Lf, WARTSILA Presses Maintenance Manual “Marine” Vessel: Type: Engine No.: Book No: Warsi Switzerland Ltd POBox 1s (F-8401 Winterthur tp vwawartsia. com SwizerlaneGeneral information " Group'0 For Particular Attention ... 0000-11 Preface 0001-1181 Table of Contents. --0002-1/A1 Engine Numbering and Designation . -0¢08-1iA 7 General Guidelines for Maintenance ~ Safety Measures and Wamings ott—viAt V7 Clearance Table 7 : 0330-1101 Main Bearing and Thrust Bearing Page — Crankshaft and Main Boring Page 2 ~ Grosshead Guide Pages yjinder Liner : Page 4 Cylinder Liner (wth Vertical Cooing Groove) Pages Piston Rod Gand Page 6 ~ exhaust Valve Page? = Top and Bottom End Bearings 10 Connecting Rod Page 8 = Piston Goong and Crosshead Lubricating Link Page 9 — Working Piston and Pston Rings Page 10 = Wheels for Camshaft Drive Page 11 ~ Camehatt and Reversing Servorotar Page 12 = Gearing or Ausiiary Drives (Driving Ena) Page 13 = Staring A Distributor Page 14 Roller Guides for njection and Actuator Pumps Page 15 ~ Balancer of 2nd Order (Driving End) Page 16 ~ ELBA (ctrical Balancer)... Page 17 ¥ Tightening Values of Important Screwed Connections ~ Tightening Valves of important Screwed Connections 352-11 — Tighoning inttuctions fr Normal Serows 352-281 ts Sattar RIAGBT-B/\MM / 4.03Masses (Weights) ~ nividual Components per Pieco in kg V_ Dimensions and Material Specification — Oxings and Round Rubber Rings ~ Piston and Rod Seal Rings = Supporting Rings 7 Maintenance Schedule Inspection and Overs Inervals (Guideines) Engine Cross Section and Longitudinal Section Taking Oil Samples for Laboratory Analysis 1998 / wnt / RTAGBT-8, 0350-11 oa70-1A1 0370-2181 0370-2181 0880-101 ++ 0803-11 -0900-1/81,neaaer! Maintenance 0000-1/A1 For Particular Attention “Ths manual is puta he disposal othe reient solely or use n connection wth the corasponcing type ct Sulzer ial engin. thas always tobe treated as conidential “The intelectual pepory regarding ary and allot he contents of this manual, particulary the copyright, reals with Wartsia NSD Switzerland Lid. This document and pars thereat must no be reproduced or copied witout ther rien permission, and te contents thereot mus not be imparted to ard party nor be Used for any unauthorized purpose: ‘Before the operator intends o use the engine or boloe mairtenarce work s undertaken, the Operating Intactions rte Maintenance Manual respectively tobe ead carey ‘Toensure the best efciency,reiabilly and Hetime ofthe engine and its components, only orignal spare pats ‘shouia be usea '5o be ensured as well that all equipment and too! for maintenance aren good condition, ‘The exent of any supplies and services is determined exclusively by the relevant supply contract, “The data, isiructions and graphical lustations ot in his marual are based on drawings made by Wartlli NSD Switzeriand Ltd and carespond othe actual standard atthe time of printing (yer of printing s indicat on tle pave) ‘Those spscifeations and recommendations of the cassiicaton sciebas which are essential forthe design have been conidored then It must be recognize that such data, nstuctone and graphical ustatone may be sub jostle changes due to furor development, widened experience or any othe reason. ‘This manuals primal intended for use by the engine operating ae maintenance personne. It ls assumed that it wi aay be atthe disposal of such personnal fx the operation ofthe engines andr forthe required martenace wok ‘This manuel has been