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V.No. Book No. / ..
New Sulzer Diesel
New Sulzer Diesel AG
Winterthur, Schweiz
Maintenance Manual
for Sulzer - Diesel Engines
RTA76
Installation I Vessel:
Type:
Engine No.:
Mailing address:
New Sulzer Diesel AG
PO Box Telephone 052 262 49 22
CH8401 Winterthur Telex 896 06070 sz ch
Switzerland Telefax 052 2249 17
© 1990 New Sulzer Diesel Ltd. Switzerland Printed in Switzerland
000
For particular Attention
This manual is put at the disposal of the recipient solely for use in connection with corresponding DIESEL
ENGINES.
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 NEW SULZER DIESEL LIMITED, WINTERTHUR, SWITZERLAND. 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 attempts to use the engine or before maintenance work will be undertaken, the respec-
tive manual 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 particulars. data. presentations etc.in this manual correspond to the situation existing at the time of
going to press and they are based on drawings made by NEW SULZER DIESEL. It must be recognized
that such particulars. data. presentations etc. may be subject to later modifications due to further develop-
ments. experience or any other reason.
This manual is primarily intended for use by the engine operating and maintenance personnel. It is as-
sumed that it will a~ways 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 con-cerned will always be carried out by personnel having the special knowledge and skill needed to handle in a
workmanlike manner diesel engines of the corresponding size. the pertaining 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 is generally assumed that the operating and mainte-
nance personnel are familiar with the rules concerned.
This manual has been prepared to the best knowledge and ability of its authors. How-
ever, neither NEW SULZER DIESEL nor their employees assume any liability under any
legal theory whatever including negligence for claims for any damages whatsoever or
claims of any other nature such as regarding additional supplies or services or other
demands, with regard to this manual and its contents or to any modification thereto or
in connection with any use thereof.
NEW SULZER DIESEL LIMITED
WINTERTHUR SWITZERLAND
New Sui... Diesel
10.91
,'" '
Pi ston rod nut
Informat on
The engine can be equipped with "long" or "short" piston rods.
With the long version, the rod of the piston is led through the crosshead from above and secured at the bottom with a suitabl e nut.
In the case of short piston rods, connection is effected by means of a strong bolt, which is inserted at the bottom so that it passes through the crosshead and into the piston rod.
To rule of the possibility of mistakes, the data relevant to engines equipped with short piston rods are printed on greencoloured paper.
Customers are requested to remove the pages of the manual that do not apply to their particular engines.
"Long D piston rod
Pi ston rod bolt
."Short" pi ston ! rod
SULZER Group: 001
RT PRE F ACE Sheet: 1
Pre f ace
The aim of the "M a i n ten a n c e Man u a 1" is to help to ensure that the maintenance which has to be carried out at specific intervals is done correct1 y. It is assumed that the staff charged with such work posses the necessary know- how. Information covering engine operation as well as the description of the func- tioning of specific systems is contained in a separate book "Description and Operating Instructions".
The "Maintenance Manual" is divided into the following main chapters:
• General Guide Lines for Maintenance
• Maintenance Schedule
• Tables of Weights, Clearances and Values for Bolted Connections
• Work Sheets
• Too1s List
The following are a few explanations to the above items:
The "General Guide Lines for Maintenance" contain in addition to indications regarding precautionary measures to be taken recommendations on how to carry out the work.
In the "Maintenance Schedule" the intervals are specified at which the various maintenance operations are to be carried out.
The "Tables of Weights. Clearances and Tightening Values for Bolted Connections" deal with weights of individual engine components, normal and maximum permissible clearances as well as the proper tightening of certain important bolted connections. The "standard clearances" mentioned in the Table of Clearances 012/1 &f correspond to those partly resulting from manufacturing tolerances or those adjusted on the ~
engine. The maximum clearances or max./min. dimensions stated are those values which may result from wear after a prolonged period of operation and which are neither to be exceeded nor gone blow. In parts where the clearance can be corrected by a change in the thickness of shims, discs, distance pieces etc. the original standard clearan-ce should always be aimed at, and adjusted. Wherever this is not possible, the worn parts must be replaced or reconditioned by building up (chrome plating, welding buildup or metal spray. Should during an overhaul, clearances or dimensions be found close to the permissible limits, it has to be left to the engineer in charge of the engine to decide whether or not the parts have to be replaced. This depends for example on the time of opera-tion until the next overhaul and on the wear to be expected from experience made over a certain time span.
Detailed instructions are given in the "Work Sheets" on the procedure of maintenance work on certain engine parts.
The tools and devices are specified in the "Tools List" which are needed for mainte-nance work and which are normally supplied with the engine.
All the information contained in the text and the illustrations of this book are valid at the time of going to press.
Modifications will be incorporated in the next edition.
SULZER Group: 002TABLE OF CONTENTS
RT for Maintenance Manual Sheet: 1
FOR PARTICULAR ATTENTION
PREFACE Table of contents for Maintenance Manual Engine cross and longitudinal section Numbering of bearings and cylinders as well as definition of engine sides
000
001 002 004 008
G E ~ E R A L GUIDE LINES FOR MAINTENANCE
Precautionary measures for maintenance work Recommendations for carrying out the work
011
TABLE OF CLEARANCES
Crankshaft and thrust bearings Crosshead guides Cylinder liners Piston rod glands Crosshead and crank pin bearings Crosshead lubrication Working piston and piston rings Piston telescopic pipe glands Gear wheels for camshaft drive and PTO gearbox PTO gearbox Camshaft and reversing servomotor Ancillary gear drives Ancillary and starting air distributor drive Intermediate shaft for ancillary gear drives Roller guides for fuel injection and actuating pumps Drive for cylinder lubricators Overspeed, pickup and remote tachometer transmitter Balancer drive elements (2nd order 4 to 6 cyl. engines) Balancer drive elements (1st and 2nd order, 4 cyl. engines)
012/1 012/2 (2a RTA58) 012/3 012/4 012/5 012/6 012/7 012/8 012/9 012/9a 012/10 012/11 012/11a 012/11b 012/12 012/13 012/14 012/15 012/15a (RT68, RT76)
lNFORMATION ON THE TIGHTENING OF IMPORTANT SCREWED CONNECTIONS
MASSES OF INDIVIDUAL COMPONENTS (per unit in kg)
DIMENSIONS AND MATERIAL SPECIFICATIONS OF THE RUBBER RINGS
MAINTENANCE SCHEDULE (Table of intervals)
013
014
015
021
WORK SHEETS
Checking the lubricating oil by the spot test method Taking of oil sampl es for 1aboratory anal ysi s
Loosening and tightening the bearing thrust bolts 117/2 Removal and fitting of a bearing cover and an upper 117/3
beari ng shell
Removal and fitting of the bearing cover and stopper 117/4 bridge in the thrust bearing assembly
Removal and fitting of a lower main bearing shell 117/5
Bedplate
Main bearings
Checking the foundation bolts
042/1 042/2
11 0/1
I R 1 Q h
002/1a RT
~
r/'
Thrust bearing Checking the axial clearance Removal and fitHing of thrust bearing pads
Tie rods Checking the pretension and tensioning the tie rods
Cyl inder jacket Transporting acyl inder 1iner with fi Hed cylinder jacket Removal and fitting of the water guide ring
Cylinder liner Measuring bore wear Removal and fitting Removal of wear ridge, rectifying 1ubricating
grooves and edges of scavenge ports
Lubricating quills Function check
Piston rod gland Removal and fitting and measurement of wear
Cylinder head Removal and fitting Hydraulic loosening and tensioning of cylinder head studs Mechanical loosening and tensioning of cylinder head studs
Manual rectifying the seal ing face for the fuel injector in the cylinder head
Fuel injector valve Checking, dismantling, assembling and setting Cleaning and overhauling injector nozzle Lapping of injector body sealing face Checking a circulating valves
Starting valve Cleaning and checking
Relief valve Dismantling, assembling and checking
Exhaust valve Removing and fitting the exhaust valves in the cylinder head Dismantling and assembling EKchanging and grinding the valve seat Grinding the seat face on the valve spindle
Crankshaft Measuring the crank deflection
Torsional vibration Taking a silicon fluid sample
damper (on crankshaft and camshaft)
Axial damper
Turning gear
Cftnneeting rod and
Cllnnlllcting rod bearings
-,Dismantling and assembling
- Oil change and checking worm gear wheels
Checking running clearances
- Loosening and tensioning connecting rod bolts Separating the crank pin bearing body from the connecting rod shank
Inspecting the crank pin bearings - Inspecting and if necessary replacing crosshead
bearing shell s - Removing and fitting a connecting rod
120/1
120/2
190/1
211 /1
211 /2
214/1
214/2
214/4
215/1
231/1
270/1
270/2
270/3
270/4
272/1
272/2
272/3 272/4
273/1
274/1
275/1
275/2
275/3
275/4
310/1
313/2
314/1
320/1
330/1
330/2
330/3
330/4
330/5
330/6
I P
'"
VVC./~U
332 i 1Crosshead Checking the clearances
_ Removing and fitting a crosshead with working piston removed 337/3
340/1Working piston Removing a working piston 340/2 Fi tting a working pi ston
_ Loosening and tightening the piston rod nut (resp. bolt) 34J/3wi th a sped al spanner 340/4 Checking the piston top surface 340/5 Dismantling and assembling
_ Pressure testing cooling space (leak tightness test) 340/6 342/1Exchanging pi ston cool ing tel escopic pipes
34212Piston rings Checking piston ring wear
360/1Piston cooling Checking the stand pipes 362/1Maintenance of glands for the telescopic pipes
Camshaft drive gear Checking of running clearances, backlashes and condition of 410/1teeth 410/2_ Removing and fitting the intermediate gear wheel 410/3 Replacing the split gear wheel on the crankshaft
420/2Cam sha ft Removing and fitting a camshaft section Dismantling and assembling of hydraulically fitted components 421/0
Removing the fuel injection and the actuator cam 421/1 42l/lb Pressing on the fuel injection cam 42l/lc Pressing on the actuator cam
Adjusting the fuel and the actuator cam 42l/ld
42l/le Removing and 42l/lfFitting the flange coupling 42l1lg Removi ng and 421/1 hFitting the camshaft coupling
Removing and fitting the gear wheel on the camshaft 421/4
430/1Starting control air Removing and fitting the pilot valves
di stri butor
) Starting air shut- Cleaning and function checking 432/1
off valve
453/1Running direction Inspecting and function checking
safeguard
455/1Shutdown servo Oismantling and assembling
mo tor
510/1WOODWARD governor Installing, removing and maintenance
530/1Safety cutout de Mai ntenance, fundi on check
vice
aD2/lc RT
Fuel injection p u ~ p s Adjusting and checking the timing Lapping the sealing faces of the covers of the suction,
delivery and spill valves Checking and setting the relief valve Checking and setting the static pressure regulating
val ve Tighten of nipple for plunger bush
551/1
551/2
551/3
551/4
551/5
~
Scavenge air receiver Maintenance of valve
air receiver Maintenance of water
groups and cleaning
separator elements
the scavenge 640/1
640/2
Auxil i ary blower Mai ntenance 654/1
Scavenge air cooler Cleaning (airsideJ with engine at stand still Cleaning (water side) with engine at stand still Removing and fitting the cooler stack
650/1
660/2 660/3
Cylinder lubricators Cleaning 721/1
Driving shaft to the flow control valve of the cylinder lubrication
Dismantling and assembling 722/1
'..../
p. l.O.Gearbox Checki ng the too th profi 1e and tooth backl ash, re-aligning the gearbox housing, checking the running performance
Removing and fitting gearbox components as well as the
intermediate gear wheel. Gei slinger coup1 ing, external check for oil 1eaks and
constant venting
740/1
740/2
740/3
EfficiencyBooster Removing and fitting the hydraulic coupling as well as the flexible packet coupling. Checking the oil level
of the hydro coupling and the alignment of the power turbine.
Funcion checking and maintenance of the shutoff flap and the corner valve
750/i
750/2
Balancer Fitting, Removing, Tensioning the Roller Chain Fitting, Removing the Flexible Coupling and a Camshaft
section resp. lf
710/1 770/1e and 1f (2nd
order and 1g(l st+2nd order)
Exhaust pi pe Adjusting the Belleville washer exhaust pipe mounts
spring packs on the 811 /1
Hydraulic ~i~e
valve drive to .~hau.t Overhauling the pipe seal faces 8461
TOOLS Explanation 940
Hydr. Jacks and pumps Arrangement and application 940/0 & Oa
Hydr. pretensioning jack s
Storage, care and spares stock General application instructions
940/0b &Dc
940/DdOh(Oi, RT84)
Tools list Standard tool s Recommended tools Tools obtainable on loan
940/1;41
940/48;51 960/60
12.89
CJ04/1 RTA 76
RTA 76 846/1
811/1
660/1+3
3 6 2 1 1 - - _ - + t + - ~ ~ ~ . . , j : ~
551/1+5_....,...":;~
231/11,20/2~t"--~1L",...;:::j~ 'C
,1,21/1 +I, ~~--..JL~:t;;I
3g)/I----~~LII-_~~~~
110/1
10.86
001,/2
RTA762 7 ~ / 1
2 1 1 / 2 - - - - - - ~ - i Y t r - T t r ~ 1 t 1 1 1 1 :tI+==t==\:+t;
3'0/~2~'~5.8 211/1-------:=;tl11~
721/1
J30/2
330/5
3'0/3 1H~.~770/1 7 ' 0 / 1 - - _ ~ + : . . . - . .
'It il
~ 1 0 / 2 i : ~ - ~ . ~ " ; 1 ; f ~ . ~ ~ ; F r n t,
,
1t
332/1+2
~ , "" ' ~,:~
~~I +t:, ... ::.~~W "0/3
330/1f'
330/6 1 1 7 / ~
117/3 117/5
120/1
190/1
120/2 310/1 330/2 330/3
9 -1O'Z 198.411
5.87
®(j)
Exhaust side
linksdreh(~l1d
counterclockwise
GruppeNumerierung von Lagern und ZylindernSULZER ~008Groupsowie Bezeichnung der Motorseiten
BlattRT Numberings of bearings and cyl inders and nomination of engine sides Sheet 1
Antriebseite Freies Ende
Driving end Free end
Zylinder
Numbering of main
bearings
~ ~ ~ ~ N u m b e r i n g of
cylinders
Schubstangen
Numerierung
Numbering of
connection rods
Kurbelwellen
lager
Numerierung r-+-t--...
Drucklager
Thrust bearing
3 107156. 218
Linksmotor Rechtsmotor
Left-hand engine Right-hand engine
Numerierung
Exhaust side
Brenns.toff
pumpenseite
Fuel pump. side
rechtsdrehend
clockwise
Ansicht von Antriebseite
View from driving end
2.8~L.B.
Table of Contents
Maintenance Instructions
Clearance Tables
Tightening Values for Bolt Connection.s
Weights
Maintenance Schedule
WorkSheets
ToolUsts
'/
SULZER Group: 011
GENERAL GUIDE LINES FOR MAINTENANCERT Sheet: 1
The maintenance work to be carried out on the engine at specific intervals is described in the "Main-
tenance Schedule ll of this book and is to be understood as a ~
Experience will show whether the intervals may be extended or have to be shortened as mode and condi-
ti ons of operati on, qual i ty of fuel and 1ubri ca ti ng oil used, as well as many other factors i nfl uence the condition of the engine to a great degree.
Precautionary Measures for Maintenance Work
Prior to carrying out any maintenance work on the engine (especially on the running gear), the following precautions have to be taken:
• Close the automatic shutoff valve for starting air as well as the shutoff valves on the starting air receivers •
• Close all the shutoff valves in the control air pressurereducing unit and the drain cocks in the two air receivers arranged above it •
• Open the drain valves placed in the pipes before and after the automatic starting air shutoff valve and leave in this position until maintenance work is c o ~ p l e t e d •
• Open all indicator cocks on the cylinder heads and leave in this position until maintenance work is comp1eted •
• Engage turning gear (gear pinion must be in engaged position) and lock the lever •
• Where the engine has been stopped due to overheated running gear or bearings, wait at 1east 10 mi-nutes before opening the crankcase doors •
• The crankcase doors must always be locked with all the closing dogs whenever the engine is running
even if this is only for a short time in order to make temperature checks leg. after changing bear-ings during an overhaul, etc.) •
• In the case of a fire in the engine having been extinguished by means of C02, the spaces effected
must be well ventilated before work can be carried out within them.
Recommendations for carrying out the work
Prior to turning the crankshaft with the turning gear, make sure that nobody is inside the engine and that no loose parts,tools or devices can get jammed. Also ensure that the coupled propeller turns too (danger in surroundings).
When carrying out maintenance work, use the tools and devices intended for the work in question which, as a rule, are supplied with the engine (see "Tools List ll at the end of this book).
Tools and devices should be ready prior to use and be in perfect condition.
Hydraulic tools are to be checked from time to time for tightness and faultless functioning (see also sheet 940/0a).
All work must be carried out with the necessary care, observing utmost cleanliness.
During maintenance, openings of pipes, open oil bores, etc. must be temperarily closed to avoid the entry of any dirt.
All parts overhauled during the course of maintenance have to be checked for perfect functioning prior to starting the engine. Pipes which were removed have to be checked for tightness after re-fitting.
-.J
RTOllila
Clearances of moving parts ~ u s ! be cl,ecked periodically. Should the maxi~u'll perrrissit,ll " J;'Jes (see clearance tabl es) have beer reache~ or have even beer, exceeded, these parts n us ~ :12 re~,l a-
ced by either new or renovated snes, except where the clearance car be readjusted by re~ova1 of
sh ims.
Parts taken from the spares stock are to be replaced. When ordering new parts only the code numbers of the code book must be used and engine number, type of engine and name of installation must be
mentioned.
When tightening studs, nuts or bolts, the utmost care must be taken not to damage their threads and that they can be screwed in by hand until metaltometal contact is obtained. The specified
lubricants are to be used.
Where tightening values are stated, these must be strictly adhered to (see table "tightening values
for bolted connections 013).
Locking devices of bolts, nuts, etc. must be fitted correctly and secured properly.
_ Used rubber rings must always be replaced by new ones when an overhaul of any engine component ta-
kes place; they lust conform in dimension and quality to the specifications in the list group 015. The fitting of piston seal rings and rod seal rings requires the greatest of care to prevent slid-ing rings being damaged, overexpanded or distorted. RECOMMENDATION: Before fitting the sliding
ring of a piston seal ring heat it first in boiling water.
Table of Contents
Maintenance Instructions
Clearance Tables
Tightening Values for Bolt Connectior]s
Weights
Maintenance Schedule
WorkSheets
ToolUsts
1
SULZER Gruppe: 012Kurbetwellen - und DrucklagerSpiele Group :
BlattRT76 Crankshaft and Thrust BearingsGearances Sheet
Kurbellllellenlager
CRANKSHAFT BEARING d
u
Differenz aj a2 = max. 0,1 mm bei gespannten Bruckbolzen
Difference al a2 = max. 0,1 mm with thrust bolts tensioned
v. 4 107. 197.046
0
/
o
d Drucklager
THRUST BEARING
o
2'101.198 :812
f f
'1
Nennmass Spiel neu
Nominal dimension Clearance nelll
b = 790
0,68B= 790 +0,58 +0,48 c = 0,48
e = 20
maximum Nennmass Spiel neu maximum durch Abnutzung durch Abnutzung
due to lIIear Nominal dimension Clearance nelll due.to lIIear
o f = 100_0 03
0,8 2,5
~ d = 375 dl + d2 = 15
g = 225
1983
2
SULZER J.C"p,'ele KreuzkopffiJhrung GruPp~:012
1--====----+---------------1 Group :RT76 rJ CROSSHEAD GUIDANCE BlattLLearanCes Sh~~t
Brennstoffpumpenseite
..... o
FUEL PUMP SIDE
2- 107. 198.414 .. * Wenn die Gleitschuhe auf der Brennstoffpumpenseite anliegen, muss die Ko'ibenstangenachse zur Zylinderachse
um das halbe Spiel 'bl' gegen die Brennstoffpumpenseite verschoben sein,
* WHEN THE GUIDE SHOES LIE AGAINST THE FUEL PUMP SIDE, THE PISTON ROD AXIS MUST BE DISPLACED BY HALF THE CLEARANCE 'bl' TO THE FUEL PUMP SIDE RELAT IVE TO THE CYLINDER AXIS.
** Das Spiel 'bl' gilt nur fur kalten Motor ohne angezogene Zuganker und Druckbolzen. Durch das Anziehen von Zuganker und Druckbo1zen vergrossert sich das Spiel im Bereich des U.T.P. Diese Spielveranderungen bleiben fur das Betriebsverhalten des Motors ohne Bedeutung.
** THE CLEARANCE 'bl ' IS ONLY VALID FOR COLD ENGINE ON WHICH THE TIE RODS AND JACK BOLTS ARE NOT TIGHTENED. TIGHTENING OF THE TIE RODS AND JACK BOLTS INCREASES THE CLEARANCE MAINLY IN THE REGION OF B.D.C. THE FLUCTUAT ION OF TH IS CLEARANCE DOES NOT AFFECT THE DPERAT ION OF THE ENG INE.
Nominal dimension
Nennmass
Clearance new
Spiel neu maximum durch Abnutzung due to wear
Nennmass
Nominal dimension
Spi e1 neu
Clearance new
maximum durch Abnutzung due to wear
a = 370 B = 924 b]
0,5 ** = °,2 0,6
A = 370
0,2b =924_0,25
0,09
°03 0,15
cl
c2
= 0,15
= °15
..
..
0,25
°25
0,4
°4
5.84
3
SULZER . , Gruppe: 012SJ----_===p=l=e=e_---I-_zy_It_"nd_e_re_in_s_a_tz ~ Group :
RT76 rJ B/attLLearanCes Cylinder Liner Sheet
A
I
I
'/ I
1- 107. 197. 095
NennnTlss
Nominal dimension
A = 1094,5
B= 1100,5
C = 760
Spiel neu
Clearance nelll
1, 1 al + a2 = 0 7 ,
b b 1, 1 1+ 2=07,
maximum
durch AbniHzung
due to wear
max.¢ = 765,3
Nennmass
Nominal dimension
F = 1020
G = 945
H = 935
Spiel neu
Clearance new
f 0,6f l + 2 = 0 2 ,
1,3 gl + g2 = 0 9 ,
h 0,8 hI + 2 = 0.5
maximum
durch Abniltzung
due..:to wear
E = 1030
5.84
SULZER
RT76
Spiele
Clearances
Kolbenstangen StopfbiJchse
Piston Rod Gland Box
012
4
~ c:
.S:! ~
0_ ::lo c: ~.s:!c: ~
:::d~ ~
:§c: .....!:!l 111111 ::lCII .:(Q
T
c
~TEFLON
.... . Beim Kontrollieren des Spieles il muss der Abstreifring CI) auf
dem Fuhrungsring ~ aufliegen.
WHEN CHECKING THE CLEARANCE AT il THE SCRAPER RING CD MUST LIE ON GUIDE RING (I).
Beim Kontrollieren der Spiele II, III 1 und klmUssen das Schloss CD und der Abstreifring CI) auf dem Fuhrungsring (l) aufliegen.
WHEN CHECKING CLEARANCES II, ml AND kl CLAMP CI) AND SCRAPER RING CI) MUST LIE ON GUIDE RING (l).
c
kd ---TEFLON
~ 4-107.198.444
Nennmass Spiel neu maximum Nennmass Spiel neu maximum
durch Abnutzung durch Abnuhung Nominal dimension Clearance new due to wear Nominal dimension Clearance new due to wear
min. Dicke = 39a = 45
min. thickness il = °~ 0,08 0,5
min. Dicke = 15b = 20
min. thickness kl = 0,05 y 0,26 0,8
min. Dicke = 18c = 20
min. thickness 11 = °~ 0,1 0,5
e = 30 el = 0,4 or 0,7 O,a ml = Dor 0,23 0,5
f = 35 fl = 0,4 or 0,7 0,8
G= 280 280,3 gl = 0,056 or 0,160 0,4
110/,
5
SULZER Sp,'e/e Q 5 Grupp~: 012J-_-====-_---+_IiJ_e_r_e_u_n_d_u_n_t,_c_h_u_bs_t_a_ng_e_n_la_ g _ e_r~ Group :
RT76 rl Upper and Lower B/attLlearanCes Connecting Rod Bearings Sheet
Obere Hal He
UPPER HALF
d
.~
'../
Spiel neu
Clearance new
a1 + a2 = 0,32TO,50
b = 0,34 .. 0,56
cl + c2 = 0,60TO,80
d1 + d2 = 0,30TO,70
Lagerschale
BEARING SHELL
'=I====!r+I
4-107, 1~,693
Nennmass
Nominal dimension
° a = 65°_0,08
d = 284
e = 790
maximum
durch Abnutzung
due to wear
0,6
Nennmass
Nominal dimension
E = 790+0,58 +0,48
= 13 ± 13
g = 335
Spiel neu
Clearance new
f = 0,48 T 0,66
gl + g2 = 15 ± 0,5
maximum
durch Abnutzung
due to wear
0,7
5,84
SULZER
6
c, c
) /
RT76
maximum Nennmass Spiel neuNennmass Spiel neu
durch Abnutzung
due to wear Nominal dimension Clearance newNominal dimension Clearance new
1,20,09 0,2 c = 65 c1 + c2 = °6a = 60 al = 0 03
b = 95 bl + b2 = 4
~~-~~~+---+---r---I--l "./
maximum
durch Abnutzung
due to wear
1983
/
ArbeitskolbenSULZER (jruppe: 011"Spiele und Kolbenringe Group: L-
Working Piston Blatt 7RT76 Clearances and Piston Rings Sheet
a
b
c m J
c
m J
40 40f
~11111·.llill--_--..,..--n m
I K
Fuer die Wiederverwendung von gebrauchten Kolbenringen ist die Ringbreite an den Stellen A, B und C massgebend. Gebrauchte Kolbenringe koennen weiterverwendet werden, wenn bis zur naechsten Revision die minimaIe Ringbreite nicht unterschritten wird (siehe Blatt 34212b)
The ring width at the positions A,B and C is the decisive criterion for refitting of used piston rings. Used piston rings my by refitted, if they will keep within their min. ring width till the next revision (see groupe 342, sheet 2b).
I [mm]24 rT'TTT1T'I=
23 IHlffiI33:
Kolbenring-breite 'I'
Piston ring width 'I'
21
22111111120 19....LLJ..L.U.U...
760 761 762 763 764 765 766 [mm]
ZylindereinsatzDurchmesser 'a' I Cylinder liner bore 'a'
Spiel normal. neu maximum durch NennmassNennmass Spiel normal, neu maxmum durch Normal clearance. Abniltzung Normal clearance, Abniltzung
Nominal dimension new max due to wear Nominal dimension new max. due to wear
765,32 g = 2BOa = 760
5,0 .;. 5,45 H= 25b = 755
14 + 0,33 j = 0,4353,0 .;. 3,45 0,65J =c = 757 1 7
14 + 0, 1B
+ 0 29
k = 0,285dmin . 75B,21,3 .;. 1,7d = 75B,7 0,55K= 1
siehe Diagramm
+ 0 14
0,9 .;. 1,2f = 759,1 1 = 24 see dia ram
0 m= 13,920 025
.r.
"""
auf dem Fuhrungsri ng WHEN
LIE ON
WHEN
AND SCRAPER RING CD MUST
Nennmass
Nominal
a 50=
A 50=
d 39=
0 = 39
SULZER G r u p p ~ : Kolbenkiihlrohr - StopfbiichsenSpiele Group 012
RT76 Blaff Piston Cooling Pipe GlandsClearances Sheet 8'. -
~
t ~
k .......
bI,1 , ::;::::::.;;.~-=;;.oi r;; ~ r::,m:::u;:::::::.d •. ~
I I: · C?T~ a ~~ ~ ~ A I~0.' ~ ~rI
1'\ I'\~ 1'\ ~ D 1'\I
el, ".") "',,'\ d1
Ir Ff l ~• I , f.I
i I
d d2
rlIr Lc:: PJ
~~~~il· ~~;~%~~~~~~
ii,~: f~~~~:
ii~t~~~~~ ~~@~~t
: ~ ~ ~ ~ 1 ~ ~ ~ ~ ~ ! ~ n J :
~.~ ••
I
l~
0
I I ,
L..
I I "/I
I U~ ~ H-
J 2-107."1.061
.. a1 0 02
A
Beim Kontro11ieren des Spie1es b] muss der Abstreifring CD 0 aufl iegen.
CHECK ING THE CLEARANCE AT b1 THE SCRAPER RING CD MUST GU IDE RING 0·
Bei mKontrol1ieren der Spiele fl, gl und cl muss das Schloss
CD und der Abstre ifri ng CD auf dem Fuhrungsring 0 aufliegen
CHECK ING THE CLEARANCES fl, gl AND cl THE CLAMP RING CD LIE ON THE GUIDE RING (1).
~
D d1 d d2
~~ ., ~
~~~l!~j f.~~~~~f
:~M l~l~~t ~. 1
I
~. tre :fWl ~@~~~1
~ ~ ~ ~ l f ? : ; ~ ~ ; ~ j l @
!t Ir·.I
Ur. 41
~j~l~f:~ ~:~~~;~;~~
Ki1~W~ ~~{~~~It~
,
dimension
Spiel neu
Clearance
al + a2
0,08bl =
°0,23cl =
0 05
dl d2+
new
0,114 = 0,050
0,05 0,40 = 0,3 0,05
maximum
durch Abnutzung
due to wear dimension
max. ~ = 5J
max. diam.
0,5
Nennmass
Nominal
h = 9,5
i = 7,5
Spiel neu
Clearance
0,08 ~f]
0
0,25gj =
0 02
0,15ml =
0,05
'../'-1Ul. 198."7
maximum
durch Abnutzung
new due to wear
min. Mass = 7,5
min. dimension
min. Mass = 6
mi n. dimension
0,5
1.85
I
9
SULZER
RT76
''"../
Spiele
Clearances
maximumSpiel neuNennmass
Nominal dimension Clearance new
durch Abnutzung
due to wear
A= 270
a = 270
b = 290
al
bl
0,234 = 0 142
1,1 + b2 = °6,
0,35
1,5
C= 340
c = 340
d = 290
C] 0,348 0,252
1,1 d1 + d2 = 0,6
0.45
1,8
Rader zum Steuerwellenantrieb
und P T.O. Getriebe
Wheels for CamshGft Drive and
Drive for PT.D.-Gear Box
1 107 197 322
Nennmass
Nominal dimension
G r u P p ~ : 0 1 2 Group :
Blatt S h ~ e t
Spiel neu
Clearance new
maximum
durch Abnutzung*
due to wear
Zahnflankenspiele/Backlash of teeth
norma1 max.* norma 1 max.*
0,32 0,78°54
0,43 0,782
0,65
0,43 0,753
0,66
6.87
SULZER
~ - = S = = p = i e = l = e _ - - - + _ p _ . _T._O_,_G_et_n_·eb_e l ~~~~~e:: 012 RT76 Blatt 9 ,
L ..L::G::e::Q::r:::Q::n::c:::e::s=J_p_T._O_'_D_r_iv_e ---l...:S~h~ee::..t...:...- __a--l'---""
c ~1
Nennmass
Nominal dimension
a = 340
b = 250
c = 190
d = 220
Spiel neu maximum
durch Abnuhung
Clearance new due to wear
0,348 al = a 252 0.45
b _ 0,343
,
0,631 0,285
0,31 0,56
C] = a,252
d _ 0,321 0,581 0,258
1,1 1,8e =
0,6
b bl
Nennmass Spiel neu
Nominal dimension Clearance new
f = 1,51 1,0
0,91 9 = a,50
maximum durch Abnutzung*
due to wear
2,0
1,5
Zahnflankenspiele/Backlash of teeth
normal
CD 0,43
0,66
CD 0,32 0,51
max. *
0,75
0,66
normal
CD 0,32
0.47
max.*
0,58 "
6.87
10
Steuerwelle undSULZER G r u p p ~ : 012Spiele Umsteuerservomo tor Group :
BlattRT76 Camshaft andClearances S h ~ e tReversing Servomotor
c d ~
:1i,
I'
o
4 - 107 199.345
Nennmass
Nominal dimension
a = 300
A= 300+0,200 +0,150
Spiel neu
Clearance new
0,232 a j 0,150
0,45 bl + b2 = °,14
maximum/minimum
durch Abnutzung
due to wear
0,35
0,6
Nennmass
Nominal dimension
Spi e1 neu
Clearance new
0,3 c =
0,1
O,16d1 + d2 = 0,10
maximum
durch Abnutzung
due to wear
0,4
0,3
5.84
11
SULZER Getriebe fur HilfsantriebeSpiele
RT76 Gearing for Auxiliary DrivesGearances
Siehe auch Bl'att 012/13
See also sheet 012/13
.~~. ~~';;;:t:~ 01 Siehe auch Blatt 012/11b
(:;\~
~~
~ ""'-",\1 See also sheet 012/llb
Siehe auch Blatt 012/14
See also sheet 012/14
2- 101.197.010
Nennmass Sp ieI neu
Nominal dimension Clearance new
maximum
durch Abnutzung*
due to wear
Zahnf1ankenspiele/Backlash of teeth
normal
CD 0,12 0,26
CD 0,14 0,26
0,10 0,21
max.* normal max.*
0,47 CD 00'2100 0,34,
0,40
0,38
1983
Getriebe filr Hi/fsantriebe undSULZER Gruppe:Spiele Group 012Anlass - Steuerluftverteiler
RT76 BlattGearing for Auxiliary Drives andClearances Sheet 110Starting Control Air Distributor
Anlass - Steuerluftverteiler
STARTING CONTROL AIR DISTRIBUTORe 0-1
, o
cp I
0,175 h ; 1,0b ; 50 b] 0,30,] 1O 0,5
0,175 . 0,20c ; 45 cl 0,3 0,3
1 ; °,150,1] ° 0,175 k ; 0,22d ; 50 d1 0,30,3
3 107. 19'1058
Nennmass Spiel neu
Nominal dimension Clearance new
a ; 80 a1 0,090
0,030
0,110 0,14
0,136m; 60 m1 0,2
0,060
Zahnf1ankenspie1e/Back1ash of teeth e ; 1
norma] max.* normal
0,10f ; 1 0,30°20
maximum
durch Abnutzung
due to wear
0,15
maximum
durch Abnutzung*
Nomina] dimension
Nennmass Spiel neu
Clearance new due to wear
°1,0
,59 ;
max.*
1 ~ See also sheet 012/11 -==::::1
2 -107. 197.306
SULZER G r u p p ~ : 0 1 2Zwischenwelle fur HilfsantriebeSpiele Group :
BlattIntermediate ShaftRT76 11bClearances S h ~ ~ tfor Auxiliary Drives
J Si ehe auch B1 att 012/11
Nennmass Spiel neu maximum
durch AbnUtzung
Nominal dimension due to wearClearance new
0,106 Zahnflankenspie1e Backlash of teeth0,2a = 100
a1 0,036 norma1 max.* normal max.*
b 0,8 CD 0,12 CD 0,120,9 0,47 0,500,3 0,26 0,28
1983
12
Rollenfilhrungen zu Brennstoff-SULZER Gruppe: 012Spiele und Hubgeber - Pumpen Group :
BlattRoller Guides to Fuel PumpRT76 Gearances and Actuator Sheet
ol,)
e E
:: ~:~:~:~: ~: ~: ~: ~: ~:'
mfff)-:.:-:.:-:.:-:.:-:
4 - 107. 197. 325
--C "tJttt+
b2b
B b1
Nennmass
Nominal dimension
= 64 0,030 a 0,060
b =265 0,250 0,300
B265 +0,052 ° =108 0,036
'' c 0,058
C =108 +0,052 +0,030
Spiel neu
Clearance new
0,030 al = °,090
0,250 bl + b2 = °352,
0,066cl
0,110
maximum
durch AbniJtzung
due to wear
0,35
0,5
0,16
Nennmass
Nominal dimension
d = 90 0,036 0,058
o = 90 +0,022
° = 120 0,36
e 0 54
E = 120 +0,25 +0 15
Spiel neu
Clearance new
0,036dl °080
0,5181 + e2 = °79
maximum
durch AbniJtzung
due to wear
0,12
1,5
5.84
Zahnradpumpe zum AntriebSULZER Gruppe: 01.'')Spiele der Zylinderschmierpumpen Group: L
Gear Pump for BlattRT76 Gearances Cyl. Lub. Pump Drive Sheet 13
1 3 -107.134.605
Siehe auch Blatt 012/11
See also sheet 012/11
Nennmass Spiel neu maximum Nennmass Spiel neu max i mu'm durch AbnUtzung durch AbnUtzung
Nominal dimension Clearance new due to wear Nominal dimension Clearance new due to wear
0,050 a = 38 al
0,009
min. 0,055b
max. °130
0,15
max. 0,20
min. 0,14 0,40CD max. 0,26
min. 0,06 0,20CD max. 0,13
5.84
Antrieb fur Uberdrehzahl, Pick up Gruppe: 012Spiele und FerndrehzahlGeber Group :
BlattOverspeed J Pick up - and RemoClearances te Tachometer 7ransmitter - 0 rive Sheet 14
3 ~ Si ehe auch B1 att 012/11
SULZER
RT76
~r-7
Ueberdrehzah1GeberAntrieb
Overspeed TransmitterDrive -'-- -_ ...._-----------.. -
----
~ A ~ ~- ~a. at II
~
~ I" ~~~-~-~_l
~ ~--" ~ ~ ~--
.....b
Nennmass Spiel
Nominal dimension Clearance new
a = 22 a1
=
b =
c = 1,0
d = 1,0
e = 22 e1
=
-0'\ See also sheet 012/11
A~
;+-~ - - /
,~ \. ~ - f'rndr,hzahl-6,b'r - --+-} {+} Remote Tachometer ''i-' 1 2""t-' Pi ck-up-Geber-Antri eb Transmitter-Drive
Pick-up-Transmitter~rive 4 -107. 197. 333
-~ "
ri- ~
=~ l
~ ~ ~ '"~ -"~ "'"~f', r-- t-""
-l\r:: j ~
.... ~t\.'\jr~ ~'"r / / /v / / / ,-.::::
I~ n~ ~L~~ +- ...," "'" -"', -"\ " " " ~ -ts1 ~
V////// ~
I L
~ ~ Ott
-.-1 e.
n I"J ~
e, e
~ .~ 4 107.197.320
3107.f97.321 L / ----<
Pick-up-Geber / Pick-up-TransmitterC
d Ueberdrehzah1-Geber / Overspeed Transmitter
neu maximum Nennmass Spiel neu maximum
durch Abnutzung durch Abnutzung*
due to waar Nominal dimension Clearance new due to wear
0,040 0,15 f = 1,5
0,094
min. 0,1 max. 1,0
min. 0,2 max. 1,° g
max. 0,5 - max. 0,5
Zahnfiankenspie1e/Back1ash of teeth
normal * normal max. * max. 0,040
0,15 CD 0,12
0,51 CD 0,10
0,38= = 0,210,094 0,29
CD = 0,12
0,510,29
5.84
SULZER
RT76
Spiele
Clearances
Massenausgleich -Antriebselemente 2.0rdnurg
Balancer drive units Second order
G r u p p ~ :
Group
Blatt S h ~ e a t
012
15
gezeichnet fur freies Ende DRAWN FOR FREE END
1- 107. 198.403
Elast. Kupplung
FLEXIBLE COUPLING
, '1
Nennmass Spiel neu maximum Nennmass Spiel neu maximum
durch Abnutzung durch Abnutzung Nominal dimension Clearance new due to wear Nominal dimension Clearance new due to wear
a = 210 0,30
0,4 e = 390 el 0,58
0,7al = °17 °40, b b 0,6 2,0 f = 124,7 fl = 0,3 .. 0,7 1,51 + 2 = I 4,
c = 390 0,58
0,7 g = 300 0,304
0,4cl = °40 gl 0,208,
d = 124,7 d1 = 0,3 T 0,7 1,5
1983
Gruppe:Massenausgleich -Antriebselemente SULZER Spiele 012Group1.+2. Ordnung
BlattRT76 Balancer drive units Clearances Sheet 1501. and 2. order
gezeichnet fur freies Ende
DRAWN FOR FREE END
Elast. Kupplung
FLEXIBLE COUPLING
Spiel neu maximum Nennmass maximumNennmass Spiel neu
durch AbnDtzung durch Abnutzung Clearance newNominal dimension due to wear Nominal dimension due to wearClearance new
0,30 0,4a " 210 al"017,
0,6 2,0bl + b2 " 1 4,
0,58 0,3040,7c " 390 0,4 9 " 300cl ~ 0,40 gl = 0,208
0,40d " 124,7 dl " 0,3 ;. 0,7 1,5 h = 265 0,5hl = 0 25
5.84
Table of Contents
-\......-,----------------------------------
Maintenance Instructions
Clearance Tables
lightening Values for Bolt Connections
Weights
Maintenance Schedule
WorkSheets
ToolUsts
,,
'"
'-..-/
'-..-/
"''
SULZER Indications
RT76 of important
1 2
0-:::>
0
Name of screwed connections<...
