MM RT Flex84t D - WECS 9520 - Dynex - 2014 07 PDF

RT-flex84T-D
Maintenance Manual
“Marine” WECS−9520 / Dynex
Vessel:
Type:
Engine No.:
Document ID: DBAC352008
Wärtsilä Switzerland Ltd 24hrs Support: +41 52 262 80 10

PO Box 414 technicalsupport.chts@wartsila.com
CH-8401 Winterthur
Switzerland
E 2014-07 Wärtsilä Switzerland Ltd, Printed in Switzerland

Intentionally blank
Modification Service
Engine Documentation
RT-flex84T-D_WECS-9520_Dynex Summary for Maintenance Manual

Page No. Modification Title Subject
(MM) Page or
Date No. Manual
new exch.
2008 Maintenance Manual, Issue 2008 x
Due to the major revision you receive a new complete Manual
Date of publication 2008-12-12
0330-1/A1 1.09 Clearance Table Former key No. 5, 6, 8 deleted: No. 2, 3 (max. clearance), x
(24, 25) 5 corrected
3425-1/A1 (1) 7-65.977 Piston Rings Reversible ratchet 94338b deleted x
9403-5/A1 (20) Tool List Tool 94338b deleted x
9403-5/A1 (40) 2.09 Tool List SW-download package 94930 as standard tool added x
6420-1/A1 (2) 5.09 Scavenge Air Receiver 2ND precatcher plate removed to improve water separation in x
the underslung receiver
0002-1/A1 2010-01 Table of Contents Former Gr. 2740-1/A1 replaced with 2745-1/A1; tool list x
specified with new page numbers
Index Gr. 2, 9 x
0330-1/A1 18, Clearance Table Diagram and remark concerning RC piston rings added; key x
19, 25 No. 3: altered to 0.12-0.24 mm (max. 0.3 mm)
0352-1/A1 1, 5 Tightening Values 2138-1: Description changed for 1-part lubricating quill; 5564- x
1_68: lubricant altered to Never-Seez NSBT-8
0352-2/A1 (1) 7-69.624 Tightening Values Columns specified with "Thread diameter" and "Fine thread" x
0370-1/A1 (2) 7-69.800 Dimension and 5556: O-ring 1.78x34.65 between flange - upper housing x
Material Specification: added
O-rings
0370-2/A1 (1) 7-77.791 Piston & Rod Seal 5556-1: former seal replaced with rod seal ring 70x3.53 x
0380-1/A1 2, 6, Rings
Maintenance Schedule Former Gr. 2740-1/A1 replaced with 2745-1/A1; Gr. 8: General x
8 remark concerning tightening of pipe holders added
1112-1/A1 7-74.710 Checking foundation New arrangement of engine seating / foundation introduced x
bolts
2124-2/A1 (1, 3, 7-72.443 Cylinder Liner Brackets 94203a with reduced height introduced; last sentence x
7) added concerning removing insulation bandage by
means of tool 94345e
2124-3/A1 (2) Cylinder Liner Section I-I with lubricating groove profile added x
2138-1/A2 7-73.638 Lubricating Quill on Multi-part quill replaced with one-part quill, and arrangement x
7-71.843 Cylinder Liner with CLU4-C lubricating pumps introduced
2722-1/A1 Injection Valve Remark concerning opening pressure of 375 bar and x
(5, 6) reference dimension 'x1'= 50.05 mm in Fig. 'B' added
2745-1/A1 2010 7-76.791 Relief Valve for Former Gr. 2740-1/A1 replaced with 2745-1/A1 x
Cylinder Cover
2751-2/A1 2010-01 7-77.818 Exhaust Valve Rotation device 94290 deleted and therefore dismantling and x
assembling procedure revised
2751-3/A1 Replacing and Rotation device 94290 deleted; new valve grinding device x
Grinding the Valve 94291 introduced and therefore grinding procedure revised
Seat
2751-4/A1 (1) Grinding the Seating New valve grinding device 94291 introduced x
Surface on Valve
3403-3/A1 (4) Head
Piston Securing agent LOCTITE No. 0648 specified f. spraying nozzle x
3425-1/A1 Piston Rings Checking CC and RC coated piston ring wears revised x
4325-1/A1 (2) 7-72.925 Shut-off Valve for Control valve modified x
Starting Air
5556-1/A1 7-69.800 Fuel Pump Fitting & dismantling device 94592 introduced instaed of x
7-77.791 rotation device 94290; dismantling and assembling procedures
7-77.818 revised; tool 94550 and description concerned added
5564-1/A1 (3) 7-69.624 Injection Control Unit Lubricant of screw (10) altered to Never-Seez NSBT-8 x
1/5 23.7.2014

(MM) Page or
Date No. Manual
new exch.
6420-1/A1 7-76.902 Scavenge Air Receiver Relief valve (16) newly designed and arranged in the SAR x
9403-5/A1 16, 7-77.818 Tool List Tools 94272d, 94278, 94278c, 94290, 94290b and 94203 x
25, 32, 37, 41, 7-72.443 deleted; tool 94272c, 94550, 94592 consisting of 94592a, b, c,
42 d, e and 94203a added; tool box 94720 specified for CLU4-C;
new valve grinding device 94291 designed
5556-1/A1 2010-07 7-69.800 Fuel Pump Connection pin (18_M22x1.5), figures and texts concerned x
(1, 2, 7-9, 13, 7-77.791 updated; Fig. 'O' detailed stamp areas mentioned; Parag. 4.6:
15, 17) 7-77.818 Remark added; Remark to Fig. 'D1', 'E1', 'H1', 'I1' added;
Parag. 4.11: tightening torque of 80 Nm for pin (18) mentioned
5556-2/A1 7-72.876 Fuel Pump Removal of a jammed pump plunger revised x
0002-1/A1 2010-08 Table of Contents 0370-1 and 0370-2: Title ▼ Dimensions (and Material x
Specification deleted); 8135-1 added; Tool List: Pages adapted
correspondingly
Index Gr. 0, 8, 9 x
0370-1/A1 Dimensions Material specification deleted x

0370-2/A1 Dimensions Material specification deleted x
0380-1/A1 (6) Maintenance Schedule 8135-1: Exhaust Waste Gate (LLT) added x
2138-1/A2 (1) Lubricating Quill Tool box with No. 94720c specified for CLU4-C (compact) x
3130-1/A1 Vibration Damper 1st sentence on page 1, addresses and information about x
(1, 4) labels updated
3130-2/A1 (1) Vibration Damper Attention concerning interrupted oil supply to the damper x
3146-1/A1 (4) Axial Damper added
Remark concerning signs of wear of seal rings added x
8135-1/A1 2010 Exhaust Waste Gate Low-Load Tuning introduced x
9403-5/A1 2010-08 Tool numbers for all general tools introduced (94000 - 94017, x
(1-5, 36, 40) 94022, 94025, 94026, 94032, 94045, 94050); tool box with No.
94720c specified for CLU4-C (compact); spur-geared chain
block with WLL 5000 kg specified with 94017b; tools newly
sorted on 47 pages