prepared on the assumption that operation and maintenance ofthe engines concerned vl lvays be cared out by personne having the special knawledge, Waning and quaiieons needed to hand in a drkman tke manner dese! engines of the coresponding sie, the associated aunary equipment, as vel as fue «nd other operating media, ‘Therefore, onerally appicabie rules, which may also concem such tems a protection against danger re speci ‘id inthis manualin exceptonal eases eniy. must be assumee ha the operating and maintenance personne are ‘amir wih the rules concerned ‘This manual has been prepared tothe best knowledge and abilty of ts authors. However, neither Wartslé [NSD Switzerland Ltd nor their employees assume any labilty ~ under any legal aspect whatsoever — in Trews npr) fe foto no be ues ropa |= Te arene nmostone ut beara naccortarce mathe arnt npreiores anata No Swarr 1 3.000352-1/A1 Maintenance ‘Tightening Values of important Screwed Connections [2751-2 |(@ Exhaust valve, sew for grooved valve womnoreS fone pace (@ east vaho, cron or einder 0 = wowworee (@ ona are ro ry eid TST] coving bof: toot 58 15° | moore @ Couping bot or ropaer shat Miea or | momeore@ 90-1 [@ Coupling bts, cankshah—veraton | M7Exa ‘wr | mounares | Sampo [@ Coupirg bats, crankshaft rea a | woonoree ‘courant . {3146-1 |@ Fixing bot for adel dtunr wih boopate | Mae (630) womneree [3300-1 | @ Conmesing rx, ud ortop end boarng | a2 1000 : cy ete ap hc: ep ond ep Lf es @ Connecting od uator bottom end | MSE [1000 « Bearng 12m 009-9 | > epsom |_| cs tata tnd aan Ee [3408-1 |@ Pistonro, waisted su or crosshead | MOO | 1000 =) | festering se enor popes 308-3 | Paton vod, wasted exow'orpison | wam2 | | (225) | 70" | woworea own | @ Sorayng pao piston rod mio Remo rotgtowntonn [swe ed rung er pols, ees posave nba tsb ue haan oth ie Bn aS conesan ar ‘rams 02m hare aspen |. Teambarin © rt heikaetonon pages 8. [+ Thelen prsse (ae fr orn any be wa compar, [+_Thezzone omens mt bores nanan wee vas non saree 3.00 2 st NBD Stated UsERED rrraccr-s Maintenencs (0352-1/A1 “Tightening Values of Important Screwed Connections 4103-2 |g imemedote gear bearing or camahat | M0 40° | wocnore® ive waisted sow ‘Screwed connection, goar sin hub ot | awz | | (600) | 70" |maaswinan, (© Sermons whee |saeses (ot are ah LOTTE No.2 | | 105-5 |@ Goar wheel on wantahat, nasi | Nana (eo) | eS sesamin : anges conection [pores ets an TEN. 2) | [@ Twopar gee whoo! oncankshat, | WaO® [Elongation 1202008 sees vatsed sad pare weed mm on 2209-1 |@ Camstat, scow or Range eouping | M20 50° |aiminae (Gand ofindes) sats Reversing sevometo onghudna mie wo pease © ESionng | eres |® Revesng senonoter asienng wer 70° reais |® between that ena wing | Beanee [@ Veraion camper—canshat coving | wae 7 |eaapenee @ Wisse su forinecion pump housing, | wa | 1000, oy [om Dearing over or cama bearing 208-5 [@ Twopat gear wheel oncanshet, | w2ez | | @o0) | 70" [pease serene connerion gear = Wb Ses | ranes wrt OcTT 26 I | [@ Wialsted sudo bearing cover, camshaft | wa? | 1000 | 5) pyaar ive jee | ice es | [eel | JF 1@ Waisted stu tor injection pump housing | Maa | sor fe “ojindractet | . @ Hevaaon natforinjecton pump hewsing | ws s o ince octet aren uaa cb, equa peace ibormt beacuse neato ect ck nace Someraor cor ‘Tims oscemp ‘bars 02) + te nmber in Croton stators on pape 618 The ver inpronnaes Je tinatn em be ud er comet, +The sso conosons mut betes nazararce nh vas not npretaes, Wana NS Swarr 3 3.000352-1/A1 