'-'"
11C Holding down bolts (epa xy
11 Main bearing, jack bolts
19C Tie rod
2lC Cylinder jacket . ijol ts
fastenlQg Fitted bolts
27[ Cyli nder cover, elastic bolts
27£ Fuel valve, elastic bolts
27£ Indicator valve, screws
Fuel injection valve: Cap nut 272 Fue1 injection valve: Cap nut to 2P
(Pretension with 20 bar, or a hammer blow)
27~ Startinq valve spindle, Nut
27~ Elastic bolts for val ve cage
2 7 ~ Exhaust valve spindle, nut
3lC Flywheel, Coupling bolts
3lC Crankshaft, coupling bolts
3H Axial vibration damper, central waisted
330 Connecting rod boltstop
330 Connecting rod boltsbottom
340 Piston, elastic bolts
340 Piston rod nut (long piston rod)
340 Piston rod bolt (short piston rod)
410 Gearwheel on Crankshaft, elastic bolts
410 Intermediate wheel bearlng tor camshattdrlve elastic 8.
42C Reversing servomotor, connection lJi nn
42C Reversing servomotor, longitudinal bolting
Remarks: * The tightening values apply only when ** The pressures indicated apply only for the
n~. W~~n othe~ j~ck~ ~re use~ tee ectlve Jac plS on sur ace.
ConvArsion fador: 1 Nm = 0 102 mko
for the
screwed
resin chocks)
Nozzl e
bolt
between shaft and
Molykote use
the required
Group:tightening 013 connections
Sheet: 1
4 53 5 7 I ~ . c CD c
c en c o ~ 0 Ie = o~ co
f' <... o ~
CD '"'" = ~ = c +' <J)I c
0_ en
CD '" c '" '"o~CD CD E u c0<... <J) CD .~
C <D c: CJ1 c: ""0 l+-...... .•
-+-' ....... r-CD CD:::> CD C 00--=
=
....... -+-' -+-' +' :::> "" <... c u '" CD .-C 0' <... .-C c CD u'" CD
<... ""0 0 CD CD u CD .-C
=<"'0 = <... >... Or- 0.. ....... Ot-- o ~ ::::> <... CI.. ...... ...c
<J)""O en== (I') (I')> >->-- >- +' 0
Nm*bar**
M54x4 500 11 0/1
500 117/2Ml15x5
500 190/1M150x5 (1. step 350 bar)
M55 elongation 0,55:0,04 o 4n~0 0':1
500 1800 4-M90x5 270/2
Illop eage oflloTfneaa tl ushM12 272/1
with nozzle holder)
M20 80
1500250 272/1M54x2
max.150 45 04See instruction sheet 272/
M30Xl 273/190 0 4-
150 0
500 275/1M54x5 4-
500 275/1M45x3
29 0 4-
M85x4
M85x4
42 0
4
0 4M100 500 314/170
330/2 600
M80x5 500
M80x5 (1. steo 350 bat ) 90
0 4- 330/2
340/5M48 50 0.4
300- 4 or 5 340/3M140x5 teeth
55lJ 4= or 11
M100x5 340/3teeth Elongation
M56x4 410/31 15 ± 0 05
410/245 0
M42 440
0M35 .4
0M20 30 4
Paste G is used as lubricant on the thread. of the original jacks supplied with the engi
pressures must be calcualted in proportion of
1 bar = 1 02 kn/cm2
HOWZim 3.90
SULZER Indica+:ions for the tightenin,Q;
Group:
of important screwed connectionsRT76
Sheet:
54 52 31 I ~ • c Q,) C
C en c o ~ 0 0' . ~
0' C .....
I
e- 0' ~ '" "'" '-
c en c ro ro'" ro
.~ 0''r'" '" E c Q,) C CJl C
0 ' en '" o . . . ~ = '" c 0~ ~ ~ -+-' or- roro0-
:::l ..c 0 '-' c: '' ..c c '" 0' ' 0 0' '-0 '"'- 0 0 '"
Or- 01--- . ~ :::l>-. 0,- 0....c '-'- Name of screwed connections I-e-~ e ..... 0e-''" = en en
bar** Nm*
M5555"1 fie rod for fuel pump housing 50 0
4-
2 teeth M145x4Nut to pl unger guide551
90 0
M30El asti c stud fo r hydraul i c actuator cyl i nder551 4
90 0
4M45Elastic stud for fuel pum p block551
60Valve cover for fuel pump block M12551
300Pressure nipple for sucti on and spi 11 valves M39x2551 .
M30 325 150
740 Fixing of gearbox to engine 4
740 Fixing of generator support (top) G71 0M42
PTO740 Fixing of generator support (bottom) M64x4 " 600 M3U 114U
740 Beari ng .bo 1ts 1990M36
570M24740 Flange bolts
M30 n140740 Fixing of gearwheel to coupling
B180M42740 El asti c bolts for fixing of bearing
770 Bearing cover on coupling shaft, elastic stud M36
600
Fixing bolts for balancer, housing with col umn, 770
M48770 Clamping cover on balancer mass, elastic stud
600M48el asti c studs
M30 540770 Screwed connecti on of fl ex. and camshaft coupl ing
900M36770 Screwed connecti on .of fl ex • and camshaft coupl ing
Top edge of the discM30Sl iding foot for exhaust pipe811
1Avel with rAd
30 0
Tie rod for exhaust pipe M64811
Remark: * The tightening values apply only when Molikote Paste 'G' is used ** The pressure
~ ~ ~ ~ ; ? , ! h 1 ~ ~ J ~ ~ ~ ~ + ~ ~ e
r 'nn·
4-
60 0
85 0
30 0
45 0
100 0
40 0
mark
as lubricant indicated apply only for the use of the original, jacks supplied
u ~ ~ d the required pressures must be calculated in
1 Nm ~ n In? mkn 1 h~~ ~ 1 n'J '-'n/nm'J
013
2
7
, c' C 0
'- en '' C .~ 0 '+- 0....- •• 'f"""" -+-'-+-'
'' ro '"
'" '' '"0.. . .-....s::: en 0 en
551/5
551/1
551/1
551/1
77 0/1
770/1
770/1
811 /1
the thread. the engine.
ef-
on with
proportion of the
.4:
4
4
4
4:
4
spring 1M'
4.86
Table of Contents
'-------------------------------------
Maintenance Instructions
Clearance Tables
Tightening Values for Bolt Connections
Weights
Maintenance Schedule
Work Sheets
Tool Lists
SULZER
liJ E I G H T SRT76
individualof in kg
components oer
Secti 0 n Components
117 Main bearing cover (narrow) 4 ;
9 ;
8 cyl.
12 cy 1•
Main bearing cover (wide)
Main bearing shell (narrow) per pair,
Main bearing shell (wide) per pai r,
Main beari ng thrust bolt compl.
120 Thrust bearing segment
190 Tie rod without
Lower ti e rod nut
Upper ti e rod nut
211 Cylinder jacket compl.
Cylinder jacket
Accessori es for cylinder jacket:
Waisted stud bolts (8 off, total = 464 kg) with nut
Water guide ring
End cylinder jacket
Cylinder jacket end piece
213 Water guide jacket
214 Cylinder liner
231 Pi ston rod gl and
unit
Parti cul ars
incl.
nuts
with
without accessories
without accessories
Group: 014
Sheet: 1
RT58 RT76
454 370
571
inc 1• shim 215
shim 368
156
135
1714
40
33
accessor. 19587
13500
58
544
16700
3025
163
4923
145 I
[: 0'
SULZER
RT76 of individual in kg
Section Components
270 Cylinder head
Cylinder head
272 Fuel injector
273 Starting valve
Relief valve274
275 Exhaust valve
Exhaust valve spindle
310 Crankshaft (~emi buil t) 4 cyl.
5 cyl.
6 cyl.
7 cyl •
8 cyl.
9 cyl.
10 cyl.
12 cy1•
Flywheel (light)
Flywheel
312
Connecting rod (shaft dia 600)
Lower connecting rod
330
W E I G H T S Gro up: 014
Sheet: 2
RT58 RT76
3340
5210
31
63
7
1680
123
81000
97100
113200
129300
145300
17 0100
186200
218400
3400 ..
7000
6400 .. 16500
6090
750
components
bearing (shaft dia. 600)
per unit
Parti cu1ars
without valves
compl.
com pl.
camp l.
compl.
com pl.
with val ves
incl. thrust beari no
n
shaft
n
n n
n n
n n
n n
n
n
n
n
compl.
upper half
G H T s
components oer unit
SULZER W E I
RT76 of individual in kg
Secti on Components
330 Lower connecting rod bearing (shaft di a.
Upper connecting rod head
Upper connecting rod head
Beari ng shell for upper connecti ng rod head
Connecti ng rod bolt fo r lower bearing
Connecting rod bolt for upper bearing
Connecti ng rod shaft
Crosshead pin
Guide shoe for crosshead
short piston rod
337
340 Working piston long piston rod
Piston crown
Piston sk i rt
shod desi gnPiston rod
lona desion
Piston rod nut (only for short piston rods)
Piston rod screw (only for long pi ston rods)
342 Pi ston cooling telescopic pipe
360 Piston cooling stand pipe
Piston cooling box361
410 Gearwheel on crankshaft
Intermediate wheel for camshaft drive
600)
bearing
upper
lower
with
with
compl.
and
compl.
compl.
Parti cul ars
lower half
half
half
nut
nut
without guide shoes
with piston
telescooic Dioes
with bolt
with nut
with bearing journal s 1 or 2piece
Group: 014
Sheet: 3
RT58 RT75
462
260
430
33
43
43
3104
2190
380
rod 3350
3387
948
262
2125 2147
60
16
15
9
229
2456
2290
SULZER
RT76 of individual in kg
Secti on Components
420 Camshaft 4 cy1•
5 cyl •
6 cy1•
7 cy l.
8 cy1.
9 cy1•
10 cyl.
12 cyl.
421 Fuel pump cam
Actuating pump cam
510 WOODWARD governor (PGA200J
551 Fuel injection pump body
651 Exhaust gas turbocharger VTR
n n n
n n n
n n n
Silencer with air filter
n n n n
Air fi Her segments for VTR
n n n for VTR
654 Auxiliary blower
IN E I G H T s components
564
VTR 714
rotor VTR 564
n VTR 714
for VTR 564
for VTR 714
564
714
Group: 014
Sheet: 4 per unit
RT58 RT76Parti cul ars
with cams and shaft 5516 couplinQ
n n 7414
n n 8311
n n 10211
n n 11044
n n 12867
n n 13698
n n 16495
161
210
compl. 115
compl. without plunger 667 and guide bush
6300 comp1.
n 12100
n 487
n 980
n 713
n 1370
6 x 15.
6 x 20
compl. wi th 1132 ~
el eetr. motor 1295
WEI G H T S
of individual components per unit
SULZER
RT76
Secti on
660 Charge
"
air cooler
" II
770 Balancing mass
" II
Flexible Coupling of
Roller Chain of
2nd
811 Exhaust pipe
Components
GEA, SERCK 4,5,7,8,9 and 10 cy1.
GEA, SERCK 5,6,7,9,10 and 12 cyl.
lst order (Balancer 4cyl.) Campl.
( II 4.. 6 cyl.) Campl."
Balancer
3tBalancer 4"
4 cyl.
5 cyl.
6 cyl.
7 cyl.
8 cyl.
9 cyl.
10 cyl.
12 cyl.
Group: 014 in kg
Sh eet: 5
Parti cul ars RT58 RT76
2350
3350
4486
1628 .. 2050
2240
322
470
5156
5878
6595
7660 ..
9770
10210
11308
5.8'"
( ( ( e " a:; Dimensions in mm
~laterialGro upDIMENSIONS AND MATERIAL SPECIFICATIONS
in specificaOF THE RUBBER RINGS RT 58 RT68 RT76 RT84 tionsCode'
ThickBook Thick Thick. Thi ckWhere applied 1.0 ness I,D. ness I. D. ness ness
Relief valves on casing doors (type Horbiger)
1.0.
A
Tie rod (bottom)
170 460 12 541 14 618 700 2018
A113,67191 6,99 132,72 6,99 151,77 6,996,99 164,47
Special
Cylinder liner (collar, water guide jacket)
750 900211 9Water guide ring 9 900 11 009 9
8002'14 9 955 1010 seamless
Cylinder liner (guide part in cylinder jacket)
9 9 1160 9
800680 9214 9 900 rubber
Piston rod gland (ring carrier)
990 99
300231 5 340 5 380 5
Piston rod gland (ring carrier)
- -
266.29231 3.53 A- - -
304,17231 6,99 354,97 A6,99 393,07 6,99 417,96 6,99Piston rod gland (lower housing) = c..n
Piston rod gland (upper housing) 329,57 A231 6,99 367,67 6,99 417,96 6,99 430,66 6,99 special seam
Cylinder head 270 800 9 955 9 1060 less rubber
272
9 1160 9
B*85,09 5,33 85,09 5,33 85,09 5,33 85,09 5,33
B*
Fuel injector (nozzle holder)
36,09272 36,09 3,53 3,53 36,09 3,53 36,09 3,53
Fuel iniector (circulating valve)
Fuel injector (collar nut)
B*
Fuel injector (spring tensioner)
34,59272 34,59 2,62 2,62 34,59 2,62 34,59 2,62
B*
Starting valve (sleeve)
18,64272 18,64 3,53 3,53 3,53 3,5318,64 18,64
A
Starting valve (housing)
69,22 100,975,33 5,33274 100,97 5,33 5,3311 0,49
A85,09 5,33 107, 32 5,33274 120,02 6,99 132,72 6,99
C5,3343,82 43,82274 5,33 43,82 5,33 43,82 5,33
B*
Cylinder head relief valve
6,99275 367,67 430,66 6,99 532,26468,76 6,99 6,99Exhaust valve (valve cage val ve seat). = = <<.0 B275 304,17 6,99 367,67 6,99 393,07 430,666,99 6,99Exhaust valve (air cylinder upper housing)
r-
= Gro up Dimensions in mm
DIMENSIONS AND MATERIAL SPECIFICATIONS i n Material Code specifi -OF THE RUBBER RINGS RT58 RT&8 RT7& RT84Book cationsIhick Ihick Thick Thi ck-I.0. I•D. I.0. I .0.Where applied ness ness ness ness
Exhaust valve (air cylinder housing) B304,17 &,99275 &,99 3&7,&7 393,07 &,99&,99 430,&&
275 120,02 5,33Exhaust vlave (sleeve) 145,42 &,99 1&4, 47 &,99&,99 177,17
GilExhaust valve (valve guide} 275 3&7, &7 &,99 430,&& &,99 494,1& 532,2& &,99&,99
B275 3,53 59,92Exhaust valve (vent housing) 47,22 3,53 &&,27 3,53 72 ,&2 3,53
B*
Piston (inlet and outlet connecting piece)
275 291 ,47 &,99 354,97 &,99 393,07 430 &&&,99 &,99Valve caQe for ~xhaust valve
340 37,47 5,33 37,47 B5,33 37,47 5,33 5,3337,47
Piston (tQlc~c0pic pipe) 36,09340 3,53 3&,09 G
special
3,53 4&,99 5,33 4&,99 5,33
Piston (skirt) 345 7 420340 9 490 9 550 9 seamless
rubber500 7 &00340 9 750&80 9 9Pi ston (crown)
APiston cooling llqwcr part of box) 3&1 215,27 &,99 215,27 &,99 215,27 215,27 &,99&,99
Pfston cooling stand pipe (inlet & outlet) upper U3,53 24,993&1 24,99 3,53 32,92 3,53 32,92 3,53
Piston cooling stand pipe (inlet & outlet) lower B2&,573&1 26,57 3,53 3,53 37, &9 37, &9 3,533,53
A53,34 53,345,33 5,33 6&,04 5,33 66,04 5,33362Piston cooling gland
A494, 1& &,99417 9b &,99421 532,26 &,99 608 08 &,99Camshaft with reversing servomotor (casing)
A3,53 29,74 3,5329,74421 37,34 5,335,33 37,34Camshaft with reversing servomotor (connecting piece)
17 , 69 3,53421 A37,69 3,53Camshaft with reversing servomotor (connecting piece) 43,82 5,33 43,82 5,33
12,37 2,&2428 12,37 2,&2 AGearbox for ancillary drive (bearing housing) 12,37 2,&2 12,37 2,&2
15,54 2,&2 15,54 A2,&2428Cover and housing for ancillary drive 15 54 2,&2 15 54 2 51'
I,37, &9 3,53 ',3,53431~tart( oilot valve ( 37,&9 3,533,53 37, &937,61 (
'"I
= =
8
( ( ( (
.c
.=DIMENSIONS AND MATERIAL SPECIFICATIONS Gro up Dimensions in mm ~~a teri a1
OF THE RUBBER RINGS in RT58
specifi-Code RT68 RT76 RT84 cations
Where applied Boo k Thick- Thick- Thick- Thick-1.0. ness 1.0. ness I.0. ness I.0. ness
Starting control air distributor (starting cut-off valve) 431 78,74 5,33 78,74 5,33 78,74 5,33 78,74 5,33 A
Starting control air distributor attachment (cover) 431 78,74 5,33 78,74 5,33 78,74 5,33 78 74 5 33 A
Control valve to starting air shut-off valve 432 44 04 3,53 44.04 3 53 44 04 3 53 44 04 3 53 A
COAtrol valve to starting air shut-off valve 432 13,94 2,62 13.94 2.62 13,94 2,62 13.94 2 62 A
Starting air shut-off valve (Arrangement) 436 10 2 10 ') 10 2 10 2 AL
Starting air shut-off va}ve (Casing) 436 170,82 6,99 17 0.82 6,99 202, 57 6 99 202. 57 6,99 f,
Starting air shut-off valve (cover) 436 148,59 6,99 148,59 6,99 177,17 6,99 177,17 6,99 A
Siarting air shut-off valve (Valve for slow turning) 436 62,87 5,33 62,87 5,33 62,87 5,33 62,87 5,33 A
Starting air shut-off valve (valve plate) 436 10 2 10 2 10 2 10 2 A
Valve for slow turning (bush) 437 78,74 5,33 78,74 5,33 78,74 5,33 78,74 5,33 A
Valve for slow turning (cover) 437 59 69 5 33 59 69 5 33 59 69 5.33 59 69 5 33 A
Valve for slow turning (housing) 437 69,22 5,33 69,22 5,33 69,22 5,33 69,22 5,33 A
Valve for slow turning (cover) 437 43,82 5,33 43,82 5,33 43,82 5,33 43,82 5,33 A ----
Valve for slow turning (busht 437 63,09 3,53 63 09 3 53 63 09 3 53 63 09 3 53 A
Peversing control val ve (control) 451 104,14 5,33 104 14 5 33 170.82 6 99 170 82 5 99 A --
Reversing cantrall valve (valve plate) 451 10,82 1,78 10,82 1,78 10,82 1,78 10,82 1,78 A --
Shut-down servomotor (cover) 455 116,84 6,99 116,84 6,99 116,84 5,99 115,84 5,99 A
Shut-down servomotor (piston rod) 455 28,17 3,53 28,17 3,53 28 17 3 53 28 17 3,53 A Made by
--
Shut-down servomotor (changeover val vel 455 4,42 2,62 4,42 2,62 4,42 2,62 4,42 2,52 Westi nghouse
= en I
rv
.U"1
= .p
r
rn
DIMENSIONS AND MATERIAL SPECIFICATIONS OF THE RUBBER RINGS
Group in Code
Dimensions in mm M~teria1
apecifi cations
RT58 RT68 RT76 RT84
Where applied Book
1.0. Thickness I.0 •.
Thickness 1.0.
Thick-ne ss I.0.
Thickness
Shut-nnwn servomotor (valve olate) 455 10,82 1,78 10,82 1,78 10,82 1,78 10,82 1,78 A
Control air supply unit 460 9,25 1,78 9,25 1,78 9,25 1,78 9,25 1,78 C
Starting system blocking cylinder 461 29,74 3,53 29,74 3,53 29,74 3,53 29,74 3,53 C
Valve group for starting system 461 10 2 10 2 10 2 10 2 A
Valve group to the reversing blockage 461 20,22 3,53 20,22 3,53 20,22 3,53 20,22 3,53 A
Valve group on the gear box 461 4,42 2,62 4,42 2,62 4,42 2,62 4,42 2,62 Made by
Westinqhouse
Bp;lr;nn nil monitorina 461
532
9,19 2,62 9,19 2,62 9,19 2,62 9,19 2,62 A
(
(
Safety shut-down device (intermediate piece) 72,62 3,53 72,62 3,53 72,62 3,53 72,62 3,53 B
Safety shut-down device (valve plate) 532 4 42 2,62 4,42 2,62 4,42 2,62 4,42 2,62 tiade by
We!'\tinf}house
Actuator oi stan 558 139,07 5,33 170,82 5,33 183,52 5,33 196,22 5,33 A
Fuel pump relief valve 558 66,27 3,53 66,27 3,53 66,27 3,53 66,27 3,53 B"
Relief valve indicator 558 21,89 2,62 21,89 2,62 21,89 2,62 21,89 2,62 B"
Regulating linkage air cylinder 581 72,62 3,53 72,62 3,53 72,62 3,53 72,62 3,53 B
Safety valve for reciver type 224 EV , 646 210 8 210 8 210 8 210 8 A
Scavenge air cooler Type GEA 660 849 10 849 10 849 10 849 10 A
Scavenge air cooler Type GEA 660 741 10 741 10 929 10 929 10 A
Charqe air cooler Tv De SERCK 660
660
845 8 845 8
9,70
A
Quadruple lip-ring JF4 No. 7A 9,70 1,78 9,70 1,78 1,78 9,70 1,78 9 PO 31
Gear pump 721 150 3 150 3 150 3 150 3 A
,= '--"
cv
(J1
en ~
( ( ( ( I
( ,( .( (
r-
= Group
\ Dimensions in mmDIMENSIONS AND MATERIAL SPECIFICATIONS r~ateri a1 OF THE RUBBER RINGS in
speeifi Code RT58 RT68 RT76 RT84
IhlCk .1 hi ck Ihick Thickcations
Book 1.0. I. D. I. D. 1.0.Where applied ness ness ness ness
Gear pump 721 50 3 50 3 50 3 50 3 A
Cylinder lubricating pump regulation 721 26,57 3,53 26 57 3,53 26 57 3 53 26 57 3 53 A
Flow regulating valve 726 26,57 3,53 26,57 3,53 26,57 3,53 26,57 3,53 A
Throttling disc for cylinder cooling water manifold 830 145,42 7 145,42 7 189,87 6,99 189,87 6,99 A .
Ba1 anci ng of masses (Di sc) 32,92 3,53 32,92 3,53 32,92 3,53 32,92 3,53 A
Chain tensioner (Bearing journal) 78,97 3,53 A
Hydraulic pipe to exhaust valve 846 72,39 5,33 85,09 5,33 A
Hydraulic pipe to exhaust valve 846 139,07 5,33 170 82 6,99 189 87 5 33 215 27 6 99 A
Hydraulic pipe to exhaust valve 846 132 94 3 53 164 77 2 62 183 74 3 53 202 57 6 99 A
S ~ G a " 1 pipG for fuel pipe 846 37,47 5,33 37,47 5,33 37,47 5,33 37,47 5,33 A
Pressure regulating valve for fuel suction and spill pipe 870 18,72 2,62 18,72 2,62 18,72 2 62 18 72 2 62 A
Fuel pipe shutoff cock 870 17 04 3,53 17,04 3,53 17 04 3 53 17 04 3 53 Vi tom Comn
Shroudi ng for fuel hi ghpressure pi pe and fuel val ves 870 40 64 5 33 40.64 5 33 40 64 5 33 1.0 64 5 33 B*
Shrouding for fuel highpressure pipe and fuel valves 870 59 69 5,33 59 69 5 33 59.69 5 33 59 69 5 33 8*
~ontro1 element cabinet 9,19 2,62 9.19 2 62 9 19 2 62 9 19 2 62 A
Blow through valve to fuel injection valve 21 82 3,53 21 82 3 53 21 82 3 53 21 .82 A
Blow through valve to fuel injection valve 9,25 1,78 9,25 1,78 9,25 1,78 9,25 1,78 A
= C5l
I
-+
C5l
= -+
3.53
-~-.--
J Dimensions in mm'" DIMENSIONS A~D MATERIAL SPECIFICATIONS Group r1aterial
OF THE RUBBER RINGS in specifiCode RT58 RT58 RT75 RT84 cations
----~- ~ - - - -Book Thick ThickI. D. 1.0. I. D. Thick I. D. ThickWhere applied ness ness ness I- ~ s - . : ! ___ 1--- ~ - -
L _______ . - - ~ .
~ - 1 1 -
f------- ~ - - - - -
.__._ .._" ..
.-
1 ._- 1 --._--- -
1 1-
= ~
U1
1 -U1
_._-
-. .-
_. 1 -
. _.
Tool No.
"
Plugs for closing off the piston cooling box (lower) 94395 25,57 3,53 25,57 3,53 37,59 3,53 37,59 3,53 A
Plugs for closing off the piston cooling box (upper) 94395 24,99 3,53 24,99 3,53 32,92 3,53 32,92 3,53 A
Required characteristics: Quality A: Synth. rubber, with high elasticity, heat resistant to at least 1000C Quality B*: Viton rings, highest heat resistance up to at least 200°C
and resistant to water, oil and fuel. Seamless moulded ring. with exceptional chemical resistance 0
Qualitv8: Silicon rubber, with high elasticity, heat resistant to at least 150 C QualityC: Synth. rubber, seamless moulded rings hardness 9U·95.
I and resistant to water, oil and fuel. Seamless moulded rings. U1
co
IP-
( ( ( (
Table of Contents
-"-'~---------------------------------
Maintenance Instructions
Clearance Tables
Tightening Values for Bolt Connections
" - - " - ' - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - -
Weights
Maintenance Schedule
WorkSheets
ToolUsts
••
021/1
Work - Intervals 1) ::...,SULZER <...
Sheet (Service hours) tl
Maintenance Schedule IRT"'
.... ~§ <1J
<1J0 .... -e: -'-o
aa
Component Work to be carried out t:) V) Cl lrJ
, ILubri cab ng oil Spot test J42 •
(engine) Laboratory analysis 042 2
Cooling water Check inhibitor concentration (according to supplier's instructions)
Vi Vi <1JI a \.Jaa 4.1
a a c: ala a a
C"l c: aa Q;) <1JrlrJa I 10 ~ \0 ~
•
For the ~irst time af-ter 1500Check holdingdown bolt tension
Bedplate metal chocks 110 1 •
synthetics chocks • Main bearings
Check thrust bolt tension 117 2 •(retension if necessary) According to classifi-
Remove and inspect main bearings 117 ~,4 cation society
Remove and inspect lower bearing shells 117 5 •
Thrust bearing Check both axial and radial clearance 120 1
Check that bottom drain hole is clear 120 1
2 According to classifi-Remove and inspect thrust bearing segments 120 cation society
I I I I I I I
Initially after one .......... Tie ro ds Check tension, retension if necessary 190 year, thereafter every
four years. I I I I I I I
Cyli nder jacket Check the condition of the water guide ring 211 Always after removal
and the water spaces of acyl inder 1iner
I I I I
I.1 At each piston withCyli nder 1i ner Determine the bore wear (in situ) 214 drawal
Remove cylinder liners 214 2 II I I I I 4 At each piston wi th.Remove wear ridge from bore 214
drawal Reworking the edges of the scavenging ports 214 4 •Recut the lubrication grooves 214 4 I I I I I • Replace rubber rings 214 3 Every time before re-
fitting
L.B. 1.89
0212
Intervals 1)Work ,~SULZER 0 Vl Vl
(Service hours)Sheet
Q.lMaintenance Schedule a uaRT (\Ja <:)a <:) c:a..... <:)aQ a a~ <:)Q.l a c:::J
~
~C) Q.lIII coa I0
IC).... .c::. '-CJ aa It) I It) LD
V)Component C")a It)Work to be carried out cY)\Q ~0
At each pi ston IIi th
and accumul ator
1215Check for correct functioning a ~ d tightnessLubricating quills drallal
I I I I I
I I I I I I
every time a piston is
necessary)
1231Clean rings and determine lIear (fit nell parts asPiston rod glands lIithdralin
I I
At each piston IIi· t h
drallal 270 1Inspect combustion chamberCylinder head
Clean sealing face for the fuel injectors in the cylinder head, re-machine seat if necessary 271 4 •
Before starting the
engine after an-exten-Test spray (dependent on the fuel treatment)
Check tightness of all external connectionsFue1 injector
272 1 ded stop •Clean and overhaul injector nozzles 272 2 •Lap the contact faces of the nozzle ho1de r 272 3 •Checking a circulating valves 272 4 •
rom time to time
running. If it is hot, the 'valve has to be dismantled Remove one starting valve and dismantle (random
Starti ng val ve Fuel the pipe before the valve IIhile the engine is
273 1 •ch eck). (Depending on its condition, determine the time schedule for overhauling the remaining valves)
Cylinder head Test, dismantle, reassemble and adjust 274 1 •relief valve
275 2-4Overhaul and regri~g the valve seai and spindleExhaust outl et •by machine if neiessary.-All o v e r h i ~ l - \ I o r k must be recorded on the sheet 'Exhaust Valve Record', form 4-107.044.059 -1/-2. Checking the piston seal ring in the air-cylinder casing and the rod seal
va1ve
•ri nQ in the Qui de bush.
Crankshaft Measure crank deflections (in any case if vessel has gone aground] 310 1 •
313 2Remove a silicon fluid sampleViscous torsional •vibration damper
Axial damper Dismantling and assembling 1314 •checking the throttling nozzles •
L. B. 10.85
0213
WorkSheet
Intervals 1) ~
(Service hours) ;; SULZER
RT
Component
Turning gear
Upper and lower connecting rod bearings
Guide shoes
Crosshead pins
Maintenance Schedule
Work to be carried out
Check oil level, top up oil if necessary. Check oil condition and charge oil if necessary
Check bearing clearances
Inspect bearings and replace if necessary
*Removal and fitting of a connecting rod
Check running clearances
*Remove crosshead when the piston has been removed
320
330
Vi Vi <lJ lJ ClJ C
C Q>
~
Each time before use
• I·
1 • 330
330
14,~
6
• •
332
337
1
3 •
•
Working pi ston Withdraw, clean and measure grooves
Checking the piston top surface
340
340
1,3
4 ••
Open up cooling spaces and clean (at least piston annually)
one 340 5 • Check tightness after re-assembly 340 6 (on1 y when it has
di smant1 ed) been
Visually check through the scavenge ports (Enter charge air receiver and turn crankshaft •with turning gear)
Working piston Align the piston cooling telescopic pipes 342
Pi ston rings Remove, clean and determine wear. Fit new rings if necessary 342
Pi ston cool i ng Remove stand pipes and guide bushes
check condition of the 360
Dismantle telescopic pipe glands, termine wear
clean and de362
Check the condition of the spaces and cleanPiston underside
(only after they have
been refitted)
.I 1 T.T J) IAt each plston wlth
dra lIa1 I I I
1111 I I I at each piston wfth
drawa1 I I I I I I I
at each piston withdr.a\l~ 1
•
021/4
SULZER
RT'
Component
Maintenance Sche
Work to be carried out
dule
of
Camshaft driving gearwheel s
Camshaft bearings
Reversing servo-mo tor
Fuel cams
Actuator cams
Check condition of the teeth
Check backlash and bearing clearance termediate wheel
*Remove intermediate wheel
*Replacement of the 2piece gearwheel crankshaft ,thrust bearing collar
Oetemine bearing clearance (see Clearances 012/10)
*Remove
Inspect running surfaces
Inspect running surfaces
Oi smantl e, cl ean and inspect Check pilot valves for easy movement
Vent
Starting control ..air distributor
Starti ng ai r shut-off valve
Running direction safeguard
Shutdown servo-mo tor
WOODWARD governor
Oi smantl e, cl ean and inspect (seat" anparticular)
Check performance
~ h e c k performance
Dismantle and clean
Check oil 1evel (top up if necessary} ~harge oil (flush out casing)
d
Work- Intervals 1) ~
Sheet "-
(Service hours) tJ V)
V)
C) C1l
C) 0 u C)
C) 0 ClJ C) 0 c:
g. .... ..: a C)
C) 0<1J C)
~ c: C1l C) Co) C) <X:l <;j <1J
0 o r I... ~ tJ C) lJ") a I lJ") LD ~ t:> Cl lJ") ~ (Q - (Y')
410 1 • the in
410 1 • 410 2 • 410 3 •
Table of •
420 2 •
421 1 • 421 1 •
430 1 •
spring in After each manoeuvring
• ._.