0380-1/A1 2010-11 Maintenance Schedule 5564-1 and 8750-2: filter (control oil) replacement properly x
(4, 7) amended
2708-2/A1 Cylinder Cover Hydr. tensioning device 94215: Pre-tensioning jacks properly x
(1, 2) specified with 94215a (left) and 94215a1 (right)
2722-1/A2 Injection Valve (OBEL 1.General: 4th sentence added; 3. Judging an injection valve: x
(1, 3) Test Bench) revised
5612-1/A1 (2) 7-65.660 Exhaust Valve Control To prevent any clogging, throttle (22) is no longer secured with x
Unit LOCTITE, however fitted with oil and tightened with 3 Nm
8750-2/A1 (3) 7-33.014 Fuel Pressure Control To prevent any clogging, new filter (35) is not secured with x
Valve LOCTITE, however fitted with oil and tightened with 10 Nm
9403-3/A1 (2) Hyd. Pre-tensioning Jack 94215a1 added x
Jacks
9403-5/A1 (11) Tool List Jacks specified with 94215a (left) and 94215a1 (right) x

0002-1/A1 2010-11 Table of Contents New group 7218-1/A2 added x
Index Gr. 7 x
0380-1/A1 (6) Maintenance Schedule 7218-1: Procedure specified for checking gas (nitrogen) pre- x
charge pressure
7218-1/A1 2010 Lubricating Pump Procedure specified for checking gas (nitrogen) pre-charge x
CLU4 pressure and refilling the accumulator
7218-1/A2 Lubricating Pump x
CLU4-C
2/5 23.7.2014

(MM) Page or
Date No. Manual
new exch.
0380-1/A1 (7) 2011-02 Maintenance Schedule 8744: Check of supply unit fuel drain pipings added; x
8750: Check of non-return valves in IFA deleted
2138-1/A2 Lubricating Quill on Test procedure of non-return valve modified (test medium x
(1, 4) Cylinder Liner altered to oil) and required tools added
5556-1/A1 Fuel Pump Section 5: Oil flow check added x
(1, 20)

0380-1/A1(6) 2011-07 Maintenance Schedule 7218-1: Interval of checking gas pre-charge pressure adapted x
7218-1/A1 Lubricating Pump Procedure of checking / refilling the gas pre-charge pressure x
CLU4 adapted according to TB RT-110 (Issue 1, 31.05.2011)
9403-5/A1 Tool List 94119: Measure corrected X = 460 mm (main dimension) x
(7, 19, 36) 94345: Measure corrected X = 600 mm
Case 94720 deleted. 94720c as new standard
0330-1/A1 (7) 2011-10 EAAD082322 Clearance Table Clearance *3 and max. value updated to 0.2…1.3 and 1.5 mm x
2124-1/A1 Cylinder Liner Positon of setting screw 'ST' newly defined x
2751-4/A1 (2) Grinding the Seating Recon. conditions due to corrosion at the valve plate newly x
Surface on Valve defined. Case when reconditioning is not possible added
3103-1/A1 EAAD082941 Head
Crankshaft Crank deflection limits adapted according to design message x
0002-1/A1 2012-04 Table of Contents New group 6735-1/A1 added; x
Index Gr. 6, 9 tool list: new page 40, therefore following pages renumbered x
2138-1/A2 EAAD082645 Cylinder Lubrication LEE non-return valve removed from lubricating quill and x
(1, 2, 3) repositioned in screwed union (7); 94934h and 94934i added
6735-1/A1 2012 EAAD082508 Scavenge Air Waste New group introduced x
Gate
9403-2/A1 2012-04 Hyd. Pre-tensioning Fig. 'J', tools 94934h (item 28) and 94934i (item 29) added x
(3, 4) Jacks
9403-5/A1 (40) Tool List Tools 94934h and 94934i added, following pages renumbered x

0352-1/A1 (3) 2012-05 Tightening Values 3403-1: Lubricant oil changed to MOLYKOTE G; x
3403-3_33: Tightening value changed to 1000 bar [115°];
3403-3_34: Oil as lubricant introduced
0370-2/A1 (4) Dimensions 94346: Dimensions for O-rings and back-up rings added. x
0380-1/A1 (7) Maintenance Schedule 8750-2: Interval of 36 000 Op.h changed to ''only necessary x
when PCV fails''
9223-1: Work to be carried out and intervals revised
3403-1/A1 Piston Locking screw (11) and Locking element (12) deleted, x
therefore text and illustrations renumbered. Waisted screw
replaced through waisted stud and nut.
3403-3/A1 EAAD082171 Piston Waisted bolt replaced with hydraulically tightened waisted stud x
and nut
8750-2/A1 Fuel Pressure Control New maintenance concept for the PCV introduced according to x
Valve (PCV) Technical Bulletin RT-125 (03.04.2012)
9223-1/A1 Crank Angle Sensor CAS modified according to Technical Bulletin RT-127, i.e. item x
(1, 3, 4, 7) Unit 'MB' and paragraphs 3.2 & 3.7 added
(20, 21, 22) 2012 New paragraphs 9.3, 4, 5, 6 and section 10 added x
9403-2/A1 2012-05 Hydraulic Jacks and Fig. 'G', tools 94934c (item 30) and 94935b (item 31) added x
(2, 4) Pumps
9403-3/A1 (4) Hydraulic Pre- Tool 94346 'Pre-tensioning jacks for waisted studs of piston x
tensioning Jacks and crown' added
Pumps
9403-5/A1 (20) Tool List Tool 94346 added x

8750-2/A1 2012-05 EAAD082683 Fuel Pressure Control Amendment: Shortened execution adaptet in figure 'B'; x
Valve (PCV) prop (23) deleted
3/5 23.7.2014

(MM) Page or
Date No. Manual
new exch.
0002-1/A1 2012-07 Table of Contents New groups 5610-1/A1, A2 added x
Index Gr. 5
0330-1/A1 Clearance Table Fuel pump with connection pin and addidional O-ring as well x
(24, 25) as plunger diameter updated
0352-1/A1 Tightening Values 2124-2_9: Filling piece in cylinder liner deleted and following x
(1, 8) items up to (13) renumbered
0380-1/A1 (5) 2012-07 Maintenance Schedule 5610-1: Interval of checking gas pre-charge pressure referred x
to 7218-1
1903-1/A1 Tie Rod Tensioning altered to one procedure: 100 bar -> 1000 bar with x
a tie rod elongation of 17.0 … 19.0 mm
2124-2/A1 Cylinder Liner Filling piece with waisted bolts deleted. Key of illustration and x
(1, 4, 6, 7) numbering adapted
2124-3/A1 Cylinder Liner Check bore deleted x
(1, 2)
2722-1/A1 Injection Valve with 1. General: Test & Calibration fluid specified, therefore line x
(1, 2) OBEL Test Bench shifted to page 2
2751-1/A1 Exhaust Valve Dismantling tool 94008a-M100 introduced. Figure 'G' added. x
(1, 6)
2751-2/A1 (2) Exhaust Valve Bore 'BO' in damper (36) and corresponding detail in Fig. 'B' x
adapted
3206-1/A1 (2) Turning Gear Address of Lubrication Engineers Inc. changed x
5556-1/A1 (7) EAAD082996 Fuel Pump Fig. 'O' designed with a 2nd O-ring on lower housing; spring x
dowel removed from guide piston / thrust piece
5610-1/A1, A2 2012 EAAD082961 Pressure Reducing Pressure reducing valve with hydraulic accumulator (1) and x
Valve 8.11-1 procedure for checking gas pre-charge pressure introduced
6420-1/A1 (3) 2012-07 EAAD082712 Scavenge Air Receiver Relief valve with disc springs added. Opening pressure of RV x
changed to 4.1 ± 0.2 bar relative
7218-1/A1, A2 EAAD082961 Lubricating Pump Figure 'E' changed (8.11-1 with hydraulic accumulator) x
CLU4, CLU4-C
8752-1/A1 Fuel Pressure Piping Fuel presssure pipe 16 and Parag. 2.4 added x
(1, 4)
9403-5/A1 Tool List Tool 94930: 2 USB keys deleted; x
(2, 38) 94008a-M100 added
2722-1/A1 (1) 2012-11 Injection Valve Cross reference to Operating Manual 2722-1 (Pressure release x
and drainage of injection valve) added.
5564-1/A1 (1) Injection Control Unit Further information regarding replacement of ICU added x
0002-1/A1 2013-02 Table of Contents Tool list specified with new page numbers x
Index Gr. 9
5552-6/A1 EAAD084033 Supply Unit Instruction for the lubrication of SU during maintenance works x
updated due to changes on the lubricating device
9403-5/A1 EAAD084033 Standard Tools Tools 94844, a, b, c, d and e for lubrication of SU added x
(37, 38)
5552-4/A1 2013-05 EAAD083955 Supply Unit Instruction for the removal of the intermediate gear wheel x
updated and extended by an additional tool (94571e and
94571f)
5552-6/A1 EAAD082818 Supply Unit Instruction for the lubrication of SU during maintenance works x
updated due to changes on the lubricating device
9403-5/A1 (29, EAAD082818 Standard Tools Support tools 94571e and 94571f added for the removing of x
39) the intermediate gear wheel; tool 94844f for lubrication of SU
added
0002-1/A1 2013-08 Table of Contents 3425-1/A1, A2: checking wear of … ring grooves added x
Index 3 x
0011-1/A1 (1) Safety Measures and Attention concerning clean areas (no water or cleaning fluids) x
Warnings added
4/5 23.7.2014

