

1 Piece . . . . . AF11
1 Piece . . . . . AF12
1 Piece . . . . . AF14
1 Piece . . . . . AF17
1 Piece . . . . . AF19
1 Piece . . . . . AF22
1 Piece . . . . . AF27
94007
94007C8
94007C19
94007C40
Tongs
1 Piece . . . . . Type C 8
1 Piece . . . . . Type C 19
1 Piece . . . . . Type C 40
94007A10
94007A19
94007A40
1 Piece . . . . . Type A 10
1 Piece . . . . . Type A 19
1 Piece . . . . . Type A 40
94007A41
1 Piece . . . . . Type A 41
000.380/93
000.379/93
000.377/93
000.376/93
000.375/93
014.381/06
2010-07
2/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94008
Withdrawing gears
for taper & cylindrical dowels and pins
1 Piece . . . . . M4
1 Piece . . . . . M5
1 Piece . . . . . M6
1 Piece . . . . . M8
1 Piece . . . . . M10
1 Piece . . . . . M12
1 Piece . . . . . M16
1 Piece . . . . . M20
94008M4
94008M5
94008M6
94008M8
94008M10
94008M12
94008M16
94008M20
for removal of Cyl. cover waisted stud

1 Piece . . . . . M100x6
X = 193 mm
94008aM100
94009
94009M4
94009M5
94009M6
94009M8
94009M10
94010
94010a
94010b
94011
94012
94012a
94012b
94013a
9401319
9401320
9401321
9401322
9401324
9401327
9401330
9401332
94013b
9401346
9401355
Grip screw
2 Pieces . . . .
2 Pieces . . . .
2 Pieces . . . .
2 Pieces . . . .
2 Pieces . . . .
M4x150
M5x150
M6x150
M8x150
M10x150
X
WCH00836
000.372/93
1 Torque spanner
(Range of adjustment 225 Nm)
Adapter piece 3/8
Adapter piece 3/8
010.229/02
1 Torque spanner
010.230/02
1 Torque spanner
with extension tube and tool box
adapter piece -,
shell type ratchet -
1 Torque spanner
with open end spanner inserts:
AF19
AF20
AF21
AF22
AF24
AF27
AF30
AF32
010.231/02
013.558/05
Torque spanner
with open end spanner inserts:
AF46
AF55
3/ 62
2012-05
94035/A1
Maintenance
RT-flex96C
Standard Tools
94017
2 Spur-geared chain blocks

platform with crane rail
(WLL 7500 kg)
012.232/04
94022a
1 Socket wrench insert

AF3
010.233/02
94022b
94022b46
94022g
Socket wrench inserts

1 AF46
1 Adapter piece
94025
1 Tool box with socket wrench set
016.718/08
000.368/93
94026
1 Tool box with hex. head drivers

000.368/93
94032
1 High pressure grease gun

for lubricating grease nipples on
fuel pump regulating linkage
000.370/93
2010-07
4/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94045
94045M10
94045M12
94045M16
94045M20
94045M24
94045M30
94045M36
94045M42
94045M48
Eye bolts
8 Pieces
8 Pieces
8 Pieces
8 Pieces
8 Pieces
8 Pieces
8 Pieces
8 Pieces
4 Pieces
94045aM16
Eye screw
6 Pieces . . . . M16x145
....
....
....
....
....
....
....
....
....
M10
M12
M16
M20
M24
M30
M36
M42
M48
93.7472
93.7468
Eye nut
4 Pieces . . . . M48
(WLL 8600 kg, single-strand)
94046
94046M48
001.584/97
94050
94050a
94050b
94050c
94050d
94050e
94050f
94050g
94050h
1 Tool for pressure measurement

for pneumatic elements
1 Compressed air pump
2 HP hoses
1 Adjusting tool
1 Measuring connection M12x1
1 Measuring connection M14x1
5/ 62
002.552/98
2010-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
94101
1 Inside micrometer
(Measuring range 501010 mm)
with case
000.366/93
94101a 1 Extension
Length of 480 mm
94113
000.365/93
1 Measuring device
for checking external diameter of a main
bearing
X = 1150 mm
94113a 1 Template
for contact surface between main bearing
cover and shell
X = 300 mm
016.819/08
016.812/08
X
94114
2 Double pre-tensioning jacks

for waisted studs to main bearing,
including a metal box
X = 296 mm
012.234/04
94116
1 Lifting tool
for removal and fitting of
main bearing shell
X = 320 mm
(max. lifting capacity 250 kg)
008.541/01
X
94117
2008
2 Roller supports
for removal and fitting of main bearing
with screws M30x60 and washers 68 mm
X = 140 mm
6/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94118b 1 Turning-out device

for removal and fitting of a narrow,
asymmetric main bearing shell
X = 385 mm
X
008.542/01
94118c 1 Turning-out device

a broad main bearing shell
X = 436 mm
94118d 1 Turning-out device
for removal and fitting of the last
main bearing shell at free end
X = 422 mm
008.545/01
94119
1 Lifting yoke
a main bearing shell
X = 390 mm
000.768/99
94120a 1 Lifting eye bolt