432 1 period
432 1 • 453 1 •
455 1 •
510 1 •510 1 •
",-./
on the
L.B.
0
021/5
Intervals 1)Work :::....SULZER .... IService hours)Sheet
RT Vl Vl
u ~Maintenance Schedule C
CC CIJCC c:.....g. CIJ C c c c c:~ l'\i
~ 0 c c c co I ~ 0 ~ 0 c lI") C I lI")Component Work to be carried out l:) ~ Cl lI") .... ~ <.0 .... ~
Safety cutout O i s ~ , a n t l e , clean and inspect (replace round device rubber rings if necessary) 530 1 •
Fuel injection Clean, remove and inspect valves 551 ,4 •pumps Check timing and readjust if necessary 551 1 •Lubricate articulated joints of regulating 551 1
linkage • *Lap sealing faces for the valve covers 551 2 •Check and adjust relief valves 551 3 •
Charge air recei- Observe outlet of the permanent drains ver •Inspect, clean and recondition nonreturn valves 640 1 •(or replace them with either a new or cleaned
set)
Clean receiver 640 1 •Check and clean the water separator elements 640 2 • I
• u -..- ~ I
E~haust gas turbo- Wash the compressor during service 650 1 • > L '" L +' e Q) CI)charger (every 25 to 75 running hours) CI) c: CI)
-.- c:: r-
Q) 0 '" Q) Q) or- ~
(./) U +-' c:
Wash the turbine during service charger Exhaust gas turbo-
CI)(every 250 to 1000 hours) 650 1 Q) c: u 0 •
.,.... or
> +' L UAir filter CleanQ) : : : o ~
CI) L( 6p max, : lQO mm WG) •+' :::0 '"
Q) CI) c: Q) c:
. ~en e '"
Clean impeller and casing 654 1Auxiliary blower •I
.. u ...... :::J I
> L '" L +' e Q) CI)Clean during service (air side) 660 1 initially weeklyCharge air cooler CI) c: CI)
.,.... C r- • Q) 0 '" Q) <D .,.... ='
(.I) U +-' c::::
C ~ e a n at standstill (air side) 660 1 •(6 P max. : 300 mm WG)
Clean the inside of the water tubes 660 2 •Remove cooler for general cleaning 660 3 •
1. 89I . R_
021/5
SULZER
RT Maintenance Schedule
Component Work to be carried out
Cyl inder 1ubri ca-to rs
Drain casings and wash out
P.T.O.gear trans-mission
Check conditions of teeth; establish backlash and bearing clearances (compare with clearance table 012/9a) external checking for oil leakage
with and cl ear vents
Gei sl inger Di smantel coupl ing, inspect, clean and replace coupl i ng all seal rings{
Overhaul, or replace spring stacks respecti vel y
EfficiencyBooster Check oil 1evel in hydro coupling (if necessary refill with oill. Check rubber pads of flex. pad coupling (replace if condition demands it).
Analyse the oil of the hydro coupl i ng (renew if condition demands it).
Turbine part of power turbine, check every 8'000 hours in acc. with manufacturer instructions.
Planetary gearbox of power turbine, have it o v e r ~ ;
hauled at manufacturer works as instructed by the them every 16'000 hours.
Check function of shutoff flap (in case of bad operating condo every 3'000 hours).
Gneck function of angle valve (in case of bad operating conditions every 3'000 hours).
Wash power turbine during operation (Depending on operating conditions every 250 till 1 'ODD operating hours).
Balancer Retension roller chain ori vee1em ent s (After fi Hi ng a new chain first time at 500 op.
hours) • with Measure roller chain stretching (if req. replac-
ing roller chainl. Geislinger coupl i ng (See group 740).
Work Interval s 1) Sheet (Servi ce ho urs)
>0-L <U </l
a a c </l
'" a 00 u a 00
'" c a. <' >0- co a a
'"0 '" '" ~
.~ 0 00 00 I '" I """"" I
c
'" L
= '= en
<U
= 0
'" '" ~
0 ('V") u:J
'" ~
'" C"Y)
'= =
721 1 • 740 n,i •
• 740 3 •
•
750 1 • 750 1 •
I
750 1 •
•
•
750 2 • 750 2 • 751 •
770 1 •
•
L. B. 12.89
021/7
Intervals 1)Work :.......SULZER C)(Service hours)Sheet VI til
C) <lI
RT lJ Maintenance Schedule
C)C) QJ
C)C) c
C)C)C):.., C)g. ~ C'\j C
C)C) co <lIC)OJ:::: Ia C)C)a IIe)... C. (:) l.I) Ie)Work to be carried out <0 ~ ~C'1Component Cl "-
Exhaust pipe Check the condition of the exhaust pipe mounting 811 'I • bolted connections
C l ~ a n the sliding surfaces and inspect for wear
Check pretension of tie rods on RT76 and 84 en-
gines (see sheet 013/2)
••
846 1Hydraulic Conduits Reconditioning the sealing surfaces • t0.'£ xhaus t val ve
Before 'and afterStarting air pipes Drain (water)
every manoeuvring
peri od
Compare with master instrument and adjustPressure gauges • • and pyrometers
Clean or exchange filter inserts. (Depending onFuel and 1ubricat- • the make observe the supplier1s special instruc-
ti ons) ing oil filters
The indicated intervals 1) must be taken as guide only. Exoerience must show ~hether these intervals can
be extended or must be shortened, as operating modes, quality of fuel and lubricating oils used as well
as iJany other fadors infl uence the condi bon of engine components.
On the engine sedional drawings, sheet 004/1 and 2, those parts are r.larked with group numbers, under
which socalled 'worksheets ' are found in the corresponding book section.
Of the following engine components 'work sheets' exist, although these parts are not marked on the sec-
tional drawings:
Enaine CO~Donent Work sheet
Lubricating quills and accumulators 215/1
Vibration damper 313/2
Axial damper 314/1
Turning gear / 320/1
Starting control air distributor 430/1
Rotation di redion safeguard 453/1
S h u t - d o ~ n servomotor 455/1
Speed governor 510/1
Safety cutout device 530/1 P.T.O. Gearbox 740/1;3
EfficiencyBooster 750/1 +2
Remark!
The maintenance work r.larked in the column "work to be carried out" with* must not be carried out periodi
cally, but only when required. The respective work sheet' serves as information only.
L. B. 11.86
Table of Contents
-""-"---------------------------------
Ma.intenance Instructions
Clearance Tables
Tightening Values for Bolt Connections
Weights
Maintenance Schedule
WorkSheets
ToolUsts
I
SULZER Checking of Lubricating oil by
GROUP 042 scot testR-MOT.
SHEET
Even the best lsbricating oil ages and becomes dirty in service. Conse~
quently, it has to monitored and cared for. A simpl e method for checking the condition of the oil is the socalled spot test.
Such a test should be carried out approximately every 500 service hours,
:,:'.'., 'Jo'''''''~' .~~,
follows:.. ' by proceeding as
. . . '\ ' ~ " ~ When the oil has its normal service temperature and the oil pump is.
., '" .". running, some oil should be drained from a cock in the oil piping• "', . ~ .,.
system in order to clean the cock from dirt collected possibly in it. Newer engines are fitted with a cock to the left of the camshaf drive bearing housing for taking oil samples.
Only then should the oil necessary for the test be filled in a clean container (preferably glass).
Shake the container with oil sample well.
Dip a clean glass or metal rod (diam. = 3 to 5 mm) into the oil and
let a drop fall in the middle of the filter paper.
Allow the filter paper to remain in a horizontal position at normal
room temperature for some hours (if possible on a hollow pad to ensure that the filter paper with the spot moistened with oil does not
get into contact with any other matter).2 In order to enable comparisons, the same filter paper quality should
always be used (obtainable from oil firms).
From the five spot tests shown at left, the gradual increase of oil
contamination can be seen clearly.
• Test 1 and 2: The drop is from an oil having only very few running
hours. The dark spot is not very sharply outlined showing the oil is
still in good cond iti on.
Test 3: The drop is from an oil which was already in service for a3
relatively long time. Asharply outlined black spot is clearly visible,
compared to the normal, bright colour of the oil. This oil can, hOlever,
still be left in service.
• Test 4: This test already shols a clearly limited black zone in the
centre. Oil which produces such a picture should be analysed. Acertain improvement could be obtained by replacing a part of the used oil
by new oil.
Test 5: Oil which produces such a picture must be analysed at once by a laboratory. The analysis will show a too high degree of contamination.
4 Such oil must be replaced as soon as possible. (see sheet 042/2).
We recommend gluing the spot tests on a sheet of paper in the sequence
of the samples taken in order that the progress of contamination can be clearly seen. For each spot test, indications regarding date of taking,
running hours, etc. should be recorded. The more experience one gets lith
such spot tests, the better the capability of judgement.
Note: The pictures of the oil samples here are only valid for pure mineral oil, such as that usually employed for crosshead engines. They are not typical for heavy duty oils
5 (oils with deterging and disperging additives).
4.83
'"
SULZER
RT Taking Oil Samples for
Laboratory Analysis Group:
Sheet:
042
2
In intervals of abt. 3'000 operating hours a sample should be taken of the engine oil and sent to a laboratory for an analysis. The oil sample is taken in the same manner as desribed on sheet 042/1.
The receptacle with the sample of oil must be marked for the laboratory with the following information:
Ships name or name of plant
Engine type
Engine serial number
Date of sampling
Operating hours of oil and of engine
Oil brand and quality
Oil Inspection:
The condition of the lubricating oil charge or its alteration during operation can be inspected on the basis of a few analysis data. With regular checks a deterioration can be detected at an early stage and remedial measures put in motion.
The following indications for limit values are to be taken as guiding ones, which should not be exceeded in service, and in the case of the flash point not to fall below.
Flash point above 180°C
Alteration of viscosity within 10% and +20% of the fresh oil
Non soluble below 0,5%
Water content below 0,5%
SAN none
Should any of these limit values be reached, measures must be taken to bring the lubricating oil back to within the normal conditions. This can be achieved e.g. by increased separation (Purificator), treatment in a renova-ting tank or by partial replacement of the oil charge in the engine. We recommend consulting the oil suppliers as well in such cases.
,..../
L.B. 1.89
SULZER Group: 110
BEDPLATERT
Sheet: 1Checking the Foundation Bolts
Tool s: Kev to Drawing
Pretensioning jack 94145 1 Reli ef val ve 8 Foundation bol t Highpressure oil pump 94931 2 Vent screw 9 Chock Highpressure hose 94935 3 Draw nut 10 Ship's foundation Feeler gauge 94122 4 Pis to n 11 Nut
5 Distance sl eeve K Checki ng hol e
5 Nut M Pressure gauge 7 Bedpl ate P Highpressure oil pump
.------,( ) M
R Tommy bar V Relief valve
I
\. y Measuring point
I The foundation bolts should be checked at long inter'----' val s for t:ghtness, e.g. during an overhaul. (see
group 021 sheet 1) Follow the instructions given on sheet 94D/Dd "General Instructions for Use" for hydraulic pre-tensioning
jacks on bolted connections.
Procedure: - Tension the foundation bolts with a pressure of
X* bar and keep this pressure constant until a check has been made by inserting a feeler gauge through the checking hole 'K' to see if there is any clearance
between nut 6 and the bedplate. 8
- If there is no clearance, it means that the tightness has remained the same. The pressure can therefore be released and the pre-tensioning jack removed. However, should clearance be found, nut 6 has to be ti ghtened with the ai d of the tommy bar 'R' until it
I lands whilst maintainig a pre-tensioning pressure of
"-.../ X* bar (check clearance with a feeler gauge). After9 wards release the pressure and remove the pre-ten
sioning jack.
Note:
Should there still be clearance between nut 6 and the bedplate 7 with a pre-tensioning pressure of x* bar, and the nut cannot be turned, it means that it is seized on the foundation bolt. It therefore has first to
be freed. Afterwards tension the affected foundation bolt again with X* bar and tighten the nut down fully
1-107.197.065 (after having previously smeared the thread with 'Moly
kote' grease).
X*; 600 bar for Metal chocks
X*; 600 bar for Synthetic material chocks
Slackening off foundation bolts
Attention: To slacken off, the tensioning jack must be set onto the bolt in such a way that there is
a clearance of approx. 2 mm at 'Y' between the distance sleeve and the draw nut before starting to tension the foundation bolt. If not done, it will not be possible to remove the pre-tensioning jack later. The tension the foundation bolts with about X*+ 20 bar and turn the nut 6 back by one turn. After releasing the pressure to '0', remove the pretensioning jack and afterwards the nut.
1 an
......Engine fixation RTA 58~84/ RTA 84 M Engine fixation RTA 58784/ RTA 84 M Q
Engine seated on metallic chocks Engine seated on Epoxy resin chocks
~ I I ~
Bedplate
Section I-IFitted holdingdown bolt
IBedplate
.. -_.Tank top
Epoxy resin chock 'Tank top I. -107197075
( '\ ( ( (
SULZER MAIN BEARING Group: 117
RT Loosening and Tightening of Bearing Sheet: 2Thrust Bolts
Tool s: Key to Drawing
Tommy bar 94115 1 Thrust bo 1ts 9 Mi 11 ed faces to hold with Special feeler gauge 94123 2 Engine frame centre open end spanner Depth gauge 94126 piece 1a Piston sealing ring
Highpressure oil 94931 3 Bearing cover 11 Locking wire pump 4 Vent val ve
3 Pressure gauges 94932 5 Locking wire 13 Shims (up to 1000 bar) 6 Locating screw D Pressure chamber
2 Connecting pieces 94933 7 Cy1 i nder V Re1 ease val ve Highpressure hoses 94935 8 Nut Pair flat pliers
Open end spanner
to pos. 9
2
1
11
9n /3 I ~ ::N~~~I~ . //
I ~ L~*~.~;;~ _~=~ I"~ .l[_~
-t=.lk/ V 9'931
' ~ ' 1 3
2107.156.246
Attention:
Loosening and tightening of bearing thrust bolts may only be done if tie rods are ti htened accordin to instructions.
The thrust bolts are designed in such a way that they can be loosened and tightened hydraulically. The tools delivered with the engine are to be used for this purpose.
I P 1.RfJ
117/2a RT
L 0 0 sen i n g the Thrust Bolts
Procedure: (see Fig. 'A')
Remove locking wire 11. Unscrew closing pl ugs for oil inlet into cyl inder 7 and replace connecting pieces 94933.These have to be screwed in tightly. Then couple the connecting pieces to the high- pressure oi 1 pump 94931.
Tension the thrust bolt with approx. 620 bar and maintain this pressure until both nuts 8 are slackened by approx. 1 to 2 turns only at first. Release the pressure by opening the release valve 'V' of the pump and remove the connecting pieces 94933.
Slacken the nuts 8 sufficiently to remove the thrust bolts. After removing the thrust bolts, close their oil inlets with the closing plugs so as to prevent any foreign matter entering the pressure chamber.
Ten s ion i n g the Thrust Bolts
Procedure:
Compare the three pressure gauges 94932 against a master gauge for accuracy.
Clean the seats for the spherical thrust bolt ends on bearing cover and on the frame centre part.
Check that the shims are fitted between the lower and upper bearing shells.
Fit both thrust bolts and tighten their nuts 8 with tommy bar 94115 (without extension). Care must be taken beforehand that the cylinders 7 are positioned in such a manner that the connecting pieces with pressure gauges can be fitted.
Tightly screw in both connecting pieces 94933 and connect up to the oil pump with hydraulic hoses.
Measure distance 'al' and 'a2 1 with the aid of depth gauge 94126. The difference between the two distances must not exceed 0.1 mm. If necessary, the bearing cover 3 is brought into its correct po-sition by means of the thrust bolts by slightly slackening nut 8 of the bolt on whose side distance la' is smaller, and by tightening the nut of the thrust bolt of the other side with a fork spanner. When tightening the nut, the thrust bolt must be held with a fork spanner.
If the difference between 'all and 'a2' is within 0.1 mm, tighten both nuts with tommy bar 94115 as far as they will go.
Remove locking wire 5 and slacken vent valve 4 slightly while operating the highpressure oil pump until the air has escaped from the pressure chamber 10'; then tighten vent screw 4 has secure with locking wire 5.
Pump until 600 bar are shown (check that the same pressure shows on all three pressure gauges). Maintain this pressure until the nuts 8, tightened with the tommy bar 94115, make metaltometal contact with cylinder 7 (check for contact with feeler gauge).
Release pressure from the pump and again measure the distance 'al I and 'a2'. Should the difference exceed 0.1 mm. the thrust bolts must be loosened, the bearing cover position corrected, and the pre-tensioning process repeated.
Finally, secure the nuts with locking wire 11, remove the two connecting pieces, and close the oil inlet holes with plugs. For safety's sake, check that there is sufficient vertical bearing clearan-g (table of clearances 012/1) using the special feeler gauge 94123.
Note: Please bear in mind that with new thrust bolts or bolts which have been dismantled, the oil level in the pump falls relatively low during pretensioning because the pressure chamber of the thrust bolts has to be filled first. Where a motordriven highpressure pump is used, the oil level must, therefore, be watched carefully in order to prevent dryrunning of the pump.
L. B. 2.84
SULZER Group: 117MAIN BEARING
RT Removal and Fitting of a Bearing Sheet: 3 Cover and an Upper Bearing Shell
Too 1s: Key to Drawings
1 Suspension bracket 94111 1 Bearing cover 1 Roller support 94117 2 Upper bearing shell 1 Eye bolt M12 94113 3 Plank 2 Lifting devices, 4 Wooden block
each 10 kN (1 ton) R Eye bolt Various ropes Plant (approx. 30x250x3000 mm)
9""
'----+--+--3
'---tt--t-- 1
~~~2
1101. 013.223
®
1
2
- -tt--=~~::::::::::+-l---I+,L r-r-rt-__ 91.117
,
.L_...JL::I:::::L -----f--- 0lOi125.238"
Rem 0 v a
The crankshaft is to be turned so that the crank web nearest to the bearing to be removed is appro-ximately in a horizontal position. After loosening and removing the bearing thrust bolts according to Sheet 117/2, the roller support 94117 and the suspension bracket 94111 are to be fitted according to Figs. 'A' and 10'.
Using a rope and a lifting device, lift bearing cover only a few mi11imetres at first. Should the upper bearing shell also be lifted, lightly tap both sides of the bearing shoulder with a piece of wood or a lead hammer in order to separate the bearing shell from the cover.
Now lift bearing cover (without bearing shell) high enough for it to be moved along the engine with a second rope and lifting device. Deposit it on a plank which should rest on the crank web and be supported by a wooden block at the outside end (see Figs. lA' and 'B').
Sliding it along the plank, the bearing cover is taken out of the engine by means of lifting devices as shown in Fig. 'cr.
L.B.
1
1
l17/3a nI
l-J-------trT:
3 - - 4 1 - - - ~
94117 #._
9 4 1 1 1 - - t t - - ~ ~ - * - - - - . J ~
1107073223
@
94111
1
94113 '
2
,
,
I I,L__+_ 1-
1-107.197. 554
jee s a ~ e o r ~ c e d ~ r e nab :0 te f ~ 1 1 lowed for : ~ e remove: of t:eJc _ per tearira snell. To 0010 it,
"owever, an eye to It 'R' ~ ~ L ''/
be screwed irto t ~ e r ~ r e a d e d ·0-
1e or the crowr Jf the Dear: ,g
shell cac'o. Lift ere teari ng
s~iell usi rg wi re rope over Fe
roller suppcd ar:d a liftir.g de
vice ard re~ove it from the
crankcase (see Fig. 'D' .
Fitting
When fi Hi ng beari ng shell ard
bearing cover, the procedure for
removal is to be followed in re-
verse. Pi ease make sure that:
care is taken that the parts
do not get damaged, "-../
no di rt seUl es on the beari ng
pin or the back of the bearing
shell,
the bearing pin is clean and
liberally oiled before the
bearing shell is fitted,
the back of the bearing shell
and the bore of the bearing co
ver are clean and free of oil!
For alignment of the bearing co-
ver and tensioning of the thrust
bolts, note instruction sheet
11 7/2.
2.84L.B.
SULZER MAIN BEARING Group: 117
RT Removal and Fitting of the Bearing Cover and Stopper Bridge in the Thrust Bearing Sheet: 4 Assembly
Tools: Key to Drawing
1 Suspension clamp 94111 1 Bearing cover (wide) R Eye bolt 1 Roller support 94117 la Bearing cover (narrow) 1 Eye bo 1t 2 Upper bearing shell (wide) 2 Lifting devices of 2a Upper bearing shell (narrow)
10 kN [It) each 3 Oil catcher upper part 4 Stopper bridge
Removal
For the removal of the 'wider' bearing cover, refer to the instructions given on Sheet 3 of Group 117. The removal of the 'narrow' bearing cover in the thrust bearing assembly is made easier if the stopper bridge 4 (drive side) is first removed (see also Group 120, Sheets 2 and 2a). By means of a lifting device the bearing cover can then be brought into the space thus created (see Fig.) and from there re-moved sideways out of the gearbox double column.
0-107.197.657
Fitting
Fitting of the bearing cover follows the removal procedure only in reverse order, whereby the instruc-tions on Sheet 3a of Group 117 also apply.
L.B. 5.84
SULZER
RT MAIN BEARINGS
Removal and Fitting of a Lower Bearing Shell
Group: 117
Sheet: 5
Tools:
Eye bolt
Roller support Device for turning out the bearing she 11
2 Wi re ropes 1 Support 1 Highpressure oil
pump with hoses, etc. 2 Hydraulic jacks
230 kN (23 tons) 1 Clock gauge with
magnetic stand
9411 3 94117 94118
94119 94141
94931
94936
Key to Drawings
1 Crankshaft
2 Lower bearing shell
* Note: The support 94141 is intended to be used for the removal of broad bearing shells. It can, however, al so be used for the narrow bearing in way of the thrust block with the aid of another jack. This is placed outside the engine beneath the crankshaft flange.
9'936
1
1· 107.197.351 /
P--t7l-~!L,~~~:::jl--9"'7---tttp:jj..4.----j. _"+:\1.:::::, 9'"9
9'"8
Prior to removal of a lower bearing shell, the thrust bolts, the bearing cover, and the upper bearing shell of the bearing concerned must be removed according to the instructions on sheets 117/2 and 117/3.
L.B. 2. 4
117/5a RT
The following instructions are val id for all main bearings, i.e. al so for the narrow one in way of the thrust block.
Removal
Turn the engine until the undersides of the rel evant pair of crank web s 1i e parall el with the bed-plate separating face.
Fit a clock gauge (if possible, with magnetic stand) above a crank web near the bearing to be re-moved and set to '0'.
Fit device 94118 to a separating face of the lower bearing shell, using the special Allan key from the tool kit.
Attach a wire rope to one of the short hooks of device 94118 and guide it outwards alongside the bearing shoulder to the opposite side and further on over the roller support 94117 (if necessary, two wire ropes may be used).
Using the hydraulic jacks, arranged on the support 94141 as shown on the illustration, the crank of the bearing to be removed is lifted 0.1 to 0.15 mm. This amount has to be checked on the clock gauge. Keep pressure constant!
Remove the bearing shell by pulling on the wire rope. ~
Once the bearing shell rests on top of the crank pin, the wire rope is removed and the eye bolt 94113 screwed into the back of the bearing shell. The bearing shell can now be lifted and removed from the engine (see sheet 117/3).
Note: Two neighbouring lower shells must never be turned Qut at the same time.
Fitting
Prior to fitting the lower bearing shell, its back is to be coated only lightly with Molykote paste G. The crank pin and the inner face of the bearing shell should be liberally coated with clean lubri-cating oil. Check that the bearing saddle bore is clean and undamaged!
Put bearing shell on top of the crank pin, using eye bolt 94113 and roller support 94117, i.e. in reverse sequence from removal according to sheet 117/3. Make sure that the bearing numbers corres-pond with those on the bearing saddle.
Remove the eye bolt and, should the crankshaft have been lowered, lift it again by 0.1 to 0.15 mm.
Slide in bearing shell until the separating faces have the same distance on both sides from the top face of the bedplate (check with depth gauge).
Release pressure from the pump and remove all the tools from the engine.
Attention: Should the crank web deflection be measured before the upper bearing shell and the bearing cover are fitted, care must be taken that the lower bearing shell does not turn. It should be blocked with suitable pieces of wood.
1.B. 3.86
1
SULZER Group: 120
THRUST BEARING RT Sheet:Checking the Axial Clearance
Tool s:
Inside micrometer Feeler gauge Clock gauge with magnetic stand
94101 94238
1 2
Flywheel coupling flange Upper part of oil catcher
3 End casing (drive end)
4,4a Stopper bridge 5 Thrust bearing collar 6 Crankshaft 7 I Astern I thrust bear
ing pads 7a 'Ahead' thrust bearing
pads S Axial clearance X Check dimension
- 'ffl--.--+I--.+-~~.----l-- -I-I-----l4+----f
1
Schub --. -+'-;-;';"'»4.;..;
THRUST Check that the drilling is clear every 6-8000 running hour~.
1107.159.075
L.B. 2.84
RT120/1a
Should the classification society demand measurir,g of axial clearance of the thrust bearing flange in
the thrust bearing, or should other reasons call for it, this can be done in various ways:
Method 1
The total displacement which results from pushing the crankshaft axially both ways until it contacts the thrust bearing pads "Ahead" and "Astern", is measured with a clock gauge. This is then checked against
the figure marked on the sheet "Checking Dimensions" in the engine documents supplied. A possible increase against the nominal figure signifies w e ~ r of the thrust bearing pads.
O. 8 ~ 1.2 (RT 58 84)
New clearance =
0.7+ 1.26 (RT 38 / 48)
Method 2
The crankshaft is displaced axially until it rests on the engine side thrust bearing pads ('Ahead') and is then fixed in this position. The distance between the flywheel coupling flange and the upper part of the oil catcher is measured with an inside micrometer at the position indicated (see Fig. IB'l. The
amount by which the distance 'X' is smaller than that given on the sheet "Checking Dimensions" corres-ponds to the wear of the engine side thrust bearing pads ('Ahead'l. By displacing the crankshaft axially until it rests on the thrust bearing pads for 'Astern'. the inside micrometer can be used to determine
the total axial clearance as well.
94101
® 2 3
6
SULZER
RT 7684 Removal and
THRUST BEARING
Fitting of Thrust Bearing
Group:
Sheet:
120
2
Eye bo 1t M16
Ass. sp,",r s , t ~
Tools:
Carrier lug with
nut
Turningout device
{ 4 T 8 RT76
94155 for 4 T 7 RT84
19 T 12 RT76 94155a for 18 T 12 RT84
2120
11-11
1
2
94155
Key to illustrations
1,la Shims 7 Retaining clamp
2,2a Thrust bearing pads 8 Oil pipe
3 Split gear wheelan 9,9a Retaining plate
thrust bearing flange 10 Screws
4 Screws S Nut for 94155
5 Screws with spacer sleeves OF Thrust bearing flange
6 Claddings W Drilling for inserting
carrier lug 94155
®
5
I-I
.&:.
3107.198.871
10
20
3 1107.195.533
5 W
,.--
LA')
120/2a RT76/84
Re.moval
Should it become necessary to remove thrust bearing pads, teh retaining clamps 7 of the respective row of thrust bearing pads must be removed. To reach these, remove the oil pipes 8 and the two claddings 5, then the retaining clamps 7 can be removed on the required side. (See Fig. 'A'l The access to the thrust bearing pads being now freed by the removal of the above mentioned parts, in- sert the carrier lug 94155 into the drilling 'WI of the split gear wheel 3 on the thrust bearing flange and fasten it with the nut'S' (by only light tightening) in its position. (Fig. '8 1 )
Turn the crankshaft with the aid of the turning gear, thus pushing the thrust bearing pads out, where they can be singly removed. To pick up the pads use the eye screw.
On engines 9 to 12 RT75 and 8 to 12 RT84 the turningout device 94155a is to be used for the removal of thrust bearing pads, as shown by Fig. 'cr. In this case the turningout device is to be placed onto the thrust flange as shown and tightened by means of two screws 10. The crankshaft is then to be turned with the turning machine until an eyebolt can be screwed in to a pad which then can be lifted up and taken away.
Remark: Generally only individual thrust bearing pads for the 'AHEAD' operation must be replaced so that
the crankshaft remains in its proper position. Should it however happen that III the thrust bea-ring pads of the 'ASTERN' operation have to be removed, care must be taken that the crankshaft does not shift from its proper position. This might happen for example if the ship is heavily stern trimmed. (To avoid such a shifting, insert a hard wood plate of the same t~ickness as the pads in the place of the thrust bearing pads). When all the pads which require removing are out, the carrier lug 94155 must be removed and strored away. This tool is not required for fitting the thrust bearing pads.
Fitting
Make absolutely sure that all the thrust bearing pads are meticulously clean and smeared with fresh en-gine oil; the thrust bearing pads must each be replaced in its original position, note the numbering of the individual pads. Please also refer to following sheets for the arrangement of thrust bearing pads on engine with rigid propellers and controllable pitch propellers respectively.
Fitting the thrust bearing pads for the 'AHEAD' operation should pose no problems i.e. the thrust bea-ring pads con be pushed in by hand, as the crankshaft in a stern trimmed ship rests against the 'ASTERN' thrust bearing pads. With all the thrust bearing pads in position the end ones on the fuel pump side and on the exhaust side must protrude by the same distance over the upper edge of the bedplate; the retain-ing clamps 7 can now be refitted.
When fitting the thrust bearing pads for the 'ASTERN' operation it may be necessary to slide the crank-shaft axially towards the free end in order to obtain the space necessary to insert the pads.
Attention!
When inserting individual new or remetalled thrust bearing pads, ascertain that their thickness (final dimension) corresponds exactly to their adjacent one's. ~
When replacing a complete row of new or remetalled thrust bearing pads the clearance must be adjusted to the original values (as shown in the clearance tables 012/1) (by using the inside micrometer tool No. 94151 as shown on sheet 120/1).
120/2c RT
~
'-
Anordnung der Orucklagerkl6fze fur Moforen mit VERSTELLPROPELLER
Arrangemenf for flvusf pads of engines wifh CONTROLLABLE PITCH PROPELLER
luri,iclt voralJ$ O$/ern ahead
~
rechfsdrehender Mofor
clockwise rotating engine
AuflogeflOche Support Stlfoce surface
Auf/agefldcne Support ~
PrapeNerscni,b ·5· Propeller IhrJsl "S·
von Anfriebseife gesehen
Klofze auf Moforseife von Anfriebseife gesehen "5" voraus
KI6fze auf Anfriebseife looking from driving end "5" ahead pads on engine end
looking from driving end "5" zuruck
pads on driving end ··S'·osl"",n
KlOt.. fUr Zuriick-
\
J
Molorsei/e
Engine end
Antdebs.".
Driving end
KlOI;ce fiir ·Vorous·
Pads for "astern Pads for "ahoad" . ~
- ~
zuruck VOI'OUS
astwn anead
~
linksdrehender Motor
counfer clockwise
rotating engine
Auflagefliiche Supporl surface
2107,159,094 Ie Auflageflache Support sur/ace
2.81,
120/2b RT
~
Anordn<Jng der Drucklagerkl6tze fiir Motoren mif FESTPROPELLER
Arrangement for thrust pads of engines with FIX PROPELLER
varOU$zuriick aheodostflrn
~
rechtsdrehender Motor
clockwise rotating engine
AuflogefloCM . ~ $Upperl surface
Anlrlt}bsede Molorselle
Engine end {)rIVing end
PrO()f!lIersclMJb "5" Propeler //rus/ -S"
I'on Antriebseite gesehen ~ S " "orous
Klotze auf Antriebseite "S·· ahead -·S·.. lunicl<looking from driving end
pads on driving end "5" astern
Klo/ze /ii "Zuriicl<" Kl6tze IUr "Voraus"
Pods lor -aslern" Faas lor "ohead"\ i.
zurUCK astern
Auf/oge/lOch. Support surface
von Antriebseite gesehen Ktotze auf Motorseite
looking from driving end
pads on engine end
....orous ahead
~ ~
Auf/age/ldcM
Suppor' surface
tinksdrehender Motor
counfer clockwise
rotating engine
Auf/agef/oche
Support sur/ace
2-107.159.093
2.84
SULZER TIE ROD Group: 190
RT Tensioning of Checking the
Tie Rods and Pretension
Sheet: 1
Tool s: Key to Drawings
2 Pretensioning jacks 94180 1 Cyl i nder jacket 17 Clamping screw 1 Highpressure 94931 2 Intermediate ring 18 Column
oil purn p 3 Upper tie rod nut 19 Bedplate 3 Pressure gauges 94932 4 Bolt 20 Rubber ring 2 Connecting pieces 94933 5 Lower part of 21 Lower intermediate ring 1 Highpressure hose 94935 cyli nder 22 Lower nut
5 Cylinder 23 Set screw 7 Pi stan 24 Locking plate 8 Fl ange ri ng 25 2piece bush 9 "Belleville" washer 25 Screw for 25
lOBoIt AN Drainage groove 11 Vent screw K Checking slot 12 Tommy bar S Measuring point 13 Ti e ro d V Vent valve 14 Bolt X Measure of elongation 15 Protecting hood Y Measuring point 15 Bore for solvent Z Checking point
10 94933 11
9 o 94932
8 94933Z
941807
6 94934094932
3 94935
94931 V 94934
y Gezeichnet fur RT 58
DRAWN FOR RT 582
1
We recommend that all tie rods be checked for correct pretension after the first year of service of the engine and, if necessary, be pretensioned to the value specified. After that, it is suffi- cient to make random checks during a major overhaul. When making such checks, it is ~ necessary to slacken the main bearing thrust bolts or the clamping screw of the tie rod.
5
1107.185.529
",. I
L.B. ?RL1
... l ....
130jla
Checking the Fretersion of Tie Rods
Procedure:
_ Remove the threedproteeting hoods 15 fro" all tie rods 2rd cle2rl the coded face of the interme- ...,;'
diate ring 2.
_ Screw both pretensioning jacks onto two tie rods lying opposite eech other until the lower part of the cylinder 5 rests on the intermediate ring 2. If necessary, turn the whole pretensioning jack back a little so that the holes in the tie rod nuts are easily accessible. Slightly s l e c ~ e n vent
screws 11.
_ Connect bot: pretensioning jacks with hoses to the highpressure oil pump and operate pump until
any air present in the pretensioning jacks has escaped; then retighten vent screws.
_ Operate pump until 600 bar are reached and maintain this pressure.
_ Using a feeler gauge inserted through the checking slot 'K', check at 'SI if there is any clearance
between the tie rod nut 3 and the intermediate ring 2.
_ If any clearance does exist, tighten the tie rod nut with tommy bar 12 until it rests firmly on the intermediate ring (check with feel er gauge) and the rel ease the pressure. If no cl earance exi sts, the pressure can immediately be released and the pretensioning jacks removed. All the tie rods have
to be checked in this manner and, wherever necessary, the tie rod nut has to be tightened.