(MM) Page or
Date No. Manual
new exch.
0330-1/A1 Clearance Table Key No. 6 and 7: points A and B added x
(18, 19)
0380-1/A1 Maintenance Schedule 2728-1: Monthly check of nut on solenoid added according to x
(2, 3) Technical Bulletin RT-143 (05.02.2013);
3103-1: Interval changed "according to classification society"
3403-1: Intervals changed to 18 000-36 000 operating hours
(3, 8) 2013-08 3403-4: Intervals changed to 500-1000 operating hours x
3425-1: Work to be carried out and intervals changed;
WECS electronic components: ALM-20 added
2722-1/A1 Injection Valve Sec. 11 added; system oil as test media mentioned; Sec. 3: x
(1, 3-6, 8) keeping opening pressure changed from 10 to 30 seconds;
Sec. 4: => 4th sent, Sec. 5: => 3rd, 4th and 5th sent. added
2728-1/A1 Starting Valve CHECK: Periodical venting of starting air manifold (OM 0320- x
(1, 3) 1) and monthly check of nut (18) on solenoid added
3103-1/A1 Measuring Crank 1. General aspects; 2. Condition of measuring and 4. Crank x

Deflection deflection limits revised
3425-1/A1 Piston Rings Determination of wear rate of chrome-ceramic piston rings and x
(Four Piston Rings) measuring piston ring grooves introduced
9403-5/A1 Tool List Tools 94291a, 94356 (only figure modified) and 94357 added x
(43, 44)
9403-5/A1 (47) 2014-04 Tool List Tools: 94211, 94212 deleted x

2138-1/A1 2014-07 RT-166 Lubricating Quill New Quill design x
5/5 23.7.2014
Intentionally blank
0 General Information
1 Bedplate and Tie Rod
2 Cylinder Liner and Cylinder Cover
3 Crankshaft, Connecting Rod and Piston
4 Driving Wheels and Shut-off Valve for Starting Air
5 Supply Unit, Injection and Exhaust Valve Control
6 Scavenge Air Receiver and Auxiliary Blower
7 Cylinder Lubrication
8 Piping
MM / RT−flex / Register
9 Crank Angle Sensor Unit, Tools

This page is intentionally left blank
RT-flex84T-D Maintenance Group0
General Information Group 0

For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001−1/A1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002−1/A1
Engine Numbering and Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008−1/A1
General Guidelines
− for Maintenance: Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 0011−1/A1
− for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts etc. . . . . . . . . . . . . . . 0012−1/A1
Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

− General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
− Crankshaft and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3
− Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
− Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
− Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9
− Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
− Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13
− Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15
− Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
− Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
− Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
− Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
− Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Tightening Values
− of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1
− of Standard Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−2/A1
Masses (Weights): Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . 0360−1/A1
Dimensions
− O-rings and Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370−1/A1
− Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370−2/A1
− Back-up Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370−2/A1
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) . . . . . . . . 0380−1/A1

Engine Cross Section and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0803−1/A1
Wärtsilä Switzerland Ltd 1/ 1 RT−flex84T−D / MM / 2010-08

RT-flex84T-D Maintenance 0000−1/A1
For Particular Attention
This manual is put at the disposal of the recipient solely for use in connection with
the corresponding type of diesel engine.
It has always to be treated as confidential.
The intellectual property regarding any and all of the contents of this manual, par-
ticularly the copyright, remains with Wärtsilä Switzerland Ltd. This document
and parts thereof must not be reproduced or copied without their written permis-
sion, 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 un-
dertaken, the Operating Instructions or the Maintenance Manual respectively is to
be read carefully.
To ensure the best efficiency, reliability and lifetime of the engine and its compo-
nents, only original spare parts should be used.
It is to be ensured as well that all equipment and tools for maintenance are in good
condition.
The extent of any supplies and services is determined exclusively by the relevant
supply contract.
The data, instructions and graphical illustrations etc. in this manual are based on
drawings made by Wärtsilä Switzerland Ltd and correspond to the actual stan-
dard at the time of printing (year of printing is indicated on title page).
Those specifications and recommendations of the classification societies which
are essential for the design have been considered therein. It must be recognized
that such data, instructions and graphical illustrations may be subject to changes
due to further development, widened experience or any other reason.
This manual is primarily intended for use by the engine operating and maintenance
personnel. It must be ensured that it will always be at the disposal of such person-
nel for the operation of the engines and/or for the required maintenance work.
This manual has been prepared on the assumption that operation and mainte-
nance of the engines concerned will always be carried out by qualified personnel
having the special knowledge, training and qualifications needed to handle in a
workman-like manner diesel engines of the corresponding size, the associated
auxiliary equipment, as well as fuel and other operating media.
Therefore, generally applicable rules, which may also concern such items as
protection against danger, are specified in this manual in exceptional cases only.
It must be made sure that the operating and maintenance personnel are familiar
with the rules concerned.
This manual has been prepared to the best knowledge and ability of its au-
thors. However, neither Wärtsilä Switzerland Ltd nor their employees as-
sume 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.
Wärtsilä Switzerland Ltd

Winterthur
Switzerland
Wärtsilä Switzerland Ltd 1/ 1 2008

Preface
The instructions contained in this ”Maintenance Manual” are intended to help to

ensure that the maintenance which must be carried out at specific intervals is cor-
rectly carried out.
It is a precondition that the personnel charged with such important work possesses
the necessary training and experience.
Information about the operation of the engine as well as descriptions of the func-
tion of the various systems are part of a separate book, the ”Operating Manual”
containing also under 0010−1 explanations of the layout and structure of the Oper-
ating and Maintenance Manuals as well as of the used symbols, signs and special
characters.
More detailed instructions on the operation and maintenance of components from
sub-suppliers can be gathered from the instruction leaflets of the respective
manufacturers. Outside makes are, for example, such engine components, tools
or devices which are not manufactured in accordance with production drawings
from Wärtsilä Switzerland Ltd.
The ”Maintenance Manual” is divided into the following main chapters:
− General guidelines for maintenance

