ec WARTSILA Weer enc) RTA84 Maintenance Manual “Marine” Vessel: Type: Engine No.: Book No.: Wartsila Switzerland Ltd Tel. +41 52 262 49 22 PO Box 414 Fax 4415221249 17 CH-8401 Winterthur httpy/wwer.wartsila.com Switzerland ‘© 2002 Wattsta Switzerland Lt, Printed In SwitzerlandInformation ‘The engine can be equipped with long” or *short” piston rods, ‘With thelong version the soda the piston sled through ee andsecuredat thebottomwitha suitable nut, diate cas Stor aston connection is effected by means ofa strong bot, which sinserted at the bottom x9 Con abs and into the piston a. ‘Tonle out the pons of takes the data relevant to engines equipped with short piston roasare sede greencoloured paper. Customers are requested to remove the pages of the manual that do not apply to their particular engines. Piston rod bolt Piston rod nut 4-17 240.418 K.ketg,BE | Maintenance 00/1 For Particular Attention ‘This manual is put at the disposal of the recipient solely for use in connection with the comesponding type of Sulzer diesel engine. Ithas always to be treated as confidential. ‘The intellectual property regarding any and all of the contents of this manual, partculatly the copyright, remains with \Wartsila Switzerland Ltd, This document and parts thereof must not be reproduced or copied without their written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Before the operator intends to use the engine or before maintenance work is undertaken, the Operating Instructions or the Maintenance Manual respectively is to be read carefully. To ensure the best ef should be used. Itis to be ensured as well that all equipment and tools for maintenance are in good condition. jency, rellabllity and lifetime of the engine and its components, only original spare parts ‘The extent of any supplies and services is determined exclusively by the relevant supply contract, ‘The data, instructions and graphical illustrations etc. in this manual are based on drawings made by Wértsila Switzerland Ltd and corraspond to the actual standard at the time of printing (year of printing is indicated on tite page). ‘Those specications and recommendations of the classification societies which are essential for the design have been considered therein. It must be recognized that such data, instructions and graphical illustrations may be sub- ject to changes due to further development, widened experience or any other reason. This manual is primarily intended for use by the engine operating and maintenance personnel. it must be ensured that twill aways be at the disposal of such personnel for the operation of the engines andlor for the required mainte- nance work. ‘This manual has been prepared on the assumption that operation and maintenance of the engines concerned will ‘always be carried out by qualified personnel having the special knowledge, training and qualifications needed to handle in a workman-like manner diesel engines of the corresponding size, the associated auxiliary equipment, as well as fuel and other operating media, ‘Therefore, generally applicable rules, which may also concern such items as protection against danger, are speci- fied in this manual in exceptional cases only. {It must be made sure that the operating and maintenance personnel are familiar with the rules concemed. ‘This manual has been prepared to the best knowledge and ability of its authors. However, neither Wairtsila Switzerland Ltd nor their employees assume any liability — under any legal aspect whatsoever, including Possible negligence — in connection with this manual, its contents, or modifications to it or in connection with its use. Claims relating to any damage whatsoever or claims of other nature such as, but not limited to, demands for additional spares supplies, service or others are expressly excluded. Wartsila Switzerland Ltd Winterthur Switzerland ‘Wartslla Switzeriand Lid 2002Table of Contents Maintenance Instructions Clearance Tables Tightening Values for Bolt Connections Weights, Rubber Rings Maintenance Schedule Work Sheets Tool ListsRTA Maintenance 01/1 Preface ‘The aim of the "Maintenance Manual” is to help to ensure that the maintenance which has to be carried out at specific intervals is done correctly. Its assumed that the staff charged with such work possesses the necessary know—how. Information covering engine operation aswell asthe description ofthe functioning of specific systems iscontained 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, Dimensions and Material Specifications of the Rubber Rings, Clearances and Values for Bolted Connections © Work Sheets © Tools List ‘The following are a few explanations to the above items: ‘The "General guide Lines for Maintenance” contain — in addition to indications regarding precautionary mea- sures to be taken — recommendations on how to carry out the work. Inthe "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 aswell a the proper tightening of certain impor- tantbolted connections. The "standard clearances” mentioned in the Table of Clearances 012/l & following corre- spond to those partly resulting from manufacturing tolerances or those adjusted on the new engine. ‘The maximum clearance or max,/min, dimensions stated are those values which may result from wear after a pro- longed period of operation and which are neither to be exceeded nor gone below. In parts where the clearance can becorrected by a