_ After checking has been completed, the tie rod threads have to be protected against corrosion by
coating them with nonacidic grease. Afterwards, the protecting hoods must be screwed on tightly.
Note: If it is impossible to tighten the tie rod nut with the tommy bar although trere is clearance
at'S', thi s means that the thread is bi ndi ng. In thi s case remove screw pl ug in bore 16 and press in some releasing agent or lubricant. Insert a strong brass or copper bar into a hole in the tie rod nut through the slotted orifice in the lower part of the cylinder and first loosen,
then tighten the nut with several heavy hammer blows. Make sure, however, that the edge of the hole is not seriously deformed or it will be impossible to remove the pretensioning jack. Seal
off the bore 16 again with the screw plug.
_ After completion of the checks, the pretensioning tools have to be preserved and the connections
bl anked off. Thereafter they are to be dored ina safe pl ace.
Loosening and Tiohtening the Tie Rods
Shoul d, for some reason or other, any ti e rods have to be removed, the foll owi ng poi nts have to be
carefully observed:
_ Tie rods may only be loosened or tensioned when the thrust bolts of the main bearing have been
previously loosened (see sheet 117/2).
The clamping screws 17 must also be removed.
Loosening and tensioning has to be carried out in two stages. The order in which the tie rods are to be loosened or tensioned is shown in schematic illustration (Fig. 10 1
), i.e. in pairs, first
tie rods a/a, then bib, etc.
L 0 0 sen n 0
_ The procedure for loosening the tie rods is the same as the one described above for checking pre-
tension, except that after being screwed down onto the intermediate ring (2) the pretensioning jacks must be released again by 3/4 turns so that a measurable clearance of 4.5 mm is achieved at 'yr. At this starting point connect the jacks to the highpressure pump with the hoses and operate
the pump until a pressure of 600620 bar is reached. The tie rod nuts are now loose and can be unscrewed with the tommy bar 12 until they touch the pretensioning jack cylinders.
_ Before releasing the hydraulic pressure to zero, it is of great advantage to place a hardwood wedge under the lower tie rod nut in the bed plate, whereby the wedge will take the full weight of the tie
rod.
The pretensioning jacks can now be removed.
L.B.
190 1b RT76
Tension ng
Initial Position and Preliminaries:
Clamp screws 17 may not be tightened.
The lower tie rod nut 22 is in position and secured by set screw 23.
Clean the seating surface of the intermediate ring 2 and of upper tie rod nut 3 and coat them with MOLYCOTEPaste.
Coat the thread of the upper tie rod nut liberally with MOLIYCOTEpaste and screw the nut on. (Check for ease in thread).
Screw in the eye screw into the tie rod and lift tie rod carefully until the lower tie rod nut rests firmly against the bearing shield. (We recommend using a hand lifting tackle attached to the crane hook to lift the tie rod gently to its position; with the crane it is difficult to feel when the lowe nut has touched the bearing shield and a broken rope may be the result).
Tighten the upper tie rod nut now with the aid of the round bar 12 till its firmly seated on the intermediate ring, remove the lifting tackle. (Now no clearance must remain between the bearing shield and the lower nut).
Procedure for Tensioning.
- After all above preliminaries have been completed, measure the distance 'X' on all the tie rods and record these. (See Fig.IC').
- Fit the pre-tensioning jack on both tie rods a/a, taking care that the cylinder lower part 5 rests on the intermediate ring 2 (watch for easy accessibility of one of the slotted horizontal openings needed
for tightening the nut with the round bar 12~) •.
- Connect the pre-tensioning jack to the high pressure oil pump with the high pressure hoses.
- Open the vent screw 11 on the pre-tensioning jack slightly, actuate the HP pump and when oil flows ou close the vent screw 11 again.
- Check whether at 'l')Fig.'AI) very ljttle or no clearance exists. If necessary open the relief valve on the hi gh pressure oil pump, so that the oil from the jack may fl ow back to the pump whil e the pistons 7 are screwed onto the ti e rod until the cl earance I l' is el iminated. Thi sis very important, a otherwise the necessary pretensioning pressure cannot be attained.
- Actuate the HP pump and build up a pressure of 350 bar, (l-st stage) maintain this pressure until the
two upper tie rod nuts 3 have been firmly tightened onto their seating with the round bar 12. 0 en th relief valve on the HP pump and leave it open until the pressure has fallen to Izero ' and until no clearance exists at 'll.
- Proceed in this manner for all the tie rods in the sequence shown at the beginning of this group, measure the distance 'X' and record it as IX '. (Reference value IX I -'X' = abt. 4.4 to 4.8 mm for the
1 l short ti e rods
= ~5. 7 to 6.2 mm for tlie
~ tie rods)
Repeat the pre-tensioning procedure, however raise the pressure to 600 bar (2.-nd stage).
- Finally measure again all the dimensions 'X' and record them as 'X '. The tie rods are correctly pre2
tensioned when, with the pre-tensioning pressure of 600 bar, a total elongation 'X2 1- 'X' of:
abt. 7.7 mm on the short tie rods abt.10.5 mm on the ~tie
rod s has been obtained.
- After terminating the pre-tensioning process coat the protruding portion of the tie rod threads with acid-free grease and fit the protecting caps 15. Finally all the clamping screws 17 must be firmly tightened!
Follow the remark at the end of the section "Checking the ~ie Rod Pre-Tension"!
~ Remark: In place of the high pressure oil pump 94931 used together with the pre-tensioning jacks for tightening and loosening of the tie rods, for easier and quicker progress the 'Airhydraulic pumpl 94941 can be used.
1984
---
190/1c RT
23 24
RT 58 RT 58
~ , < ~ 1
"" "~,,>'> 13
" " ,
. ~''''' ~.,~ . "'-. ~
~'" '",~,,;
~~~>;
\
\ \
\
D
--20
®
1
DI 18
13
DI-III
17
25
DI
",A3a
\
\
26
19
gezeichnet fur DRAWN FOR
Hier buendig FLUSH
~ - - . . . ~
1 17
~
19
21
22
13
22
0-107.195.506
L.B. 5.84
190/1d RT
@ @
13
130
/
c .~~
~~ .!! ~ .b_ C:Q:: ~Cl
f e c 0 b d
,-j f
f e c 0 b d
3 -107.195.507
L.B. 2.84
SULZER Group: 211CYLINDER JACKET
RT76 Sheet:Transport of a Cylinder Liner with Cylinder Jacket 1
Too 1s:
1 Suspension girder 94202 2 Web supports 94203
5
3
3- 107.198.424
94203
94202
1
2 AF
3 -107.197.559
Key to Illustrations:
1 Cylinder liner 2 Cylinder jacket 3 Cylinder head stud 4 Cylinder head nut
5 Position of the suspension pin for transport ing the end cylinders
Remark:
For transporting the cylinder jacket alone or with fitted cylinder liner the suspension girder 94202 must be
used. The two web supports 94203 are placed o~ the suspension girder to form a
combination device as shown in the illustration on the left. They are
tightened down with two cylinder head nuts each.
This tools arangement ensures the saf
positioning of the cylinder liner whi ch is important for a good seal on the landing face 'AFr.
4
94203
94202
SULZER Group: 211CYLINDER JACKET68 Removal and Fitting of the Water Guide RingRT 76 Sheet: 2
84
Tools: Key to Illustration
Set of suspension or Suspension
3 Eye screws M24 1 Tommy bar
ropes 94265
1 Cylinder jacket
2 Water guide ring
3 Eye screw 4 Rubber ring
H Jemmy
N Recesses AF Landi ng face
AF
,
H 2
3
7
3 - 107.197. 336
211/2a RT68/76/84
To remove a water guide ring, proceed os follows:
(Cylinder liner is removed).
_ Fit eye screws with suitable washers into the three threaded holes just below the upper edge. ~
Pay particular attention to the fact, that the eye screws threads are not too long; they might other-
wise jam the water guide ring, requiring removal, in the cylinder jacket.
Attach the eye screws by a three rope set to the crane.
Ease the water guide ring from its seating with a jemmy 'HI attacking in two opposite recesses 'N' at the bottom edge of the water guide ring, do not pull with the crane before the ring has been eased of
When the water guide ring is thus loosened off its seating pull in small steps with the crane, if ne-cessary assist the lifting with the jemmy from below.
Preparations for Fitting •
• Clean the guiding and landing surfaces on the water guide ring and on the cylinder jacket
.Place ~ rubber rings of the specified quality into the grooves
.Smear rubber rings and guiding surfaces liberally with tallow.
Fitting
Insert the water guide ring, hanging on the crane, into the cylinder jacket. Pay particular attention to the requirement that the ring must only slide in on its own weight through the guide portions, unc til it finally rests on its landing at the bottom.
Check that the water guide ring really rests on its landing and does not protrude above the seating surface 'AF' for the cylinder liner on the top of the cylinder jacket.
5.84
1
SULZER Group: 214CYLINDER LINER
RT Sheet:Measuring Bore Wear
Tools: Key to Drawi ng
1 Inside micrometer 94101 1 Cylinder liner
1 Measuring gauge 94225 2 Oi 1 groove
94225 94101 1
,, 107.197.056
Whenever a working piston is re-
moved for overhaul, the cylinder
liner bore has also to be measu-red. The figures found are to
be recorded so that they can
serve as comparison with earlier
or later measurements. In this way, normal wear can be determi-
ned and followed.
Comparisons with other measure-
ments can, however, onl y be made if the measurements are always taken at the same place. For this reason, use the measuring gauge 94225 which is part of
the tool kit.
The measurements have to be taken in both longitudinal and transversal direction to engine axis by putting the inside mi-
crometer 94101 into the holes especially provided for this
purpose in the measuring gauge.
The ridge formed during the
course of operation at the top of the cylinder bore has to be removed carefully without dama-ging the running surface for the
piston rings.
') PIlT . R .
SULZER
RT76
~:
1 Suspensi on gi rder 942 ': 2
1 Jacki ng gi rder 94204
1 Jack support 94205
2 Suspension straps 94206
2 Screws to 94206 94207 1 Hydr. Jack wi th 94950
HP Hose 94935
High pressure oil 94931 purnp
CYLINDER LINER
Removal and Fitting
Group:
Sheet:
(, ey to Illustrations
1 Holding p~2re :" Cy 1i nder head 2 Holder 11 11dter gui de ri ng 3 Centring pin 12 Cylinder jacket 4 Ro 11 pi n 13 Cylinder liner 5 Screw 14 Water guide ring 6 Screw AF Seati ng surface 7 Screw H Hard wood bedding 8 Locki ng p1ate S Screws to 94204 9 Locking p1ate
5
1107.197.587
®
214
2
1984
214/2a RT
It is vital that the following preparations are carried out before a cylinder liner is removed:
• Drain the cylinder cooling water from the respective cylinder, i.e. first shut the two valves
cylinder cooling water inlet and outlet; The drain valve is situated immediately behind the cooling
water inlet valve at the bottom of the cylinder jacket on the fuel pump side, the cooling water
outlet valve however on the top above the exhaust valve cage. Open the drain valve in the cylinder
cooling water outlet pipe of the respective cylinder.
• Remove the pi stan rod gl and (see Group 231, Sheet 1).
• Remove both bolts 5 (one each on fuel pump and exhaust sides, see Fig. Ie') which hold the cylinder 1iner onto the cyl inder jacket.
• Discommect all cylinder lub. oil pipe connections from the lubricating quills.
© II
10
11
6 4 2 8
13
® 11
1
9 1107.195.505
II II
Brennstoffpumpenseite FUEL PUMP SIDE
I 3
5 ---i!dIiI~
7'~E~
2.84
----------~
214/2b
Removal (Figures 'AI and 'B')
Procedure:
With the bearer 94204 suspended from the crane, lower it through the cylinder liner bore and bolts it to the bottom edge of the cylinder liner with both the bolts'S'.
Bring the crosshead to T.D.C.
Place support 94205 and jack 94950 above each other on the crosshead.
Connect up jack to highpressure pump 94931 and then jack the cylinder liner out of its guide sec-tions.
Lay two planks of wood opposite each other between cylinder jacket and cylinder liner collar in order to prevent the cylinder liner from sliding back into its guide section.
Lift off and remove jack together with support from crosshead. Remove jacking girder 94204.
Place the suspension beam 94202 on the cylinder liner and connect it to the susptnsion straps 94205 ~ith screws 94207.
Lift out and take away the cylinder liner with the crane.
Preparations for fitting:
.Thoroughly clean guide sections and sealing surfaces of cylinder liner and jacket and dress any da-mage •
• 'nsert rubber rings of the quality and dimensions specified into the grooves of the cylinder liner•
• Coat all the rubber rings and guide sections of the cylinder liner and jacket with tallow •
• Thoroughly clean seating surface 'AF' of cylinder jacket •
• Check that water guide ring has been fitted.
Fitting (Figure'E')
Fit the transporting device to the cylinder liner to be installed in the same way as was used for 'Removal' (See Fig. 'B').
With the cylinder liner hung on the crane bring it above the cylinder jacket. Before lowering it smear the seating surface 'AF' of both the cylinder jacket and that on the cylinder liner collar with a nonsetting sealing compound.
Lower the cylinder liner, thereby ensuring that the centring pin 3 (Fig. 'C') engages in the centring hole in the cylinder jacket (on the fuel pump side).
Place a cylinder head on the cylinder liner and screw it down with four evenly distributed nuts. Tightening these in a crosswise manner will result in the cylinder liner being pressed fully down into the cylinder jacket (Fig. 'E').
After removing the cylinder head insert the screws 5 and tighten them.
Putting the cylinder liner uprjght (Figure 'F')
There are two diametrically opposite threaded holes at the same level cut in the collar of the cylinder liner. These servo to accept the two special bolts 94207. These, together with the slinging wires, make up a suspension device which is used when handling a bare cylinder liner in the ~orkshop during manufacture or such like.
For as
reasons of safety, transport device on
this suspension arrangement should board.
never be used
Always use the device as shown on Fig. 'B' for this purpose •
.!..J • _. ,...,~..,
214/2c RT7G
®
®
~~::="''''''''~,-==--il..+
I !
!
2-107.197.688
Gezeichnet fur RT 58 DRAWN FCiR RT 58
H
94202
94206 94207
4 -107. 198.851
H
1984
4
SULZER Cylinder Liner Group: 214 Removing the wear Ridge, Redressing theRT Sheet:lubricating Grooves, as well as the Edges
of the scavenge Ports
Too 1s: Key to III ustrati ons
1 Wear ri dge gri ndi ng devi ce 94299 1 Roller support 7 Air hose
Emery cloth 2 Holder 8 Hose oiler
Assorted files 3 Holder 9 Thread nozzle
Fine grain carborundum 4 Spacer ro 11 er 10 Carbide milling cutter
oil brick 5 Pipe (column) 11 Cylinder liner 6 Grinder
® Check drilling
([) Scavenge port
(f) Lubricating grooves
Due to wear by the piston movement in the cylinder liner running surface ridges are formed on top and bot-
',,, om to where the piston does not reach. Due to the wear the lubricating grooves in the cylinder liner loose heir depth, furthermore the corner radii of the scavenge port edges become smaller and thereby sharper. It
also happens that the edges get damaged.
When a piston is removed the opportunity should be used to measure the bore of the cylinder liner (see 214, sheet 1) and to remedy any changes which occurred. The following points are of particular importance:
• Protect the space below the cylinder liner with suitable material from falling particles.
• After completing the reconditioning clean the bore of the cylinder liner thoroughly and remove any trace of metal dust (particulartly from the lubricating grooves).
• Carefully remove waste particles which may have passed into the scavenge space through the ports.
• Actuate the cranks of the cylinder lubricators until oil flows from all the lubri-cating points, thereby flushing any metal dust which accumulated there.
Removina the wear Ridae
When grinding away the wear ridge take greatest care not to damage the running surface within the area co-
vered by the piston and piston ring stroke from T.D.C. to B.D.C.
We therefore recommend using a wear ridge grinding device (Fig. '0 1 ) for carrying out this work. It is
listed in the tools list under "Recommended special tools".
Redressi na the 1ubri cat; na arooves
If the depth of the lubricating grooves has worn to less than 1.5 mm (new depth 2.5 mm) redress them to their original depth and slightly chamfer their edges with an oil stone or similar.
Redressinq the Edqes on the scavenqe Ports
On the next page the edge shapes on new cylinder liners are depicted. In case the condition of the edges
requires reconditioning (depending on the degree of wear or aamage) aim at matching these shapes. Take great care not to damage the running surface in the cylinder liner bore. Polish the passages into the run~
ing surface with emery cloth.
L. B. 5.85
214/40 RT68 76 e14
/ I
j
(
985
214 /4b RT
I5 1 \ @\
\ \
~
: -~91,299 II
0-107. 215.291.
10 gezeichnet fur RT 58
DRAWN FOR RT 58
Hartmetall - Fraser Zahnung III
HARD METAL CUTTER TOOTHING III
¢8
~() DCI 0
SULZER
RT Lubricating Quills and Accumulators
(MULTI LEVEL LUBRICATION)
Function Check
Group: 215
Sheet: 1
Key to III ustrati ons:
1 Accumul ator cyl i nder 10 Cyl i nder 1i ner
2 Spring 11 Lubricating qui 11
3 ~,ccumulator piston 12 Filling pin
4 Cap nut 13 Steel ball 5 Diaphragm 14 Nonreturn valve ho us
6 Accumulator-casing ing 7 Cap nut 15 Non-return valve in 8 Backing screw cylinder liner 9 Copper sealing rings 16 Spring guide
17 Steel ball 18 Copper joint ring
When pulling a working piston, the cylinder lubrication system should also be checked for correct fun
ctioning. (The function check must also be carried out in case of malfunctioning of the cylinder lubri
cation)
Turn the crank of the respective cylinder lubricating pump until oil emerges from all the lubricating points in the bore of the cylinder liner. On cyl inder liners with two rows of lubricating points (MULTI LEVEL LUBRICATION) the oil delivery for the upper rQW must be set on the cylinder lubricating pump to
30% (Abb. 'A') and for the lower row to 70% (~bb. 'B') of the total quantity delivered. To ensure that thi s proportion is maintai ned see that all 1ubri cati ng .poi nts 0 one row yi el d the same oil flow.
Should deliveries differ, re-adjust on the cylinder lubricating pump the setting screw pertaining to the respective lubricating point.
Use the occasion to check at random several accumulators. Open them to inspect the diaphragm 5. If oil is found in the inner space of the accumulator piston 3 or in cylinder 1, the diaphragm is leaking and must be replaced by a new one.
New diaphragms are supplied in special plastic boxes, ready for fitting. Fit the diapragm with greates
care so as not to damage it.
In case a non-return valve must be replaced, remove first the backing screw 8 after which the valve can be pulled out together with the filling pin 12 which is joined to it. Non-return valves are only supplied complete with filling pin as replaoement parts.
After fitting the new valve tighten the backing screw 8 moderately and lock it with a center punch.
When replacing a non-return valve 15 in the cylinder liner (Fig. "B") the thread must be sealed with 'LOCTITE', Replacement of non-return valve 15 is only possible on the removed cylinder liner. After changing the non-return valve a leakage check must be carried out.
Remark: Lubricating quills for the II Multi Level Lubrication" have filling pins 12 of different lengths. The fi lli ng pi ns of the 1ubri cati ng quill s 11 for the upper row of 1ubri cati ng poi nts are lon
ger than those for the lower lubric~ting points/grooves.
I ~
215/10 RT
1
4
8---~
12''
fA' FUr obere Schmiernufen\CJ FOR UPPER LUBR/CATION GROOVES
3 -107. 125.039
11 10
9.1
9 1112
® FOr untere Schmiernuten FOR LOWER WBR/CAT/ON GROOVES
Ganze 6ewindelange abgedichtet mit Loctite ENT/RE THREADED LEN6TH SEALD W/TH LOCTITE
4 -107. 240. 301
15 17 16 18
L. B. 1988
1
SULZER PISTON ROD GLAND Group: 231 Removal and Fitting as well as MeasuringRT Sheet:the Wear
Too 1s: Key to 111 ustrati ons
2 Eye screws 1 Sc rew 9 Roll pin, Dowel 16 Ring holder in lower
2 Jacking screws 2 Locking plate to item 10 Garter spri ng casing
Hand 1amp 3 Screw 11 Garter spri ng 17 Upper casing
Assorted spanners 4 Locking p1ate to item 3 12 Oil scraper irng, 18 Cylinder jacket
De'lice far fitting 5 Scraper ri ng, 3 parts 2 parts 19 Oring the garter sprirgs 6 Sealing ring, 3 parts 12a Oi 1 scraper ri ng 20 Garter spring
of the oil scraper 7 Guide ring, in 1 piece 3piece 21 Ori ng ri ngs 94231 8 Piston rod 13 Seal ing ring, in 22 Lower casing
o 1 pi ece 23 Oring
14 Ring holder in upper 24 Lock piece
casing 25 Spacer ring (bronze)
15 Ring carrier with 10' AD Threaded hole for I-I ring groove jacking screw or eye
screw respectively~ I I
5
6
71
22
Geze;chnet fur RT 58
DRAWN FOR RT 588
3
1
AD 11
1-107. 198.897
20
~. B.
231/1a RT
During every piston overhaul the piston rod glands must also be removed and checked. Parts which are badly worn must be replaced (please refer to indications further down on this sheet).
It is very important to have the glands in excellent condition when they are reassembled, as the next dis '/ mantling is not possible without removing the piston i.e. not before the next working piston overhaul.
The piston rod gland is removed as a complete unit after the piston has been pulled out. For removal of the gland, loosen and remove the screws 3 and jack the gland out of its centring guide with the jacking screws inserted in the threaded holes 'AD' and tightened equally.
When the gland is loose, remove the jacking screws and insert two eye screws in their place. Attach the gland to these eye screws and lift it with the crane through the bore of the cylinder liner.
It is advisable to immerse the whole gland in a container with cleaning solution and to subject it to a preliminary cleaning before it is dismantled for inspection.
After removing the screws 1 separate the two gland groups and remove the individual parts. The ring hol- ders are equipped with threaded holes permitting their removal with grip screws.
The ring holders 15 are somewhat smaller in diameter than the ones in the upper casing, they are therefore the first to be refitted in the lower casing.
After dismantling check the wear by measuring the following parts:
Upper gland group: Scraper ring 5 (in 3 parts) Sealing ring 5 (in 3 parts) Guide ring 7 (in 1 piece)
Lower gland group: Oi 1 scraper ri ng 12 (2piece) according to Fig. 'B' Oil scraper ring 12a (3pi ece) according to Fi g. 'Bl ' in design variant Sealing ring 13 (lpiece)
The admissible wear on the wearing parts is indicated in the clearance table group 12 sheet 4.
Any parts which are near to the still acceptable limit values or have already exceeded them must be repla-ced by new ones. In doubtful cases it is better to decide on replacement, as they can only again be che-cked when the next piston overhaul is taken in hand, which can be as long as 10'000 operating hours away.
The garter springs 20, 11 or 10 as well as the rubber arings 19, 21 or 23 must also be replaced unless they are in perfect condition.
When assembling a gland ensure that the individual parts are i~stalled in the same order and position as shown on the figures 'A' and 'B' or design variant 'Bl'(note also the design variant Fig.'e' for the RT5~)
Remarks: In one of each oil scraper and sealing ring group a hole is drilled in the ring above into which the roll pin (dowel) of the ring below has to fit (see detail on Fig. 'BI).
All the oil scraper rings including the sealing rings must be easily movable when the screws 1 are fully tightened. The screws 1 must be locked with locking plates.
Do not at first install the following parts of the upper gland group: scraper ring 5, sealing ring 5, lock piece 24 and the garter springs 20 and 11. Fit these parts only after the working piston has been fitted.
I Q
231/1b RI
Fitting
Smear the rubber Orings 19 and 23 and the corresponding centring surfaces liberally with TALLOW
(sheeps fat), then insert the cornpleate gland into the cyl inder jacKet. Tighten the screws 3 and
lock them wi th the lock i ng pl a tes 4.
~ f t e r fi Hi ng the worki ng pi ston fi t the i terns 5, 5 and 24 and cl amp them wi th the garter spri ngs
20 and 11 to the pi ston rod.
®
----Pos.7
Pos.13
Gezeichnet fur RT58 2 107.198.894
DRAWN FOR RT58
2.84
231/1c RT
Kolbenstongenstopfbuchse - Ausfuhrungsvorionte
PISTON ROO GLAND-DESIGN VARIANT
Pos. 5
Pos.6
Pos.?
Pos.120
Pos.25
Pos.120
Gezeichnet fur RT 58 DRAWN FOR RT 58
2 107 215 238
, ,.,
231/1d RT 68 75 84
Vorrichtung zur Federmontage der Oe/abstreifringe
DEVICE TO SPRING MOUNTING OF OIL SCRAPER RINGS
4 107.240.113
101¥'
'-"
SULZER Group: 270CYLINDER HEAD
RT76 Removal and Fitting Sheet: 1
Too 1s:
Hydr. Jack 94215 1 Cylinder head 5 Fuel injection valve K Safety chain
Suspension device 94265 2 Nut 6 Starting air valve R Eye screw
3 Protective caps 94265(a) 2a Cylinder head studs 7 Indicator valve S Suspension screw
Various spanners 3 Outlet of cylinder 8 Relief valve X Threaded holes for
cooling water 9 Water guide ring jacking screws
4 Exhaust valve cage
8x
2
20 UJUJ Q) C) .... -....
Q)C-' V)~'Q) V) V) '-V) 0.. V)I
II) ,::,o . : ~ 6 .'::' o ~
1;;0.. O\:t .0>(C:-.J
C:UJ '0::{ lo4,JQ),::,
Q5~ 3 s
emoval Drain the cylinder cooling water from the affected cylinder, i.e. first shut the two valves for cylinder
cooling water inlet and outlet; the drain valve is located directly behind the cooling water inlet valve at the bottom of the cylinder jacket on the fuel pump side, the cooling water outlet valve however is on the top above the exhaust valve cage. Open the vent valve in the cylinder cooling water outlet pipe of the respective cylinder!
Disconnect all the pipes to the cylinder head and to the exhaust valve.
Clean all the thread protrusions on the cylinder head studs.
Loosen the nuts of the cylinder head studs (in accordance with the instructions on sheet 270/2) and re- move them to a clean safe place.
On each cylinder head stud situated nearest the suspension screws'S', a protective cap 94265(a) must be
placed; they are needed to centre the cylinder head and thus protect the stud thread •
. Attach suspension device 94265 to crane, hook it onto the 3 suspension screw'S' and, to stabilize the cylinder head (with fitted exhaust valve) pass the safety chain 'K' through the eyelet of the eyescrew IR' and attach it.
Lift the cylinder head carefully with the crane (see Fig. IB').
emark: The three screws'S' are fitted with Loctite in the cylinder head and therefore locked; they should therefore be left there also after removing the suspension device.
1 t07. 198. 438x
270/10 RT76
®
K I.4.J
94265
9R
I V)
. ~ '-
~ g j II)
o ~
2a
94265 (a)
////
~ ,
I
. ~ ,
l I j
I
~ ~ ~
3- 107. 215.283
5.85
270/lb RT
Fi tting
Note the following points before replacing the cylinder head:
~ Neither foreign matter nor dirt may be present in the combustion space.
The landing faces of cylinder liner and cylinder head must be clean and undamaged.
Place a 2 mm thick soft iron sealing ring on the cy1inder 1iner so that it 1ies flat over its fu11 cir-
cumference.
The inside of the water guide jacket 9 bolted to the cy1inder head as we11 as the re1evant guide sec-tions on the cy1inder liner collar must be clean and smeared with tal1ow.
~ rubber rings of the specified size and qua1ity have to insert in the grooves of the cy1inder 1iner. They too must be smeared with ta11ow.
The cy1inder head stud bolt threads must be clean and smeared with MOLYKOTE paste.
P1ace a protection cap 94265(a) over each of the three cy1inder head studs situated nearest the suspen-sion screws (S). (This instruction app1ies on1y to the engines RT 68, 76 and 84).
Once the above conditions have been met, 10ver the cy1inder head carefu11y over the cy1inder head stud bo1ts with the aid of the suspension device 94265. The correct position wi11 be assured by the guide pins (see Sheet 214/2a).
After removing the suspension device, screw on a11 the nuts by hand onto the cylinder head studs, check- ~ ing that they run freely. If necessary, dress the stud bolt thread until the nuts can be screwed on by
hand.
With the aid of the hydro tensioning device 94215, tension the stud bolts according to Sheet 270/2 then connect up all the pipe connections.
Finally, close the drain and vent cocks and reopen the jacket cooling water inlet and outlet cocks.
SULZER Group:CYLINDER HEAD 270
RT76 Hydraulic Loosening and Tensioning Sheet: 2Of Cylinder Head Studs
: 00 1s: :'\ey 1:0 III usl:ral:i ons:
Simull:aneous pre Screw 10 Do ub 1e cylinder 17 HPhoses tensioning device 94215 ~
L Eye screw 11 Pi stan 18 Coupling plug
~ i r hydraulic HP 3 Suspension stud 11 a, b Piston seal ri ng 19 Branch piece
oil Pum p 94941 4 Coupl i ng socket 11 c, d Rod seal ring 20 Connecting piece
5 Round nut 12 Cylinder head nut 21 Cyl i nder head
5 Vent screw 13 Cyl i nder head R Round bar
7 Cover wai sted studs W Emplacement fa r nut
8 Stack of spring 14 Pressure limiting valve when not in use
washers 15 Flow through valve X Measuremen-l: abt.
9 Screw 15 Pressure gauge 7 mm
17 17
o
94941
"',/,/,; ( ) ( ; ( ) ( > ~ ~ ~ ~ ~ ~ .,,,,/,/,"',/,/,/\./,/,/,/,/,/,/'J''''''''''/'J'/'/'/,/,/
,/,/,/,/,/,/,/,/
''''1''''/',.,/,/,"',/,/,/,/,/, / ........ ,/,/,/
) ( ) ( ) ( ) ( ) ' m ~ " . . . , . , . . . , f " , " < ' 7 " " " ' ) / ( 'J,/,/,/'J,/,/,/,/ .... ,/,/,/,/, /,/,/,/,/,/ .... /\,/,/,/ .1',/,/,/,/,/,/,/,/,/,/,/,/ '
1-107. 198.417
o- 107. 198.423
ii,I , :
a±Ii
2
3
1
10 12
\
\ 9
®
1981,
270/2b RT76
1) Pre par a t ion s for DeTensioning or Pretensioning
Clean the threads of all the cylinder head waisted studs (C.H.Studs) and the area around the cylin-~ der head nuts (C.H.nuts).
Arrange the simultaneous pretensioning device 94215 over two each C.H.studs on the cylinder head (Arrangement as per Fig. 'AI).
Open the vent screw 6 on each pretensioning jack; with this its piston 11 settles automatically in-to its initial position.
Pick up the two round nuts 5 of each pretensioning device, (which are emplaced at 'WI in the devi-ceslcentre when not in use), and screw them onto protruding part of the waisted studs until they
touch the pi llton 11. Afterwards turn back the round nuts 5 by ~ turn.
Check the dimension 'X' on each of the jacks, it should read obout 7 mm. When this tallies on all jacks the piston are in the required starting position and the piston stroke is assured in every case.
Connect the individual high pressure hoses with each other as shown on Fig. IAI and with the air-hydraulic pump 94941 (pump).
Check oil level in the pump (oil level glass or dipstick)j when necessary top up (with oil accrding to instructions of the pump suppliers).
Connect the pump with air pressure hose to compressed air system (required air pressure = 7 bar).
Remark: For the actuation of the airmotor only filtered and slightly oily air should be used. The pump may not be started, if the oil 1evel is low or the oil tank is empty (oil 1evel gl ass).
2) Hydraulic DeTensioning
When all preparations according to section 1) have been completed proceed as follows:
Turn the hand lever on the flow through valve 15 to supply o{l to the jacks. Turn the turnbutton on the pressure limiting valve 14 till its stop, in the direction of the arrow (minus).
Open air pressure supply, thereby starting the pump.
Shut the vent screw 6 on the jacks, as soon as the pressure oil flows without bubbling.
Turn the pressure limiting valve 14 slowly in the direction of the arrow + (plus), until the pres-sure gauge 16 shows a pressure of 600 bar.
When this pressure is attained turn all the C.H.Nuts upwards with the aid of the round bar IRI un-til they touch the cylinder 10.
Set the hand lever on the flow through valve 15 to release the oil pressure to zero.
Shut off the air supp1Yj the pump is thereby stopped.
Disconnect all high pressure hoses between the jacks and to the pump.
Loosen the round nuts 5 from the waisted studs and place them in their emplacement at 'WI on the pretensioning devices.
3) Hydraulic PreTensioning
~~~£~~~~~~~:
In addition to the preparations listed in section 1) the following is necessary:
The threads of the C.H.nuts and their landing surfaces must be coated with MOLY-_COTE paste G.
1.89
270/2c RT76
Prior to mounting the pretensioning device, tighten all the C.H.nuts with the round bar till they are firmly seated. (Check seating with a feeler gauge.)
Mark the position of all the C.H. nuts to the cylinder head with a marking pen or similar with a line (for 1ater checks on the ti ghteni ng ang1 e).
Tensioning
Position the hand lever on the flow through valve 15 for oil supply to the jacks. Turn the turning button on the pressure limiting valve 14 till the stop in the direction of the arrow (Minus).
Open the air supply line, whereby the pump is started.
Close the vent screw 5 on the jacks as soon as the oil flows without bubbling.
Turn the pressure limiting valve 14 slowly in the direction of the arrow + (Plus), until the pressure on the gauge 15 shows 500 bar.
Keep the pressure constant, tighten all the C.H.Nuts down with the aid of the round bar 'R' till they seat firmly on the cylinder head. (check the seating with a feeler gauge!),note whether all the nuts have been turned by about the same angle i.e. about 180
0 •
Should the tightening angle on any of the C.H.nuts be considerably less than the others, it signifies that the pretensioning jack on that particular C.H.nut did not elongate the C.H.stud sufficiently, '' as for example oil leakage occurred in the seal rings 11a, band 11c, d or that the coupling plug 18 in coupling socket 4 was not correctly tightened, so that no oil could enter the pressure space of the jack. (The couplings are equipped with non return valves which open when the screw connection is ti ght).
If necessary the tensioning has to be repeated, after first loosening all the C.H.studs.
When the tightening angles on all the C.H.nuts are approximately the same, release the pressure by, turning the hand lever on the flowthrough valve 15, till the gauge 16 shows zero.
Shut off the air supply; the pump is thus stopped.
Unscrew all the round nuts 5 from the waisted C.H.studs and place them in the emplacement 'W' of the tensioning device.
Check once more the marking lines on C.H.nuts and cylinder head to verify that the tightening angle ~ the C.H.nuts is about 180
0 •
When this is correct, disconnect the HP hoses between pump and tensioning device and remove them. The open hose couplings to be protected with dust caps. Lift the device with the crane and store away.
4) Overhauling the hydraulic Pre. Tensioning Jacks
In case the seals lla,b and/or 11c,d must be replaced in a pretensioning jack, proceed as follows:
Loosen the screws 9 and remove them with the lower spring washer stacks 8.
_ Loosen the screws to the cover 7 and vent screw 6 and remove them.
lift the cover 7 off the p~sten 11.
Pull the piston out of the cylinder using two eye screws.
Assemble the pretensioning jack in the reverse sequence to dismantling, taking care that all the parts
are meticulously clean and carefully oiled with clean engine oil.
When assembling the piston seals lla,b or the rod seals 11c,d special care must be taken that the sli-
de ri ng in not di stored.
1.89
SULZER Group: 270CYLINDER HEAD
RT Mechanical Slackening or Tightening of Sheet: 3 the Cylinder Head Waisted Stud Bolts
(exceptional case)
ATTENTION
1 Pneum. impact 94264 Neve r simply slacken off or tighten all the neigh-
spanner bouring nuts as they come. This may only be done cross-with socket wise and in stages as described below. Failing to heed
head in sed thi s advi ce can 1ead to cyl inder head damage. 1 Impact ring spanner
Whenever possible, ~ slacken off or tighten up the cylinder head waisted stud bolts using the hY- draulic tensioning device. This is to avoid any risk of uneven tensioning of the stud bolts which could
cause deformation of the cylinder head. The cylinder head waisted stud bolts may only be slackened or tightened using the following procedure in exceptional cases, e.g. when the hydro tensioning device cannot be used.