− Clearance tables, tightening values of screwed connections, masses
(weights), seal rings
− Maintenance schedule
− Design groups
− Tool lists
A few explanations to the above:

− The ’General Guidelines for Maintenance’ contain, in addition to recommen-
dations on precautionary measures to be taken, also suggestions for carrying
out the work.
− The above mentioned tables inform about normal and maximum acceptable
clearances, the tightening of important screwed connections, weights of indi-
vidual engine components as well as the type and use of various sealing rings.
− The ’Maintenance Schedule’ indicates nominal intervals in which various
maintenance operations are to be carried out. Please note that the mainte-
nance intervals are based on experience and are subject to operation of the
engine under standard conditions.
− Detailed instructions are given in the ’Design Groups’ on the procedure of
maintenance work on certain engine parts.
− Tools and devices necessary to carry out maintenance are described in the
’Tool Lists’, and are generally supplied with the engine.
All information contained in the text and illustrations of this manual are valid at the
time of printing.
Modifications will be incorporated in the next edition!

Table of Contents
Table of Contents
General Information Group 0

For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000−1/A1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001−1/A1
Engine Numbering and Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008−1/A1
General Guidelines
− for Maintenance: Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 0011−1/A1
− for Lifting Tools: Wire Rope Slings, Span-sets, Eye Bolts etc. . . . . . . . . . . . . . . 0012−1/A1
Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

− General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
− Crankshaft and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3
− Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
− Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
− Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9
− Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
− Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13
− Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15
− Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
− Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
− Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
− Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
− Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Tightening Values
− of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−1/A1
− of Standard Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352−2/A1
Masses (Weights): Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . 0360−1/A1
Dimensions
− O-rings and Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370−1/A1
− Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370−2/A1
− Back-up Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370−2/A1
Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) . . . . . . . . 0380−1/A1

Engine Cross Section and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0803−1/A1
Wärtsilä Switzerland Ltd 1/ 5 2013-08

0002−1/A1 Maintenance RT-flex84T-D
Table of Contents
Bedplate and Tie Rod Group 1

Bedplate and Thrust Bearing: Checking the Foundation Bolts . . . . . . . . . . . . . . . . . 1112−1/A1
Main Bearing
− Loosening and Tensioning of Jack Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−1/A1
− Removal and Fitting of a Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−2/A1
Thrust Bearing
− Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203−1/A1
− Removal and Fitting the Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224−1/A1
Hydraulic Engine Stays: Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A2

Tie Rod: Checking the Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . 1903−1/A1
Cylinder Liner and Cylinder Cover Group 2
Cylinder Liner
− Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−1/A1
− Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−2/A1
− Removing the Wear Ridge, Re-dressing Scavenge Ports
and Lubricating Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−3/A1
Lubricating Quills
− and Accumulators: Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2136−1/A1
− with Pulse Jet Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A1
− with Pulse Feed Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A2
Piston Rod Gland: Dismantling and Assembling, Measuring the Wear . . . . . . . . . 2303−1/A1
Cylinder Cover
− Removal and Fitting of Cylinder Cover and Water Guide Jacket . . . . . . . . . . . . 2708−1/A1
− Loosening and Tensioning of Cylinder Cover Waisted Studs . . . . . . . . . . . . . . . 2708−2/A1
− Machining of Sealing Face for Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−3/A1
Injection valve: Checking, Dismantling, Assembling and Adjusting . . . . . . . . . . . . . 2722−1/A1

Starting Valve: Removal, Fitting and Dismantling, Grinding-in & Assembling . . . . 2728−1/A1
Relief Valve for Cylinder Cover: Checking Blow-off Pressure . . . . . . . . . . . . . . . . . 2745−1/A1
Exhaust Valve
− Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs . . . . . . . . . 2751−1/A1
− Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−2/A1
− Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−3/A1
− Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . 2751−4/A1
2013-08 2/ 5 Wärtsilä Switzerland Ltd

Table of Contents
Crankshaft, Connecting Rod and Piston Group 3

Crankshaft: Measuring Crank Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103−1/A1
Vibration Damper
− Taking a Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−1/A1
− Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−2/A1
Axial Damper: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3146−1/A1

Turning Gear: Checking the Toothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3206−1/A1
Crankcase: Utilization of Working Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−1/A1
Connecting Rod
− Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . 3303−1/A1
− Inspection, Removal and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . 3303−2/A1
− Inspection, Removal and Fitting of Top End Bearing with Piston in Situ . . . . . . 3303−3/A1
− Inspection, Removal and Fitting of Top End Bearing with Piston Removed . . . 3303−3/A2
− Removal and Fitting with Piston in Situ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−4/A1
− Removal and Fitting with Piston Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−4/A2
Crosshead
− Checking the Clearances and Fitting the Guide Shoes . . . . . . . . . . . . . . . . . . . . 3326−1/A1
− Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−2/A1
Piston
− Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403−2/A1
− Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403−4/A1
Piston Rings: Checking Wear of Piston Rings and Ring Grooves . . . . . . . . . . . . . . 3425−1/A1
Driving Wheels and Shut-off Valve for Starting Air Group 4
Driving Wheels
− Checking the Running and Backlash Clearances and Condition of Teeth . . . . 4103−1/A1
− Removal and Fitting of Intermediate Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−2/A1
− Replacing the Gear Wheel on Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−3/A1
Shut-off Valve for Starting Air: Cleaning and Function Check . . . . . . . . . . . . . . . . . 4325−1/A1

Table of Contents
Supply Unit, Injection and Exhaust Valve Control Group 5
Supply Unit
− Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive . . . . . . . . . 5552−1/A1
− Removal and Fitting of Camshaft and Bearing Shells . . . . . . . . . . . . . . . . . . . . . 5552−2/A1
− Removing and Fitting the Fuel Cams with Conical Bushes . . . . . . . . . . . . . . . . 5552−3/A1
− Removal and Fitting of Intermediate Wheel to Camshaft . . . . . . . . . . . . . . . . . . 5552−4/A1
− Removal and Fitting of Gear Wheel on Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 5552−5/A1
− Lubrication of Supply Unit During Maintenance Works . . . . . . . . . . . . . . . . . . . . 5552−6/A1
Fuel pump
− Removal, Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−1/A1
− Removal of a Jammed Pump Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−2/A1
Pressure Reducing Valve 8.11−1

− Checking the Gas Pre-charge Pressure (with Lubricating Pump CLU4) . . . . . 5610−1/A1
− Checking the Gas Pre-charge Pressure (with Lubrication Pump CLU4−C) . . . 5610−1/A2
Injection Control Unit: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5564−1/A1

Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling . . . . . 5612−1/A1
Regulating Linkage: Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5801−1/A1
Scavenge Air Receiver and Auxiliary Blower Group 6

Checking the Air Flaps and Cleaning the Scavenge Air Receiver . . . . . . . . . . . . . . 6420−1/A1
Auxiliary Blower: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545−1/A1
Scavenge Air Cooler: Removal and Fitting of SAC and Cooler Pre-stage . . . . . . . 6606−1/A1
Water Separator: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708−1/A1
Scavenge Air Waste Gate: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . 6735−1/A1
Cylinder Lubrication Group 7