with collar nut M24
005.933/00
7/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
Rope ( 10 mm)
with a shackle for removal and fitting
of main bearing cover and shell
94120b
94120c
94120d
94120e
94120f
94120g
94120h
94120i
94120k
94120l
94120m
94120n
94120o
94120p
2 Pieces . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
1 Piece . . .
X = 300mm
X = 500mm
X = 600mm
X = 800mm
X = 1000mm
X = 1200mm
X = 1500mm
X = 1600mm
X = 1700mm
X = 1900mm
X = 2000mm
X = 2200mm
X = 2800mm
X = 3200mm
005.932/00
94120q 1 Rope ( 10 mm)

with two shackles for removal and
fitting of main bearing cover and shell
X = 1000 mm
94122
008.551/01
1 Feeler gauge
000.361/93
94123

for main bearing
X = 625 mm
000.395/93
X
94124
1 Depth gauge
measuring range 250 mm
012.237/04
94126
1 Depth gauge
measuring range 700 mm
000.394/93
2008
8/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
X
94141
1 Support
main bearing shells
X = 1430 mm
008.133/96
94142
2 Working platforms
consisting of 3 grids each
X = 1150 mm
000.392/93
94143
2 Working supports
X = 9201170 mm
009.323/01
94145
1 Pre-tensioning jack
for foundation bolts and engine stays,
X = 170 mm
008.132/96
9/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Ladder
for working in crankcase
X = 1550 mm
X
94147
000.706/97
94155
with screws
for turning out thrust bearing pads
(for 6 & 7 cylinder engines,
with 1-part gear wheel)
X = 266 mm
003.973/96
94155a 1 Turning-out device

with screws
(for 6 & 7 cylinder engines,
with 2-part (spare) gear wheel)
X = 266 mm
004.036/96
94155b 1 Turning out device

with screws
(for 812 & 14 cylinder engines)
X = 331 mm
001.581/97
94180
2 Hydraulic pre-tensioning jacks

for tie rods,
X = 480 mm
012.239/04
2008
10/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
1 Device
for fitting and transporting a cylinder
liner (with big crane hook)
consisting of:
1 Lifting gear
X = 400 mm
94206
2 Suspension straps
with 2 screws each
X = 275 mm
94207
2 Special screws M48
001.409/96
94202
94206
94202
94201
94207
94201a 1 Device
for fitting and transporting a cylinder
liner (with small crane hook)
consisting of:
X
012.240/04
94202a 1 Lifting gear

X = 340 mm
94202a
FASTENING HERE,
IF PLATES 94202b
ARE NOT USED
94202b 2 Plates
X = 164 mm
94202b
94202c 2 Guide elements

X = 164 mm
012.241/04
94206a 2 Suspension straps

with 2 screws each
X = 325 mm
94206a
2 Special screws M48
94207
94202c
94207
11/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94209
4 Suspension straps
with screws M20x25
for removal and fitting of the
antipolishing ring
X = 146 mm
94208
005.928/00
1 Lifting hook
for removal and fitting of the
antipolishing ring
X = 1000 mm
X
012.242/04
94215
1 Hydraulic tensioning device

with connecting elements
for cylinder cover studs
consisting of:
94215d
94215c
94215a 4 Pre-tensioning jacks

94215b 4 Pre-tensioning jacks
94215c 8 High pressure hoses
1200 mm long
94215d 1 Suspension device
94215a
2008
12/ 62
94215b
RT-flex96C
94035/A1
Maintenance
Standard Tools
1 Cylinder pressure measuring tool

(indicator),
including a wooden box
X = 165 mm
94219
012.243/04
94224
1 Ladder
for measuring cylinder liner bore
X = 3600 mm
000.420/93
94225
94238
1 Measuring gauge
for measuring cylinder liner bore
(accessory for it:
inside micrometer tool 94101)
X = 3246 mm
000.419/93
1 Feeler gauge
(10-part)
for checking bearing clearances
Leaf length = 600 mm
000.418/93
13/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94252
1 Hydraulic tensioning device

for exhaust valve cage
consisting of:
2 pre-tensioning jacks
X = 345 mm
012.245/04
94259
6 Retaining screws
for exhaust valve
X =
112 mm
X
012.246/04
94261
1 Valve seat fitting and dismantling

device
X = 810 mm
001.426/97
94262
1 Valve protector
(only to be applied for transporting a
complete exhaust valve)
X = 750 mm
001.425/97
94263
2 Jack screws M16x150

for guide bush to exhaust valve
000.413/93
2008
14/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94265
1 Suspension device
for cylinder cover & exhaust valve cage
(with big crane hook)
X = 1000 mm
including:
a = 2 Special eye nuts
X = 365 mm
(max. lifting capacity 12 000 kg)
b = 3 Protection caps
X =
110 mm
b
a
a
003.971/96
94265c 1 Suspension device

for cylinder cover & exhaust valve cage
(with small crane hook)
X = 932 mm
including:
a = 2 Special eye nuts
X = 365 mm
b = 3 Protection caps
X =
110 mm
012.247/04
b
a
a
003.971/96
15/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94266
1 Cradle
for removal and fitting of water guide
jacket
X = 1855 mm
012.248/04
94266a 4 Support
for cradle (Retrofit)
WCH01146
1 Device
for overhauling injection valve seat in
cylinder cover
X=
565 mm
X
94270
001.432/97
Protection cap
for injection valve
(1 piece each nozzle)
X=
110 mm
94271
705603/F101167d
2013-05
16/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
1 O.M.T. test bench