Slackening
Mark four nuts lying crosswise opposite each other with paintand slacken them back only through the following angle with the pneumatic impact spanner:
Engine type RT 58 RT 68 RT 76 RT 84
Slacken off all the other nuts and remove them. Finally evenly slacken off the four nuts in several steps which had previously been turned back through the abovementioned angle.
Tightening
Thoroughly smear the bolt threads as well as the contact surfaces on the cylinder head with MOLYKOTE paste and screw all the nuts fully down hy hand until metaltometal contact is obtained.
Now tighten them evenly using a spanner with a short, sharp jerk (by hand). Check their seating with a feel er gauge.
Mark the '0' position on each nut and on the cylinder head at a corner with a felttip pen or similar. Furthermore mark the positions for the 1st, 2nd and 3rd stage beside each nut on the cylinder head (for the rel evant engine type) according to fig. I BI.
Place the socket head insert such that the 10 1 mark (on its circumference) lines up with the '0' mark on the nut as well as the cylinder head.
Tighten the four nuts 1, 2, 3 and 4 crosswise through 60 0
(=lst stage) and then all the other nuts in the order shown on Fig. 'A'.
Finally, tighten all the nuts through a further4 0 (= 2nd and 3rd stages) as required by the correspon ding engine type. The relevant values con be seen on Fig. 'B'.
L.8.
®
270/30 RT
8
2
'O'Marke
I. -107. 215. 229
L. B. 1984
''
SULZER
RT Manual Fuel
CYLINDER HEAD
O v e r ~ a u l of Sealing Face Injector in the Cylinder
for the Head
Group:
Sheet:
270
Tool s: Key to Drawings
Overhauling 94270
device Ring spanner AF 36
1
2 3
4
5
Cylinder head
Milling cutter ho 1der Guide flange
Setscrews
Profi 1i ng cutter
6 Centering mandri 1 S Screw
* Threaded holes to take the screws'S' when the
tool is not in use.
SW36 When fitting the fuel injector, the seat seal ing
face in the cylinder head must be clean and un-damaged as the sealing is metallic.
Should any blowby of combustion gases have been noticed during engine operation, the nuts of the fuel injector are not, under any circumstances, to be tightened further as a counter measure as this might lead to deformation of the injector.
2 Dirty or slightly damaged sealing faces can be reconditioned on the spot by using the over-hauling device 94270 which forms part of the
5 tool kit. This is done by carefully inserting the profiling cutter, bolted to the milling
cutter holder, into the hole in the cylinder 3
head with the guide flange. This flange is clamp-ed down with 2 screws'S' which are kept screwed
into the threaded holes marked * when not in use.
When the tool is being used, the centering man-dril on the profiling cutter on the one hand and
1 the guide flange on the other, give the tool the necessary stability and direction. Cutting is do
ne by pressing down lightly with the hand on the milling cutter holder at the same time as turn-ing the hex. head evenly with the other hand using the AF 36 ring spanner. Try to remove as little material as possible but
sufficient, however, to obtain the desired stand ard for the seating area.
Putting some sticky grease on the profiling cut-ter will prevent any foreign matter entering the combustion chamber during overhaul.
5
6
2 - 107. 197. 324
T 0 1'" 0 I
SULZER FUEL INJECTOR ,co"' 27;l Checking, Dismantling, Assembling and SettingRT
Sheet: 1
0Too:s: ey J r a w i r ~ s
~ 1 ~,
~ y d r a u 1i c ti ghteni ng devi ce ;42c~' f- i ' en sc re ',J
~irjector test stard ~ ' = F t N G E ;:.r2 ~ :JDr-:f;Q C': ate
;1: JLnl1 r,g arg' e brac~et B e l : e v ~ l ; e washer pac""
Scre~'eo socket 94274 N::::: 1 e "cider
Ho seD1 pe (: 5'= bar j 9427:'; Sr,ri ng tensioner
VariGcs spanners 6 Fl anged nut 1 CI ring
8 Corneeti ng piece
Bush wi th fl at seat Circula-
: C Compression spring
o 8 tion val ve11 Needl e
9 12 10 1 ring
13 Needl e seat10
14 Compression spring
15 Spring p1ate
16 10' ri ng 111 17 Guide bush
2 18 Spindle
3 19 Lim i t stop/guide bush12 20 Cap nut
13 21 Nozzl e body with needl e seat
22 Nozzl e needl e
" 23 Do we 1 pin
24 Heavy spring do we 1 pin
25 Spill valve
15 26 Nozzl e tip
27 Nozzle sleeve16
17
schem. Anordnung
der Federscheiben-
pakefe 3 18 2PDuse
TWO PIECE NOZZLE
1
2
2019
20 21
2721
22
26
1107.195.535
272/1a RT
® 942740
94274b
5
6
94273
94272
94275
MA
4 107. 197082
© @ 20
0776 3380-6 0776 3380-9
L.B. 2.84
272/lb RT
For testing, dismantl ing, assembl ing and setting the fuel injection valve utilize the l'ORANGE Valve Test Stand 94272 belonging to the engine tool set. Pay attention to the following points:
Keep the valve test stand clean and always fill only c 1 e a n Diesel fuel (gaso;"l) into \...-t its tank. Do not pour the once used fuel oil back into the test stand. (For fill ing remove the
cover which is secured by two spring latches).
From time to time the pressure gauges have to be calibrated or compared with a TEST pressure gauge and reset if necessary.
When working with the fuel injection valve the connection at top left is to be used, to which the left hand pumping lever and the upper pressure gauge (0500 bar) belong. The connection at top right the lower pressure gauge (0 1500 bar) and the pumping lever at the right are used for testing the relief valves of the fuel injection pumps.
Judgeing a Fuel Injection Valve (Called F.I. Valve for short),
A f.i.valve atomizes correctly when at specified opening pressure fuel oil is sprayed from all the nOlZ
le holes in equally atomized condition. This should be accompanied by a loud 'chatter', and after the end of the pumping stroke no fuel should 'dribble' from the injection nozzle.
To check whether the atomizing is equal, hold a clean sheet of paper in front of the spray holes of the injection nozzle, and bring the f.i. valve to spray by single short pump jerk. On the 'spray pattern'
thus obtained it is easy to establish whether individual spray holes are partly or fully blocked.
Attention! Never actuate pump when a finger or" a hand is held directly against the injection nozzle! (Danger of accident). I
Injection nozzles which do not spray properly must be taken apart and reconditioned or replaced. (See sheet 272/2/3 and 4).
Testing an F.I.Valve (See Figs. 'A' and IB').
Working Sequence:
Place f.i. valve injection nozzle downwards into the holding angle of the valve test stand and fas-ten with the two nuts.
Clean injection nozzle outwardly with a brass wire brush (removing combustion residue.)
Loosen and remove connecting nipple 8 with needle seat 13 and fit in their place screwin connection (too1 No. 94274),
Join hp hose (tool No. 94275) sideways to the screw~in connection.
Loosen screw on flushing valve 25 (Fig. IBI) a little and actuate the pump lever until fuel oil flows bubblefree from the hose (tool No. 94274b); Then tighten the screw on the flushing valve firmly.
'" Check fi rst wi th a few short pump 1ever jerks the atomi zati on of the fuel, then wi th slow equal pump strokes observe at what pressure the f.i.valve opens (see pressure gauge 'MAl). The specified opening pressure is given in the test and timing records of the engine.
Finally unscrew and remove hp hose with screwin connection; fit and tighten connecting nipple 8 with needle seat 12 firmly.
Dismantling a F.I.Valve (See Figs. lA', 'C', and 10 1 )
The following basic rules must' always be observed: 1) The cap nut 20 to the f.i.valve may never be loose-
ned, before the spring tensioner 5 is not unscre-wed sufficiently to detension the spring 14 comple-tely (Fig. 'A').
2) Never interchange nozzle needle and nozzle body
Each nozzle needle belongs to its mated nozzle body
into which it has been individually fitted with
greatest precision.
I D
RT272/1c
Working sequence:
_ Bring holding angle 94273 \\rith f.i. valve into horizontal position (Fig. 'C').
_ Place spanner 94269a (of hydro tightening device 94269) on cap nut 20 and loosen the cap nut ~ ; t h the aid of hydraulic jack 94269b and pump 94269c (Fig. 'C'), then remove the injection nozzle.
Attention! The spanner 94269a must always be set back before the piston of the jack is fully pushed out. At the start of pumping the spanner must stand as close as possible to the jack while its piston is fully pushed in. The relief valve 'EV' at the pump to be slightly opened.
Remove spring tensioner 5, spindle 18, spring plate 15 and spring 14 and inspect their condition.
- If necessary lap the sealing face of the nozzle holder 4 (pI. refer to 272/3).
Assembling a F.I. Valve
Always observe the following basic rules:
1. Fit only completely clean nozzles, which were washed in kerosene and blown out with compressed air.
2. If the spindle 18, the spring plate 15, the spring 14 and the spring tensioner 5 are already fitted, the spring tensioner may only be screwed in by about one turn, so that the spring 13 is absolutely not under tension. Should this rule be neglected then the nozzle body 21 does not lie flat on the nozzle holder 4, for the assembling.
Working sequence:
Adjust the holding angle 94273 with nozzle holder 4 so that the sealing face is on top (Fig. 'D').
Wipe sealing face on nozzle body 21 and nozzle holder 4 with the clean hand and place the nozzle body with needle on top. Take care that the needle does not fall out and that the cylindrical locating pins 22 of the nozzle holder fit into the corresponding holes in the nozzle body (Fig. 'd').
Smear thread and seating surface of cap nut 20 with MOLYKOTEG paste and tighten it by hand till seated firmly.
Swing angle support 94273 about in horizontal position, mount spanner 94269a and tighten the cap nut 20 with pump 94269c and hydro jack 94269b at a pressure of 250 bar.
If 2P injection nozzles are fitted, pretighten cap nut 20 first to 20 bar or by a hammer stroke on the spanner. In this position mark cap nut 20 and nozzle holder 4 with a felt marker (' 0' mark). With this mark as starting point tighten the cap nut by further ~ 45° or hydraulically to a pressure of 150 bar. Should a new nozzle head 26 have been fined, reloosen cap nut 20 after tightening, then repeat the above described tightening procedure. This ascertains that any clearance or deformation has been taken up.
Attention! The spanner 94269a must always be set back before the piston of the jack is fully pushed out. At the start of pumping the spanner must stand as close as possible to the jack, while the piston is fully pushed in. The relief valves 'EV' at the pump to be slightly open.
The pressure of 250 bar respectively max. 150 bar ~ for the 2P nozzle is only correct when MOLYKOTE Paste G is used as lubricant and the jack has an effective piston area of 6.41 cm2 which corresponds to the E!'\ERPACjack CRC55 supplied with the engine tool kit. For the correct tightening effort the spanner 94269a should stand at approximate right angles to the jack.
Remove hydraulic tool and spanner and swing the holding angle 94273 with f.i. valve to a vertical position, (injection nozzle pointing downwards).
Fit the lightly oil smeared parts 18, 15 and 14 and screw in the spring tensioner 5. Do not tighten the collar nut 6 before the opening pressure is set and checked.
/f
L.B. 1.89
RT272/1d
Setting the opening pressure
Adjust the Li. valve in the test stand as described under "Testing an F.I. Valve" (Fig. 'B').
Move pump lever 'H' slowly up and down, while simultaneously tightening the spring tensioner 5 until the specified pressure (pI. refer to the test and timing records of the engine) is attained. Check then with a few short fast pump jerks whether the injection nozzle atomizes equally and thereby 'chatters'.
When this condition is reached, tighten the collar nut, thereby locking the spring tensioner.
Maintenance of injector test stand L'ORANGE
Depending on how frequently the injector test stand is used, grease must be pumped into the lubricating nipples ' S ~ ' from time to time.
Likewise, the two filters 'FL' must be removed and cleaned periodically or replaced by new ones.
\\Then cleaning the fuel oil container, do not use any fibrous cloth materials or cotton waste. Use only brushes and compressed air instead. Do not reuse fuel collected in the transparent plastic drip tray.
It is necessary to subject the injector test stand occasionally to a highpressure test. For this, close the connecting nipple with the steel ball and cap nut supplied. When pumping strongly - up to approx. 600 bar (left-hand pump) and 1200 bar (right-hand pump) -, the pointer of the pressure gauge in question should remain in the same position. Rapid pressure drop shown on the pressure gauge indicates leakage.
Fitting a fuel injector into the cylinder head
Before fitting a fuel injector into the cylinder head, make sure that the seat in the head is clean. If necessary, re-condition this seat with the tool supplied with the tool kit (see sheet 271/4). The sealing must be metallic, i.e. no joint whatsoever may be fitted.
Procedure:
- With a new O-ring on the nozzle holder, carefully fit the fuel injector into the cylinder head.
- Press down the fuel injector evenly onto its seat with the two Allen screws. The correct tension has been achieved when the had of both Allen screws is level with the nozzle holder (see detail on Fig. 'a').
SN
0776 3380-16
L.B. 12.85
2
SULZER Group:272FUEL INJECTOR
RT Cleaning and Overhaul Sheet: of Injector Nozzle
Too 1s: Key to Drawi ngs
Case cont.Special 94280 1 Nozzle body a ~ positioning holes c channel for circulating
tool s 94281 94285 2 Nozzl e needl e b drill ings for fuel f ue1
Face pl ate 94286 3 Needle seat f sealing face
3a Nozzl e head } 4 Backi ng sl eeve f 2P 1
or nozz e
o 5 Cap nu t
Injector nozzles which no longer atomize perfectly may not be used again. It is often sufficient to clean them thoroughly to
Needle lift 'N' fully restore them. If this proves insufficient, the nozzle ha
to be repaired. Unskilled handling renders a nozzle useless. We recommend, therefore, that such nozzles be sent to a specia
list firm or to the manufacturers.
Cleaning Injector nozzles
Remove carbon deposits from the outside of the nozzle with the wire brush 94284.
Carefully clean carbonedup spray holes by hand, using a drill 94285 which should be 0.025 mm smaller than the nominal diameter of the spray holes. Once all spray holes have been cleaned in this way, tap the nozzle with its sealing face pointing downwards against a piece of wood or lead so that the deposits fallout. Thoroughly wash the nozzle with paraffin, gas oil, perchlor or similar and blowout with compressed air. If further cleaning is necessary in the interior of the nozzle, a me-tal object may never be used. A wooden dowl rod covered with a piece of cloth is the most suitable thing to use for
this purpose. With a clean nozzle, the nozzle needle (after having been dipped in clean paraffin or gas oil) should slide onto its seat under its own weight.
Checking Spray Holes
Check with the plug gauge 94286 supplied that the spray ho-
les have not been scoured out excessively. If the plug gauge can be inserted into one of the spray holes, the nozzle is
a to be sent to a specialist firm or the manufacturers for"re-placement of the needle seat.
Reconditioning of Injector Nozzlesb Should careful cleaning of the nozzle not suffise to resto-re its serViceability, although nozzle needle, needle seat
as well as spray hole diameters are in order, or should the needle lift IN' (the<measure engraved on the nozzle body) have increased by more than 0.1 mm, the nozzle must be re-conditioned by a specialist firm.
a
Should any damage show on the sealing face If I this must be
lapped at right angles to the bore of the needle guide, on the face plate 94288.
2
Spray Holes>Spritz/6cher
f
1
3
c 3-107.195.530
272/20 RT
Alternativ - AusfiJhrung : 2P- DiJse
ALTERNATIVE DESIGN: 2 -PIECE FUEL NOZZLE
Node/hub 'N'
NEEDLE STROKE
DicMflache 'f'
JOINT FACE
1
2
I
o
b
a
1986 10
5
30
Spritz/ocher
SPRAY HOLES
c
3
~
~
SULZER FTJEL INJECTOR Group: 272
RT Lapping of Injector Body Sheet:Contact Surfaces
Tools: Key to Drawi ngs
1 Lapping disc 94281 23 Nozzle holder 1 Copper dri ft 94282 3D Hardened bush
No te 1 Withdrawing device 94283 Tools only delivered
for locking pin under separate order Lapping powder 94287
1 Lapping plate 94288
Rough or slightly deformed nozzle holder sealing surfaces have to be reconditioned. If the surface is only slightly worn, reconditioning by lapping in is insufficient. In more severe cases, however, it is necessary to grind the contact surface by machine and then lap it, making sure that the seat is at right angles to the axis of the nozzle holder. After the contact surface has been machined, the hardened bush in the centre of the injector body must be approx. 0.02 mm below the face edge. This is obtained by grinding the bush with only very little of a fine grinding paste using a drilling machi ne and the copper drift94282. {A disc punched out of fine emery cloth may be used in place of the grinding paste (see Fig. 'AI overleaf).
Before starting to lap the contact surfaces, check the faces of the lapping disc 94281 for flatness. Where necessary, lap them in on the castiron lapping plate 94288 with lapping powder/paraffin (kero- sene) mixture until flat.
After having been a long time in service the contact surface of an injector body will be slightly con- vex (arched outwards). The centre area must, therefore, be lapped in first with the small lapping disc (Fig. IB').
For checking the contact surface to be lapped in, use the dry, special bronze check disc 94283. From time to time this disc has to be checked for flatness on a dressing plate. Since the check disc is made of bronze, the contact spots appear slightly yellow (Fig. 'C').
The lapping disc works more effectively where it is pressed by the thumb. Rotating should therefore be done over the whole surface during lapping.
As soon as yellow spots are visible on the whole contact surface when checking with the check disc, the reverse side of the lapping disc, which has a greater diameter, should be used to finish. lapping the face (Fig. '0 1
). Care should be taken not to rotate too far over the edge of the face in order to prevent it from becoming convex. The final face must berchan, smooth and flat or slightly concave (arched inwards), but never convex! During the last check, contact spots should be visible everywhere on the contact face with the excep-tion of the hardened bush.
After lapping, the injector body must be washed with paraffin or similar and blown out.
Diameter of lapping tools in mm
da eb c
548 4615 40
1982
272 3a
I 94281
8) ®
/
94283 94281
t: E
81==~;;r-"""'--~~7-l7-...r-7'-' C)
®
~300 mm
Should the dressing plate have become uneven,
it must be planed flat again and given a surface profile as shown in Fig. lE'
I
'"
SULZER
RT
F U ELI N J E C T ION V A L V E
Testing a Circulating valve
Group: 272
Sheet: 4
Tools:
Fuel injection valve test stand l' ORANGE Mounting angle bracket Testing device Hose pipe
094274c
942
94272
94273 94274c 94275
Key to III ustrati ons
1 Fl ushi ng val ve la Valve spindle to item l. 2 Screw cap (for engines RT58,-68,-76,-84,-84M) 3 Screw cap (for engines RT52,-62,-72)
4 Connnecting PieCe} 5 Needle seat of circulating valve 6 Needle
I S' Val ve seat
94272
B
94275
MA
4 - 701. 240. 729
For testing the good function of the circulating valve belonging to the fuel injection valve, the 1'ORANGE fuel injection valve test stand tool No. 94272 has to be used.
For this the outlet opening 'B' (see illustr. 'A') is utilized the which are allocated pumping lever 'H' and pressure gauge MA. (0-600 bar).
Working Seguence for testing the Function
- Mount testing device 94274c onto mounting angle bracket 94273 of the valve test stand and fasten it fi rml y thereon.
- Remove compression spring from the circulating valve, then screw circulating valve in to the testing device (illustr. IBI) carefully and without a packing and tighten it firmly with a spanner.
- Seal the connecting piece 4 with screw cap 2 or 3 depending on the circulating valve to be tested, tighten screw cap well as the sealing is achieved also here metallically.
- Coupl e HP hose 94275 on outl et openi ng 'B' and joi nit to the testi ng devi ce 94274c. After ti ghteni ng up the connecti ons open the fl ushi ng val ve 1 sl i ghtl y by spi ndl e 1a.
L. B. H .88
272/4a RT
Actuate pumping lever IHI till the pressure spaces are filled and the Diesel fuel flows bubble free
down from the check drilling in the testing device.
Shut the flushing valve with the spindle lao
Continue actuating pumping lever till the pressure gauge indicates 600 bar.
To be certified as "GOOD" the raised pressure of 600 bar should not drop below 100 bar ~ithing 30 sees.
If this is not the case, the reason is a leaking valve seat 'SI, the needle guide has become too
wide in the needle seat 5 or because the screw cap seals insufficiently. This can be immediately checked by leakage from the check drilling.
For the reconditioning to perfect function the defective circulating valve must be handled in an authorized workshop where the correct needle running clearance is restored.
@
'5'
~ . . l ~ - - - : , : , : : : : : : : ~ - r - - - - D r u c k f e d e r ausgebaut SPRING TO BE REMOVED
Kontrollbohrungen
CHECK BORE HOLES
4-107. 240.130
L. B.
1
2 r~
101
1
9
6
7
8
3
19
SULZER STARTING VALVE Group: 273
RT76 Cleaning and Checking Sheet:
o I-I20
l1I1
R
1
I
Tools:
1 Special spanner head 94293
1 Spring tensioning device 94294
2 Jack screws 94296
Grinding paste (medium, &fine) Cleaning kerosine.
Key to III ustrati ons
1 Stud in the cylinder head 2 Nuts 3 Guide bush in the cover 4 aRing for bush 5 Oring for casing 6 Cylindrical dowel pin 7 Spindle guide 8 Valve seat 9 Joint ring
10 Cyl i nder head
11 Valve spindle 12 Casing 13 Bush 14 Piston rings 15 Ring 16 Cover 17 Piston 18 Rod seal 19 Compression spring 20 Spring plate" 21 Castellated nut with split pin
22 Screw A Threaded holes for tool 94294 R Eye screws S Clearance
H,J Control Air pipes
If functional defects are noticeable on a starting valve during starting or manoeuvring, or with the engine in operation a starting air pipe feels noticeably hotter, near the connection to the cylinder, than the others, the respective starting valve must be dismantled at
the next opportunity and retified.
If no such problems occur, it is recommended to dismantle for checks yearly one starting valve after the other, the intervals depending on the condition of the parts, and to rectify as found necessary.
19R4
-----------------------------------------------------
273/1a RT76/84
Di smantl i nq a Starti nq Ai r Val ve.
(called Valve in the following Text)
Remove control air pipes 'H' and IJI from the valve and remove the nuts 2.
Attach valve with eye screws 'R' to crane and lift out. ® If this is not feasible with little effort, loosen and remove the screws 22, fit the jack screws 94296 in their place and jack the valve out of its guide in the cylinder head. Remove the jack screws 94296, fit the, screws 22 and tighten them. The val ve
can now be pulled out by the crane.
Remove the joint ring 9 and close the opening in the cylinder head temporar-
ily to prevent any foreign matter falling into the combustion space.
Place the valve on a work bench and start dismantling. Use spring tensioning device 94294 to compress the spring 19 as shown in Fig. 'B' to relieve the valve spindle 11.
Remove the split pin and, holding the squa- re spindle head steady with another span- ner loosen the castellated nut 21 and re- move it.
Relieve the tension device 94294 and remove the screws 22.
After ectracting the cylindrica dowel pin 6, remove the spindle 11 downwards and the other parts of the valve including the spindle guide 7 upwards. If necessary the valve seat 8 can be screwed out of the casing 12 with the special spanner head 94293.
Clean all the parts, refit the valve seat 8 with its copper joint 9 and the spindle guide 7, upend the valve casing 12 and lap in the spindle 11 with a little grinding paste on the valve seat 8.
If the valve seat has been lapped several times or even machined the clearance lSI must be established as it diminishes with each rectification of valve seat or valve spindle. In an extreme case the valve con no longer shut.
The clearance'S' must be minimum 1 mm (see Fig. 'A')
The clearance con be established by making a wax or lead impression between piston 17 and ring 15 while assembling the valve. This entails loosening the screws 22 once more and removing some of the parts.
Assembl
Clean all the parts and smear them with clean engine oil.
The threads and the locating face of the valve seat must be lubricated with a highly heat resisting lubricant such as THREAD GARD; or LOCTITE ANTI SEIZE COMPOUND:
The assembly is done in reverse sequence to the dismantling procedure.
5.84
273/1b RT76/84
Only new Orings may be used for the assembly, Concerning the correct dimensions and quality ~ specification please refer to the indications in group 015.
The valve spindle being subject to high stresses during operation it is necessary to prestress it somewhat. This is acieved by first tightening the nut 21 until its firmly seated, then holding the
square spindle head with another spanner, tighten the nut 21 by an angle of 90 0
Important! The nut tightened in this manner may under no circumstance be loosened to fit the split
pin, as the prestressing would be partly lost. In such a case tighten the nut further, while holding the square head of the spindle steady. The valve spindle must under no circumstance slide on the valve seat as this would damage the seat surface.
After completing the assembly check the easy movement of the spindle by tapping several times with a lead pig with medium force on the upper end of the spindle in the spindle axis. The valve spindle
must then each time spring back on its seat.
5.84
1
SULZER Group: 274RELIEF VALVE FOR CYLINDER HEAD
RT Dismantling, Assembling and Testing Sheet:
Too1s: Key to Drawings
Injector test 94272 1 Spring tensioner 9 Valve body 16 Closing union with stand L'ORANGE 2 Distance ring 10 Vah"a seat protecti ve cap Mounting 94273 3 Nut 11 Cyl. head 16a TREDO Seal Rl/4" angle bracket 4 Studs 11 a Copper joi nt 17 Pump lever Flexible hose 94275 5 Round rubber ring 12 Nut 18 Highpressure (1500 bar) 6 Housing 13 Tie rod hose Testing head 94276 7 Compression spring 14 Testing head 19 Stop 1ever Copper joi nt (for 94276 ) 8 Spring plate 15 Connecting union e 38 x a 24 x 1 II
2 Jacking screws M12 Various spanners
o ~--1
,..2 All the cylinder head relief valves are to be removed fro. the cylinder heads at inter-
- W : u J : ~ ~ w : E ; : : : : - - - 3 vals of approx. 68000 running hours -earlier, if necessary with the two jacking
1eE=4 screws M12 and checked for absolute ti ght-ness and correct opening pressure, with the
1 1 + " " d - J . ~ ~ - 5 aid of the injector test stand. Even if the opening pressures are still cor- rect, it is advisable to check a few relief valves at random and, depending on the con-
I ~ ' > " ' - - - - 6 to onesdition found, check the remaining too. The correct 0 pen i n g pre s sur e is marked on the rectangu-lar flange of the valve housing and given in the setting records of the engine.
7
..+/--"'-----8
~rt~~i1l+_"_--9
:::N-<'~---..::-----,-----10
110 ~ - - - - 1 1
Gezeichnet fUr RT 58
DRAWN FOR RT 58
2 -107.195" 511
L.B. 2.87
274/10 RT
1
94273
@ 12
2
13
9
10
110
14(94276) 16 18(94275)
Gezeichnet fur RT 58
DRAWN FOR RT 58
1-101.191.081
2.84
18
19
17
274/1b RT
Dismantling and assembling
@© 1
2
94273
(94275)
14 (94276)
16
15
0776 3380-4
Procedure for dismantling
The relief valve, clamped in the test stand according to Figs. 'B' and 'C', is moved into horizontal position.
Unscrew spring tensioner 1 and remove spring 7 and spring plate 8.
Clamp valve housing at the rectangular upper part in the vice and unscrew valve seat 10. After that. the valve body 9 can also be removed.
All components should be thoroughly cleaned and checked.
a
® -- I
2- 107.125. 231.
1985
Pro c e d u r e for G r i n din 9 j n
Valve seats whose contact surfaces are in bad condition are best reground by machine, aiming at the
following angles:
Seat of valve body 9 _ 44° Seat of valve seat 10 _45 0
Valve seats which are only slightly damaged, however, can be reconditioned by grindingin by hand, following the procedure below (Fig. 'Ell:
Clamp valve body 9 into a bench vice. Using a small pointed stick, place a few dots of grinding paste onto the seat of the valve body, towards the greater diameter (Fig. 'E'/'a'l.
Put valve seat 10 onto valve body 9 and turn valve seat backwards and forwards. Clean the faces se-veral tiles and repeat the grinding process until a r.elatively narrow, shiny band towards the smaller diameter indicates the contact area (Fig. IE'/'b').
Finally thoroughly clean valve seat and body.
Pro c e d u r e fo r Ass e III b 1 i n g
Thoroughly clean all cOlponents and lightly oil them.
Coat valve body 9, the landing faces of spring 7 and the threads of spring tensioner 1 with Molykote '..../ paste G.
Use a highte.perature resistant lubricant, such as THRED GARD or LOCTITE ANTI SEIZE COMPOUND, for coating the threads of valve seat 10. (These lubricants can of course also be used for the parts lentioned above).
Clalp the relief valve at the rectangular upper part in the vice and screw the valve seat 10 with valve body 9 fitted into the housing 6 and tighten firlly.
Place relief valve vertically into the test head 14 already screwed into the lounting angle bracket of the test stand and firMly tighten with nuts 12 (Attention! First insert copper joint 11 into test head ).
Fit spring plate 8 and spring 7 and screw in the spring tensioner 1 at first without distance ring 1 until the distance to the valve housing corresponds approximately to the thickness of the distan ce ring.
Pro c e d u r e for T est i n g
Connect highpressure hose 18 to connecting union 15 of the test head (see Fig. ICll and operate ~ pump lever 17 until the relief valve opens (check the opening pressure on pressure gauge).
Dependi ng on the openi ng pressure found, further ti ghten or loosen spri ng t.nsi oner 1 until the cor-rect opening pressure has been established.
Now measure the distance between the spring tensioner 1 and the valve housing and prepare a distance ring 2 of corresponding thickness.
Unscrew the spring tensioner and insert distance ring. Test relief valve once again.
Fitting the Relief Valve into the Cylinder Head (see Fig. IAll
Before fitting the relief valve, thoroughly clean the bore and contact surface in the cylinder head. Make sure that no foreign matter enters the combustion chamber when carrying out the work with the cylinder head fitted.
Fit the relief valve with a rubber ring in perfect condition and place a new copper joint onto the contact surface in the cylinder cover. Coat the outside of the valve housing with a little grease or oil to protect it against rust.
Coat the threads of the studs 4 with Molykote paste G and, after fitting the valve, very firmly tighten the nuts crosswise and in even stages.
5.84
SULZER Group: 275EXHAUST VALVE
RT76 Sheet: 1Removal and Fitting of the Exhaust Valve
Tools: Key to Illustrations
Hydr. Pretensioning device 94252 Valve protection 94262 Pneumatic impact wrench 94264 Suspension device 94266
2 Jack screws 94267 1 HP Oil pump or 94931 1 AirHydraul ic pump 94941 3 HP hoses 95935
o
./ " 93 t'
~ - - ) .
4-107. 197, 676
Gezeichnet fur RT 58 DRAWN FOR RT 58
1 Wai sted stud 6 Upper casing 2 Nut 7 Casing to hydraulic part. 3 Valve seat S Cylinder head 4 Valve cage 9 Soft iron sealing ring 5 Air cyl inder AF Seating surface
housing R Round bar
After disconnecting the flangedon pipes and loosening the four nuts holding the exhaust valve to the cylinder head the exhaust valve can be lifted out as a complete unit with the crane and the suspension device 94266.
Should the valvm cage be jamming in the cylinder head (due carbon formation), two jack screws (94267) have been pro-vided. Insert these in the threaded holes on the valve ca-ge (see 270/1, Fig.'A') and jack the valve cage out of the cylinder head.
Remark:
Follow the instructions on sheet 940/0d on the utilization of hydraulic pretensioning jacks on screw fastened con-nections.
Instructions for TQosening and tightening the bolts with a pneumatic impact wrench (which is an exceptional case), see sheets 275/1c and /d.
Concerning the draining of the cylinder cooling water
please be guided by the instructions in group 270 Cylinder head, section 'Removal'.
Working Procedure for Removal
Set the hydraulic pretensioning device 94252 consisting of four hydro jacks and straps onto the waisted studs (Fig. '8') and screw them on until their casings are seated on the valve cage 'AF'.
Connect the jacks to the HP oil pump (or air hydraul ic pump) with the HP hoses 94935 and 94935a as shown in Fig. 'C'.
Set oil pressure on the pump to 600620 bar and keep it constant until the nuts 2 (Fig. 'C') have been loosened with the round bar 'R'; set oil pressure to zero.
Unscrew the pretensioning device and remove it. Remove al so the nuts 2.
Hook the suspension device 94266, hanging on the crane, into the eye screws on the valve cage and lift the ex-haust valve out.
If the exhaust valve is not dismantled immediately on
the spot, the valve protection 94262 must be fitted (see Fig. '0') and the valve stored carefully away.
11 R"
275/1a RT76/84
R
AF 1-1
® Working Procedure for Fitting
Before inserting the exhaust valve in the cylinder head attend
to the following points:
The seal ing surface in: the cy1 i nder head as well as on the ex haust valve must be clean and undamaged.
The soft iron joint ring of 2 mm thichness set in the cylin-
der head must lie flat.
The arings 12 (Fig. 'B', page 275/2a) have to be replaced by new arings of specified dimension and quality, they
have to be smeared with clean tallow.
These preliminaries having been completed the complete ex- haust valve is attached to the crane with the suspension de- vice 94266 and slowly lowered onto the sealing surface taking great care that the thread of the studs is not damaged by
grazing.
Smear the stud threads with MOLYKOTE paste. 1
The correct position of the valve cage is determined by a cylindrical pin set in the cylinder head.
Remove the suspension device and fit the nuts 2 by hand onto the studs, check ease of threading.
Tension the studs with the pretensioning device 94252 and at
a pressure of 600 bar (see also group 013 sheet 1).
2
©
1-107.198.418
0- 107. 197.345
AF
5.84
RT7t).84275/1b
I-I ®
94262
3-107.197. 672
fi An
275/1c RT
Mechanical Slackening and Tightening of the Valve Cage in the Cylinder Head [~~s~~!i~~gl=s~~~l
Whenever possible, always slacken off or tighten up the valve cage waisted stud bolts using the hydrau-
lic tensioning device. This is to avoid any risk of uneven tensioning of the stud bolts which could lead to deformation of the valve cage.
The nuts of the valve cage waisted stud bolts may only be slackened or tightened with the pneumatic im- pact spanner (tool No. 94264) using the following procedure in exceptional cases, e.g. when the hydro tensioning device cannot be used.
Slackening
Mark two nuts lying diagonally opposite each other a+a according to diagram 'EI with paint and sla-cken them back only through the following angle with the pneumatic impact spanner;
EI~gi ne type RT 58 RT 68 RT 76 RT 84 RT 84M
4 60 0 60
0 60
0 60
0
Slacken off the other two nuts b+b (on RT 76 and RT 84 engines) fully and remove them. Finally ~
slacken off the nuts in several steps which had previously been turned back through the abovementio-ned angle.
Tighten ng
Thoroughly smear the bolt threads as well as the contact surfaces on the valve cage with MOLYKOTE pas-
te and screw down all the nuts by hand until metaltometal contact is obtained.
Now tighten them evenly using a spanner with a short, sharp jerk (by hand). Check their seating with a
feeler gauge.
Mark the '0' position on each nut and on the valve cage at a corner with a felttip pen or similar. Furthermore, mark the positions for the 1st, 2nd and 3rd stage beside each nut on the valve cage (for the relevant engine type) according to Fig. 'F'.
Place the socket head insert such that the '0 1 mark (on its circumference) lines up with the '0' mark on the nut as well as the valve cage.
Now tighten the two nuts and then the other two through 30 0
(=lst stage).
Finally tighten all the nuts through a further 4: 0 (=2nd stage and 3rd stage) as required by the cor-responding engine type. The relevant values can be seen on Fig. 'F'.
'"
275/1d RT
® RT58 u. 58 RT75 u. 8'
a a
a b
®
RT 76 150 o_.- ~
8'
4 107. 199.585
L.B. 1984
275/1e RT
Remark: Replacement of waisted Studs.
Should a waisted stud 1, of the valve drive, have to be replaced, (in the following text called stud for short),
then the following points must be observed:
Before fitting the stud 1 clean and degrease the threaded bore in the cylinder head as well as the stud thread.