Maintenance ERE more ‘Tightening Values of important Screwed Connections |@ Hexagon nut for injection pump housing ~oyfnder jacket {contr waits ic aera ae a. yan fen eesti ei ere Seer 5612-1 [@ tnecion pure lek, meagan nator | Mz? oo [aetna wed Sud eine 1S Mpsonnue tek weoweobante fwwons) | cen | a5 | womores fvmnpmne ot ed met Sees I@ econ ur noc, exewod wa @ mone Chnectin var coe 2512-+ (© Nol fx purge bush iwio * womnares [3516-1 [@ Actus pump, pogo nt torwaied | NO oleae oy stents ae 7722-1 |@Compensaing stat ot ropa wor ws | wonoree Sater med sud ends or farina F731 |@ Scowed comectoncalmn—tawsng | WOM | wowace Enero @ Seteomomesiasstioare | wie on | a asm fone ven LOCTE 289 | I@ Sc x an sing ot bw we @ | w compensating shatt, outside A 1@ Scomedcormecn courtswagnt— | NY2 we wemnoree oearvnea | Nanas soe ea bs nd pemes rm nue ep OF wens in orn eases ee tenes sn ee ere + Trenunoarsin rf etutatone nae 6108 + Tmexauss nprsmees.) a romaton omy, be wed compre. [+ Tesoeved comecn nt be tre azar we tvs not pare. 3.00 ‘ isla NSD Gaawtans(ERE racer Maintenance 0352-1/A1 ‘Tightening Values of Important Screwed Connections 2733-1 |@ Cap nut tor screwed connection otfuet | MoOx2 180 on Pressure piping, injection pump ~ fue! Setioutor (ee arco in geup 659-1) |@ Cap mut forscrewod connection of fuer | MEnD 70 or pressure piping uel ditroutor~ jection vave (see arctosin oo 039-1) ie sia srt, eed rane by pntbn eames roan o be eave ha po ane Carer nor Teme az ‘ae tei J+ Tomas in rf ons on pages 08 +) Te ves inprsters(.) eet ifomaton sn be dr meson, ‘Tre soumedoomraston mtb ees nasa va han a poses We NSD Suntan 8 3.000352-1/A1 Maictenance ‘Tightening Values of Important Screwed Connections Motorabstitang (mit Reibbeligen) ENGINE STAY (FRICTION TYPE) : Lagergehause tur Stoverwellenanicd [BEARING HOUSING FOR CAMSHAFT DRIVE0352-1/A1 ELBA Imegierter Massenausgiich INTEGRATED BALANCER Waras NSD Swed at0352—1/A1 Maintenance oy ‘Tightening Values of important Screwed Connections LUmsteverservometor REVERSING SERVOMOTOR €) 3.00 ae Wists nso ontnanatMaintenance 0352-2/A1 ‘Tightening Instructions for Normal Screws “This table valid for al screws that are not considered ingroup 0952-1 “Attention Remark “These tightening Instuctions are valid only i 8) te screws are made ofthe 8.8 material 1) the treads have been hbicated wih ot Its recommended to ubiate the threads for serene which come int contact wth "hot pat ke ‘exhaust piping, expansion pices, et. wih aheat-esistng Mbrican, eg. THREAD GARD, ‘Serew thread Tightening torque Nim Me 2 Mio a a 70 wie 0 ie | wie 250 w20) 350 E wee 450 Mae 600 7 Near etee ooo 0 “ye00 wes 1600 = M36 2100 D Mag 0 Maa 2900 Mas > 3300 mae. ‘3700 M52, os 2100 M6 4600 Meo. 5200 Wars NSD Swans 1 19980352-2141 Maintenance toning Instructions for Notmal Screwed Connections Wiolsted stucde must be tightened according to the values in the following diagram: Boor iting @ waisted stud clean and degrease the stud tread and the tap hoe © Screw nthe ste right oth bottom ofthe tap hoe, and itn, “fenton | Rways ute a stud diver or two nuts. Tool ike a pipe wrench et. which would damage the ‘Sud shank must never be Used, For the protection ofthe stu inthe oylnder jacket and oyinder cover fl the annular pce above the thea wh a rnom-hatéening Sealing compound (se group 2751-1), ‘Anzugsmomente tr Dehnblzen ‘TIGHTENING TORQUE FOR WAISTED STUDS proven ir etszen "TGHTENNG TORQUE FOR ViAsTeD S008 0 7 £ au Ee oa sf 56 | A g bz ES 