Service Information

Low Speed 2-Stroke Engines Bulletin No.: DUQ1-184E

Date: 2015/08/12
All RTA / RT-flex / W-X engines
Cylinder Liner Calibration

1. Introduction

In order to estimate piston running condition and/or determine suitable overhauling

interval of cylinder liner, it is very important to understand exact trends of cylinder liner
wear. There is a possibility that erroneous liner wear data by an improper measurement
leads to a misjudgment about cylinder liner condition.
This Service Information provides tips on the measurement of inside diameter of
cylinder liner to obtain reliable liner wear data.

2. Calibration point of cylinder liner

Standard calibration points around

upper part of cylinder liner are defined
by relative position to the top dead
center (TDC) of piston head. TDC
position was determined by the setting
of compression shim, so it is varied
according to engine rating among same
engine type.
In other words, positions of liner
calibration points, which are distances
from top sealing surface of cylinder liner,
are different depending on the thickness
of compression shim.

Fig.1: Measurement of inside diameter

Therefore adjustment of measuring
of cylinder liner
gauge is required for each engine.
Measuring holes of the gauge are made to be matched to the calibration positions in case
thickness of shim is zero. To match measuring holes to correct calibration positions, adjust
setting screw as its lower protruding length is the same as the thickness of compression
shim (refer Fig.2).
Thickness of compression shim fitted on each engine is described in the setting table in
its inspection record of shop trial, or please contact us if it cannot be found.
 Bulletin No.: DUQ1-184E, Page 2 / 5

When the properly adjusted gauge is hooked over the top face of cylinder liner, position
of the topmost calibration point (point A) must be on the non-sliding surface area above
wear ridge of top ring TDC.

Fig.2: An example of measurement gauge adjustment by setting screw

depending on thickness of compression shim (W-X82)

Diameter at point A is used as a reference of liner wear, since wear amount on the
non-sliding surface can be considered as zero. Cylinder liner wear is calculated by using
the formula below.

1000

W = Liner wear [mm]

WR = Wear rate [mm/1000h]
D = Liner diameter in sliding surface (point B to …) [mm]
D0 = Liner diameter in non-sliding surface (point A) [mm]
T = Liner working hours [h]

Before starting measurement, non-sliding surface above TDC must be thoroughly

cleaned from any deposits or lacquer, as point A is used as a reference.
Maximum liner diameter may be observed at the top ring TDC in case cylinder suffers
severe corrosive wear. Therefore, it is recommended measuring diameter at top ring TDC
position in addition to standard calibration positions.

To permit comparisons with previous measurements, it is required that measuring is

carried out in the same place as previous measurement. However, liner bore ovality may
not be round but undulating shape as shown in Figure 3.
 Bulletin No.: DUQ1-184E, Page 3 / 5

Therefore, it is necessary to
pay attention to difference of
calibration position in a
circumferential direction. This
means that calibration should
be done precisely in P-S and
F-A direction. For example of
RT-flex96C engine, accurate
P-S or F-A direction is 9 degree
in CCW direction (75.4 mm left)
from lubricating quill, as shown
in Figure 3.
Fig.3: An example of liner ovality patterns (RT-flex96C)

3. Liner calibration method without removing cylinder cover

In this chapter, an in-situ measurement method of cylinder liner diameter by a special

device is introduced. This method allows to measure liners during routine piston underside
inspection at port or anchorage, without removing of cylinder covers or exhaust valve
casings from liners.
After moving a piston down to its bottom dead center (BDC), special prove and
measuring base are put on the top of piston crown through a scavenge port (see Figure 4).
Prove can remotely be manipulated by wireless, and execute rotation and measurement
on the base. By moving piston up and down by using turning gear, liner diameter can be
measured at arbitrary level.
However, obtained raw data is including deformation amount of cylinder liner by
tightening cylinder cover bolts since this method is carried out without removing cylinder
cover. For comparison with data measured after removing cover, deformation amount
should be considered. An example of comparison of liner wear profiles is shown in Fig.5.