(Use Perchlorate, Aceton etc.)
Screw in the stud with clean thread, without 'Loctite' right to the bottom, and tighten to 50 200 Nm.
Utilize always stud driver or 2 locked nuts. Tools like pipe wrench etc. which would damage the stud shank
must never be used.
For the protecting of the stud in the cylinder head, fill the ring space above the thread with a well adhering,
water and oil proof sealing compound (as shown in illustr. below) the sealing compound must remain plastic at
normal operating temperatures.
Should waisted studs for cylinder head, relief vave or starting valve have to be replaced, proced likewise for
sealing their ring spaces with the sealing compound, the properties of which were described above.
Recommended jointing compound and adhesive primers
Jointing compound No. of Hardener adhesive Manufacturer compount's primer
RTV ME 622A 2 ME 622B G790 Wacker Chemie AG, Sonnenhalde 15
CH4410 Li esta1
Po1astosi1 M56 2 OL1 P3 Product of Poland
Si1cosed 105 2 Aor 0 without Wachendorf AG type Auf dem Wolf 10
designation CH4002 Basel or OP
other equiya1ent products of further manufacturers may also be used.
4-107. 2l,(). 235
Dichtmit tel FILLING - COMPOUND
L.B. 12.88
2
SULZER Group: 275
RT EXHAUST VALVE
Dismantling and Reassembling Sheet:
Tools: Key to Drawings
Pretensioning jack 94251 1 Damping e1 ement 17 Retaining ring Retaining frame 94290 2 Vent housing 18 Bell evill e washers with swi vel devi ce 3 Housing head 19 Locking ring
1 Highpressure oil pumps 94931 (hydrau1 ic part) 20 Sight glass 1 Highpressure hose 94935 4 Piston 21 Distance sleeve 1 Feel er gauge 94122 5 Ba r re1 (hydr. cy 22 Nut
'1 Depth gauge 94124 1inder) with 23 Securing sleeve with bo 1t 1 Fitting and With- 94263 retaining ring and locking plate
drawing device 6 Sleeve 24 Piston ring 7 Cylinder 25 '0' ring
8 Retaining ring for piston 26 Piston sealing ring
sealing ring 27 '0' ring 9 Upper housing 28 Rod sealing ring
10 Air cylinder housing 29 '0' ring
lOa All en screws E Vent screw 11 Valve cage R Tommy bar 12 '0' rings B Shim ring
13 Valve spindle EX Tapped hole for jacking
14 Turning wings screw 15 Guide bush with rod seal 16 Sealing air throttle
The handling tool 94290 is used for inspection and dismantling of the exhaust valve. It accepts the comp1e te valve assembly after it has been removed from the engine and its swivel device allows the valve to be set to any position required. (See also dismantling sequence on illustration 'E' and 'Ff)
Dismant1in (order)
1. Sl acken off all four bolts whi ch c1 amp the housing head and lift it off the upper hous-ing 9 with the hydraulic part. The piston 4 remaining in the hydraulic cylinder 5 is held by the retaining ring and is therefore preven-ted from falling out.
2. Also slacken off housing 9 and lift it off the air cylinder housing 10 with the crane.
3. Slacken off sleeve 6 and lift it off the cy1 i nder.
4. By removing the bolt securing arrangement com-prising: bolt with locking plate and securing sleeve, the spindle nut which has to be loose-ned can be laid bare.
5. Screw the pretensioning jack 94251, Fig. A, onto the protruding threaded part of the valve spindle by hand until it rests against the dis-tance sleeve 21 without clearance.
Note: Please follow the instructions given on Sheet 940/0d for the use of hydraulic pretensioning jacks on bolted connections.
22-2 1 - - ~ / I 1
13 -----'<CAl
~ ~ - - R
2 107.197. 013
I R
275/20 RT
24
1.. --+ .-1
12
L.B. 11.84
Gezeichnet fur RT 84 DRAWN FOR RT84
2-101215.246
275/2b
5. Connect up the highpressure oil pump 94931 to the jack 9 4 2 ~ , 1 with a highrressure hose. Sl ightly
open the vent screw 'E' on the jack. Operate the highpressure oil pump and hOld the 'Jert screw
open until bubblefree oil escapes, then close it.
I Bring the pressure at the pump up to an indicated 500520 bar. The nut is now loose and, while '-.-/
keeping the abovementioned pressure constant, can be completely slackened off with tommy bar 'R'
and removed.
7. Remove di stance sl eeve 21, and cyl inder 7 after the other.
8. Separate the air cylinder housing 10 from the valve cage 11 by slacking off and removing the two
allen screws lOa and take it away.
9. Remove the twopiece locking ring 19 after removing the tension spring which surrounds them.
1O. Remove the retaining ring 17 with the Belleville spring washers let into it. Aslo pull out the rod
spindle seal inserted underneath in the guide bush 15.
ll. Operate the swivel gear on the valve handling device. Swivel the valve cage into the vertical posi-
tion (for removing the valve spindle upwards), still with its valve spindle. Where there is little
headroom, the valve spindle has to be removed horizontally (see Fig. 'G').
12. Remove valve spindle.
©
Removal and Fitting of '-107198.1.3'
guide bush if necessary
Ausbau DISMANTLING
94263 I
------- '
I
, 15 fn::=±=:vrI: /
. 11
2 107. 199. 574
@
I
l
Einbau ASSEMBLING
L. B. 11 ALL
RT275/2c
Reassembly
Reassembly follows in reverse order of dismantling.
Pl ease note: Carefully examine the condition of the piston sealing ring 26 (this is held on the air cylinder housing by retaining ring B) at every opportunity but at the latest when overhauling an exhaust valve according
to the maintenance schedule. Worn or defective piston rings as well as rod spindle sealing ring 28 mUST
be renewed.
Please follow the instructions given on Sheet 940/0d for the use of hydraulic pretensioning jacks on
bol ted connections.
Pressure necessary to pretension the valve spindle = 600 bar
_ Should an exhaust valve be fitted with either a new valve seat or spindle, the valve seat has to be le-velled beforehand every time in the installed condition using the available valve seat grinding m a c h i n ~
The instructions for this one given in Group 275/3.
_ In addition to this, at each exhaust valve overhaul, particularly after grinding of the valve seat and/ or valve spindle the valve damper 1 has to be removed. The dimension 'H' has to be determined using depth gauge (tool 94124) from the upper edge of the top of the housing 3 down to the bottom of the dam-per bore in piston 4. To do this, the exhaust valve must be closed. (Using the feeler gauge, check that the valve head sits on the valve seat without clearance.) The tnickness 'hI of the new spacer ring 'B' should be determined using the follbwing formula:
RT 58: h 150 H~0.5 ~
RT 68: h 180 H~0.5
RT 76: h 200 H~0.5
RT 84: h 220 H~0.5
RT84M: h = 220 H~0,5
Fit the damper with readjusted shim ring pack. Individual'e shim rings of thickness 1 mm are available.
_ On engines where a coarse filter is fitted between vent housing 2 and housing head 3, this must be
checked and cleaned after each overhaul.
@
L. B.
Gezeichnet fUr RT 58 DRAWN FOR RT 58
1. 89
275/2d RT
® Auslassventil - Zerlegungs - ~eihenfolge
EXHAUST VALVE - DISMANTLING - SEQUENCE
07853099-1 07853099-2
07853099-3 07853099-4
....
07853099-6 ~ J
07853099-5
L.B
275/2e RT
Schwenken der Vorrichtung SWIVELLING THE BENCH
o
07853099-8
Venti/spindel-Ausbau VALVE SPINDLE-DISMOUNTING
VERTICAL POSITION HORIZONTAL POSITION----,..,---- ,. , ~.4 4. '.- II~ _ Ji-
'r'
07853099-9
Schleifen des Venti/sitzes
07853099-10
GRINDING THE VALVE SEAT
07853099 -11
L.B. 1985
SULZER Group: 275EXHAUST VALVE
RT Exchanging and Grinding of Sheet: 3the Valve Seat'"
Too1s: Key to Oralliinos
1 Valve seat removal device 94260 1 Valve cage 10 Piston
1 Valve seat fitting device 94261 2 Ring halves 11 Piston sealing ring
1 Valve seat grinding machine 94278 3 Valve seat body 12 Rod sealing ring
1 Pilot 94278a 4 Clamping ring 13 Draw bolt
1 Holding strap 94278b (4piece) 14 '0' ring
1 Gauge 94279 5 Bracket AF Seating surface
1 Highpressure pump 94931 6 Clamping plate E Vent valve
1 Highpressure hose 94935 7 Nut L Clip
1 Feeler gauge 94122 8 Coupling union R Eye bolt
Engineers marking blue 9 Cylinder V Blocking valve H Hammer
Valve seats which have badly damaged seating surfaces or which have reached their wear limit as a result of being
reground several times, must be exchanged. It is best to have the valve cage sitting vertically when exchanging a valve seat (see Fig. 'C'). This is also
necessary for the following grinding with the valve seat grinding machine. The valve guide is not to be removed
when doing this.
As with all other maintenance work on the valve seat, the grind has to be recorded on the form "Ex_ haust Valve Record" No. 4107.044.0591/2. Form samples are enclosed at the end of Group 275 Sheets 3e/3f.
Removing a valve seat (Fig. 'A')
@
L
8---_-.I:':~-~ E-__
9l..."J ~ = = l : : : : : : i
1 0 - - ~ . 1 d 7 h + r , + r i + ' + ! J \ l 1 - - - - + . : ~ r ~ " y
1 2 - - ~ ~ ~ ~ = r l i
13--;:::::rL;:Zlt:L
1- 107. 197. 671.
94260 7
6
5
3
L.B. 7.87
275/3a RT
Insert both ring halves 2 of the valve seat fitting device 94251 into the groove on the circumferen-
ce of the valve cage 1 and bolt them into one ring.
Lead the valve seat removing device with clamping plate through the bore of the valve seat until
the support 5 lies on the ring.
With the aid of the nut 7 and a spanner, push the clamping plate 5 down as far as it will go. Simu1-taneous1 y the c1 ampi ng ri ng is pressed out radi all y and fi na11 y gri ps under the val ve seat wi th its c1 awed part.
Connect up the highpressure oil pump 94931 to the valve seat removing device with the highpressure
hose 94935.
Open the vent Screw 'E' slightly and, while operating the hydraulic pump, keep it open until bubb1e-
free air escapes. Now close the vent screw.
Increase the pressure at the pump until the valve seat has been pressed out of its seated location.
After swinging out both clips IL', lift the valve seat together with the removing device off the
val ve cage.
Fully release the oil pressure in the removing device by opening the blocking valve 'V' on the pump.
Slacken off nut 7 and separate the valve seat from the removing device.
Fitting a valve seat (Fig. 'B')
Set the valve cage in the vertical position, as for removal of the valve seat.
The bore as well as the landing shoulder for the valve seat in the valve cage must be thoroughly and carefully cleaned. Any unevenness or damage would result in leakage at the seating surface 'AF'.
Smear the bore which takes the valve seat in the valve cage with clean oil or a lubricant such as
Thred Gard, Loctite Antiseize Compound, etc.
Also smear the '0' ring 14 with the same lubricant before it is inserted in the groove in the valve
seat body. Use genuine spare '0' rings.
Push the valve seat into the bore of the valve cage as far as possible by hand then, with the aid of the fitting device 94261 (see Fig. 'B'), pull it in as far as it can go. Using feeler gauge 94122 check that there is no clearance around the circumference at the seating surface 'AFI. When carrying
out this check, the fitting device must remain fully tensioned, this also being necessary during
subsequent grinding of the valve seat.
2- 107. 197. 680
L.B. 5.84
275/3b RT
Finally c h p , c ~ .ith feeler gauge 94122 carefully a11 around surface 'AF' whether no clearance remains
anywhere.
Ilhen thi sis confi rmed, the grinding of the valve seat can proceed.
Grinding the Valve Seats
Valve seats must be ground only with the vaJve seat grinding machine. Grindingin by rubbing valve spindle head against valve seat with grinding paste must be avoided as a matter of principle!
Ilhen should valve Seats be ground in the Valve Cage?
A 1 way s when new valve seats are fitted to the valve cage.
When new or reconditioned valve spindles are fitted. An exception can be made if the seating sur face is neither worn nor damaged by corrosion.
When the seat surface on the valve seat is badly damaged through operation \lith heavy fuel oil. (11
pacts, corrosi on scars).
gezeichnet fur RT 58 gllzllichnet fur RT 38
DRAWN FOR RT 38
~ 2 7 1
9'278 b
@
0101. 199.661
~ ~ , Engine h hI i 1• ~n
.. • P 1 ----~--' j Type Chamfer angle Chamfer .idth
',:
mm mm
RT 38 15 0 15 0 6 6
RT 48 15 0 15 0 6 6
RT 52 15 ° 15 ° 10 10
RT 58 15 0
30 0
10 2 5
RT 62 J50 15° 10 10 hi
15° 30 °RT 68 10 3
RT 76 15 0 30° 10 3
T84/RT84M 15° 30 ° 12 4
6.86
DRAWN FOR RT 58
275/3c RT
~s an example, illustration IC' sho~s a machine rranufactured by "H~~GER" being used.
~hen carrying out grinding of the valve seat, care has to be taken to ensure that as little grinding dust as possible enters the valve cage or remains there. It is essential that everything the thoroughly clea~er
after completion of the work. ~
For the operation of the grinding machine we refer you to the comprehensive instructions supplied together
with the machine.
The object when grinding is to achieve as clean and as smooth a finished surface as possible.
When working with the grinding machine it is particularly important to ensure that this is well centered
within the valve guide. The chamfer in the valve guide serves as a fixed landing surface for the taper on the pilot (see details in Fig.ICI). Defore mounting the grinding machine carbon deposits must therefore be fi rst removed. ' Experience has shown that when grinding valve seating surfaces next to vibrating machinery or engines, chatter marks appear. This phenomenon can be successfully avoided when the valve cage is laid on a thick rubber mat during the valve seat grinding process. In general, grinding should never be done without such an insulating lever of rubber.
In order to prevent the grinding machine from turning during grinding, the holding strap 94278b is bolted to the side of the valve seat fitting devicej its forked end surrounds the handle thus holding the machine head.
On principle grinding can be done in both directions 4 - ~ • It is just the same recommended always to grind from inside out. For the finish grinding may only be done from inside, as only in this way the re- quired angle precision can be achieved.
o +2'Valve seat angle = 30 o
Amaximum of 3 mm may be ground off the valve seat. The state of wear can be checked at any time with the
gauge (tool No. 94279) together with a feeler gauge (see Fig. '0 1 ).
@ 94279
4 107. 198.426
®
Infeed Feeding speed of R.P.M. of wheel
of cutting depth whee 1 sli de head
Roughing: 0.1 mm (4 divisions on the gradua- 3.5 mm/min 7 ~ 9 ted collar)
F i n i s h i n g ~ 0.03mm (l~ divisions on the gradua- 1.0 mm/min 3 ~ 5 ted collar)
Attention! The mlnlmum infeed setting possibility on the graduated collar for finishing is 1 division. Never let the grinder run through wi~hout resetting! (chatter marks risk).
Bring the grinding wheel back to the starting position after every run through.
Dress the grinding wheel 1 to 2 times for each valve seat with the builton dressing device.
Grinding Wheels: 0 63 x 20 x 8 mm wide, material: noble corundum, grit size 80, soft (open structure). Recommended quality: Viturbin form 1 53A 80F 13VP mf, Makers: Schmirgelscheibenfabrik A
8400 Winterthur (CH)
'-"
275/3d RT
~fter the grinding, check whether the new or the reground valve spindle seat bears correctly in the
valve seat (see group 275, sheet 3), ~ p p 1 y some film of marking b1 ue to the spindl e seat and insert the
val ve spi nd1 e into the val ve gui de bush.
Rotate the val ve spi nd1 e 3 to 4 ti mes about 1/3 ci rc1 e to and fro. For thi s movement the spi nd1 e wei ght
may have to be somewhat reduced, either by the pull of a finely controllable rope lift or by lifting
the spindle a little from below, without this there is a risk of the seating seizing up! (Fig. 'E').
The ang1 e di fference (spi nd1 e seat/val ve seat) is so chosen that at operati ng temperature the val ves
bear from the outer diameter 501CO% (Fig. 'F' ), The bearing check should reveal that the valve bears on
the whole ci rcumference but on1 y on the inner di ameter. The ang1 e di fference can be checked on the ou
ter di ameter ci rcumference gap I S' by a feel er gauge (Fi g. I G').
Htention: Please follow the instructions on the assembling of exhaust valves in group 275/2c under
For mer
00
"Remark" concerning
seating check of the valve onto a wooden block! (ll1ustr.
not rotate the valve spindle
the
seat,
on
fitting of re-ground valves and/or
tap the valve spindle head with a lEI)
the valve seat face. as this carries seizure
valve
lead
seats.
hammer
risks
or with
for
a
the
steel
seating.
ham
®
4-107. 198.. 427
®
4 - 107. 198. 868
0,045 + 0,06511.
0,07 + 0,10 11111
0,10 + 0,12 11m
0,13 + 0,16 mID
En i ne
RT 58
RT 68
RT 76
RT 84
L. B. 7.87
19844107.044.0591
[\;
-JExhaust Valve Record (see also group 275 of Maintenance Manual) Sheet 112 \.nSULZER Crouhead Engine RTA
IIT""r...L..t;)co
Installation: Engine type: RT Engine builder: . Enqine No. : . .. .
Spindle identification ( location see sheet 2): ,)
21 2: Engine Temp.
No. I Da,e
Service hoursInspection Seat load bef.Turb.
(kW) Engine I Spindle
fOCI
Work performed on : 41 Findings 31
Spindle wear I Seat wear (mm) lmm)
Remarks: 1 )
21
3)
4)
Stamps, Markings, Maker, etc.
Average values recorded during preceding service period.
Sealing traces inside or outside / Deposits: soh, hard, oily, dry, colour, quantity, distribution / Spot marks / Blow·through traces: number / Blow·through channels :
number, breadth, depth and location / Stem surface / Others. If necessary, sheet 2 should be used too.
Cleaned, ground, repairers' reconditioning code. The wear has to be determined according to sheet 2.
Notes : A)
B)
C)
01
Every inspection has to be recorded. Sheet 1 should be used for one spindle / seat only.
Once a year, a copy of these records should be mailed to the below·ment ioned address.
This record has to be handed over to the authorized repairers when reconditioning work has to be carried out by them.
Records of valves ~ r a p p e d or remachlned to a different size are to be returned with a respective notice to the below·mentioned address.
SULZER Bros. ltd., OMSerVIce Dept., CH 8400 Winterthur, Switzerland
( ( ( \
( ( ( (
4107:044.0592 1984
[0
..J V1
"-IW .....,
Crouhud Engine RTA
Installation:
SULZER I
Sheet 2/2
Engine No. : Engine builderRT
Exhaust Valve Record (see also group 275 of Maintenance Manual I
Engine type:
Iii i
Spindle identification ( location see sheet 2 I :
I n~pection No. : Date: Place:
Findings of only one spindle / seat should
be marked on this sheet!
Spindle identification marked here
~ r > i n d l e
Seat
I
I '" -+ III I
Findings to be marked in red
To be mailed to:
SlA..ZER Bros. Ltd.
OM SeNice Dept.
CH-8400 Y r ~ ~ h u r
Switzerland
I ::::-
t>'
4
SULZER Group: 275EXHAUST VALVE
RT Grinding the Seating Surface Sheet:
on the Valve Head
Taa1s: Information concerning the grinding of valve seats in valve cages
are given in Sheet 275/3.Valve grinding machine 94291 Gauge 94292 All grinding and repair work carried out on the valve spindle Feeler gauge 94122 must be recorded on the Sheet "Exhaust Valve Record", Form number Engineers marking blue 4107.044.0S9 1/2. Form samples are attached as Sheets 3e/3f
at the end of Group 27S. 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 pocketing or corrosion have to be machine
reground. It is strongly recommended that a suitable grinding machine such as tool No. 94291 be made available. The following machine has proved itself well for valve grinding and can also be ordered ai-rect from SULZER, Winterthur. (Fig. 'AI).
Valve grinding machine type VKM 5 Manufacturer: L. Hunger
Grafelfingerstr. 146 08000 Munich
9'291
Seatinq Face Anqle on Valve
Engine Type RTS8 RT68 RT76 RT84
Angle 0< 300 +12'
+10' 300 +lS'
+13' 300 +17'
+lS' 300 +20'
+18'
Only sufficient material should be ground off the valve head 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.
For the operation of the grinding machine we refer you to the comprehensive instructions supplied together with the machine.
Good results have been obtained by using the following recommended grinding wheels:
Stone quality Supplier Cut/Feed Rate Coarse Fine:
EKl L. Hunger Cut Cut 80g8 vu 156 Grafelfingerstr. 146 approx. 0.025 mm approx. 0.01 mm
08000 Munich Feed rate
with automatic oscillation system
275/40 RT
®
A maximum of 3 mm lay be ground off the valve head. The wear condition can be checked at any tile
.
(Fig. 18') •with the gauge (tool No. 94292) and feeler gauge
. . . ~ .. ..'
Where the precise anQle reQuired has been obtai-
~ during grinding, a check with larking blue with the valve on the reground valve seat in the valve cage will show only a line of touch or a very narrow band (extent of contact) this start-ing from the smaller diameter (Fig. 'e').
See also remarks on Sheet 27S/3d regarding the valve behaviour at running telperature.
P1ease note: ~ va1ve spindle with missing turning wings may not be reground. The wing hub must be shrink fitted on the valve shaft by heating it to 480
0 C. Grinding lay first begin after
the whole unit has cooled dewn. 4 107 199. 684
L.B. 11.84
SULZER Group: 310
RT Measuring ~ r a n k ~ e f l e c t i o n s Sheet: 1
Tool s:
1 Di al gauge 94305
In order to ascertain whether the axes of the crank journals deviate from the theoretical shaft axis the crank deflections must be measured. When doing so the ship must be floating freely. Under normal circumstances, it should suffice to measure the crank deflections once a year. They must, however, be measured as soon as possible if the ship has grounded or after replacing the main bearing shells. The deflections have to be measured again approx. 100 service hours after replacing the bearing shell s.
Should signs of damage of the main bearings be found during inspection of the crankcase, the crank de-flections should also be measured.
Measuring is carried out using a crankshaft dial gauge (tool No. 94305) which, for this purpose, is inserted between the crank webs of the crank to be measured. When turning the crankshaft, the altered distance between the crank webs can be read from the dial gauge as this indicates any opening or clos-ing up. The smaller the variations the better the position of the shaft.
Measuring Procedure: (Indicator valves must be open)
With the running gear in place, the crank to be measured has to be turned towards B.D.C. until the dial gauge can be fitted next to the connecting rod at the position indicated. Pretension the dial gauge slightly and set it to non (see Fig. 'A').
Turn the crankshaft 'Ahead' with the turning gear and read off and note the readings shown on the dial 0
gauge at the crank positions 90 before T.D.C., at T.D.C., 90 0
after T.D.C. and before B.D.C. (dial gauge still next to the connecting rod). The last valve serves as a check. If the correct procedure has been followed, this should be back at nearly non.
Kurbel im 0. T. P CRANK AT T. D. C.7
o
{pt_._.~
9~305 3 -107. 159091
2.87
..L '._J10/la
The difference ( L,al between the indicated val ues at B.o.C. and T.O.C. shows the amount of crank
deflection during one revolution.
All influences which effect a temporary deformation of the hull and/or the engine affect the crank
deflection. These are for example:
loaded condition of the ship
engine cold or at service temperature
differing air/water temperatures
strong sunshine
The maximum values of 6a given are valid for all conditions independent of outside influences (see
Fig. IBI)'
Where values are measured which lie outside the maximum permissible limits, the cause has to be found and the necessary remedial measures taken (defective main bearing, engine support altered due to hull
deformation, loose holdingdown bolts, defective shaftline bearings, etc. etc.).
When measuring the crank deflections, ensure that the crank journals are fully seated in their
bearings.
Crankshaft deflection ggu~
[AO- oroc - oBOC I
t 0.6 ~--+----+-------t-+--+---+-j----t--+---,--j--T----t:;?rl
~ 0,5 f----f---I;
tlc:
! 0.4
.E c: o .~
~
.§. 0o ,1 <l
o o S2
5 • piston 5 t r o k ~ {m m J
1- 107. 197. 350
2.84
10
SULZER T O R S I C N A ~ VI5RATICN ~AMPSR Group: 313 Tak~ng a Silicon ~ l u i d SamnleRT Sheet: 2(Only applicable for Engines vith
Vi s cosi ty Vi ":;rat ~ o n :am ner;
Tools: Key to Illustrations
Large screw driver 1 Cl addi ng 7 Cam shaft C Sam p1e con t ai ner
Fl at caul ker 1a Hood 7a Coupl ing o Cover
1 Medi urn hammer 2/2a Casing trough a/Sa Spacer ring K Lock by centre Centre punch 3/3a Casing cover 9 Gyrating mass punching
assorted spanners 4 Rubber ring 9a Counter weight * Alternative execution
Torque wrench 5 Intermediate shaft 10 Rubber ring
140 560 Nm 6 Crankshaft end 11 Sealing ring
6a/ b Coupling bolts 12 Threaded plug
The service life of a vibration damper is largely dependent on the RPMrange in which the engine is
run. Wear of the inner parts as well as changes in the silicon oil properties can contribute to a reduction in the dampers effectiveness. By periodic examination of the silicone-oil the makers of the vibration damper can draw conclusions on its condition. It is therefore recommended to have the silicon-oil examined periodically the first time after about 35'-40'000 operating hours. Future intervals for examinations depend on the result of this first fin
dings.
Special sample containers can be obtained from the damper makers (see Fig. 'CI).
Remark on the Drawing of a Silicon-Oil Sample
In the casing trough 2/2a or in the casing cover 3/3a, two oil drawing holes are carefully closed and sealed with threaded plugs 12. Vibration dampers of very recent manufacture will be equipped with two each withdrawing points on either side, so that the samples can be taken on the side of best accessi
bil ity. Vibration Damper on the free Crankshaft-End
2 1 11
® 12
9a
6a
, ; , I
--~ +---+--+---H----1lt- 6 I· -.U!---Jt--i
I 'r----D
6b
8a 8
9
3 o-107 156. 793
? n
313/2a RT
Vibration Dampers on the free Camshaft End
o 11
® I-I
7 12
10
30
1 -107. 197. 323
12·
gezeichnet fur RT 58 5 70 DRAWN FOR RT 58
Preparations:
Remove the hood la or cover 10' respectively.
Rotate the crankshaft or the camshaft until one of the closing plugs 12 on the sample drawing side chosen, is in the best accessible position. [Fig. 'BI)
Pay attention to the vibration damper maker concerned!
Usi ng a fl at caul ker, hammer back the squeezed materi al in the slot, whi ch serves as locking means.
Loosen the threaded plug, but do not Unscrew it yet, it must still seal the oil in.
Rotate the crankshaft or camshaft respectively until the chosen and prepared oildrawing opening
reaches the bottom most point.
Leave the damper in this position for at least two hours. [If the oilsample is to be withdrawn from a removed vibration damper the same conditions apply as regards the positions and the waiting time). In both cases the vibration damper must have cooled down to about room temperature.
Prepare the sample container, i.e. remove the screwcap and examine the bore which must be meticulously clean. Attention! The threads on the two ends are unequal on the Holset-oamper [see Fig. Ie').
2.84
313/2b RT
Drawing a Sample (see Fig. 'AI)
Arrange the prepared Oildrawing point to an easily accessible position by rotating the crank-
-~ or cam shaft respectively.
Unscrew the threaded plug 12 and in its place screw in the readied sample container.
Wait till the siliconoil flows out of the open sample container end. Depending on the viscosity
of the siliconeoil this may take some time. The process can be accelerated by the following:
-I) Rotate the damper that the sample container is as low as possible.
2) Remove the second threaded plug 12 for a short period.
As soon as the siliconeoil begines to flow out, close the samplecontainer with the one screw-
cap.
Unscrew the sample container from the damper casing (hold vertically) and fit immediately the
threaded plug 12 with a new seal ring 11. Avoid unnecessary leakage of silicone oil!).
Fit the second screw cap on the sample container and finally tighten both moderately.
Tighten the threaded plug 12 with about 2.5 mkp (18 lb.ft) and lock it by caulking metal into the slot.
Attention! The special sample container permits to draw a specific quantity of silicone oil from the damper. The total number of samplings should be limited at 10 times.
The filled sample container has to be labelled and sent to the following address for examination:
Carl Hass & Wrede GmbH or Holset Engineering Co. Ltd. Mohriner Allee 3042 P.O. Box A9 Turnbridge 01000 Berlin 47 West HUDDERSF I ELD HDl 6RD
Germany Great Britai n
The label must contain the following information:
Engine Type, Engine No. Number of operating hours
of the vibration damper, also its manufacturing serial Number (this number is stamped into the cover in the vicinity of the warning shield).
2.84
313/2c RT
©
Proben Behdlter / Sam~/e Container
I
, Hasse g Wrede Ho/set
3/8"BSF
Ml0x 1 c
C
MlOxl
1 12 11
K
4 -IC':' 159065
2.84
SULZER Axial Damper
Group: 314 RT
Dismantling and Assembling
Sheet: 1
Tools: Index to illustrations
1 Feeler gauge 94122
1 Suspension bracket 94312 1 Crankshaft 22 Oring
1 hydro pretensioning jack 94313 2 Dri vi ng shaft 23 Dowel pin
1 High pressure pump 94931 3 Bo 1ts 24 Ora in screw
1 Pressure gauge 94932 3a Locking wire (0 3mm) 24a Copper sealing.ring
1 Connection stud 94933 4 Locating bol t 25 CYlinder}26 Piston hydro pretensioning1 High pressure hose 94935a 5 Dowel pin 27 Disc jack, tool Nr. 94313
1 Pair of pliers 6 Guide bush
1 Flat chisel 7 Eye bo 1t 28 RestrIcting nozzles
1 Light hammer 8 Cylinder 29 Tapered dowel pin
1 Heavy hammer 9 Bolt 30 Spring dowel
1 Closed wrench (Type 330) AF65 10 Bolt 31,31a Pressure setting valve casing
Various open end and ring spanners lOa Locking wire (0 2mm) 32 Oil distributing casing
Various Allan wrenches 11 A11 an screw 33 Pressure setting screw
12 Bolt 34 Fl ange
13 Ring 35 Bo 1t
14 Leakageoil collecting
casing E Venting pipes
15 Bolt L Leakage drain pipe
l5a Locking wire (0 2mm) S Oil feed pipe
16 Tension bolt R Round bar
17 Nut V Pressure releasing valve
18 Locking disc VV Venting valve
19 Sealing rings W Tapped holes for tool 94312
20 Pi ston Setting distance
21 Piston running ring (2part)
DIS MAN TLIN G
_ Stop lubricating oil ~ump before starting dismantling work.
_ Remove drain screw 24 to drain the oil,and when oil stops flowing replace screw with sealing ring 24a and
tighten it. (The oil is to be collected in a container and poured back into the oil systeml _ Remove venting pipes "E", leakage pipes "L" and oil feed pipe "S" from the axial damper. The openings on pipes
and damper housing are to be blanked off to avoid dirt from entering.
Loosen bolts 12 and remove leakage collecting casing 14.
Connect crane to eye bolt 7 by a rope. Take weight.
_ Extract tapered dowel pins 29 (Fig.ICI) by means of a threaded bar with nut M12.
Loosen and remove bolts 9.
Move cylinder 8 away in axial direction (weight is approx. 500 kg).
In case the piston 20 needs to be removed, the bolts 15 and locking disc 18 must be removed.
_ The crankshaft is to be turned to such a position that the two tapped holes "WI! (Fig.JAI) are on top.
_ Screw the hydraulic pretensioning jack 94313 onto the tension bolt 16 until its cylinder 25 is hard against
ring 13 and then turn it back a half a turn (Fig.'B').
_ Connect pretensioning jack and high pressure pump with the high pressure hose 94935a and tension the tension '' bolt with 600 to 610 bar pressure which is required to loosen nut 17. Unscrew the nut one full turn and remove
pretensioning jack after having released the pressure to zero.
L.B. 1984
J14/1a RT
Remove nut 17, ring 13 and the outer seal ing ring 19.
Fit the suspension bracket 94312 onto the piston 20." For this the tlO bolts belonging to the bracket are to be ~
screled into the tapped ho Ies "1'/" (F ig. 'A' and '0')
Connect suspension bracket 94312 on crane hook lith a rope and take leight.
Extract dOlel pin 5 and remove Allan screws 11 (use extracting device M12 as per sheet 9406).
Remove piston in axial direction (weight approx. 350 kg). If necessary assist by pushing lith length of lood placed betleen piston and casing.
ASS E MBLIN G
Assembling occurs in reverse sequence to dismantling, paying special attention to the folloling points:
It Badly lorn sealing rings 19 or piston running ring 21 are to be exchanged lith nel ones.
It Orings should principally be replaced lith nel ones. 4t Bolts 10 and 15 must be tightened and locked lith lire of 2 mm diam. (see viel I and IV of Fig. 'A'). The locking of the bolts is to be done in such a lay that the lire crosses""just in front of the dOlel pins 23
in order to lock them also.
4t Just prior to fitting, the folloling items must be smeared lith clean oi 1: Guide bush 6" (bore), piston 20, piston running ring 21, sealing rings 19 and cylinder 8 (bore).
It Piston running ring 21 and sealing rings 19 must be free Ihen fitted.
Pretensioning of tension bolt 16
Fit guide bush 6 and tighten bolts 10. Lock the bolts lith lire of 2 mm diam and then fit the inner sealing
ring 19.
After the piston 20 is placed, tighten the Allan screws 11 and then screw nut 17 onto tension bolt 16 and tighten
it lith a spanner or round bar 'R' until it is hard against ring 13.
By means of a felt pen or suchlike,a mark has to be made on one corner of the nut and a str~ch mark on the
place but on ring 13.(This is done to check the tightening angle later).
Screl the hydraulic pretensioning jack 94312 onto the tension bolt 16 until its cylinder 25 is hard against
ring 13 (Fig. '8').
Screl connection stud 94933 into the connecting nipple of the jack and connect it lith the pump using a high
pressure hose 94953.
Close pressure releasing valve 'V' on pump 94931 and lightly slacken the venting valve "VV" on the jack.
_ Operate high pressure pump until airfree oil escapes from the venting valve and then retighten ~valve 'VV'.
Apply pressure of 600 bar and keep this constant until the nut 17 is screled on hard against ring 13 (Check
seating lith feeler gauge). Only then stop pumping and open pressure releasing valve "V" on the pump.
Remove pretensioning jack and check the angle of displacement of the nut by checking the marks initially made.
This should be approx. 70 o•
. In case of great deviation slacken the nut again and repeat pretensioning procedure.
If pretensioning is correct,place locking disk 18 over nut 17 and tighten it lith the bolts 15. Finally lock the. bolts in pairs using lire of 2 mm diam. (see view I, Fig. 'AI). "
Mount the remaining parts and connect all the oil pipes lith the damper.
L.B. 1984
'/
314/1b RT
Tightening of bolts 3
In case the bolts 3 were removed for some reason, retightening has to be carried out as fol lows:
Smear some oil onto threads and contact faces of all bolts 3 and screw them in by hand.
Take a closed spanner (Type 330) and tighten them only by a jerk (= 1st stage). Do not use extension or
a hammer!
Mark the position of each bolt with a felt pen or suchlike.
Finally tighten the bolts crosswise with the same spanner but this time with blows of a hammer until the bolts
are tightened through an angle of 15 to 200
(2nd stage).
Lock the bolts in pairs with wire of 3 mm diam. (see view III, Fig. 'A').
C ~ f C K I N G T ~ E RESTRICTING NOZZLES
It is recommended to check the restricting nozzles 28 after 12 to 15000 running hours. This is to be done while the engine is stopped. The drain screw 24 must be removed and the oil drained from the axial damper. The collected
oil is to be returned into the engine.
Remove the oil feed pipe'S' and the oil distributing casing 32 from the cylinder 8 and check the restricting
nozzles for signs of errosion or cavitation damages.