200 | fe Pe 7 He 52 7 3 Ag 2 ae 3 100 ood od 10 20 0 40 60 60 70.80 90100110120 0 2 9 4 9 © Govindedurhnese Gevinderchesse em) THREAD DIAMETER (nn) THREAD DIAMETER (on) 1998 ae Wt 0 Sv asEE ae) Monona oso-tias Masses (Weights) Ingividval Components per Pioce in KS Design Component ‘ Group 1194 Main bearing shel 3 {137 Main bearing cover (rma! Bern) 198 224 Trwstbearing pac a 4717 Casing ree end) 766 4720 Oia, upper pat (ving end) 181 {720 Oilbaffle, ower part (ving er) o 1909 Terod completo 363 4903 Terod nut | {003 Intermediate rng forte rod mut 6 2106 Wasted std in oyinder acket 28 2120 Supporting ring +1050 2124 Oyinder ner 1900 2190 Water guide jacket 98 2303 Pistonrod gland fi fi 108 2708 Waisted stu for valve cage 10 F708 Oylinder cover witout accessories ‘et 778 linger cover complete wit valves and water guide jacket +500 ‘2722 Injection valve complete ce 2728 Staring vale complete 25 27a) Rete valve complete 25 ‘2751 Exhaust valve complete 46 bret Exhaust valve spindle an ‘3109 Balance weight on crankshaft 190-419 3122 Flywheel (ght s257-1612 Fiywee! (nea) 3154-0544 3140 Aa dotuner cylinder (pat) 225 an Connecting rod complete 1097 See Wasted std wih rt for boom end bearing 2 Sots Wasted stud with rut or op end bearing 4 $3906 Connecting rod shank ad ane [ower Bearing half for bltom end bearing with wasted sts : 5 Soro Bearing she fr bottom end bearing 6 $3e12__ Upper bearing hal for top end bearing : 115 So18 Bearing eel fr top en bearing (crosshead) . at 3626 Crosahead without guide shoes 659 eee Gresshead complete with guide shoes ‘023 3808 Guide shoe complete 180 ‘3408 Weting piston compte wth piston ro 836 ‘3406 Piston crown 195 3409 Piston sit 3 ants Piston oc 526 ‘2603 Toggle lever to piston cooling and crosshead lubrication ta Someta 1 49)0360-1/81 Maintenance Individual Components per Piece in kg 4106 4105 44108 ‘4108 aie ane 4206 4210 ans, 5512 5522 524 5557 6708 ree 7738 103 e139 e140 403 Gear whee! on crankshaft sar Gear whee! (@-par} on crankshatt compte 896 Intermediate gear wheal complete with bearing pins and bearings fox camshalt de 855 Intermediate whee! bearing to camshaft drive 48 Gear whee! @-part complete wih shaft on camshaft 010 Gear whee! @-part complete wih shaft on camshaft and boarng im6 ‘Cam toljection pump “0 Cam o exhaust vate actor pump 33 Camstatsoction complete without couplings (5+ 7 eyinders) ‘76-860 CCamsttt section complete without couplings (6+ 8 cylinders) 52 SKF shaft couping 14 Flange coupling 37 \iraton damper for camshaft according to design 120-590 Balance cise : 12 ‘Baring cove for injection pump housing 83 Plunger and guide bush 10 Injection pump block complete wihout plungor and guide bush (2 cinders) sae Injecton pur block compete without plunger and ghie bush (ender 27 “Trough fr injecton pump housing (2 cylinders) 68 “Trough fr injocton pump housing ( eyinder), 6 Exhaust gas turbocharger VTR 564 D (complete) 6200 Exhaust gas turbocharger VTR 454 D (compte) 3600 [Exhaust gas turbocharger MET 53 SE (complete) ‘3600 Exhaust gas turbocharger MET 66 SE (complete) 3600 Cover belore scavenge ai cooler 287 ‘Axilar blower complet with oltre motor 75-520 Elecire motor "35-180 Scavenge ai cooler GEA 120,90/2816 1200-1400 Scavenge ai cooler GEA 1508/2416 1800-2000, Water separator (pasi) 60 Water separator (sto) Eo Balancer (ving end) [Compensating shaft wih beating (5 cylinders) 590 Compensating shat with bearing (6 cylinders} 410 ELBA (oloctical balancer) 1960 Front