for setting and testing of:
injection valves
relief valves
(on intermediate fuel accumulator)
X = 2030 mm
94272
001.406/96
94272
1 OBEL test bench

for setting and testing of:
injection valve
safety valve
relief valve
X = 1498 mm
including:
94272a 1 Valve holder

for checking and adjusting relief valve
X = 136 mm
94272c 1
Valve holder
for checking and adjusting relief valve
to cylinder cover
X = 66 mm
WCH00863
94272a
X
94272g 1 Adapter piece

for adjusting injection valve
X = 100 mm
94272g
X
17/ 62
94272c
2012-05
86
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Gauge
for checking wear on exhaust valve
seat
X = 220 mm
94279
001.633/97
94292
1 Gauge
for checking wear on disc of exhaust
valve spindle
X = 290 mm
004.061/96
2010-07
18/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
1 Grinding device
for removing a built-up wear ridge at
top of cylinder liner running surface
X = approx. 600 mm
X
94299
000.463/93
94305
1 Crankshaft checking equipment

for measuring crank deflection
(in wooden box)
X = 364 mm
000.412/93
94314
2 Pre-tensioning jacks
for connecting rod studs to bottom end
bearing, including a metal box
X = 330 mm
94315
for connecting rod studs to top end
bearing, including a metal box
X = 245 mm
008.129/96
94323a 4 Retaining pins

(with special fixation)
to prop up crosshead guide shoes
when removing or fitting a connecting
rod or crosshead
X = 138 mm
018.037/09
19/ 62
1.09
94035/A1
Maintenance
RT-flex96C
Standard Tools
94324
1 Cover and lifting plate

to crosshead
X = 505 mm
94325
012.263/04
2 Holders
for removal of a crosshead guide shoe
X =
70 mm
001.631/97
94325a 2 Guide pieces

for removal of a crosshead guide shoe
X =
70 mm
001.630/97
X
94326
1 Device
for removal and fitting of bottom end
bearing
X = 406 mm
012.265/04
2008
20/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94330
1 Lifting device
for removal and fitting of a connecting
rod
X = 1000 mm
001.627/97
2 Roller supports
rod, and for inspection of bearing shell
to top end bearing
X = 1955 mm
94331
000.773/99
94332
1 Carrying roller
rod, and for inspection of bearing shell
to top end bearing
X = 300 mm
001.625/97
21/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Lifting device
to piston for removal of top end bearing
cover
consisting of:
94333a 2 Suspension straps

X = 180 mm
94333
94333b 2 Wire rope slings with hooks

X = 1940 mm
94333c 2 Eye bolts M36
001.314/97
94334
1 Device
for removal and fitting of bottom end
bearing
consisting of:
94334a 1 Lifting beam

with screws M24x50
and movable pipe
X = 990 mm
012.266/04
94334b 1 Suspension
with screws M24x35
X = 560 mm
X
012.267/04
2008
22/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94334c 1 Lifting support

X = 515 mm
012.268/04
94334d 2 Washers
X =
66 mm
012.269/04
94334e 2 Eye bolts M64

94334f
2 Eye bolts M24

012.270/04
94334g 2 Ropes 10 mm with shackles

X = 1060 mm
94334h 2 Ropes 10 mm with shackles

X = 1200 mm
94334i
005.932/00
1 Rope 12 mm with shackle

X = 1600 mm
X
94335
1 Holder
with screw M24x35
for fixing the crosshead
X = 494 mm
012.271/04
23/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
X
94338
1 Piston ring tensioning device

X = 500 mm
Y = 303.5 mm
Y
17.830/08
94339
1 HYTORC torque machine

for screwed connection
of crosshead and guide shoe, with
94339c 1 HP hose
working pressure max. 1000 bar
length approx. 3500 mm,
94339c
001.624/97
94339a 1 Reaction arm

for HYTORC torque machine
X =
76 mm
001.623/97
94339b 1 Socket wrench insert

for HYTORC torque machine AF 55
X =
78 mm
001.622/97
1.09
24/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94340
for piston rod screw connection and
screwed connection of turning gear,
X = 160 mm
705603/F101168
94341
1 Piston suspension device

(with big crane hook)
X =
811 mm
001.408/96
94341a 1 Piston suspension device

(with small crane hook)
X = 871 mm
94341d
94341c
94341c 2 Distance plates
94341d 2 Distance plates

014.383/06
25/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94342a 1 Insertion funnel

for fitting the piston,
including: 2 Holders
2 Screws M16 x 35
2 Screws M48 x 65
X = 1187 mm
005.923/00
94342b 1 Insertion funnel (2-part)

for fitting the piston,
including: 2 Holders
2 Screws M16 x 35
2 Screws M48 x 65
2 Fitted screws M8 x 55
X = 1187 mm
012.664/05
2 Distance holders
for removal and fitting of piston rod
gland and piston
X = 600 mm
94345
001.407/96
94345b 1 Clamp ring (2-part)