Lubrication Pump CLU4: Checking the Gas Pre-charge Pressure . . . . . . . . . . . . . 7218−1/A1
Lubrication Pump CLU4−C: Checking the Gas Pre-charge Pressure . . . . . . . . . . . 7218−1/A2
Piping Group 8
Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8135−1/A1
Servo Oil Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . 8447−1/A1

Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding . . . . 8460−1/A1
Intermediate Fuel Accumulator: Checking and Setting of Relief Valve . . . . . . . . . . 8750−1/A1
Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling . . . . 8750−2/A1
Fuel Pressure Piping

Removing, Fitting and Regrinding of Sealing Faces . . . . . . . . . . . . . . . . . . . . . . . . . 8733−1/A1
Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8752−1/A1

Table of Contents
Crank Angle Sensor Unit, Tools Group 9

Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting . . . . . . . . . . . . . 9223−1/A1
Tools: Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−1/A1
Hydraulic Jacks and Pumps: Arrangement and Application . . . . . . . . . . . . . . . . . . . 9403−2/A1
Hydraulic Pre-tensioning Jacks

− Storing, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−3/A1
− General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−4/A1
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−5/A1

− Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 01 − 41
− Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 42 − 46
− Special Tools Obtainable on Loan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 47 − 49

General
Engine Numbering and Designations
General:
Turbocharger Turbocharger 2
1
Cylinder
1 2 3 4 5 6 7 Numbering
DRIVING FREE END

END
1 2 3 4 5 6 7 8 9
014.268/06
Thrust Bearing Pads Main Bearing Numbering
Rail Unit
FUEL SIDE EXHAUST SIDE
Supply Unit
Clockwise
Rotation
014.269/06

Engine Numbering and Designations
flex Parts:
Fuel Pump Row
Bank A
Pump A2
Pump A1
Fuel Pump Row Counting Direction

Bank B Fuel Pumps
Actuator A1
Pump B2
Pump B1
Pump 1
Pump 2
Actuator B1
Pump 3
Counting Direction
Servo Oil Pumps
014.270/06
DRIVING
END
Control Oil Pumps Crank Angle Sensors
Sensor 2 Sensor 1
Pump 2 Pump 1 (GT5127C) (GT5126C)
DRIVING FUEL SIDE

END
014.271/06
013.061/05
FREE END
2008 2/ 2 Wärtsilä Switzerland Ltd

General Guidelines for Maintenance
Safety Measures and Warnings
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4
2. General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4
3. Precautionary measures before beginning of
maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/4
4. Special safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4
5. Recommendations for performing work . . . . . . . . . . . . . . . . . 3/4
1. General
The maintenance work which is required to be carried out on the engine at regular
intervals is described in the Maintenance Schedule 0380−1 of this manual and is to
be understood as a general guide. The maintenance intervals are dependent on
the mode of operation, on the power as well as on the quality of the fuel used. Fur-
ther details are set out in the maintenance schedule.
Experience will show whether the intervals may be extended or need to be short-
ened.
Strict compliance with the below mentioned recommendations regarding
safety measures and maintenance work is mandatory; the recommenda-
tions are not exhaustive.
2. General safety precautions
D It is the operator’s duty to assure that all personnel is familiar with all safety,
health as well as environment protection rules released for operating and
maintaining a diesel engine plant. In particular greatest attention has to be giv-
en to the functioning, handling and dangers of cranes and lifting devices.
D The safety officer has to make sure that all precautions have been taken in
order to avoid dangerous situations.
D The operator has to nominate a person responsible for assigning work tasks
to every person who is participating in maintenance work.
D Make sure that fluids or gases draining or escaping cannot cause accidents,
fires or explosions during maintenance work. Keep the engine and the sur-
roundings clean. Cleanliness increases the quality of the work and helps to
prevent accidents.
Before beginning maintenance work on the diesel engine the corresponding
systems which are influenced by the maintenance work must be relieved of
pressure and/or drained if necessary. A protocol must be established evi-
dencing these activities.
D Certain media, i.e. fuels etc., are highly inflammable, therefore all precaution-
ary measures have to be taken that they do not come into in contact with fires,
glowing or hot parts. Smoking in the engine room is strictly forbidden.
Special attention has to be paid to the rules of fire fighting.
Make absolutely sure that in case of fire alarm no fire extinguishing gases can
be released into the engine room while people are still inside. Emergency es-
capes are to be marked and personnel is to be instructed of what to do in case
of fire.
D Oils and other media can cause slippery surfaces. In order to avoid injury all
surfaces which can be stepped on must be kept clean and dry.
Attention! Do not use water or any cleaning fluid to clean the WECS electronic
components and control boxes on the engine as well as on the rail unit. Damage
can occur if water goes into these electronic components or control boxes.

3. Precautionary measures before beginning of maintenance work
Before starting any maintenance work on the engine (particularly on the running
gear), take the following precautionary measures:
⇒ Close the shut-off valves on the starting air bottles.
⇒ Close all the shut-off valves in the control air supply unit, and open the drains
on both air bottles until it is depressurized.
⇒ Close by hand the (automatic) shut-off valve for starting air and open the vent
and drain valve to the main starting air piping on the engine as well as the vent
valves on the shut-off valve for starting air, and leave them in this position until
maintenance work is completed.
⇒ Open all indicator cocks on the cylinder covers and leave them in this position
until maintenance work is completed.
⇒ Engage turning gear (gear pinion must be in engaged position) and lock the
lever. (see also 3206−1 and 0750−1 in the operating Manual).
D Where the engine has been stopped due to overheated running gear or
bearings, wait at least 20 minutes before opening the crankcase doors.
D The crankcase doors must always be locked with all the clamps when-
ever the engine is running, even if this is only for a short time in order to
make temperature checks (e.g. after changing bearings during an overhaul,
etc.).
D In the case of a fire in the engine having been extinguished by means of CO2,
the spaces affected must be well ventilated before work can be carried out
within them.
Attention! When performing electric welding near or on the engine, electromag-
netic fields or peak voltage may occur, which may damage the electronic compo-
nents of the WECS (Wärtsilä Engine Control System).
Therefore, prior to performing electric welding in the vicinity of the mentioned com-
ponents, the following precautions must be taken:
D Stop the engine if it is in operation.
D Power off the electronic system and wait one minute.
D If the welding point is within a radius of two metres from an electronic module
and/or a sensor, disconnect the modules and/or sensors.
D Close the covers of all electric boxes and protect cables, sensors, etc. against
sparking and heat.
D Shield the check and control units with a conductive material and connect
them to earth.
D Run the welding cable from the welding apparatus directly to the welding point
without any unnecessary loops; also, avoid leading the welding cable parallel
to cables of the electronic control unit.