Fig.4: Installation of the liner measuring device on top of piston crown

 Bulletin No.: DUQ1-184E, Page 4 / 5

Fig.5: Difference of wear profiles of upper part of cylinder liner (example of RT-flex84TD)

Under the condition cylinder cover was tightened, liner bore around 500mm from the top of
liner was observed slightly larger than it was measured without cylinder cover.
Moreover, upper non-sliding surface cannot be used as a reference point since
deposits cannot be removed. Alternatively, sliding surface above scavenge port, where
wear amount is relatively small, is usually chosen as reference surface.
Currently, in-situ measurement service by this method is available for following engine
types.

- RTA96C / RT-flex96C - RTA84T, T-B / RT-flex84T-D

- RT-flex82C - W-X82
- RTA58T-D / RT-flex58T-D - RT-flex50, -B, -D

4. Appendix
 Appendix 1： Table of standard calibration positions for typical engine type.

5. Contact details
 For questions about the content of this Service Information, or if you need field service,
please contact :
Technical Support Department Aioi Office
Customer Support Center of IHI Power Systems Co., Ltd.
Phone: +81-791-24-2286
e-mail: ips-du-support@ihi-g.com
 If you need spare parts and/or tools, please send your enquiry to :
Parts Sales Department Aioi Office
Customer Support Center of IHI Power Systems Co., Ltd.
Phone: +81-791-24-2285
e-mail: ips-parts-a@ihi-g.com
 Bulletin No.: DUQ1-184E, Page 5 / 5

Appendix 1

Table: 1

Distance from upper sealing surface of cylinder liner

at each standard liner calibration points

RTA96C RTA84T -B
Engine type W-X82
RT-flex96C RT-flex84T-D
Comp. shim [mm] 0 10 20 25 0 21 28 31 38 0 20 36 67
Max. permissible
966.7 845.9 825.7
diameter [mm]
A 207 197 187 182 170 149 142 139 132 180 160 144 113
Distance from upper sealing surface

TDC 212 202 192 187 175 154 147 144 137 240 220 204 173
at each measuring position [mm]

B 240 230 220 215 210 189 182 179 172 279 259 243 212
C 310 300 290 285 275 254 247 244 237 324 304 288 257
D 388 378 368 363 335 314 307 304 297 453 433 417 386
E 720 710 700 695 860 839 832 829 822 603 583 567 536
F 958 948 938 933 890 869 862 859 852 876.5 856.5 840.5 809.5
G 1308 1298 1288 1283 1505 1484 1477 1474 1467 1027 1007 990.5 959.5
H 1664 1654 1644 1639 2120 2099 2092 2089 2082 1603 1583 1567 1536
I 2020 2010 2000 1995 2860 2839 2832 2829 2822 2103 2083 2067 2036
J 2320 2310 2300 2295 3590 3569 3562 3559 3552 2603 2583 2567 2536
K 3200 3190 3180 3175 3123 3103 3087 3056
L 3779 3759 3743 3712

RT-flex58T-D
Engine type RTA58TD RT-flex58T-D (self-support RT-flex50, -B RT-flex50-D
liner)
Comp. shim [mm] 0 19 0 36 0 47 0 17 20 0 20 30
Max. permissible
584.0 584.0 584.0 503.5 503.5
diameter [mm]
Distance from upper sealing surface

A 152 133 152 116 164 117 75 58 55 95 75 65

at each measuring position [mm]

TDC 156 137 188 152 188 141 87 70 67 115.5 95.5 85.5
B 193 174 193 157 211 164 108 91 88 139 119 109
C 238 219 238 202 245 198 159 142 139 170 150 140
D 285 266 285 249 285 238 210 193 190 205 185 175
E 660 641 660 624 721 674 436 419 416 513 493 483
F 878 859 878 842 921 874 662 645 642 822 802 792
G 1424 1405 1424 1388 1292 1245 888 871 868 1022 1002 992
H 1970 1951 1970 1934 1763 1716 1339 1322 1319 1406 1386 1376
I 2275 2256 2275 2239 2236 2189 1790 1773 1770 1790 1770 1760
J 2760 2741 2760 2724 2760 2713 2241 2224 2221 2275 2255 2245