X =
90 mm
011.508/04
2008
26/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94345c 1 Gauge
for fitting scraper rings
X = 400 mm
011.507/04
94345d 1 Cover plate

for covering bore of piston rod gland in
cylinder jacket (when piston and gland
are removed)
X = 792 mm
000.400/93
94345e 2 Assembly tools

for tensioning springs
to piston rod gland
X = 160 mm
004.284/98
94345f
4 Distance pieces
for fitting rings
to upper gland group
2 pieces each 11 and 19 mm
X = 520 mm
005.655/99
94346
for waisted studs to piston crown
X = 126 mm
012.276/04
27/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Propping device
consisting of 4 supports for changing
compression shims
X = 700 mm
X
94347
008.552/01
94348
1 Tap M27
for cleaning carbon deposits in
threaded holes of piston crown
000.398/93
94350
1 Device
for supporting piston and removal of
piston rod gland
X = 1174 mm
Y = 1297 mm
2012-05
28/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94363
2 Jacking screws
for separating piston crown
from piston skirt
X = M20
94364
2 Jacking screws
for separating piston skirt
from piston rod
X = M24
705603/F101198
X
94366
1 Template
for shape of top of piston crown
X = 1030 mm
001.423/97
94366a 1 Template
for shape of top of piston crown
(for use with piston in situ)
X = 1115 mm
94410
001.422/97
6 Adjusting devices
for alignment of intermediate wheel
X = 270 mm
705603/F101217
X
94411
1 Suspension device
for removal and fitting of intermediate
wheel
(for 11 cylinder engines)
including: 2 Shackles
1 Screw with nut M36x340
X = 500 mm
014.384/06
29/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94412
1 Tightening device
(supplied only for engine equipped
with 2-part gear wheel on crankshaft)
X = 150 mm
consisting of:
94412e
94412a
94412a 1 Clamping fork with extension

94412b 2 Impact ring spanners AF 75
94412d
94412c 1 Forked piece

94412d 1 Hydraulic ram 44.8 kN
ENERPAC RC-57
94412c
94412b
94412e 1 Retaining wrench AF 75

003.987/96
Remark: The following tools (9441294412g) are for version with

Single Wall Column provided according to 41033/A2:
94412
1 Tightening device
(supplied only for engine equipped
with 2-part gear wheel on crankshaft)
consisting of:
94412e
94412f
94412b 1 Impact ring spanners AF 75
015.227/07
94412c 1 Forked piece

X
94412d 1 Hydraulic ram 44.8 kN

ENERPAC RC-57
94412d
94412c
94412e 1 Holding wrench AF 75

94412f
94412b
1 Extension
X = 640 mm
015.202/07
94412g 1 Retaining device

with screw M20x50
X = 700 mm
2008
94412g
30/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94426
1 Connection piece
for repositioning the driving wheel of
servo oil pumps
X = 247 mm
004.027/96
X
94426a 1 Adapter piece
for removing and fitting 2-part fuel cam
X =
45 mm
94550
012.278/04
1 Lifting plate
for removal and fitting of Dynex servo
oil pump
X = 190 mm
1 2-part clamping ring

for removal of non-return valve to fuel
pump with 4 screws M10x60
X = 210 mm
94435
Devices (roller lifting tools)

for cutting out & in of fuel pump(s),
depending on number of cylinders:
4 pieces for 67 cylinder engines
X =
116 mm
94430
019.235/10
94551
1 Fitting & dismantling device

for removal and fitting of guide pin to
fuel pump
X = 304 mm
014.385/06
94552
1 Lifting tool
with head screws M12x70
for removal and fitting of a fuel pump
X = 120 mm
012.280/04
31/ 62
2010-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
Lifting tools to supply unit

for 914 cylinder engines
94553
1 Lifting support
for removal and fitting of covers and
bearing covers to supply unit,
including: 3 Head screws M16x30
X = 2087 mm
X
012.281/04
94553a 1 Lifting support

for removal and fitting of cover before
camshaft wheel to supply unit,
including: 8 Head srews M12x40
X = 1645 mm
012.282/04
Lifting support with

94553c 1 Lifting plate
for removal of bearing cover
X = 320 mm
94553c
2008
32/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
Lifting tools to supply unit

for 68 cylinder engines
94553b 1 Lifting support
for removal and fitting of cover and
bearing covers to supply unit,
including:
1 Flange (1)
with 4 screws M16x35
1 Distance plate (2)

X = 2383 mm
1
014.386/06
94554
94554a
94554b
94554c
94554d
94554e
1 Fork lever
for lifting camshaft
consisting of:
94554b
94554d
94554e
Face plate
Rocker arm
Nut
Bolt with circlip
Web with screw
X = 329 mm
94554a
94554c
X
012.283/04
94555
Spacers
for cutting out of individual fuel pumps,
depending on number of cylinders:
X =
95 mm
008.764/01
33/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
X
94556
for waisted bolts to intermediate wheel
bearing of supply unit,
X = 195 mm
00.7014
X
94557
for gear wheel and waisted bolts to
camshaft bearing,
X = 155 mm
012.284/04
94558
2 Sleeves
X = 166 mm
X
012.285/04
94559
1 Socket wrench
X = 206 mm
012.286/04
94560
2 Round bars 6 mm
X = 100 mm
X
012.287/04
2008
34/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94561
1 Device
for removal and fitting of pinion to
supply unit
X = 1376 mm
014.387/06
X
1 Cam adjusting gear
X = 194 mm
consisting of:
94562
94562a 1 Angle rail

including: 2 Fitted bolts M16x40
1 Washer
(there are appropriate tools
depending on number of cylinders)
94562e
94562f
94562a
94562e 1 Guide tube