4. Special safety measures
D Prior to turning the crankshaft with the turning gear, make sure and take no-
tice:
− that no person is inside the engine and no loose parts, tools or devices
can get jammed.
− bear in mind that the coupled propeller turns too (danger in surround-
ings).
− that lubricating device 94844 has been installed to prevent bearing
bushes of the servo oil pump drive in the supply unit from being damaged
(dry running) due to turning the engine during overhaul works.
D At all times when somebody is inside the engine casing another person must
stand by in order that he can give the necessary aid if something unexpected
happens to the person inside the engine. The person who is inside the engine
casing must be equipped with all safety gears which are required to prevent
suffocation within the limited space and atmospheric conditions. Moreover an
antifall guard must be carried at dangerous places!
D The allowed load capacity of the engine room crane, the lifting tools, ropes
and chains must be sufficient for the parts to be lifted (see 0012−1 and
0360−1).
Pay also attention to the weight distribution and attachment of the lifting tackle
in order that the part which must be lifted cannot tip over or crash down!
D Sharp edges, mating faces etc. as well as ropes are to be protected by wood-
en pieces, leather or special edge guards which are placed between the part
and the rope or chain.
D Always use gloves, a face shield and wear safety goggles when working with
hydraulic tools.
D For your own safety keep away from under hanging loads, never undersling
hanging parts with your fingers or hands and never embrace lifting ropes with
your hands.
D Removed parts must be secured in the engine room.
D For reasons of safety, openings resulting from removed engine components
must be closed!
Remark: For further instructions see also Safety Precautions and Warnings (Gen-
eral Information) 0210−1 in the Operating Manual.
5. Recommendations for performing work
D Pay attention to Utilization of Working Platform 3301−1.

D Carry out all work carefully, observing utmost cleanliness!
D For maintenance work on the engine use the tools and devices intended for
the particular job, which, as a rule, are supplied with the engine (see tool list at
the end of this manual).
⇒ Tools and devices must be made ready prior to use, make sure they are in
perfect condition.
⇒ Calibrate gauge tools before using and at periodical intervals.
⇒ Check hydraulic tools periodically for tightness and perfect functioning.
⇒ Protect running faces and sealing faces of removed parts by suitable means
to prevent damages.

⇒ Close all openings which form when certain parts are removed e.g. pipes, oil
holes etc. to prevent dirt from entering the engine. (This includes also the
pipes which are removed).
⇒ Check all repaired, overhauled or replaced parts for perfect functioning before
starting the engine.
⇒ Check all pipes which have been removed, for tightness after they are refitted.
⇒ Clearances of moving parts must be checked periodically. Should the maxi-
mum permissible values (see Clearance Table 0330−1) have been reached or
even exceeded, these parts must be replaced.
⇒ Arrange to replace all parts taken from spares stock. When ordering new
parts refer to the Code Book, mention code numbers and description.
D When tightening studs, nuts or screws, take the utmost care not to damage
their thread. They must be screwed in by hand until metal to metal contact is
achieved. Always use the specified lubricants on the threads.
D Adhere to tightening values wherever they are indicated. Use the specified
lubricant on the threads (see 0352−1 and 0352−2).
D Locking devices of bolts, nuts, etc. must be fitted correctly and secured prop-
erly. Use locking plates and locking wires only once.
D For threads of screws and studs which are getting very hot, (i.e. exhaust pipe
or turbocharger fastenings) apply a high temperature resistant lubricant be-
fore assembly, to prevent a heat seizure.
D Used rubber rings must always be replaced by new ones when an overhaul of
any engine component takes place; they must conform in dimension and
quality to the specifications in the 0370−1.
The fitting of piston seal rings and rod seal rings requires the greatest of care
to prevent damage, over expansion or deformation. Before fitting the rings
heat them first in boiling water.

General Guidelines for Lifting Tools
Wire Rope Slings, Span-sets, Eye bolts, etc.
1. General
The permissible capacities of the engine crane, lifting tools, ropes, chains, lifting
eye bolts, etc. must always correspond with the weights of the parts to be lifted
(see also Masses (Weights) 0360−1).
Remark: The admissible lifting (max. loading) capacity in kg corresponds to the
WLL = Working Load Limit.
For fitting and removal of engine components or their transportation, only the tools
which are in perfect condition and intended for this purpose may be used. Ropes
which have begun tearing or otherwise are defective and tools which are damaged
have to be exchanged.
For safe and proper handling of crane, suspension tools or transport of loads we
recommend to proceed as follows for safety reasons:
D Determination of the weight of load
D Determination of the suspension centres and weight distribution
D Choice of attachment elements
D Attaching and disconnecting
2. Attachment elements
2.1 Wire rope slings

The lifting capacity of the wire rope slings is listed under their tool number in Tools
List 9403−5.
2.2 Span-sets
Span-sets have the advantage of easy and simple handling. The code and the
colour normally indicate the maximum admissible total load. Loops and knots in
the span-sets reduce their lifting capacity by one third.
2.3 Eye bolts and eye nuts

Only those eye bolts and eye nuts may be used which are in accordance with DIN
580 & 582:2003−08 or which fulfil or exceed these values, including the safety
factor.
All calculations for components and tools where eye bolts and eye nuts are used
are laid out accordingly and based on the mentioned standards.

General Guidelines: Wire Rope Slings, Span-sets, Eye bolts, etc.
Lifting capacity (for information purposes only):
Eye bolts & Lifting capacity [kg]

eye nuts, single-strand double-strand (45°)1)
thread size
45 _
M8 140 100
M10 230 170
M12 340 240
M16 700 500
M20 1200 860
M24 1800 1290
M30 3200 2300
M36 4600 3300
M42 6300 4500
M48 8600 6100
M56 11 500 8300
Remarks: The details listed in the table above are based on DIN 580 &
582:2003−08, requiring that the eye bolt or the eye nut:
− is completely turned in or screwed down;
− lies flat and fully on the seating surface;
− was checked for visible damages (e.g. corrosion, deformation) before using it.
− 1) Fullload is only permissible in the direction of the ring, therefore the
eye bolts or eye nuts must be brought to the right position, if necessary by us-
ing distance rings.
D If there are through holes, a washer should be placed from the opposite side
under the nut or screw head.
D Whenever possible, do not apply an angle of inclination bigger than 45° (in all
directions with regard to the ring level), and especially avoid lateral pulling!
D For varying use on different objects to be carried, eye nuts or eye bolts with
thread diameters one size higher should be used.
2.4 RUD-eye bolts and RUD-swivel lugs

Only those RUD-eye bolts & RUD-swivel lugs may be used with a safety factor 4.
Manufacturer:
RUD-Kettenfabrik
Rieger & Dietz GmbH u. Co.
D−73428 Aalen
Germany
www.rud.com

2.4.1 Remarks on the use of RUD-eye bolts

− they must be completely screwed down, lying fully on the seating surfaces.
− they are hand-screwed with their own star-profile wrenches (do not use any
extension).
D In order that after tightening the ring of the RUD-eye bolt is freely rotatable, the
star-profile wrench must be removed from the inner hexagon of the screw as
shown in Fig. ’A’.
D Prior to loading the RUD-eye bolt adjust it in force direction (RUD-eye bolts
are not suitable to be turned under load).
D Lateral loading is permitted in no circumstances! (Fig. ’B’)
A B
FORCE
DIRECTION
DIRECTION
FORCE
Ring
Star-profile
DIRECTION
wrench
FORCE
Screw
013.444/05

2.4.2 Remarks on the use of RUD-swivel lugs

− they must be completely screwed down, lying fully on the seating surfaces.
− they are hand-screwed with an open end wrench.
D Prior to loading the RUD-swivel lug adjust it in force direction (Fig. ’C’ and ’D’).
D Loading as shown in Fig. ’E’ should be be avoided if possible!
C D E
FORCE
DIRECTION
DIRECTION
DIRECTION
FORCE
FORCE
013.445/05
2.5 Shackles
Only those shackles may be used which are in accordance with American Stan-
dard RR−C−271A or which fulfil or exceed these values, including the safety factor.
All calculations for components and tools where shackles are used are laid out ac-
cordingly and based on the mentioned standards.
Normally, the permissible lifting capacity of the shackles is specified for one single
strand.
Attention! If tools are combined (e.g. beams with shackles, RUD-eye bolts or
RUD-swivel lugs and ropes, etc.), it is always the weakest element which deter-
mines the maximum lifting capacity (see details in Tools List 9403−5).