After checking them the drain screw 24 together with gasket 24 must be replaced and tightened.
SETT ING SCREIIIS 33 (see Fig.'C', section IIII, sheet 314/ld)
The position of the setting screws 33 was determined by specialists during sea trials, wherefore special measuring
instruments were necessary. To avoid any intentional or unintentional displacement of theses screws they were
locked with welding spots ('illS).
T~E POS IT ION OF T~E SETT ING SCREIIIS MUST ON NO ACCOUNT BE ALTERED!
In case the screws must be replaced with new ones however no instruments to measure the axial vibrations are
available the new screws must be screwed in so far that the distance 'a' corresponds with the dimensions which
were engraved or punched onto the cylinder of the axial damper casing. The distances mentioned were obtained and
marked by the personnel responsible for the setting. Should the distance 'a' not be marked on the cylinder, then tt must be measured in any case before the screws are
displaced. New screws must then be reset according to the distance obtained.
L.B. 2.86
roo I I~ CXJ
"-...... C')
o 9'313
I L __ - , - - V - - - , " - + - - . " ~
I
I
·-·t--f7At-·------------H~.~~I!~!~!~!~!~!I]:~l~r~:;~:;:;:;:;~~:;:;:;:;: 9'933
I I -9'932 I I I / .. ~ ~':=2=== I ~
l·--~/ nJ = N-N 9~35a V 9'931
gezeichnet fiir RT8' 30
DRAWN FOR RT8' 1-107. 199. 695
..... ll)
~:::nC"LI l:-i
0-107.199.699
\ ( (c".......J·
r ra .lo.' _:( ( ( ~
]]
7 8 94312
@ 20
29 -29
]]]]
sw
32 24 240 31/310 33 34
gezeichnet fur RT 84
DRAWN FOR RT 84
~ I 0 - 107, 199. 598
31 32 31a
© ]]]]]]
28
,~
" ~
ct
I~
1
•
SULZER TURNING GEAR Group: 320
RT 76 Oil Change and Checking of Worm Sheet:84 Gear Wheels
Tools: Key to III ustrati ons
Assorted spanners 1 Casing 16 Intermediate flange 37 Spring stack Assorted Jack 2 Spacer disc 17 Spring stack 38 Screw with locking plate screws 3 Bearing flange 22 El ectri c motor 39 Bearing flange
4 Screw with Locking 23 Hand wheel *40 Contact pl ate
p1ate 24 Large worm wheel *41 Spring discs
5 Oil drain plug 25 Oil fi 11 er screw *42 Adjusting ring 6 Worm gear wheel 26 Engaging/disengaging *43 Steel ball 7 Cover lever *44 Idler plate 8 Retaining disc 27 Pinion shaft *45 Cover 9 Screw with locking 27a Protecting pipe over *46 Limit switch
plate pinion shaft 10 Oil 1eve1 gauge 28 Turning pinion * Only for turning gears 11 Spacer ring 28a Turriing wheel with protection coupling 12 Taper roller bea 29 Flexible coupling clutch
ring 30 Screw with locking 13 Horizontal worm plate
shaft 31 Bearing flange S Gap 1 to 1.5 mm 14 Bearing flange 32 Connecting piece 15 Screw with locking 33 Taper roller bearing
plate 34 Verti cal worm shaft 35 Intermediate ·flange
36 Spacer disc
I-I
24 23
22
10
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JI I
I 7 707. 798.859
.A.-----..L.--28a
320/1a
Before starting the turning gear make it a point always to check the oil level in the casing, for which the level dip stick 10 has to be pulled out. The oil level should be between the two marks ''
on the dipstick.
If necessary top up with oil of the following grade:
Hypoid Gear Oil of a viscositv of 220270 cSt at 40 0 C
or (16.5 19.7° E at 50°C)
The plnlon shaft 27 must always be liberally smeared with MolYkoteGrease, whereas the turning pinion 28 requires only a liQhi coat of grease. Remove some oil annually from the turning gear to check visually for wear sediments (the oil plug 5 to be firmly tightened again). If on such a check dirt is found in the oil, drain all the oil and inspect the worm wheels on their condition. Remove cover 7 and the oil filler screw 25. This check must be made in any case every four years and combined with an oil change. The oil volume is about 60 litres. Before the fresh oil is filled in rinse the casing well with rinsing oil.
Replacing the Taper Roller Bearings
Should it become necessary to replace the taper roller bearings of the horizontal or/and the ver- tical worm shaft, proceed as follows:
a) Horizontal Worm Shaft (see Fig. 'A')
Drain all the oil and remove cover 7.
Loosen and remove the four screws 9 with which the retaining disc 8 secures the worm wheel 6 on the worm shaft. Fasten the retaining disc firmly to the front side of the worm wheel 6 with two of the removed screws 9; two threaded holes are provided for this.
With the aid of the jack screw M30, to be screwed into the thread in the centre of the retain-ing disc 8, the worm wheel can be jacket off the shaft.
Loosen and remove the screws holding the bearing flanges 3 and 14 and jack the latter out with jack screws. The worm shaft can now be removed.
To fit the new Taper roller bearings proceed in reverse sequence to their removal, pay atten-tion that the spacer ring 11 is again placed between the taper roller bearing 12 and the worm gear 6, and that the spacer disc 2 is fitted under the bearing flange 3.
b) Vertical Worm Shaft (See Fig. I B')
Orai n all the oil and remove cover 7.
Loosen the screws holding the electric motor and remove the motor with the crane. Pull the gear side coupling half off the vertical worm shaft.
Loosen and remove the holding screws of the two bearing flanges 31 and 39 and press the latter off with jack screws. Now the worm shaft can be removed.
For fitting new taper roller bearings proceed in the reverse sequence to their removal, pay attention that the spacer disc 36 is placed under the bearing flange 31.
Setting of limit switch (only valis for turning gears with overload protection clutch)(see Fig.'C')
Under normal conditions a gap of 1 to 1,5mm exists between plate 40 and roller of limit switch 46 which must be considered when a switch has to be replaced.
11.84
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RT58 68 76320/1c
Vertikale Schneckenwelle
VERTICAL WORM SHAFT
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33
29
30
31
32
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8~ 12RT 76 0- 107. 198.442
477RT 84 + 12RT84
38 37 39
1984
SULZER
RT CONNECTING ROD
Checking Bearing
BEARING
Clearances
Group:
Sheet:
330
1
Tool s:
Feeler gauge possibly
94238 94123
It is recommended that the vertical bearing clearances of the lower and upper connecting rod bearings be checked every 6 8000 service hours.
To do this, turn the piston of the cylinder in question to B.D.C. and measure the clearances Ib' and If' with the feeler gauge.
Attention: Be careful not to break off a feeler blade when measuring. Should this still happen, the bearing in question must always be opened up and the brokenoff piece removed.
Regarding bearing clearances, see Table of Clearances 012/5.
Should clearances reach or exceed the limit values in this table, the bearin~s must be replaced by new ones. The bearing clearance cannot be reduced either on the upper or on the lower bearing as there are no compensat ing shims.
Shoul d, however, a consi derabl e increase in beari ng clearance be found when compared with earlier measure-ments, it is recommended that the bearing in question be examined (see Sheet 330/4 and 330/5).
Under no circumstances may the clearance be reduced by filing the butting faces of the bearings.
L.B. ') QI1
SULZER Group:330
CONNE:TING RCJ ESARINGRT 76
84 Sheet: 2~ooserring and ~ e n s i o n ~ h e C o r r n e c t i r r ~
Rod ::olts
2 Hydr. Fretensioning jacks HF Fump wi th hoses
pressure gauge and connecti ng pi ece Feel er gauge Various spanners Sledge hammer*
* Only to be used in an emergency in case the hydraul ic pretensioning
device fails.
94314 94931
94933 94122
Key to III ustrati ons
1 Connedi ng rod bo It 8a Cover with grip
2 Nut Cyl i nder
4 Rod seal ring
5 Piston seal ring 6 Pi ston 7 Vent screw 8 Screws
9 Spring discs 11 III a Cl amps
12 13 K
M
R
Schematic sketch and loosening of
Locking sleeve
Pressure rel i ef Checking slot Mark Round bar
va 1ve
for sequence of tensioning the connecting rod bol ts
8,
-9
-R
--K
x--
-$¢
®
b a 4 - 107. 134.631
Lower or Crank Pin Upper or Crosshead
Bearing Bearing
Attenti on!
Never rotate the crankshaft, when the hydraulic pretensioning jacks
are install ed!
• The zed
Important Remarks!
pretensioning for loosening
devices must or tensioning
always the
be utili-connecting
rod bolts of the crank pin bearing or the cross-
head bearing •
• Qrrly in case the pretensioning devices are not serviceable may the tightening be done with spanners and sledge hammer. For this the
, -----~ I - I 11, lla must be fitted, in order to hold'"Molykote G bolt heads and prevent them from turning •
• The connecting rod bolts to the crosshead3-ing must be fitted always with the milled
clamps
the
bear-faces
of the bolt heads parallel to the engine longi-2-tudinal axi s.
The milled faces of the crank pin bearing howe- /107/59023 ver must always be fitted across the
engine longitudinal axi s.
~ I
330/20 RT68/76/84
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0-107 198.449
330/2b RT68/7 6/8 4
• The sequence of loosening or tensioning the crosshead bearing bolts must always conform to Fig. '8' i.e. always in pairs the bolts a+a then b+b. The bolts of the crankpin bearings have to loosened or pretensioned always in pairs as shown in
Fig. '8'.
• The bolts to the crosshead bearings and those to the crank pin bearing are equal, the same preten-sioning jacks are therefore used.
• Prior to fitting the nuts onto the connecting rod bolts, smear their threads and the seating surface of the nuts with MOLYKOTEpaste G. also check the free working of the nuts on the bolts threads.
• When working on the crosshead bearings the crank of the respective cylinder must be in the B.O.C. and when working on the crank pin bearing in the T.O.C. position.
• Pretensioning jacks which had been dismantled or which had not yet been in use or unused for a con-siderable time have to be vented before using them, by loosening their vent screws 7, and actuating the HP oil pump until bubblefree oil issues. (Possibly oil must be topped up in the pump).
• The pre_tensioning jack for the connecting rod bolts are autoresetting i.e. when the oil pressure is released to zero by opening the relief valve on the pump, the piston of the jack is pressed back to
its neutral position by stacks of spring discs. Condition for this is, that the relief valve on the pump remains open for about! 1 minute to allow the oil to return to the pump.
L 0 0 sen n g the connecting rod Bolts (Crosshead and Crank Pin)
Crank Pin and Crosshead Bearings
1) Hydraulically U:ormal Procedure)
Screw the two pretensioning jacks onto the connecting rod bolt threads until their cylinders are seated, then turn them slightly back so that the slots for tightening the nuts 2 are pointing out-
wards. Couple the pretensioning jacks with the HPhoses to the HPoil pump.
Tension the connecting rod bolts with about 620 bar and turn the nuts 2 back with a round bar by
about 0 n e turn. Release the pressure to zero and remove the pretensioning jacks.
2) Mechanically
For the case that the loosening cannot be done with hydraulic jacks, the nuts must be loosened in p air s in small steps, using closed spanners and the sledge hammer (the nuts of the crosshead bearing bolts to be treated as per schematic sketch Fig. 'B'.
Tensioning the Connecting Rod Bolts (Crosshead and Crank Pin Bearing)
1) H y d r a u 1 i cally (Normal Procedure)
Insert the Connecting rod bolts into the bearing body and secure them by fitting the clamps 11 or
lla, which in turn must be locked by locking plate and screws.
Proceed further, while following the points of the section "important remarks", as follows:
~ . R 4
330/2c RT76
a) Crank Pin Bearing (Fig. IC')
Tighten the nuts a+a of the connecting rod bolts with the spanner by a strong jerk by hand. Test with the feeler gauge whether the nuts are seated fully on the facings of the connecting rod foot. Check also whether the bolt heads are fully seated! If both are confirmed, mark the initial position on the nuts and the connecting rod foot with an inking pen or si- mil ar.
Screw the pretensioning jacks onto the connecting rod I bolts (a+a) (see Fig. 'BI), until their cylinders are sea- I ted. If necessary turn back a little so that the slot Ithrough which the nuts 2 can be turned with the round bar 'R' point towards the engine outer side. I
I Shut the relief valve on the pump and tension the two con- necting rod bolts at a pressure of 350 bar (lst stage). I Keep this pressure constant and turn the nuts 2 with the I round bar 'R' till firmly seated. Check the full seating Iof the nuts at 'X' with a feeler gauge through the slot I . nO'K' (Fig. 'AI). . II .
If the nuts are seated, release the pressure to zero by opening relief valve 13 on the pump, and mount the pre- tensioning jacks to the connecting rod bolts (b+b)j Ten- ~-Eb Ii jlsion these bolts in the same manner at 350 bar.
I . Tension all four connecting rod bolts at a final pres- L'_'_'_-'-'-
i I
sure of 600 bar. (2nd stage) . I ._._-~
Check the tightening angle from the inking marks on nuts and connecting rod foot, it should be about 90 0
• In case 9~931 ~ considerably differing angles are detected, particularly 13 between the four bolts, they have to be once more loosened and the whole tensioning procedure repeated.
For safety the bearing clearance has to be checked at the bottom of the crank pin with a feeler gauge (Compare with the clearance table 012/5).
b) Crosshead Bearing
In addition to 'important remarks' at the beginning of this instruction please note that when fitting the bearing shells into the lower bearing body the surfaces are absolutely clean and the shell divi-ding faces protrude equally over the lower bearing body. (see Fig. '0 1
). The 'protrusion' X1+ X2 = -...J
0.50 ± 0.04 mm ~ust be measured after the nuts of the connecting rod had been thightened wlth the spanner by hand with a light jerk.
Check with the feeler gauge whether nuts and@ bolt heads are fully seated.
r
-,)(
Screw the pretensioning jacks onto the two bolts of one of the two bearings until the cy-linders are seated. If necessary, turn them slightly back to gain easy access to the slots for tightening the nuts
Tension the two connecting rod bolts first with 450 bar and keep this pressure constant, till the nuts have been tightened with the round bar IRI to firm seating.
t. -107. 755.830
10.84
330/2d RT76/84
(Check \lith feel er gauge). With thi s pretension the bearing shell shoul d be pressed in to an ex-tent, that no clearance remains bet\leen 10\ler bearing body and bearing cover.
Mark the position of the nuts to the bearing cover \lith a marking pen or similar.
Raise the pretension to 600 bar and keep it constant \lhile the nuts are tightened \lith round bar 'R' to full seating.
Check \lith feeler gauge that the nuts are seated and if in order, release the pressure to zero
and remove the pretensioning jacks.
Check by the markings on nut and bearing cover \lhether the tightening angle is equal on all the
nuts. Should there be considerable differences bet\leen the t\lO bolts, loosen them once more and repeat the tensioning procedure.
Mount the pretensioning jacks onto the other t\lO bolts of the second bearing and tension them in the same manner.
Finally check the vertical bearing clearance, and \lhen in order, fit the locking sleeves 12 on the connecting rod bolts. Lock the locking sleeves themselves \lith a locking plate.
2) Me c han i cally (Exception)
a) Crank Pin Bearing
Having completed the requirements of the 'important remarks', tighten the nuts by hand \lith a spanner \lith a strong jerk. Mark the position of nuts to connecting rod foot \lith a marking pen (Starting position).
Check that the clamps lla are fitted, to prevent the connecting rod bolts from turning, \lhen they are tightened.
Tighten the nuts \lith spanner and jacks in several equal steps until the tightening angle of the nuts corresponds to 85 ~ 900•
Finally check the vertical bearing clearance \lith a feeler gauge (and compared to the table 012/5), the nuts are then locked.
b) Crosshead Bearing
On these bearings the bearing shell horizontal edge protrudes some\lhat over the bearing body. This protrusion must be equally distributed on both sides, before fitting the crosshead or be-fore the bearing cover has been fitted. On .no account may any material be filed a\lay as other-\lise the necessary prestressing of the bearing \lould be diminished (see Fig. 'DI).
Having completed the requirements of the 'important remarks' tighten the t\lO nuts of one of the t\lO bearings by hand firmly using t\lO spanners simultaneously. Check \lith a feeler gauge
\lhether n~ts and bolt heads are seated.
Check \lhether the clamps 11 are fitted, preventing the bolts from turning.
Tighten the nuts of one bearing in small steps \lith spanner and sledge hammer until bet\leen the separating faces of bearing body and bearing cover a clearance of only 0.03 to 0.05 mm
remain (measure on the side as near as possible to the bearing shell).
Mark the position of the nut to bearing cover \lith a marking pen
or similar (see Fig. 'E').
Tighten the nuts finally \lith spanner and jack by an additional0
angle of 30 each. (see Fig. 'E').
Finally check the vertical bearing clearance (compare \lith the clearance table 012/5)and lock the nuts 2.
4107. 134.631
11 .84
SULZER
RT CONNECTING ROD
Changing Compression Shims
Group: 330
Sheet: 3
Key to Drawing,s
7 Upper part of lower connecting rod bearing
8 Guide path 9 Clamp
10 Retaining screws K Sight chains of 94323
2 Holding brackets 94317 1 Gui de shoe 4 Holding pins 94323 2a Fixing nut 1 Wi re rope and tools 3 Connecti ng rod
according to 4 Shim sheet 330/2 5 Crank pin
6 Connecting rod bol t
In the event that Qnly the thickness of the compression shim of a cylinder unit's running gear has to be altered, and therefore must be excHanged, proceed as follows:
Turn the crank of the cylinder in question to T.D.C. and fix the two holding brackets 94317 to the lower connecting rod bearing (Figs. 'A' and '8').
Loosen the lower connecting rod bolts as described on Sheet 330/2 and remove their nuts. Thereafter, in order to lower the connecting rod bolts onto the holdina brackets, the retaining screws 9 on the lower part of the bearing must be lo()sened first. [Fig. 'C').
o Turn the crankshaft through ~ towards exhaust side.
1
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gezeichnet fur RT 58 DRAWN FOR RT 58
2-107.198.853
Insert four holding pins 94323 with sight chains 'K' underneath the guide shoes into the holes pro vided for this purpose in the guide paths and turn them until their eccentric parts touch the guide shoes.
Secure connecting rod with lifting device and wi re ro pe.
Attention. Now unscrew the two fixing bolts 10.
Slowly turn the crank further downwards, ho 1d-ing the lower connect-ing rod bearing with the pipe of the holding bracket 94317 in such a way that the connecting rod can loosen itself parall el to the connect-ing rod bearing.
Should the connecting rod jam, joggle the pipe of the holding bracket up and down a little or tap the connecting rod from the side with a 1ead hammer.
Engine d:
RT 58 480
RT 68 560
RT 76 59°
RT 84 600
L.B. 11.84
330/3a
As soon as there is sufficient space, remove the shim, modify it to the required thickness and re-
fit it.
Should for any reason a thicker compression shim be fitted, it is absolutely essential to remove the wear ridge in the cylinder liner. (see also sheet 214/4).
Assembly
After having inserted the shim, rotate the crank slowly upwards, to join the bearing body again with the foot of the connecting rod; Guide the bearing body with the pipe of one of the holding
straps so that the separating faces lie parallel to each other.
Rotate the crank somewhat further upwards and remove the stop pins 94323 with the sight chains 'K'.
Push the connecting rod bolts upwards and fix them with the clamp 9. Lock the stays with locking plates and screws. Screw in the fastening screws 10, holding the bearing upper part to the connect-
ing rod foot, and tighten them firmly.
Remove the holding straps 94317, screw the nuts on the connecting rod bolts and tension these in
accordance with sheet 330/2. Lock the nuts as instructed.
Attention! Before you continue rotating the crankshaft and/or shutting ~
the engine crank case doors, satisfy yourself once more, that all four stop pins 94323 have really been removed from the glide paths.
The sight chains 'K' on the stop pins are drawing attention to un-
removed stop pins.
Any modification to the thickness of the compression shims must be recorded in the engine docu~
ments (setting table).
Fit the screws'S' with which the holding straps 94317 are fastened to the crank pin bearing, into the threaded holes 'X' of the straps, if the tool is no longer required.
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7
9
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x DRAWN FOR RT 68
0- 107. 125.709
11. tilt
5
SULZER Group: 330
RT Inspection of ~ o ~ e r ~ e a r i n g ~ a l v E s Sheet: 4
Key to Drawings
4 Holding pins 0',323 1a Cen"edi ng rod bo It 10 Fixing bolt 2 Eye bolts 2a Nut 11 Locking screw with 2 Liftinq devices of 1 ton 3 Connecti ng ro d locking plate
each 4 Crank pin 11a Clamp Various wire ropes 5 Wooden pl ank 12a Locking cap Pl ank (a ppro x. 5 Lower bearing half 13 Threaded ho 1e fo r F,
50 x 250 x 2000 mm) and 7 Upper bearing half 14 Dowel pin tool s as 1i sted for jobs 8 Guide shoe 15 Dowel pin on sheets 330/2 and/3 9 Guide path R E"8 :,: t Holding bracket 94317
Inspection and Removal
Where a lower connecting rod bearing is to be removed, the connecting rod bolts la have to be loosened according to Sheet 330/2 in the T.D.C. position. Screw an eye bolt R into each side of the lower bearing half 6 immediately above the clamps lla (see Fig.'AI). The lower bearing half is then se- cured with two ropes and corresponding lifting devices. The nuts 2a of the connecting rod bolts la are then removed and the lower bearing half 6 lowered onto the bedplate floor by means of the lifting devices. Attention! Do not damage threads and crank pin. The crank is then turned towards the fuel pump side and the lower bearing half removed sliding along plank 5 as shown in Fig. 'B'.
5
7
6
R
1':;'tttt1a
®
When the u p per hal f of the bearing only has to be inspected, proceed as follows according
to Fig. 'cr.
Turn the crank through oC towards the fuel pump side and insert the four holding pins 94323 into the guide paths 9. Turn the holding pins with their eccentrics in such a way that they touch the guide shoes. Attention! Do not unscrew the fixing bolts 10 (see Fig. 'E').
o Secure the connecting rod with a rope or lifting device and turn the crankshaft to approx. 105 after
T.D.C. The bearing running surface can now be inspected.
L.B.
8
9~323
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3 10
9
10
7 5f? RT68 59" RT 76 600 RT 8~
'-107. '25.408 P!:d!:=::!b------I-----"""""b&::.:!l
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330/4a RT68,76,84
If however the bearing upper part must be removed, the crank must be rotated again upwards until the
crank pin has joined the bearing upper part. Unscrew the two fastening screws 10, secure the connecting rod with a rope and lifting tackle, against a sideways swing and rotate the crankshaft again
iliili towards the fuel pump side (see Fig. 'o'l. Hold the bearing upper parts~ the moment the bearing upper gart has separated from the connecting rod. then rotate the crankshaft downwards by further abt. 60 • Lift the bearing upper part with a lifting tackle off the crank pin and with other lifting tackle out of the crankcase.
Remark: To steady the bearing upper part while the crankshaft is rotated, fix one of the holding straps 94317 to the bearing upper part, and screw in the pipe belonging to it. (please refer
also to group 330 sheet 3).
Fitting
The fitting of a bearing upper or lower part is analogous to the removal in reverse sequence. Smear the running surfaces liberally with new engine oil.
Whenever the bearing ,upper part is joined to the connecting rod foot, keep turning a 1ittl e more, so that the four holding straps can be removed!
Turn the crank to T.O.C. lift the lower part of the bearing (Fig. IAI and tension the connecting rod bolts in accordance with the instructions in group 330 sheet 2. (Do not forget to insert and tighten
the fastening screws 10).
11 12a
102a
3la
" 7
la
15
® 6 13
l1a11a DRAWN FOR RT68 v.O-'OZ'98.449
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SULZER Group: 330CONNECTING ROD
Inspection and, if necessary, replace-RT76 Sheet: ment of Crosshead Bearing Shells
Key to Illustrations
2 Hydr. Pretensioning jacks 94314 1 Pi ston rod 7 Connecti ng rod Hyd r. Tools acc. to sheet 2 Bearing upper part 8 Connecting rod bolts 330/2 3 Cro sshead 9 Retaining screw fo r
1 Ho 1di ng sti rrup 94319 4 Lower bearing body beari ng shell 3 Supporting pipes 94320 5 Beari ng shell 10 Screw plug 3 Interm. pieces 94321 6 Piston rod nut or piston 11 Clamps 1 Fastening device 94322 rod screw in short pis-1 Hydr. jack 94937a to n ro d 1 Check valve 94939 1 Hand lamp
The work to be carried out as described below necessitates the utilization of the hydraulic jack (tools No. 94937a). In its lower part a check valve (94939) is screwed in, which contains a non return valve. The check valve can be opened manually, by turning its hand grip counter clockwise, When the pump is actuated, i.e. when the crosshead is lifted with the piston, the check valve must always be closed. With the valve closed, oil can be pumped in, but it can not flow back. This renders a sudden lowering of the load, in case of a burst HP hose, impossible and reduces the possi- bility of an accident to a minimum. Moreover the load lowering can be minutely controlled by carefully opening the check valve when the
crosshead is very slowly lowered into the bearing, which is essential. When operating this check valve keep to the following principle: When raisino the crosshead the check valve must alwavs be shut (hand qrip turned clockwise) and for lowe- ring. the valve on the pump must always be first opened. and only then the hand grip on the check valve
very slowly turned in counter clockwise sense.
Remark: Description applies to long piston rod! Analogous procedure for short piston rod!
Inspecting Bearing Shells
Working Procedure:
Rotate the crank of the respective cylinder to B.D.C. and ~ the fuses from the electric motor switchgear of the turning gear!
Fix the fastening device 94322 on the glide paths as shown in Fig. IF' on the fuel pump side (570 mm above the bed plate).
Loosen all four connecting rod bolts 8, of the two crosshead bearings, using the hydraulic device as described in sheet 330/2, remove their nuts and place the connecting rod bolts on the fastening device or the crank webs respectively, after the clamps 11 have first been loosened and removed.
Mount the holding stirrups 94319 on both bearing upper part 2 as shown in Fig. 'E' and tighten with four screws. (The screws are set in the threaded holes of the stirrups when the tool is not used).
Place the hydraulic jack 94937a with check valve 94939, on the intermediate piece 94321 (24 mm) as shown in Fig. 'A'. Move this stack (jack + interm. piece) under the crosshead immediately near the pis-ton rod nut, or piston rod screw 6, respectively. Connect the jack to the HP oil pump by the HP hose
(see also arrangement 'E' on sheet 940/0).
Actuate the pump and raise the crosshead sufficiently to place the supporting pipe 94320 (L = 304 mm) for safeguard centrally under the piston rod or piston rod screw head 6 (Fig. 'B').
When the supporting pipe is properly in position lower the crosshead slowly onto it. For safety reasons
the jack is again raised till it rests firmly against the crosshead (check valve closed).
In this configuration the bearing running surface can be inspected with the aid of a hand lamp.
The inspection completed, raise the crosshead slightly, remove the supporting pipe and lower the cross-head agai n s low 1 y until it has come to rest in the beari ng shell s.
330/50 RT76
1984
330/5b RT76
2
®
11
4 -107.197. 078
Removal and Fitting of Bearing Shells 10
If the findings of an inspection necessi- tates a removal of bearing shells, raise
the crosshead sufficiently to place the supporting pipe 94320 (L = 304 mm) under
the piston rod, or piston rod screw respec- tively (Fig. 'BI).
Release the pressure and place the interme- diate pieces 94321 a+b (24 mm + 162 mm) un- der the jack.
Actuate the pump until the supporting pipe (L ; 456 mm) can be placed underneath. (Fig. 'ell.
Release the pressure and place the interme-diate pieces 94321 a + b (24 + 314 mm) un-der the jack.
With this stack combination raise the cross- head until the longest supporting pipe (L ; 608 mm) can be placed under the piston rod, or the piston rod screw respectively (Fig. '0 1 ). For safety, raise the jack till
it rests firmly against the crosshead (check valve must be shut).
Loosen and remove the retaining screws for
bearing shells 9. which hold the bearing shell in the separations. (Two screws per shell, Fig. 'G' and remove the bearing shells using grip screws.
Before inserting the new bearing shells, ascertain that the crosshead is still in good condition.
If this is confirmed, clean the bearing bore on both bearing lower parts with a clean cloth.
It is of utmost importance that under no circumstance dirt or other foreign parts are entering between bearing shell and bearing lower part!
The contact surfaces of the shell rear side and the bore of the bearing lower part must be free from damage. Immediately before inserting the bearing shells pass over them with an oily hand so that a trace of oil only is on them.
After placing the new bearing shells, they must lie in the bearing body in such a way that they protrude on each side of the separating face by the same distance. The protrusion must exist on
no account may any material be filed away from the separating faces of bearing body or bearing she11.
Smear the running surface of the bearing shell liberally with new engineoil. In case the engine has to be rotated frequently with the turning gear and the start of the engine not immediately envisaged, it is advisable to use a mixture of 2/3 steam engine cylinder oil and 1/3. normal engine bearing oil. A drilling in the bearing upper part, closed with a plug to prevent the entry of dirt.
can be used for adding this lubricant after removing the plug, as often as required while the pres
sure oil lubrication is not available. There are also special oils available for this purpose.
To lower the crosshead proceed in reverse sequence to its raising, whereby the supporting pipes
and/or intermediate pieces are exchanged against progressively shorter ones.
When the crosshead lies again in the bearing shells, remove the holding stirrup 94319 again from the bearing upper parts and replace the two screws thereof in the threaded holes provided in them. Pull up the connecting rod bolts, tension them following the procedure described in sheet 330/2.
Before replacing the fuses to the switch gear of the turning gear electric motor make absolutely certain that the fastening device 94322 and all the other tools are removed from the engine.
1984
SULZER Group: 330
RT rte~oval aGi ? i t t ~ n g Sheet: 6 of a Connecting Rod
Tools: Key to Drawings
4 Ho 1di ng pi ns 94323 Lower half of upper 4 Upper half of lower 1 Suspensi on devi ce 94311 connecting rod bearing connecting rod bearing
Various ropes 2 Connecting rod 5 Underl ay and lifting devices 3 Swinging links for 6 Connecting angle bracket Hydraulic tools acc. crosshead lubrication to Sheet 330/2
A connecting rod can be removed and fitted without either the piston or the crosshead having to be removed. The instructions for this are to be found overleaf.
Note: In order to protect the crank pin, it is best to wrap a solid protective bandage (such as thick
leather or similar) around it immediately after lifting the connecting rod and to remove it only shortly before placing the connecting rod with the bearing on the crank pin.
With regard to loosening and pretensioning of connecting rod bolts and removal and fitting of beari ngs, see i nstrueti ons on Sheets 330/1 to /5.
Brennstoffpumpen - Seite Abgas - Seite FUELPUMP - SIDE EXHAUST SIDE
Gezeichnet fur RT58
DRAWN FOR RT58
1 2
b
3
Motor5 13oLEngine
6 0~8 0 17RT 58
22 0
RT 68 56 ~ 0
19RT 76 59 13(60
0RT 8~
1-107.197.304
L.B. 5.84
330/6a RT
Removal
Turn the crank of the cylinder in question to T.D.C., loosen the lower connecting rod bolts and re-move the bottom half of the lower connecting rod bearings according to Sheets 330/2 and 330/4.
Turn the crank to ~ and remove the bearing covers of the upper connecting rod bearings accord-ing to Sheets 330/2 and 330/5.
Rotate the crank towards the exhaust side(~oc before T.D.C. see Fig. Position 'A')
Loosen the swinging link 3 for crosshead lubrication from the crosshead and let it hang down from the stand.
Insert four holding pins 94323 into the guide paths and turn them until they make contact with the guide hoses.
Secure the upper end of the connecting rod by means of a heavy wire and lifting device 'a' (Fig. position 'A').
Slowly turn the crankshaft towards the exhaust side and s i m u 1 tan e 0 u sly ease the load on the lifting device 'a' so that the connecting rod drops and swings out towards the fuel pump side. This can be continued until the crank is approx. 17
0 before B.D.C. (Fig., position 'B').
Release the load on lifting device la' until the connecting rod end lies on the connecting angle bracket (position 'B'). As a suitable underlay 5, a piece of old car tyre could be used.
Secure the connecting rod at its lower end by means of a heavy wire 'b' and suitable lifting device (pull the wire through the connecting rod bolt holes, see Fig., position 'B').
Relove the upper wire and lifting device 'a' and separate both lower bearing halves 1 of the upper connecting rod bearing from the connecting rod and take them out of the engine.
Screw the suspension device 94311 onto the connecting rod, using the four bolts intended for this purpose which are screwed into the threaded holes (M24) of the suspension device.
Using the lifting devices 'c' and 'b', lift the connecting rod off the crank pin and pull it a little way out of the crankcase (Fig., position 'C'). Protect the crank pin with protection bandage.
Once the connecting rod has been pulled out of the crankcase sufficiently, replace the wires 'b' by 'd' and 'c' by 'e' and lift the connecting rod out completely.
Fitting
The procedure for fitting the connecting rod into the engine is the same as for removal, only in reverse order (the position of the crank is the same as shown in the Fig., position 'B'.
Do not remove the protective bandage from the crank pin until shortly before the connecting rod with its lower connecting rod bearing has landed on the crank pin. Bearing and crank pin must be undama-ged. The running surfaces should be thoroughly oiled with clean lubricating oil before placing the connecting rod onto the crank pin.
Turn the crankshaft so that the crank pin moves upwards, simultaneously holding the connecting rod in a sloping position by pulling with the lifting device 'a'.
Before the upper connecting rod bearings make contact with the crosshead, the running surfaces of these parts must be cleaned again and oiled with clean lubricating oil.
Now turn the crank to T.D.C. and remove the four holding pins 94323 from the guide paths.
Finish assembling the lower connecting rod bearing, pretension and secure the connecting rod bolts.
Remove wires and lifting devices from the engine and turn crank to B.D.C" Now fit the bearing co-vers of the upper connecting rod bearings, pretension and secure the connecting rod bolts.
Bolt swinging link 3 for crosshead lubrication onto the crosshead and secure.
L.B. 2.84
SULZER Group: 332
CROSSHEADRT Sheet: 1Checking the Clearances
Too 1s: Key to Drawings
1 Feel er gauge 94238 1 Crosshead 16 Crosshead bearing possibly 94123 6 Guide shoe lower part (upper connecting
4 Screw jacks 10 Holding cover rod bearing)
14 Gui de rail fo r 18 Column secti on
guide shoe (fue1 pump side) [Qr RT 58 see also execution 15 Adjusting shims 18a Col umn section alternative' AI in group 332 ( e x h a u : s ~ side) "f the instrict;cn manua1.
Brennstoffpumpenseite
FUEL PUMP SIDE
1JP~~J--_--18-- __ U ~ P ~
6
10 10
~zZifZ~rt-----18a----I!tl~~tF.
Abgasseite 2-107.198.857
During a major overhaul, or when a crosshead is removed for any reason whatsoever, the opportunity is to be taken to measure the various running clearances and to check them against the values of the Table of Clearances 012/2, in order to determine any wear.
For measuring the clearances, follow the instructions given below:
Clearance a1 (radial clearance between crosshead pin and bore of the guide shoes)
This clearance is very difficult to measure in the engine. The most expedient way is to
determine it with the crosshead removed by measuring the pin diameters as well as the guide shoe bores with micrometers.
L.B
EXHAUST SIDE gezeichnet fiir RT 76 DRAWN FOR RT 76
332/1a RT
Cl earance bl (Cl earance between gui de shoes and guide paths )
The crank pi n shoul d be in hori zontal posi ti on (90 0
) on the exhaust si de. In thi s posi-tion' the crosshead pin is pressed automatically by the connecting rod against the guide
paths on the fuel pump side, thus leaving the full clearance on the opposite side. This clearance can then be determined using a long feeler gauge on the upper and lower end
of the guide shoes.
Cl earance cl (Axial clearance between guide shoes and gUide rails)
and c2 The crank must be in the same position as for measuring clearance bl. In order to obtain reliable figures, the guide shoes must be pushed outwards axially until they press
against the holding covers 10. In order to do this, use four screw jacks, each consisting of a screw with a tommy bar welded onto its head to hold it and a long nut, as shown in the sketch below. These four screw jacks are placed on both sides longitudinally, top and bottom, in the centre of the crosshead. The clearances should be measured at the top and bottom of each guide shoe and their
mean value used as a figure for comparison, with the value on clearance table 012/2.