1 Positioning unit
94563
1 Distance holder
for setting fuel cam No. 1
X = 365 mm
94562f
014.495/06
94563a 1 Distance holder

for setting fuel cams No. 2
X = 200 mm
014.496/06
94563b 1 Distance holder

for setting fuel cam No. 3
X = 300 mm
X
014.497/06
35/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94566
2 Supports
for removal and fitting of camshaft
X = 1097 mm
012.296/04
94566a 2 Tension nuts

to supports 94566
X = 692 mm
94567
94569a
2008
1 Assembly template
for removal and fitting of bearing
shells to supply unit
X = 100 mm
including:
94567a 1 Pipe
X =
94569
012.302/04
012.297/04
200 mm
Blank flange
to fuel pump
2 pieces for 6 & 7 cylinder engines
5 pieces for 11 & 14 cylinder
engines
with screws M12x55 mm
X =
110 mm
Blank flange
to intermediate fuel accumulator
2 pieces for 6 & 7 cylinder engines
5 pieces for 11 & 14 cylinder
engines
with screws M12x50 mm
X =
110 mm
36/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94571
1 Rail
for removal and fitting of intermediate
wheel to supply unit,
including: 2 Shackles
(Lifting capacity 1500 kg)
4 Screws M30x130
X = 2565 mm
WCH01168
94571b
94571a 2 Screws M20x200
94571a
94571b 2 Washers
012.299/04
94571c 1 Carriage
to rail 94571
X = 280 mm
94571d
94571d 8 Screws M16x130

to carriage 94571c
94571c
X
012.300/04
94571e 1 Support (Left side)
94571f
94571e
1 Support (Right side)
94571f
WCH01168
94581
1 Assembly tool
for removal and fitting of fuel pump
X = 905 mm
including:
94581a
94581a 2 Guide screws
94581b 2 Steel wires

94581b
012.301/04
37/ 62
2013-05
94035/A1
Maintenance
RT-flex96C
Standard Tools
94583
1 Pipe
for pressure built-up in fuel rail
during commissioning
X = 687.5 mm
012.303/04
94584
1 Lifting plate
for removal and fitting of injection
control unit,
including 2 screws M12x30
X = 300 mm
X
012.304/04
94586
94587
94589
4 Shut-off plugs
for servo oil rail and servo oil return
X = 144.5 mm
011.955/04
4 Conical plugs
for servo oil return
X =
20 mm
011.976/04
2 Withdrawing tools
for removing lip seal from injection
control unit
X = 310 mm & 638 mm
X
012.308/04
2010-07
38/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
1 Fitting and dismantling device

for fuel pump
X = 1029 mm
Mass approx. 89 kg
consisting of:
94592a 1 Oil trough

94592b 1 Limiter
with 4 screws M12x100 and washers
94592c 2 Screws
94592d 4 Screws (M20x50)
94592e 2 Screws (M12x90)
94593
94592c
94592b
94592e
X
94592d
94592a
016.787/08
1 Assembling device
for assembling fuel pump
consisting of:
94592
94593d
94593a 1 Tool half

94593b 1 Tool half
94593c
94593a
94593c 2 Flat bars

X = 270 mm
94593b
014.390/06
94593e
94593d 1 Metal sheet

94593e 4 Screws M30x260
94597
1 Mandrel
for fitting seal into lower spring carrier
and lower housing of fuel pump
X =
70 mm
014.494/06
94597a 1 Mandrel
for fitting seal into lower spring carrier
X =
40 mm
1 Impact wrench
for loosening and tightening fuel
pump on supply unit
X = 256 mm
94598
94598
94598a 2 Extension 1
X = 330 mm
X
94598b
94598b 1 Socket spanner insert 1

AF 46 mm
94598a
39/ 62
014.389/0
2010-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
94651
for auxiliary blower
consisting of:
009.995/02
94651c 1 Trolley
94652
2 Centring studs
for removal and fitting of electric
motor
on auxiliary blower
X = 615 mm
000.427/93
In case of a turbocharger breakdown,

engines with 2 to 3x TPL 85B
94653
2 to 4
94653a 1 to 2
Covers (depending on design)

to gas inlet housing and exhaust manifold
X = 810 mm
Cover(s) (depending on design)
for air connection
X = 750 mm

engines with 2 to 3x MET 83MA
94653b 2 to 4

X = 840 mm
94653c 1 to 2

for air connection
X = 735 mm
000.487/93

engines with 2x A190 or 3x A185
94653d 2 to 4

X = 1066 mm (A190)
X = 970 mm (A185)
94653e 1 to 2

for air connection
X = 845 mm (A190)
X = 760 mm with a pitch circle of 700 mm (A185)
2010-07
40/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
Tools for engines with SAC