3. Attaching and disconnecting
The following must be observed:

D Distribution of load:
− one strand carries the total of load weight
− two strands carry each one half of the load weight
− four strands carry each one quarter of the load weight if the load is distrib-
uted equally.
D Angle of strand:
− the flatter the strand angle, the more the strand is stressed
− the more acute the strand angle is, the less the strand is stressed.
D Place a soft-wood board between rope and engine component, because the
ropes tend to slide on smooth surfaces (e.g. tubes, shafts).
D Protect the ropes against damages by providing a wooden pallet or a rag.
Sharp edges may even cut steel cables!
D If possible always tie down the load. (danger of fall)
D Wrapping the rope twice increases friction and adhesion in such a manner
that even a smooth, oily shaft is sliding less.
D Hemp rope strands, wrapped around the hook, prevent sliding. Do not wrap
steel cables, but cross them instead.
Danger of injuries! For your own safety never stand beneath loads!
Hold the ropes in the flat of your hands and keep your fingers stretched out. Never
seize the load at the bottom, but always lead it laterally. Always put down the loads
on a perfect ground, and use sufficiently sized bases.

Clearance Table
Overview
− General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/25
− Crankshaft and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . 2, 3/25
− Crankshaft and Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . 4, 5/25
− Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7/25
− Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9/25
− Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11/25
− Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13/25
− Top and Bottom End Bearings to Connecting Rod . . . 14, 15/25
− Piston Cooling and Crosshead Lubricating Link . . . . . 16, 17/25
− Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19/25
− Driving Wheels for Supply Unit . . . . . . . . . . . . . . . . . . . . . 20, 21/25
− Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23/25
− Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25/25
1. General
The clearances listed in the column ’Nominal dimension’ of the following table cor-
respond to design and manufacturing values or to the settings on the new engine.
The values listed in the column ’Maximum clearance, dimension’ are such values
as may be reached after a lengthy operating period, which however may not be
allowed to be exceeded or fall below. On components where the clearance is ad-
justable by modifying the thickness of shims, discs, spacers etc. the value given as
’Normal Clearance’ should always be arrived at, or striven to attain. Where this is
not possible, worn parts must be replaced by standard new ones or reconditioned
by suitable material buildup.
If, during an overhaul, clearances are measured which have almost reached the
permissible limit, it must be left to individual judgement to decide whether a compo-
nent part should be replaced or remain fitted till the next overhaul. This depends for
example on the duration of the next operation period till the next overhaul and what
wear has to be expected based on experience gained.

Clearance Table
Crankshaft and Thrust Bearing
001.404/96
014.702/06

Clearance Table
Crankshaft and Thrust Bearing
Description Measuring Nominal Maximum clearance,

direction dimension dimension
Key No.
Group
(method of (normal, new) (due to wear)

measuring) [mm] [mm]
1132 Main bearing

Bearing shell width 385
1 Lateral clearance per side 17.5
1203 Thrust bearing
1224
− 0.5
Thrust bearing pad thickness 145 − 0.6
2 Thrust bearing clearance axial (total) 0.8−1.3 2.5

3 Thrust bearing pad, lateral clearance total 6

Clearance Table
Crankshaft and Main Bearing
3 1
4 4 2 2
014.708/06
MAIN BEARINGS MAIN BEARING

No. 2 ... No. 1
014.709/06

Clearance Table
Crankshaft and Main Bearing

Key No.
Group

1132 Main bearing No. 1

0
Crankshaft outer ∅ 980 − 0.10
Main bearing inner ∅ 980

1 Bearing clearance vertical 0.5−0.8 0.95
*2 Positional tolerance (bearing cover) vertical max. 0.3
1132 Main bearing No. 2 and following
0
Crankshaft outer ∅ 980 − 0.10
Main bearing inner ∅ 980

*4 Positional tolerance (bearing cover) vertical max. 0.3
All main bearing clearances are only valid with tie rods and main bearing studs
tightened.
* The difference between the two values (positional tolerance) must not be
greather than 0.3 mm when the studs are tightened!

Clearance Table
Crosshead Guide
EXHAUST SIDE
6
8
7
1 2
014.719/06
3 5
4

Clearance Table
Crosshead Guide

Key No.
Group

3326 Crosshead guide

1 Guide way (column) transverse 1140
− 0.20
2 Guide shoe transverse 1140 − 0.30
*3 Guide shoe clearance 0.20−1.30 1.5

4 Guide rail longitudinal 898.50−899.10
5 Guide rail, lateral clearance total 0.60−2.0 2.5
6 Guide shoe, lateral clearance longitudinal 0.20−0.40
− 0.02
7 Guide shoe, bearing pin outer ∅ 460 − 0.06
+ 0.063
Guide shoe, bearing bore inner ∅ 460 0
8 Bearing clearance radial 0.02−0.123 0.25
For measuring of clearances see instructions in 3326−1.

* Clearance 3 is only valid with tie rods tightened.

Clearance Table
Cylinder Liner
approx. 210−270 mm
1
2
3
4 5 008.407/03
014.734/06

Clearance Table
Cylinder Liner

Key No.
Group

2124 Water guide jacket on cylinder

cover
Water guide jacket Ø + 0.70

1270 + 0.50
1 Clearance total 0.70−1.10

1130 + 0.50

1214 + 0.50

1266 + 0.50

2124 Supporting ring for cylinder liner
Supporting ring Ø + 0.20

1041.5 0

2124 Cylinder jacket
Cylinder jacket Ø + 0.20

1030 0

2124 Cylinder liner
*7 Cylinder liner bore radial 840 845.90
* Pay attention to measuring point!

Clearance Table
Piston Rod Gland
006.097/99
3
012.607/04

Clearance Table
Piston Rod Gland

Key No.
Group

2303 Piston rod gland

*1 Ring width radial 31 min. 25
*2 Ring width radial 24 min. 22.20
*3 Ring width radial 5 min. 3.20
4 Ring clearance axial 0.10−0.26 0.50
* Ring wear
The differential value between nominal dimension and max. wear is equal for all
rings, i.e. also for undersize rings.

Clearance Table
Exhaust Valve
VALVE SPINDLE
GUIDE BUSH
1 2
~ 2/3 L
L = LENGTH
3
~ 1/3 L
001.400/97
014.751/06

Clearance Table
Exhaust Valve

Key No.
Group

2751 Valve spindle
1 Spindle outer ∅ − 0.19 84.40

85 − 0.23
2751 Guide bush
*2 Bore inner ∅ + 0.035 85.45

85 0
*3 Bore inner ∅ + 0.035 86.45

85 0

Clearance Table
Top and Bottom End Bearings to Connecting Rod
10 mm
2 2
10 mm
3 3
4 4
10 mm
6
6
5
50 mm
7
7
014.752/06
001.399/97
8 8

Clearance Table
Top and Bottom End Bearings to Connecting Rod

Key No.
Group

3303 Top end bearing

3326
Crosshead pin outer ∅ 0

790 − 0.10
Bearing inner ∅ 790

*2 Lateral clearance total 0.6−0.9
4 Axial clearance total 0.4−0.8 1.2
3303 Bottom end bearing
Crankshaft outer ∅ 0
980 − 0.10
Bearing inner ∅ 980