covert housing 198 Housing| 560 (Cover on rear sie of housing 42 lectre motor with diving goar wheel 118 Compensating shat compete 497 Balanoor weight 415, Gear whee! on compensating sat 7 Shaft to balancer weg 7 Faxed support complete 796 Expansion piece DN250 ater exhaust vale 4s Expansion piece DNG50 belore exhaust turbocharger a Expansion piece DNS50 before exhaust turbocharger 47-53ERE racer Maintenance: Dimensions and Material Specification of O-rings and Round Rubber Rings 0370-1/a1 7 7 i ii 1 $ ile |p tae i i Ai ras [Tere fare _[rem70sn eyinae ner es [Ennis ne supporing tg nth veal asin oe) Jo oon rem r7 sn Cynder onnanre emerge) (tz sao [row 77h hc ner ecppongt rome ngmcremy (2 sos [Fru 7h Cynara = we gee ast Pees fina sosn Gyr re watr ue oce ft _Jeco__[anaso sn 76 |e aa 80 [ance |reM70sn 208 0 [oons7 [Fem 70 sn Cynder cover 2708 |Cpnaer cnr - water ue ace va s0 sn 78 | Oia soe ~ wae Se sa iva 30h aa ete ater ate FP 705% string valve arn | sering vane 30 ooze |rewz0sn Sari ve fim [te [rewrosn Sarg vale 72 [toe [rewrosn | 0 [Rate vate oir cor 20 [408 |rPu70sh exnest vate 2701 [var cage pr cover 620 |ser67 |rewsosn av et cpnan cove 29 [Steer [reusosn so [ease |ppuvosn 00 [tvoee [reuzosn 20 |zszr [reuvosn [ae cage -vavo sot a0 [Zarar [reucosn aan “wave spd, se |seoo” |rewrosn scary st comecten valve cage —vave ve pss [aree [Few rosn are ame went ace pee [ines |nonzosn we dive = ager ss_frers_[nn ron eration donper 0 _[remodn targe caper feos _|uores sn eaing piston acs |Wonn tone sso |rss7_ [rem 70s Mercy peop laa i [Zorer [rou yosh Mery pon ~ ey ate oe _[2rrr |rew ron oo. 1 400osre- tsar EE ers) Dimensions and Material Specification of O-rings and Flound Rubber Rings 2 EB] s |won - wae i : Pace Leptin tgs a) Efe ci camsnan £203. |Camsrat oi cancion for rough 353 2017 |nen 70 sn ‘Camshaft ol conection fr seg 353 fes9_|neA70 sn Camshat- seve j690 _|sseo7 [Nan 7050 Starting ar cstibutor 4908, | Housing tage [530/408 |xer 70s» Guide tange~yinder 3s [sear |nen7osn ousing~ temedato poco 899 |177.47 |NBR 708n rurmodiat pico vo unt 53 |2022 NBA 70 sn Solonalé vale valve pst fi73 [34 Nea 7088 ate plate ~a2-way ve j73 |1¢_— ner 7051 ave plate —a2-way ve 55 |enr7 |Nen 70 sn sway vale vane plate 262 |s.a2_|NeA705sn Starting ar shutof valve 4305, | Bush tor staring sc housing cover jo90 | 14050 [rem 70s Shuto vee guide ~ housing 899 |17082 |rPM 708n Shutof vaNe que — staring ape 1699 |17082 |rPM708n contol awe cover i353 |asoe |NaA 70 sn Contolvale — ovsing 262 [1390 |NaA 70 sn __|snatetvaie—dmbutng pine j6.00_|14s.42 |NaA70:8n Reversing valve 4503. |Housig bush 1530 |7230 non 70s Bush~cover [533 |7239 |NeR 7081 Engine housing 1533 |7a74_|Nan 7081 Rotation direction safeguard 4506 _| Housing - intermodiate poco 10 |wanes sn (Controt air supply unit in valve group (Al [4005 | Pressure reducing valve ~ corner union j2e |20a |NeR 70h Valve body ~ pressure wansmitor ieee fi7e |e |NaR705h 628 [Pick-up 53 |aa27 [Nar 70sh Valve group (| to local manoeuvring stand 4690. | Valve beam ~3/2.ay vave 2 |10 | nae sh ‘Vale beam —sclenod vaNve 2 |10 | NaRes sn \Vale beam —cover pate 2 |10 | NaR6s sh |__| Vat beam pressure ewitch 1.78 eas [NBR 70Sh Valve group [E) to local manoeuvring stand 4807_| Connection piece —vaives 2 |e |nares se [Safety cut-out device 15307 | Salty cu-out device — casing 353 |ss09 |uvasosn Safety cut-out dovioe — vale pate Jeez |2e2 |FeM70sn Safely cut-out device cover eros 178 |925 _|we70 sh 403 2 sat Swen