change in the thickness of shims, discs, distance piecesetc. the original standard clearance should alwaysbe aimed at,and adjusted, Wherever thisisnot possible, the worn parts mustbe replaced or reconditioned by building up (chrome plating, welding build—up 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 or 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 operation 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 eng parts ‘The tools and devices are specified in the Tools List” which are needed for maintenance work and which are nor- ‘mally 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 wil be incorporated in the next edition. LB. SULZER 1982RTA Maintenance 02/1 ‘Table of Contents for Maintenance Manual FOR PARTICULAR ATTENTION 000 PREFACE 01 ‘Table of contents for Maintenance Manual 002 Engine cross— and longitudinal section ‘004 ‘Numbering of bearings and cylinders as well as definition of engine sides 08 GENERAL GUIDE LINES FOR MAINTENANCE, on Precautionary measures for maintenance work Recommendations for carrying out the work ‘TABLE OF CLEARANCES — Crankshaft and thrust bearings ora — Crosshead guides oie, (2aRTAS8) = Cylinder iners 14s ~ Piston rod glands ona — Exhaust valve O1aa = Crosshead— and crank pin bearings ons = Crosshead lubrication 01416 = Working piston and piston rings oz ~ Piston telescopic pipe glands 01/8 — Gear wheels for camshaft drive and PTO gearbox 0129 ~ PTO gearbox 01/9 — Camshaft and reversing servomotor o12/10 Ancillary gear drives o1g/L = Ancillary and starting air distributor drive o12/i1a — Intermediate shaft for ancillary gear drives org — Roller guides for fuel injection and actuating pumps o1yi2 Drive for cylinder lubricators 0143 ~ Overspeed, pick—up and remote tachometer transmitter oa ~ Balancer drive elements (2nd order 4 to 6 cyl. engines) ois ~ Balancer drive elements (Ist and 2nd order, 4 cyl. engines) o1z/isa (RT68, RT76) INFORMATION ON THE TIGHTENING OF IMPORTANT 13 SCREWED CONNECTIONS MASSES OF INDIVIDUAL COMPONENTS (per unit in kg) o1 DIMENSIONS AND MATERIAL SPECIFICATIONS OF THE RUBBER RINGS ous MAINTENANCE SCHEDULE (Table of intervals) oa WORK SHEETS ‘Taking oil samples for laboratory analysis sat Bedplate = Checking the foundation bolts non Main bearings — Loosening and tightening the bearing thrust bolts, 7 = Removal and fitting of a bearing cover and an upper 178 bearing shell — Removal and fitting of the bearing cover and stopper 17/4 bridge in the thrust bearing assembly — Removal and fitting of a lower main bearing shell 1005 LB. Sor, 1.9402/1a ‘Thrust bearing Tie rods Cylinder jacket Cylinder liner Lal ting quills Piston rod gland Cylinder head Fuel injector valve Starting valve Relief valve Exhaust valve Crankshaft ‘Torsional vibration damper (on crankshaft and camshaft) Axial damper Turing gear Connecting rod and. Connecting rod bearings 10.86 Maintenance Checking the axial clearance Removal and fitting of thrust bearing pads Checking the pre—tension and tensioning the tie rods ‘Transporting a cylinder liner with fitted cylinder jacket Removal and fitting of the water guide ring Measuring bore wear Removal and fitting ‘Removal of wear ridge, rectifying lubricating grooves ‘and edges of scavenge ports Function check ‘Removal and fitting and measurement of wear Removal and fitting ‘Hydraulic loosening and tensioning of oylinder head studs Mechanical loosening and tensioning of oylinder head studs Manual rectifying the sealing face for the fuel injector in the cylinder head ‘Checking, dismantling, assembling and setting ‘Cleaning and overhauling injector nozzle Lapping of injector body sealing face (Checking a circulating vaive (Cleaning and checking Dismantling, assembling and checking Removing and fitting the exhaust valves in the cylinder head Dismantling and essembling Exchanging and grinding the valve seat Grinding the seat face on the valve spindle ‘Measuring the crank deflection ‘Taking a silicon fluid sample Dismantling and assembling Oil change end 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 shells Removing and fitting a connecting rod SULZER RIA 20 1202 90/1 21 2112 24 2142 24/4 25/1 231/ 27011 270)2 270/3 20/4 2m 2722 278 2124 273 274 2511 27512 27513, 2754 10/1 3132 314 300 2330/1 3302 3303 3304 3305 3306 LB.RTA Crosshead ‘Working piston Piston rings Piston cooling Camshaft drive gear Camshaft Starting control air distributor Starting air shut-off valve Running direction safeguard Shut-down servomotor WOODWARD governor Safety cut-out device LB. Maintenance Checking the clearances Removing and fitting a crosshead with working piston removed Removing a working piston Fitting a working piston Loosening and tightening the piston rod nut (resp. bolt) with a special spanner ‘Checking the piston top surface Dismantling and assembling Pressure testing cooling space (leak tightness test) Exchanging piston cooling telescopic pipes (Checking piston ring wear Checking the stand pipes Maintenance of glands for the telescopic pipes Checking of running clearances, backlashes and condition of teeth Removing and fitting the intermediate gear whee! ‘Replacing the split gear wheel on the cranksbat ‘Removing and fitting a camshaft section Dismantling and assembling of hydraulically fitted components ‘Removing the fue! injection— and the actuator cam Pressing on the fuel injection cam Pressing on the actuator cam Adjusting the fuel and the actuator cam, Removing and Fitting the flange coupling Removing and Fitting the camshaft coupling ‘Removing and fitting the gear wheel on the camshaft Dismantling and assembling Cleaning and function checking Inspecting and function checking, Dismantling and assembling (only for engines with SC-Control) Installing, removing and maintenance ‘Maintenance, function check SULZER 002/1b 3321 37/3 340 340!2 34013 34014 34015 34016 342 3422, 3060/1 36/1 410n 41072 4103 4202 42100 42m 424/tb aii #2i/le anit 42g aaah aula 4430/1 43/1 53/1 455/ S101 30/1 5.87002/Le Fuel injection pumps Charge air receiver Auxiliary blower Charge air cooler Cylinder lubricators Driving shaft to the flow control valve of the cy- linder lubrication PTO.