according to 66011/A1
Remark: There are different suspension procedures for the removal and fitting of
scavenge air coolers (see also illustrations in 66061/A1 and 66061/A2). Therefore, appropriate tools are listed and supplied as follows:
X
94660
1 Lifting device
for removal and fitting of cooler
element and cooler pre-stage
X = 910 mm
014.396/06
X
94660a 1 Lifting device
for removal and fitting of cooler
element and cooler pre-stage
X = 1780 mm
014.397/06
94660b 1 Extension
to lifting device 94660
with screws M20x60 and nuts
X = 1780 mm
014.398/06
94660c 1 Extension
to lifting device 94660
with screws M20x60 and nuts
X = 1780 mm
014.399/06
41/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
94662
1 Roller plate
scavenge air cooler
including: 8 Screws M12x80
10 Screws M20x40
X = 2346 mm
012.312/04
94663
94664
1 Support
for fitting scavenge air cooler,
X = 385 mm
(WLL=10 000 N)
012.313/04
1 Beam
scavenge air cooler
X = 1738 mm
X
012.314/04
94665
4 Swivel lugs
cooler pre-stage
X = 1000 mm
X
012.315/04
2008
42/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94666
1 Wire rope sling 18 mm

with 2 shackles
scavenge air cooler
X = 385 mm
(max. lifting capacity 5600 kg at 60_)
012.316/04
94666a 1 Wire rope sling 18 mm

with 3 shackles
scavenge air cooler,
X = 600 mm
012.317/04
94666b 1 Wire rope sling 8 mm

with 2 shackles
scavenge air cooler
X = 842 mm
Y = 130 mm
94666c 1 Wire rope sling 8 mm

with 2 shackles
scavenge air cooler
X = 623 mm
Y = 130 mm
012.318/04
94666d 1 Wire rope sling 8 mm with shackle

scavenge air cooler
X = 1809 mm
43/ 62
94666e 1 Wire rope sling 8 mm with shackle

scavenge air cooler
X = 809 mm
012.319/04
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
Tools for engines with SAC

according to 66011/A2
94660d 2 Lifting devices
main cooler
X = 1780 mm
X
014.400/06
1 Extension
scavenge air cooler
X = 1740 mm
94661
014.401/06
94662
1 Roller plate
scavenge air cooler
10 Screws M20x40
X = 2346 mm
012.312/04
94663a 1 Support
for removal and fitting of main cooler
X = 187 mm
X
014.402/06
2008
44/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94663d 1 Support
scavenge air cooler
(for 6, 8, 10, 12, 14 Cyl. engines)
X = 1027 mm
014.403/06
94663e 1 Support
for fitting scavenge air cooler
X = 1653.5 mm (7 cylinder engines)
X = 1146.0 mm (9 cylinder engines)
014.405/06
94663f
2 Supports
cooler pre-stage
X = 1181 mm
014.406/06
94664a 1 Beam
scavenge air cooler
X = 1758 mm
X
012.314/04
94665b 4 Swivel lugs

cooler pre-stage
X =
98 mm
94665b
94665c
94665c 4 Discs
014.407/06
45/ 62
2008
94035/A1
Maintenance
RT-flex96C
Standard Tools
1 Wire rope sling 10 mm with shackle

scavenge air cooler
X = 2809 mm
94666g 1 Wire rope sling 10 mm with shackle

scavenge air cooler
X = 1809 mm
94666h 1 Wire rope sling 8 mm
with 2 shackles
scavenge air cooler
X = 1200 mm
Y =
115 mm
94666i
94667
94666f
012.319/04
1 Wire rope sling 8 mm

with 2 shackles
scavenge air cooler
X = 842 mm
Y =
115 mm
012.318/04
1 Carriage
for removal of water separator,
1 Eye bolt M30
1 Shackle (LC 1000 kg)
X = 641 mm
012.321/04
94668
1 Pulley device
for removal and fitting of water
separator,
X = 230 mm
X
012.322/04
2008
46/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
94669
94672
1 Support
separator,
1 Screw M16x80 with nut
X = 440 mm
012.323/04
1 Lifting device
separator,
X = 2386 mm
X
012.324/04
94673
1 Wire rope sling 8 mm with shackle

separator
X = 3350 mm
012.325/04
94720c 1 Case
consisting of:

94811
018.472/09
2 Lifting lugs
(incl. 2 shackles) for removal and fitting
expansion piece to exhaust valve cage
X = 636 mm
000.471/93
47/ 62
2011-07
94035/A1
Maintenance
RT-flex96C
Standard Tools
X
94831
1 Blank flange
for blanking off starting air pipe
during emergency operation
X = 320 mm
004.017/96
94835
1 Tool box with grinding machine

for regrinding of sealing surfaces,
including User Manual
X = 450 mm
015.218/07
94843
1 Tool as spare for high pressure

pipe
Straight length 2510 mm
(for Dynex servo oil pump only)
including: 2 O-rings
1 Clamp flange each
X = 112.7 mm
X1 = 95.2 mm
X1
015.817/07
Y
94844
1 Lubricating device
to supply unit
X = 600 mm
Y = 200 mm
X
WCH01042
2013-02
48/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
Ii
Y
94844a 1 Filling device
to lubrication device
X = 482 mm
Y = 225 mm
X
WCH01042
Y
94844b 1 Filling device
X = 203 mm
Y = 165 mm
X
WCH01042
Y
94844c 1 Filling device
X = 312 mm
Y = 140 mm
X
WCH01042
94844d 3 Flexible hoses

X = 2000 mm
WCH01042
94844e 1 Cross union

X =
94 mm
Y =
112 mm
X
WCH01042
49/ 62
2013-02
94035/A1
Maintenance
RT-flex96C
Standard Tools
94844f
1 Holder
WCH01042
94870
1 Regrinding device
for conical sealing surfaces on fuel
pressure piping (87331)
X = 106 mm
consisting of:
94870c
1 Screw-on sleeve (AF 36)