2 Schraubwinden
Screw jacks
Kreuzkopf Crosshead
Gleitschuh
Gui de shoe
Handgriff
Handle
2 107 157720
2 Schraubwinden
Screw jacks
L.B. 2.84
SULZER Group: 337 CROSSHEAD58
RT 68 Removal and Fitting of a Crosshead Sheet: 3 76 with Piston Removed (Normal Case)84
Tools: Key to Drawi ngs
4 Holding pins 94323 1 Crosshead x}suspensi on 1 Suspensi on 94324 2 Swinging link pipe Y Points for lifting
device 3 Crank pin Z devices Yare spanners 4 Gui de shoe Yare lifting devices and wire gezeichnet fur RT 58 ropes DRAWN FOR RT 58
o 94324 1
z
3
@
®
A /1Engine
48 0
1630
560
158 0
0 059 161 60
0 167
a
94324
94323
Motor
RT 58
RT 68
RT 76
RT 84
Should a crosshead have to be removed, it would normally be done at a time when the piston has al-ready been pulled and, if possible, the piston rod gland has also been removed (overhaul). Although it is possible to remove a crosshead with the piston remaining in the engine, the work invol-ved is quite considerable and presents virtually no time saving so that this method should only be used in exceptional ,cases.
L.B. 9.89
RT 58,68,76,84337/3a
Removal (see Fig. 'AI and IBll
After the piston has been pulled, proceed as follows:
Remove lub. oil pipe for the main bearing and blank off the opening thus exposed with blank flange.
Remove the thrust bolts above the main bearings on both sides.
Turn the crank of the cylinder concerned to B.O.C.
Separate the swinging link pipe 2 for crosshead lubrication from the crosshead and simply let it
hang from the longitudinal frame.
After slackening them off, remove both bearing covers of the upper connecting rod bearings from the crankcase.
Note: The further description of the removal procedure refers to the removal of the crosshead on the fuel pump side as shown on Figs. 'A', 'B' and 'cr. It is also possible to remove the crosshead from the crankcase on the exhaust side. In thi s case the work woul d be as a mi rror image.
Turn the crank pin 3 to /l before 1.O.C. (see Fig. 'A'l and secure the connecting rod with two lifting tackles and wire ropes from both the fuel pump and exhaust sides; hang the suspension de-vices from 'X' and 'yr.
Lead the suspension device 94324 through the piston rod bore on the crosshead and tighten it. Con-nect the device to the crane with a wire rope 'a'. In the case where the piston rod gland is not to be removed care has to be taken to ensure that the wire rope does not damage the scraper rings when
lowering or raising the crosshead later; install some protection.
Using the crane, raise the crosshead only so far until it is out of the upper connecting rod bearings Should the crane have to be used elsewhere, the crosshead can be supported at the height shown on Fig. 'A' and 'B' (crank pin at approx. J:. before 1.o.c.l using the holding pins 94323 (pin holes are already in the guide pathsl. It can be held there until the connecting rod has been laid onto
its side.
Carefully ease off the lifting tackle at suspension point 'X' on the fuel pump side which secures the crosshead while simultaneously gently tightening the other lifting tackle suspended at 'Y', thus swinging the connecting rod out towards the exhaust side.
Lower the connecting rod onto the edge of the connecting angle bracket. To protect the supporting position, cushion it with a suitable underlay such as a wooden plank, tyre or similar.
- On engines equipped with a power takeoff (P.T.D.) it will also be necessary to remove both the lower bearing halves of the upper connecting rod bearing for the cylinder at this level.
Using the crane and rope, lower the crosshead until its guide shoes come to rest on the crank webs.
Suspend a lifting device from IZ', another outside the engine and lead both their wires or chains
through the suspension device 94324.
Once the crosshead has been raised again slightly from the crank webs by means of these two lifting devices, the crane wibe 'a' can be released and separated from the crosshead. Turn the crosshead ho-rizontally through 90 (Fig. 'C'l.
By pulling on the suspension device outside the engine and releasing that of rbI, the crosshead can
be 1ed out of the engi ne. It can then be taken over by crane wi re 'd'.
L.B. 9.85
337/3b RT 58,68,76,84
~ )
~
Fitt ng
Fitting follows in the same way as removal, however in reverse order.
Where no crane is available which can lift very slowly, it is recommended that a heavyduty lifting tackle be mounted between the crosshead and the crane hook. With its aid, the guide shoes can be led up into the middle part of the columns very slowly and carefully (finally raise further with the crane) •
Before leading the guide shoes into the guide path bars, liberally lubricate their running surfaces with clean oil. In order to ease fitting, the bolts of two guide bars on the same longitudinal side can be slackened off to give more axial clearance. These must, of course, be tightened and secured again afterwards. In any case, the guide shoes must be pushed fully outwards to fit them.
The crosshead is to be lifted with the crane so far until the connecting rod can be raised again with the aid of the lifting device hung on suspension bracket at 'x'.
After the bearing running surfaces have been wiped clean and lubricated with clean oil, lower the crosshead into the bearings. Now remove the suspension device from the crosshead.
Mount the bearing covers, then tighten and secure the connecting rod bolts according to instructions (see Sheet 330/2).
Remove the securing wires from the connecting rod.
Bolt the swinging link pipe 1 for crosshead lubricating oil back onto the crosshead and secure it.
Fit the piston and tighten the piston rod nut or bolt (see Groups 340/2 and 340/3).
Refit the lubricating oil pipes to the main bearings and secure them. Finally, with the lubricating oil pump, running, check to see that the crosshead, lower connecting rod bearing as well as the main bearings are being supplied with oil.
L.B. 9.85
SULZER Group: 340
RT Removal of a ~orking ?iston Sheet: 1
Key to Drawings
1 Piston ring tensioning device 94332 1 Fi stan ski rl1 Cl ampi ng devi ce 94339 2 Fiston rod1 Suspension device 94341 3 Heavy type dowel pin1 Thread tap 94348 4 Bo 1t 2 Suppa rts 94350 5 Platform girder1 Device for loosening 94356
the piston ro d bo 1t Extracti ng screw for 94381 stand pipes
Piston removal
Pi stan pl aci nq
Shaul d a pi stan removal become necessary when the ship is hea-
vily listing, the application of the fixation device 94339 as shown in group 340 sheet 2
94350 is recommended with the direc-/( tive to sheet 340/2a!
Before removing a piston, the following preparations have to be made:
Drain the water from the cylinder jacket in question and remove the cylinder cover (see 271/1 and /2).
Turn piston to B.D.C., loosen piston rod nut and remove (see 340/3a).
Grind away the wear ridge at the top of the cylin-der liner running surface (see 214/4).
Turn piston to T.D.C. Remove combustion deposits 1107. 197. 300
from the threaded holes in the piston crown, using the thread tap 94348.
Screw the suspension device 94341 onto the piston crown and connect it to the crane. (Check once more whether the piston rod nut has in fact been removed).
Procedure for Removal
Usi ng the crane, pull the pi stan out of the cyl i nder 1i nero
L.B. 6.86
340!la RT
In the event that the piston does not have to be dismantled but only cleaned, it can be placed on a
girder of the upper platform. First bolt on both supports 94350 to one of the preselected platform girders to take the piston. Depending on the number of cylinders, several platform girders are so
made that further pistons can be placed after removal of the floor plate. See also the details and arrangement of both the supports on the following illustrations.
Remove the piston rings by means of the tensioning device 94338 and thoroughly clean the outside of the piston (do not use any tools that might damage the surface!).
Measure the piston ring groove depths and determine the axial clearance of the piston rings (see Table of Clearances 012/7). (If a piston has to be turned, the piston cooling telescopic pipes are to be fixed with the clamping device 94339 to protect them against bending).
Remove the piston cooling stand pipes, using the tool 94381 (see Sheet 360/1). The glands of the piston rod and the piston cooling stand pipes must also be removed so that they can be cleaned and examined.
Attention! A little water always runs out during removal of the stand pipes. Care must be taken somehow that this does not get into the oil.
Maintenance work on the cylinder liner can now be carried out as well (measuring the bore, rounding off of scavenging ports, according to the instructions given under Groups 214 and 215).
Should it be necessary to dismantle the piston, follow the instructions on the sheets of Group 340/5.
1
+
1
2
.-1!
94350
II 5
-(7
~
L.B. 2.84
SULZER
RT REmoval (",T: : h
of a short
ork i n icon
?i ~ t o~
ro')
Group: 340
Sheet: 1
Tools:
Pis a ring ensioning de ice
Clam pin 9 de" ce Suspension device Thread tap
2 Supports
94338
94 33~
94341
94348 94350
Key to Drawi ngs
p's on skirt
Pisto(\ rod
teavy type do el
Bo It
Platform girder
1
2
3 ~
5
pin
1 Device for loosening the piston rod bolt 435& Extracti ng screw 94381 for stand pipes
Piston placing
I
:t , ,
Should a Qiston removal be-
come necessary when the
shi pis heavil y 1i sti ng, the application of the fixation device 94339 as shewn in group 340 sheet Z is recom-mended wi th the di reeti e to sheet 340/Za!
Before removing a pisto , the following preparations have to be made:
Drain the water from the cylinder jacket in question and remove the cylinder cover (see 271/1 and /Z).
Turn piston to B.D.C., loosen piston rod bolt and lower (see 340/3a) .
Grind away the wear ridge at the top of the cylin-der liner running surface (see 214/4).
Turn piston to T.O.C. Remove combustion deposits
.94341 /
1 - 107. 197. 099
Pi stan
from the threaded holes in the piston crown, using the thread tap 94348.
Screw the suspension device 94341 onto the piston crown and connect it to the crane. (Check once more whether the piston rod bolt has in fact been removed from its thread).
Procedure for Remo al
Using the crane, pull the piston out of the cylinder liner.
K.K to. L.B. &.86
340/1a
In the event tha the piston does not· ave to be ismantled ut on y c eaned, it can be placed on girder of t e upper platform. c· st olt on both supports 9k350 to one of the preselected olatform
girders to ta~e the ois o. ependi g on the umbe 0': cylinders, several platform girders are so
made that furt er p'stons can be placed af'er re ova o~ t e flo r p ate. See a so he details and arrangement of both e supports on t' e ol1owing i strations.
Remove he piston rings y means of t e tensioni g device 94338 and hor ugh1y clean he outside of he p'ston (do not use any 1s hat migh damage t e surface!).
Measure the piston ri g groove depths and determi e t e axial cleara ce of the piston rings (see Table of Clearances 012/7). (If a piston has a be tu ned, the piston cooling 'elescopic pipes are to be fixed with t e clamping device 94339 to protect them against bending).
Remove the pi ston cooling stand pi pes, usi ng the tool 94381 (see Sheet 360/1). The gl ands of the piston ad and the piston cooling stand pipes must also be removed so hat t ey can be cleaned and exa i ed.
Attention! A little water always runs out during removal of the stand pipes. Care must be taken somehow that this does at get into the oil.
Maintenance work on the cylinder liner can now be carried out as well (measuring the bore, rounding off of scavenging ports, according to the instructions given under Groups 214 and 215).
Should it be necessary to dismantle the piston, follow the instructions on the sheets of Group 340/5.
1
2
I _1=F1=I~-- --l.1
94350
3
I-I 5
(f; (17- ~- "n '" 302
L.B. 2.84
2
1
SULZER Group: 340
RT ?itting of a ~orking ?iston Sheet:(hith long piston red)
Too~s:
Sistor ring tensionirg
device Clac.pjr,g de.Jice
Suspension device
Inserti ng cone
Guide cone
Centering disc
Device for tightening
the piston rod nut
Various spanners
"'---'.
F rep a rat ion s
94333 • Fit the pi ston rings (see Sheet 342/2).
.Liberally lubricate piston rings, piston skid, pis- 9433? ton rod and running surface of the cylinder liner.94341
94342 • As a check, turn the cranks of the cylinder 1ubricat-94343 ing pumps until oil flows out of all the lubrication 94346 points in the cylinder liner. 943S5
• The cover for the gland space (on fuel pump side) is
to be swung out.
94341 94342
~0 ®
94339 (LJ
~E# c:::=:J2J
©
~,,~_ +f ~ - + + - - - 9 4 3 4 6
gezeichnet fur RT 58 DRAWN FOR RT 58
0- 107 197. 076
L.B. 4.85
340/2a RT
• The threepiece scraper ring and the threepiece sealing ring with locating bracket and garter
springs for the upper gland group of the piston rod (marked with arrows on Fig. IB') must not yet be
fitted. The same applies to the gland groups of the piston cooling pipes (marked with arrows on Fig. , CI ). "-'"
eRemove the stand pipes of the piston cooling box if this has not already been done (see Sheet 360/1).
eBolt the guide cone 94343 onto the piston rod end (there must be no axial clearance between piston rod and cone). Under no circumstances may there be any burrs or dents on the tapered surface of this cone since these would damage the edges of the piston rod gland scraper rings.
eBolt the centering disc 94346 to the bottom of the piston rod (see Fig. '0 1 ).
.Check the mating faces of the piston rod and crosshead. These dents.
o.Turn the crank of the cylinder concerned through about ~ to
must also have neither grooves
the fuel pump side.
nor
ePlace the inserting cone 94342 onto the cylinder liner or suchlike and must be liberally coated with oil.
(Fig. 'AI). Its bore must not have any burrs
Fit tin g of a Pi ston
After carrying out the preparations described previously, the piston can be fitted as follows:
Place the piston over the cylinder liner and slowly lower it. Check to 94343 can be inserted into the piston rod glands without restriction.
ensure that the guide cone "'"
Once the piston has been lowered until turn the piston rings until their gaps direction.
the are
bottom piston ring is at the height of the inserting cone, staggered at 180
0 to each other in the engine longitudinal
Slowly lower the piston further until its telescopic pipes are very slightly above the piston cooling pipe glands. One man must carefully watch this phase of fitting and tell another one, who is on top
of the engine, in which direction he has to turn the piston so that the telescopic pipes can enter the glands without touching.
Attention: The for
piston must only be this purpose.
turned using the suspension device. Never use the telescopic pipes
Now lower the piston further until the guide cone can be removed from the piston rod.
Finally, lower the piston until the piston rod rests on the crosshead, making pin on the crosshead enters correclty into the piston rod.
sure that the centering
Ease the load on the crane wire a little.
Unscrew and remove the centering disc 94346 from the piston rod.
Coat threads and ten by hand.
contact surface of piston rod nut with MOLYKOTE paste G. Screw the nut on and tigh
Turn piston to piston rod nut
T.D.C., remove suspension device and (refer to Sheet 340/3).
turn piston to B.D.C. for tightening of the
- Fit stand pipes into the piston cooling box and secure them (see Sheet 360/1).
- Complete assembly of glands for piston rod and piston cooling pipes.
- Remove all gear and tools, etc. from the engine and fit cylinder head.
Remark! Should the necessity arise of having to fit a working piston while the ship has a bad list or during heavy seas, it is advisable additionally to instal the clamping device 94339, which in
this instance has the duty of guiding the piston rod safely through the cent~e of the piston rod gland. The device is then to be removed.
L.B. I, oc:
SULZER Group: 340
F ~ L r ~ ~ : ~ ~ q ~ r k i ~ g ?is onRT Sheet: 2
(',T ~ t 3 ~ o r t p ~ c : , ' n r0)
Freparations
~ L ~ , c:: .J II ....'J;ry bar: • Fi t 'he pi stan ri ngs (see ~ h e e t 342/2).
;:istor r i r ~ :ersiorirg • L'berally lubricate oiston rings, pis 0 skirt, pistonae ice
rod and running surface of the cylinder liner. Cia:;pir; device 34235
Suspensior bracket 94341 .As a chec, turn the cranks of he cylinder lubricating ,serb ng cone 94342 pumas until oil flolls out of all the lubrication points
Guide cone 94343 in the cylinder liner. Devi ce for li fti ng t' e 94344
• The cover for the gland space (on fuel pump side) is topi stan rod bo 1t be swung out. Device for tightening 94355
the piston rod bolt
arious spanners
94341 94342
~ 0
® 94339 a::::J
~
©'f c::JEJ
94343
gezeichnet fur R T 58
DRAWN FOR RT 58
o 107. 197. 077
K.Ksto. L.B. I, QC
340/2a RT
e The threepiece scraper ring and the threepiece sealing ring with locating bracket and garter springs for the upper gl a d group of the pi stan rod (marked wi th arrows on Fi g. I BI) must not yet
be fitted. The same applies to the gland groups of the piston cooling pipes (marked with arrows on I~'
Fig. Ie') •
• Re ave the stand pipes of the piston cooling box if this has not already been done (see Sheet 300/1).
eSolt the guide cone 94343 onto the piston rod end (there must be no axial clearance between pisto rod and cone).
Under no circumstances may there be any grooves or dents on the tapered surface of this cone since
these would damage the edges of the piston rod gland scraper rings.
eThe centering part on the lower end of the piston rod must be undamaged and coated with oil.
Check the mating faces of the piston rod and crosshead before fitting. These must also be clean and have a grooves or other damage.
eTurn the crank of the cylinder concErned through about 90 0
to the fuel pump side.
• Place the inserting cone 94342 onto the cylinder liner (Fig. 'A'). Its bore must not have any burrs or suchlike and must be liberally coated with oil.
eThe internal thread in the end of the piston rod has to be lightly smeared with Molykote paste.
, './
Fit tin g of a Piston
After carrying out the preparations described previously, the piston can be fitted as follows:
Place the piston over the cylinder liner and slowly lower it. Check to ensure that the guide cone 94343 can be inserted into the piston rod glands without restriction.
Once the piston has been lowered until the bottom piston ring is at the height of the inserting cone,
turn the piston rings until their gaps are staggered at 180 0
to each other in the engine longitudinal di recti on.
Slowly lower the piston further until its telescopic pipes are very slightly above the pi ston cooling pipe glands. One man must carefully watch this phase of fitting and tell another one, who is on top of the engine, in which direction he has to turn the piston so that the telescopic pipes can enter the glands without touching.
Attention: The piston must only be turned using the suspension device. Never use the telescopic pipes
for this purpose.
Remove the guide cone 94343 as soon as the lower end of the piston rod has passed the piston rod gland.
Finally, lower the piston until the piston rod rests on the crosshead, making sure that the center- ~
ing pin on the crosshead enters correctly into the piston rod,
Ease the load on the crane wire a little.
Lightly smear the contact surfaces of the piston rod bolt with Molykote paste. By using the lifting device 94344 which has been placed centrally under the bolt head, raise the bolt with the aid of a lever. At the same time turn the piston rod bolt head and then screw it in by hand (see Fig. 'E'l.
Turn piston to T.o.C., remove piston suspension device and turn pistan to 8,D.C, for tightening of
tne piston rod bolt (see sheet 340/3).
Fit stand pipes into the piston cooling box and secure them (see sheet 360/1).
Complete assembly of glands for piston rod and piston cooling pipes.
Remove all gear and tools, etc. from the engine and fit cylinder head.
Remark! Should the necessity arise of having to fit a working piston while the ship has a bad list or
during heavy seas, it is advisable additionally to instal the clamping device 94339, which in
t is instance has the duty of guiding the piston rod safely through the centre of the piston rod gland. The device is then to be removed.
K.Kstg. 1.B. 4.86
J40/2b RT
2 -107.157. 721
K.Kstg. L.B. 2.84
3
Iv. 1-107.197.395
( 9 ~ 9 3 2 )
13
(94931) ( 9 ~ 9 3 5 )
11 12
101---:'=1_==>
IIII
~ / + - / ~ = ~ : · · · ~ ~
SULZER Group: 3QOHORKING PISTON
RT76 Loosening and Tightening of Piston Rod Sheet:and Piston Rod Scre'" Respectively
Tools: Key to III ustrati ons
Tightening device complete HPOi 1 Pump
94356
94931 1
2 Pi ston
Piston rod
rod nut 10
11
Check Hydr.
valve on the HP oil pump
HP pump
Pressure gauge 94932 2a Pi ston rod screw 12 HP hose HP Ho se 94935 3 Cross head 13 Pressure gauge Hydr. Jack 94937 5 Holder for jack L Empl acement for holder Round bar Feeler gauge
94115 94122
6 7
Hydr. jack Special spanner F
5 when loosening Emplacement for holder
8 Spanner holding pin 5 when Tightening
<,TKufbel 22° iiber U. T. P schalten TURN CRANK 22° ABOVE B. D. C.
_L_---t--+ir- 1
I,
5 i
(9Io3$Q}U
2 2a 8 (9~356c)
II Remarks:
The ill ustrations shows the tightening device
94356 when tightening the piston rod nut 2 or the piston rod screw 2a respectively. For the latter alternative execution (with short piston rod) please place in the text below the piston rod screw 2a wherever the piston rod nut is men tioned.
For either tightening the piston rod fastening, or for loosening it, always use the tightening
J,' device 94356, which consists mainly of special spanner 7, spanner holding pin 8, jack 6, hol-der for jack 5 and the HP oil pump.
Mount a platform of boards in the crank case, permitting safe_ standing for the work process.
Fasten the jack holder 5 onto the resgective engine column. Rotate the crank to 22 after B.D.C ••
100 I.
340/3a RT76
Working Procedure for Loosening
Loosen the locking screws of the piston rod nut 2 and remove them with the locking segment.
Connect the hydraulic jack 6 to the HP oil pump 11 with the KP hose and place it into the holder 5 (jack piston pressed completely to initial position).
Place the special spanner 7 on the nut 2 in such a way, that it stands nearest possible to the piston of the jack 6, fasten the spanner in this position with the spanner holding pin 8.
Actuate the HP oil pump 11 and act upon the spanner 7 with the hydro jack 6, till the screwed fastening is loose. (It might be necessary to regrip, i.e. release the pressure, push the jack piston back to initial position and reset the spanner until the nut is sufficiently loose to permit turning it loose manually with the round bar).
To preserve the tool, never use the full stroke of jack.
Working procedure for Tightening:
- Clean the thread of the piston rod and the seating surface of the nut and coat them with molykote paste G.
- Fit the nut 2, turn it with the round bar till it is seated and tighten it with the special spanner 7 by a strong jerk (check with the feeler gauge whether the nut is actually fully seated).
- Mark the position of the toothed nut 2 to the crosshead 3 with an inking pen or similar.
- Fix the holder 5 on the left near the nut 2 and place the jack 6 which is connected to the HP oil pump, into the holder.
- Place the special spanner 7 on the nut 2, so that it stands as near as possible to the piston of the jack 6, and fasten it with the holding pin 8 in this position.
- Actuate the pump to act on the spanner with the jack until: 0
the nut 2 on engine with 'long piston rod' turned by 6 teeth ( ~ angle 10(' 30 )
the screw 2a on engine with 'short piston rod' turned by 11 teeth ( ~ angle '0<' 550
)
- Remove the tightening device and lock the piston rod nut 2 with the toothed segment and two screws The screws themselves to be locked with locking plates.
- Remove all tools and working accessories from the engine and store.
Loosening and Tightening with Spanner and Hammer
Should the hydraulic devices not be available, a heavy hammer can be used in place of the hydraulic jack, with which the spanner is hit.
The preparations concerning cleaning, use of molycote paste G as well as tightening angle 'CX:' remain unchanged.
1984
SULZER
RT76
Working piston
Checking the piston crown
Group: 340
Sheet: 4
Too 1s:
1 Feeler gauge
1 Template
94122
94366
The shape of the piston crown is to be checked with the template 94366
and feeler gauge 94122 (provided in the tool kit) whenever the piston is removed. The template is to be mounted on the upper piston ring and turned about the piston axis.
In cases where only light burntoff positions are established, it is quite
enough to grind or file them down and to smooth out the sharp edged marginal zones with emery cloth.
Should the burning off prove to be more serious, i.e. to a depth of in excess of X = 9 mm, the original wall thickness is to be restored by
means of buildup welding, for which the top part of the piston is to be di smantl ed.
Special welding instructions, which contain all the necessary detailed information, can be obtained from the manufacturer for such repairs.
Before the engine is started up again, efforts should be made to establish the cause of such burning and to remedy same. The burning maY'be attributable to:
- poor combustion, poor quality nozzles, heavy local
coking on the piston crown.
94366
Kolbenring
PISTON RING
4 -107.240.226
5.87
SULZER ltJORKING PI STON Group: 340
RT Dismantling and Assembling Sheet: 5
Tool s: Key to Drawi ngs
1 Spanner 94329 1 Piston crown 21 Round nut 1 Piston storage stand 94336 2 Pi stan rings 22 80 It 1 Clamping device 94339 3 Pi stan ski rt 23 Locki ng di sc 1 Suspension device 94341 4 Waisted bolts 24 10' ring 1 Suspension bol t 94345 5 Rubbing rings 25 Backing flange 2 Jacking bolts 94363 6a "Short piston rod" 25a Connecting piece 2 Bo lts 94364 6b "Long piston rod" (water i nl et) 1 Eye bolt (R) M42 (onl y for RT58) 7 Nut 25b Connecting piece 1 Spanner, type 330 8 Dowel pi n (water outlet)
9 Locking plate 26 '0' rings 10 Bolt AL 1 Threaded holes for 11 Pi stan rod nut jacking bolts 12 Piston rod bolt AL2 Threaded hole for
13 Locking screw jacking bol ts 14 '0' ring G Thread also for eye bolt'---' 15 Locking screw H Wooden underl ay
16 Locking plate R Eye bolt (only for RT58) 17 Bolt WE Water inlet 18 '0' rings WA Water outlet
19 Telescopic pipe
20 Bolt
0 94341
94339'------......id:J
Kurze Kolbenstange Lange Kolbenstange SHORT PISTON ROD LONG PISTON ROD
94345 R (only for RT58)
0-107.197.009
T • R. 5.84
'I
Xl p-
@
/94345
/6a
~ ;
/'94339 '',
/!
Kurze Kolbenstonge
SHORT PISTON ROD
Fig. 0)
R (only forRT58)
94345
1//6b
.-
\
Lange Kolbenstonge LONG PISTON ROD
3
Fig. b)
~ • • I~
4"
19
/6b /
25a(b)
H
Fig. c) Fig. d)
( ( ( ( "
51
340/5b RT
I-I
17
16
15
l', 3
'~
13
~ C'I
25aNN WE21
WA 10 9 25b ALI
6a
DRAWN FOR RT 58 G
12
~-y
9-107.195.547
ALI
11
G
---M,~~- --J,,-~-1- I
B
©
gezeichnet fur RT58
1
20
22 23
L.B. 2.84
340/5c RT
A) Dismantling (see also vari2i'1t according to section C)
Shou1 d it be necessary to di smant1 e a pi stan (cleaning of cooling spaces, remachining of the
ring grooves, etc.), it must first be inverted as ~@ shown on Fig. lA' and placed on a solid wooden un-
derlay with the piston crown facing downwards. The telescopic pipes have to be fixed with the device 94339 to protect them against bending.
Fig. a) Piston in dismantling position.
Fig. b) Lifting of piston rod together with piston94363 skirt from piston crown.
Fig. c) Piston skirt in position for separation from pi stan rod.
Fig. d) Removal of piston rod from piston skirt.6b(a)
Procedure for Dismantling a Piston
Place the piston onto an even surface according to Fig. 'a' of illustration IB'. An underlay has to
3 be placed below the piston to protect it.
a) Separating Piston Head from Piston Skirt 1
Remove 1ocki ng e1 ements 15, 16 and 17 from all nuts 7 (Fig. 'C').
Slacken off and remove all the nuts 7 using the special spanner, type 330, and sledge hammer.
Using the crane, lift the piston rod approx. 4 to 5 cm from the floor.
®
Screw both the jacking bolts 94363 into the threaded holes ALl (see Fig. 'C', section II-II) until they contact the piston crown. The piston crown 3 can then be separated
from the piston skirt by screwing the bolts down either alternately or simultaneously (Fig. '0').
Now unscrew both the jacking bo1 ts until they:y:
no longer protrude from the bottom of the pi ston rod.
b) Separating the Piston Rod from the Piston Skirt
94363 Lift piston rod together with piston skirt and, from below, screw both bolts 94364 into the threaded holes above the ones into which the two jacking bolts in the piston rod are screwed (Fig. 'EI).
Using a spanner, 1 a 0 sen both bolts 20 (Fig. 'C', section III-III) with which
pi stan rod 6b (a) and pi stan ski rt 3 are bol-ted together but.
do not remove them yet.
~ 94364 Place piston rod with piston skirt onto three wooden blocks 'HI (see Fig. IC', illustra-tion IB').
2 -107.197.014
12.84L.B.
340/5d RT
Unscrew both the previously slackened off bolts 20 by hand and lift the piston rod and piston skirt approx. 3 to 4 cm off the wooden blocks.
'/ Evenly screw down both jacking bolts 94363, thus separating the piston skirt from the piston rod. The latter can then be lifted out and also be placed onto three wooden blocks.
Remove jacking bolts 94363 and bolts 94364.
Should the telescopic pipes for the piston cooling have to be removed as well, see instructions on Sheet 340/8.
c) Removal of the Connecting Pieces (water inlet and outlet) from the Piston Rod Flanges (Fig. 'C')
In order to remove the connecting pieces 25a and 25b, the piston rod and piston skirt have to be separated. The two toothed nuts 21 which have to be slackened off with impact spanner 94329 are accessible after removing the bolt 22 with the locking disc 23.
Slacken off the nuts with heavy blows of a sledge hammer on the impact spanner 94329 and remove them.
Push the connecting pieces out of their holes or, if necessary, press them out with jacking bolts.
d) Removal of Pi ston Studs (Fi g. Ie')
The waisted studs 4 can only be removed after the piston crown and skirt have been separated from~) each other and the locking screws 13 have been unscrewed.
Attention! To ascertain that the waisted studa are later fitted in the same places, marke them
and their position in the piston crown.
B) Piston Assembly
Preparations
For assembly of a piston, the following points must be observed:
1. If possible, always use new rubber rings which correspond to our specifications with regard to dimensions and quality (see Table). The round rubber ring 14 of the piston skirt must be made of silicon rubber (heat resistant to 150
0C).
2. All cylindrical guide sections. rubber rings. contact surfaces of nuts and bolt threads must be coated with Molykote paste before assembly.
3. If the waisted studs 4 have been removed, their threads as well as those in the piston crown must be thoroughly degreased and coated with LOeTITE HV 77 before fitting. Afterwards, the studs are to be screwed in until they fully bottom. Where new studs are being used, these must be drilled in this position to enable the locking screws 13 to be screwed in. The threads of these screws must also be degreased and treated with LOCT ITE HV 77.
a) Fitting the Connecting Pieces into the Piston Rod Flange (Fig. 'C')
Smear the shafts and threads of each connecting piece 25a and 25b with Molykote and insert them intp the throughly cleaned holes.
Threadon the nuts 21 and tighten them with the impact wrench 94329 and a heavy hammer with stroRg blows. Fit the locking disc 23 (which locks both nuts 21 simultaneously) and fasten ist with the screw 22.
b) Assembly of Piston Rod and Piston Skirt
Place the piston skirt 3 onto three wooden blocks, approx. 120 to 140 mm high, making sure that the threaded hole for the bolts 20 are accessible from below (see Fig. 'd' of illustra-tion 'B').
Insert piston rod 6b (a) into the piston skirt and, from below, screw in by hand both bolts 20 until they are fully home.
L.B. 11 .84
340/5e RT58
Lift both piston rod and piston skirt with the crane. From below, push a piece of pipe through one of the eight holes for the waisted studs 4 and with it, turn the piston skirt around on its own axis until its holes for the waisted studs line up with those in the piston rod flange.
After lining up the bolts 20 can be firmly tightened with a spanner.
c) Bolting Together Piston Skirt and Piston Crown and Tightening the Piston Studs
Have piston crown ready on an even base (see Fig. Ib', illustration 'B').
Check that all waisted studs 4 are locked with locking screws 13 (see Fig. rc,),
Fit round aring 14 (see points 1 and 2 of the preparations on Sheet 340/5d).
Lower piston rod 6b (a) complete with piston 'skirt 3 over piston studs 4 making sure that the part of the connecting pieces with the 'a· rings 26 slips into the corresponding bores of the pi ston crown.
After joining the two piston parts, a gap IS' of 2.0 mm remains at the joint faces.
Screw on all nuts 7 by hand until they make firm metaltometal contact.
Nip up all the nuts with a spanner and light hammer. Mark the position of the nuts relative to the
® 3
2 -107.197. 691
6a(b)
~
piston rod flange with a felttip pen or similar. Motor
~. Tighten the nuts diagonally, in turns, and in serveral steps using the spanner type Engine
330 and ~he sl edge hammer, until the nuts Itavt! been ti ghtened by an angl e oC (as per inset on the side) from the starting position marked with the marking pen. RT 58 00°
RT 68 Secure all the nuts 7 with locking disc 15, locking plates 16 and bolts 17 (Fig. IC!).
RT 76 60 0
RT 84
C) Dismantling
Where there is restricted dismantling height available, the piston can also be dismantled without having to turn it upside down. In this case the piston storage stand 94336 (Fig. IF') is bolted to the platform girder instead of the two supports 94350 (see Group 340/1, positioning piston). The piston can then be lowered onto this stand the same way up as when it was removed. The only diffe-rence in the dismantling procedure as described for variant 'A' is that the p;ston rod remains on the stand and the piston crown and piston skirt are lifted by the crane. The tools are used in the same way.
3.87
., i ''
34015f RT
® Ausfiihrung mit Kolbenunterteil in zwei Teilen
EXECUTION WITH PISTON SKIRT IN TWO PARTS
27
(jezeichnet fiir RTA68 DRAWN FOR RTA68
II-II
......... :.. .. ...: .. ~ . _ . ~ .•._._ .
,./"'.
~
4 107. 240.J,73
Depending on there execution, working pistons may be equipped with so called one or two part piston skirts see Fig. 'C' respectively 'G'.
The working piston has to be dismantled prior to the removal of a sealing plate 27 (Illustr. 'G'). The dismantling and assembling sequence is for both executions the same. '
If on a two part riston skirt the sealing plate 27 has to be removed, in such a case screw plug 28 must first be taken off. The sealing plate can be lifted from the piston rod with the aid of two eye bolts, after the removal of allen screw 29. '
For fitting the sealing plate 27, LOCTITE type 'A' has to be applied to the threads of the allen screw 29 and the screw plug 28 as well as a new Cu-sealing to be used for the sealing plug. The allen screw has to be tightened with an angle.. of 40 0
•
L.B. 1.92
4 i7bar
SULZER Group: 340WORKING PISTON
RT Sheet: 6Pressure test of Cooling Space
'--")
(Leak Tightness test)
Tools: Key to Illustrations
Pressure testing device 94331 1 Vent valve 5 Oring Assorted spanners 2 Brazing ring 6 Connecti ng pi ece
3 Pressure flange for 7 Shutoff cock the telescopic pipes 8 Hand pump
4 Pressure test nipple ~ I Pressure gauge
When a working piston has been dis
mantled and re-assembled, a pressure test must be carried out to
ensure the tightness of the cooling space and the pipe connections.
The pressure testing device 94331 contained in the engine tool set is connected to the connecting piece 6
While filling the cooling spaces with water keep the vent valve 1 open unti 1 wi th the fi rst pump strokes and the issuing water all the air has escaped.
Test the cooling space during 15
minutes at a pressure of 4 to 7 ba~
Should the piston leak dismantle the piston again and remedy the cause of the leak.
~
94331 6
fvf
7
8
2 -107198.405
l; 0 I,
SULZER Group: 342WORKING PISTON
RT Changing of Piston Cooling Sheet: 1
Telescopic Pipes
Too 1s: Key to Drawings
Checking gauge 94330 3 Pi ston ski rt 25 Backing flange Clamping device 94339 6a(b) Piston rod 25a Connecting piece Suspension bolt 94345 9 Locking plate (water inlet) Hand 1amp 10 Bolts 25b Connecting piece
19 Telescopic pipe (water out1 et)
24 '0' ring A Eye
L Lamp R Eye bo lt
19
25
9
25b
19
25
25a(b)
3
o
gezeichnet fur RT 58 DRAWN FOR RT 58
4101.191.01.0
L.B. 2.84