-Gearbox Etficiency—Booster Balancer Exhaust pipe Hydraulic pipe to ex- haust valve drive TOOLS Hydr. Jacks and pumps Hydr. pre-tensioning jacks Tools list 12.89 Maintenance 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 Tightening of nipple for plunger bush Maintenance of valve groups and cleaning the charge air receiver Maintenance of water separator elements Maintenance Cleaning (air side) with engine at stand still Cleaning (water side) with engine at stand stil Removing and fitting the cooler stack Cleaning Dismantling and assembling Checking the tooth profile and tooth backlash, re— aligning the gearbox housing, checking the running performance Removing and fitting gearbox components as well as the intermediate gear wheel Geislinger coupling, external check for oil leaks and constant venting Removing and fitting the hycraulic coupling as well as the flexible packet coupling. Checking the oil level of the hydr. coupling and the alignment of the power turbine. Function checking and maintenance of the shut-off flap and the bypass valve Fitting, Removing, Tensioning the Roller Chain Fitting, Removing the flexible Coupling and a ‘Camshaft section Adjusting the Belleville washer spring packs on the ‘exhaust pipe mounts Overhauling the pipe seal faces Explanation Arrangement and application Storage, care and spares stock General application instructions Standard tools, Recommended tools ‘hols obtainable on loan, SULZER rah Taf 740/1 74012 74013, 50/1 7502 TIO/L sul 8461 940 9400, 08, 940/00, Oe ‘Oh (Gi, RTS4) 940/1 = 41 940/48 ~ $1 940/60 LB.RTA84 Motor Quer- und Liingsschnitt 846/1 272/146 32/2. 6846/1 3462/1: 4382/1 62/1 SSIS 420, A21/eh Nt 360/1 jS[s ol Maintenance as \ [Ic] \S ng | la 7 | 4 9} OP eth | SULZER 04/1 BN/T 660/2+3 640/1 ‘GAI/2 23/1 HOA 10.8604/2 Maintenance RTA84 zu 27a/t 275/2 2/1 2+4 270/206 | ane at t cai dr Pan rE 2n/2— 2m/1 Pp ——-340/12,4548 i : 72/1 Tell fey _|_ —-aaov2 i Ea 330/5 m0/ 70/1 i a _ 02+ — SS a er] Lia 332/162 : 337/3 ae 330/134 330/6 NNT 120/1- NI/Z _—_Z [| 19071 587 SULZERRIA Maintenance 08/1 Engine Numbering and Designation = Thrust bearing| © | @ | @ @16/0/o@ Ot Numbering of ‘Numbering of connecting rods Numbering of main bearings 9107156. 28 © Left-hand engine Right-hand engine Iq H G lo Fuel pump side ry ml S| S ——} 7 SS Li Exaustside | | //77 Exhaust side counter- clockwise 3-107, 159.086 clockwise View from driving end Le. SULZER 2.84RTA Maintenance out General Guide Lines for Maintenance ‘The maintenance workto be carried out on the engine at specific intervalsis described in the "Maintenance Sched- ule” of this book and is to be understood as a guide, Experience will show whether the intervals may be extended or have to be shortened as mode and conditions of operation, quality of fuel and lubricating oil used, as well es many other factors influence the condition of the engine toa great degree. Precautionary Measures for Maintenance Work Prior to carrying out any maintenance work on the engine (especially on the running gear), the following precau- tions have to be taker © Close the automatic shut—off valve for starting air as well as the shut-off valves on the starting air receivers. © Close all the shutoff valvesin the control air pressure—reducing unitand the drain cocksin the two airrecciv- ers arranged above it, © Openthe drain valvesplaced in the pipes before and after the automatic starting airshut-offvalve and leavein this position until maintenance work is completed. © Openalli licator cocks on the cylinder heads and leave in this position until maintenance work scompleted. © Engege turning gear (gear pinion must be in engaged position) and lock the lever. ‘© Where the engine has been stopped due to overheated running gear or bearings, wait at least 20 minutes be- fore opening the crankcase doors. © The crankease doors must always be locked with all the closing dogs whenever the engine is running even if thisis only for a short time in order to make temperature checks (eg. after changing bearings during an over- haul, ete.), © Inthe case ofa fire in the engine having been extinguished by means of CDa, the spaces affected 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 bear in mind 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 rile, are supplied with the engine (see "Tools List” 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 940/02). = Allwork must be carried out with the necessary care, observing utmost cleanliness. = During maintenance, openings of pipes, open oil bores, ete. must be temporarily closed to avoid the entry of any dirt = Allparts 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 refitting New Spleset 2.92