1 Grinding tool with
countersunk screw M6
1 Lock nut M20x1.5 (AF 30)
94870d
1 Template
X =
50 mm
94872
1 Regrinding device
for spherical sealing surfaces on fuel
pressure piping (87331)
X = 60 mm (radius of 25 mm)
94870
a
c
94870g
94870h
2013-05
016.740/08
016.776/08
1 Regrinding device
for sealing surfaces on fuel pressure
piping (87521)
X = 158.5 mm
consisting of:
94870e
94870f
94870a
94870b

1 Lock nut M33x2 (AF 50)
e
g
f
X
X
016.741/08
1 Template
X =
80 mm
50/ 62
RT-flex96C
94035/A1
Maintenance
Standard Tools
Ii
94870
1 Regrinding device
for sealing surfaces on fuel pressure
piping (87521)
(intermediate fuel accumulator FP)
X = 158.5 mm
consisting of:
94870i
94870j
94870k
94870l
94873

1 Lock nut M36x2 LH (AF 50)
X
016.741/08
1 Template
X =
80 mm
1 Turnbuckle
for removing and fitting of fuel pressure
piping
X =
70 mm
X
012.329/04
94874
1 Tightening device
for loosening and tightening connection
piece on injection control unit,
X =
95 mm
014.408/06
94924
1 Hook spanner
for crank angle sensor
X = 205 mm
94925
1 Hook spanner
X = 242 mm
94930
008.771/00
1 SW-download package
to WECS9520 for flexView operator
consisting of:
1
1
1
1
1
USBmemory stick
CAN cable (ca. 10 m)
UBS to CAN adapter
Connection diagram
Requirements
018.127/09
ca. 1000
51/ 62
80
2013-02
94035/A1
Maintenance
RT-flex96C
Standard Tools
Hydraulic parts and pump

94931
1 HP oil pump
94932
1 Pressure gauge
100 mm
working pressure 02500 bar
connecting branch G
94936
94935a
94932a
94934a
94934e
94932a 1 Pressure gauge

100 mm
working pressure 01600 bar
connecting branch G
94934d
012.335/04
94934a 1 Hydr. distributor
94935
94934c 2 Connection blocks
94942
94934d 2 Connecting elements

94934e 1 Plug piece
94935
015.220/07
3 HP hoses
length approx. 1800 mm
94935
94935a 2 HP hoses
94935b 4 HP hoses
94931
001.547/97
94932
94935c 1 Oil pipe drain

for set-up of pre-tensioning jacks
lenght = 2000 mm
94936
2 Hydraulic jacks 1000 kN (100t)
94942
1 Hydraulic unit
94934c
94935b
94935c
012.336/04
2008
52/ 62
RT-flex96C
Maintenance
94035/A1
Standard Tools
94934h 1 Hydr. distributor

with pressure gauge 0...25 bar
WCH00724
94934i
WCH00724
53/ 62
2012-05
94035/A1
Maintenance
RT-flex96C
Recommended Special Tools
94016
2 Manual rachets
94016a 2 Manual rachets

94016b 2 Manual rachets
94016c 2 Manual rachets
012.233/04
94017
1 Spur-geared chain block

Lifting capacity 7500 kg
94017a 4 Spur-geared chain blocks

Lifting capacity 3000 kg
012.232/04
94203
2 Wedges
for hydr. jacks 94936 as support
X = 130 mm
001.610/97
2008
54/ 62
RT-flex96C
94035/A1
Maintenance
94291
1 Valve grinding device complete

for valve spindle and valve seat
94291a
2 Grinding discs
(C-M No. 11373-04-05)
016.774/08
1 Tool cupboard
X = 1120 mm
X
94300
016.773/08
001.412/96
1 Connecting flange
for pre-lubrication of top and bottom
end bearings
X = 130 mm
94336
001.411/96
94344
for removal of piston rod gland
downwards
X = 1300 mm
008.550/01
55/ 62
2013-08
94035/A1
Maintenance
RT-flex96C
X
94349
1 Pressure testing device

for piston
X = 400 mm
000.461/93
94356
1 Equipment case
with instruments
for measuring thickness of chromeceramic-layer on piston rings
WCH01216
94357
1 Calliper gauge
for measuring piston ring grooves
94424

for removing and fitting
fuel cams with bush
X = 540 mm
X
94481
014.409/06
1 Metal box
for storage of spare filter cartridges
Remark: Dimensions are
depending on size of parts to
be accommodated inside.
012.235/04
2013-08
56/ 62
RT-flex96C
94035/A1
Maintenance
1 Jack
for removal of a jammed fuel pump
plunger (with 12-hole pump cover)
X = 270 mm
94595
014.499/06
94595b 1 Short tappet

to jack 94595(a)
X = 222 mm
X
94595c 1 Long tappet

to jack 94595(a)
X = 344 mm
014.500/06
94595d 1 Piston reset tool

to jack 94595(a)
(with 12-hole pump cover)
X = 173 mm
014.501/06
X
94595e 2 Screws M30
with nuts
X = 400 mm
X
014.502/06
57/ 62
2008
94035/A1
Maintenance
RT-flex96C
94650

for removal and fitting of electric motor on auxiliary
blower
000.460/93
94655
94655a
94655b
94655c
94655c
1 to 3

to air outlet casing with suction pipe
in case of a turbocharger breakdown
X
X
X
X
= 750 mm (TPL 85 type)

= 705 mm (MET 83 type)
= 845 mm (A190)
= 760 mm with a pitch circle of 710 mm (A185)
X
2010-07
58/ 62
000.487/93
RT-flex96C
94035/A1
Maintenance
Special Tools Obtainable on Loan
1 Measuring apparatus
for leveling bedplate
consisting of:
4 Supports
4 Weights with wire
1 Measuring underlay
X = 1400 mm
94105
000.459/93
4 Thread protectors
to upper threads of tie rods, when fitting
a cylinder jacket
X = 225 mm
M36
94174
001.410/96
94177
M24
X
1 Thread protector
to lower thread of tie rod
X = 158 mm
000.458/93
59/ 62
012.333/04
2014-04
94035/A1
Maintenance
RT-flex96C
94574
1 Lifting tool complete

for transporting a complete supply unit:
X = 1565 mm for 6 & 7 Cyl. engines

X = 2015 mm for 810 Cyl. engines
X = 2365 mm for 11, 12 & 14 Cyl. Eng.
consisting of:
012.334/04
94574a 1 Holder
X = 176 mm
94574b 3 Holders
X = 125 mm
2008
X
94574a
60/ 62
X
94574b
RT-flex96C
94035/A1
Maintenance
Lifting tool for transport of supply units

(with engine control system WECS9520)
94690
1 Transport tool
for 3 Cyl. rail unit module
X = 3500 mm
consisting of:
94690a 1 Lifting element

X1 = 1750 mm
x2
94690b
x1
94690b 1 Lifting element

including 24 screws M24x80 and nuts
X2 = 1750 mm
94690a
014.410/06
94691
1 Transport tool
for 4 or 6 Cyl. rail unit modules
X = 5040 mm
consisting of:
94690b

94690c 1 Bracket
incl. 48 screws M24x80 and nuts
X1 = 1680 mm
94690c
94690a
X1
014.411/06
61/ 62
2008
94035/A1
Maintenance
RT-flex96C
94692
1 Transport tool
for 5 or 7 Cyl. rail unit modules
X = 6860 mm
consisting of:
94690b
X
94690d 1 Bracket
incl. 48 screws M24x80 and nuts
X1 = 3360 mm
94690d
94690a
X1
014.412/06
94922
1 Alignment tool
X = 172 mm
008.773/00
2008
62/ 62

MM RT Flex96c - WECS 9520 - Dynex - 2014 04

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MM RT Flex96c - WECS 9520 - Dynex - 2014 04

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RT-flex96C

WECS9520 / Dynex Servo Oil Pumps

Wrtsil Switzerland Ltd

24hrs Support: +41 52 262 80 10

Summary for Maintenance Manual

Maintenance Manual, Issue 2008

Date of publication 2008-11-18

Number 15: Missing remark referring to retaining nut added

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

Tool 94323: design adapted; figures and texts concerning the

Date of publication 2008-12-12

Reversible ratchet 94338b deleted

Tool 94323a with special fixation adapted; tool 94338b deleted

Date of publication 2009-01-22

Tool list: Pages adapted correspondingly

SW-download package 94930 as standard tool added

Date of publication 2009-02-23

8135-1: Exhaust Waste Gate added

8135-1: Exhaust Waste Gate (LLT) added

0370-1 and 0370-2: Title Dimensions (and Material

Key No. 3: altered to 0.12-0.24 mm (max. 0.3 mm)

screw plug 94585 deleted therefore numbers sorted

Columns specified with "Thread diameter" and "Fine thread"

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

Summary for Maintenance Manual

Multi-part quill replaced with one-part quill introduced

Sec. 4, 6th: lubr. for nuts (2) altered to Never-Seez NSBT-8

Grinding the Seating

New valve grinding device 94291 introduced

1st sentence on page 1, addresses and information about

Attention concerning interrupted oil supply to the damper

Securing agent LOCTITE No. 0648 specified for spraying

Application of lubricating device 94844 specifically adapted

Shut-off Valve for

Fitting & dismantling device 94592 introduced instead of

Removal of a jammed pump plunger revised

Injection Control Unit

Lubricant of screw (10) altered to Never-Seez NSBT-8

Exhaust Valve Drive

Fitting instruction adapted and completed with new torques

Fuel Pressure Piping

Fixation of fuel pressure piping reinforced with an additional

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

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

Date of publication 2010-07-15

New group 7218-1/A2 added

Summary for Maintenance Manual

Procedure specified for checking gas (nitrogen) pre-charge

Date of publication 2011-02-25

8733-1/A2: Fuel pressure piping with spherical sealing

EAAD082110 Exhaust Waste Gate

Fuel Pressure Piping

Fuel Pressure Piping

Attention concerning fuel leakage pipe added; reinforced

Regrinding device 94872 for spherical sealing surfaces added

2011-05 EAAD077748 Exhaust Valve

Date of publication 2011-03-31

A new valve stroke sensor 30 adapted. Former items 33, 34

EAAD082346 Tool List

Quantity of device 94350 reduced to 1 piece and 'X' adapted to

Date of publication 2011-05-16

2138-1: Description (passage for LQ and screw-in union)

Measuring bore wear adapted with regard to setting screw (ST)