8 Axial clearance total 20

Clearance Table
Piston Cooling and Crosshead Lubricating Link
2
3 3
3 3
1
2
4
000.664/93
014.754/06

Clearance Table
Piston Cooling and Crosshead Lubricating Link

Key No.
Group

Piston cooling and crosshead

lubricating link
Pin outer ∅ 68
1 Bearing clearance radial 0.03−0.09 0.20
2 Bearing width 151
3 Lateral clearance total min. 1.0
4 Lateral clearance total 2.0

Clearance Table
Piston and Piston Rings
1 5
6
2
3 A B
9 7
10 4 A B
11
8

Clearance Table
Piston and Piston Rings

Key No.
Group

3403 Piston crown

1 Crown outer ∅ 832.7
2 Crown outer ∅ 834.6
3403 Piston ring grooves
3425
3 Height of the two uppermost grooves vertical + 0.49

20 + 0.44
4 Height of the two lower grooves vertical + 0.37

20 + 0.32
5 Groove depth radial 27.5

3425 Piston rings
Ring height vertical 0

20 − 0.03
Point A Point B
6 Ring clearance vertical 0.44−0.52 0.75 0.95
7 Ring clearance vertical 0.32−0.40 0.65 0.80
8 Ring width radial 26.5 ± 0.40
3403 Piston skirt
9 Skirt outer ∅ − 0 min. 836.8

838.9 − 0.2
10 Rubbing ring outer ∅ − 0

839.3 − 0.1
3403 Piston rod
11 Rod outer ∅ − 0.062 min. 318.90

320 − 0.119
Used piston rings may be refitted if they will keep within their min. ring width until
the next overhaul (for judging and reusing piston rings see also 3425−1).
For evaluating and reusing piston heads see 3425−1).

Clearance Table
Driving Wheels for Supply Unit
4
1
5
2 3 3 2
014.763/06
014.764/06

Clearance Table
Driving Wheels for Supply Unit

Key No.
Group

4103 Intermediate wheel

1 Shaft outer ∅ 340
*4 Tooth backlash 0.40−0.62 0.85
* Clearance 3 is only valid with tie rods tightened.

Clearance Table
Supply Unit
1 32
8
7
5
5
4
014.777/06
014.779/06
014.778/06
10

Clearance Table
Supply Unit

Key No.
Group

5552 Supply unit
1 Pinion outer ∅ 0
120 − 0.022
Bearing (fitted) inner ∅ + 0.23

120 + 0.14
2 Bearing clearance radial 0.14−0.252

5552 Camshaft unit
4 Cam shaft outer ∅ 0

300 − 0.032

7 Tooth backlash 0.16−0.29
*8 Minimum clearance 3
5552 Intermediate wheel
* Minimum clearance between cam and roller with fuel pump cut out.

Clearance Table
Fuel Pump
PLUNGER & CYLINDER

40 42 44
29 mm
B
1 1
149 mm
3
C
73 mm
014.104/06
2
6
5
WCH00832
2012-07 / V4 24/ 25 Wärtsilä Switzerland Ltd

Clearance Table
Fuel Pump

Key No.
Group

5556 Fuel pump

Plunger (40, 42 & 44 mm)
1 Clearance (plunger / cylinder) A−B radial 0.035−0.038 0.045
Clearance (plunger / cylinder) B−C radial 0.025−0.028 0.035
* Clearance (plunger / cylinder) D radial 0.040−0.043 0.5
Guide piston outer ∅ 185
Lower housing inner ∅ 185
2 Clearance radial 0.22−0.68 0.8
3 Piston / lower spring carrier axial 0.12−0.24 0.3
4 Regulating sleeve / upper spring axial 0 .5−0.7
0.8
carrier
5556 Roller guide
0
Pin outer ∅ 80 − 0.013
+ 0.04
Guide piston (bore) inner ∅ 80 + 0.01
5 Clearance radial 0.010−0.053 0.08

6 Total clearance between guide piston axial 0.26−0.54
0.7
and roller with pressure discs
* Plunger conically machined in range ’C’−’D’; i.e. clearance increases in diam-

eter of 0.015 mm.
Wärtsilä Switzerland Ltd 25/ 25 V4 / 2012-07

Tightening Values of Important Screwed Connections
Group Description Thread Tightening values Lubricant

1 2 3
[bar] [Nm] [_; mm]
1
1106 * 1 Bedplate parting faces, screw M36 2090 Oil
* 2 Bedplate parting faces, screw M56 4970 Oil
1112−1 3 Foundation bolts (metal and M64 1000 MOLYKOTE G

synthetic chocks) 1st step 600 bar
1132−1 4 Main bearing, jack bolt M100 1100 no additional

lubricant required
1132−2 5 Main bearing at driving end, nut to M64x4 40_ MOLYKOTE G

waisted stud
1715−1 6 Engine stays (friction type) M64 200 MOLYKOTE G
1903−1 7 Tie rod M130x6 1000 MOLYKOTE G
(see instructions in 1903−1) 1st step 100 bar

2nd step 1000 bar
2
2106 * 8 Cylinder jacket bolting-up / bolt M64 Elongation 0.55 ± 0.04 mm Oil
* 8 Cylinder jacket bolting-up / fitted bolt M64 Elongation 0.45 ± 0.03 mm Oil
2124−2 9 Lifting gear (tool 94202), screw M20 30 no additional

lubricant required
(see instructions in 2124−2)
10 Special screw (tool 94207) M42 30 no additional

lubricant required
11 Supporting ring, screw M24 150 see details in

2124−2
2136−1 12 Lubricating quill, backing screw M16 50 see details in

2136−1
2138−1 13 Lubricating quill (Pulse Jet), screw M8x150 10 see details in

2138−1/A1
clamping part M20x1.5 15
13 Lubricating quill (Pulse Feed) with M22x1.5 30 see details in

2138−1/A2
non-return valve
1 When using other hydraulic jacks, required pressure in bar must be calculated in relation to effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp 1 bar = 1.02 kp/cm 2
2 Tightening torque
3 Tightening angle or elongation
− Numbers in f refer to illustrations on pages 8 to 15.
− Values in parentheses (...) are for information only, to be used for comparison.
− Screwed connections must be tightened in accordance with values not in parentheses.
Respective lubricant has to be applied to threads and seating surfaces, if no other instructions are mentioned.
− Bostik Findley Inc. (USA) is manufacturer of Never-Seez NSBT-8.
* Tightening procedure not mentioned in this Manual.


1 2 3
[bar] [Nm] [_; mm]
2708 * 14 Indicator valve, screw M20 80 Never-Seez

NSBT-8
2708−2 15 Cylinder cover, nut to waisted stud M110x6 1000 (350_) Oil
2722−1 16 Injection valve, screwed connection M12 Equally tighten Allen Never-Seez
screws until spring guides NSBT-8
with cylinder cover
are flush with spring cages
M65x1.5 1st step 100 Nm Never-Seez
17 Injection valve, retaining nut, nozzle NSBT-8
body − nozzle holder 1st step to 2nd step 30_
(see instructions in 2722−1) (loosen retaining nut after initial
assembly and then repeat tighte-
ning procedure)
2728−1 18 Starting valve spindle, nut M30x2 (800) 55_ MOLYKOTE G
(spindle thread not to be lubricated in region

of locking ring)
19 Starting valve, nut to waisted stud M27 (750) 90_ Never-Seez

NSBT-8
2751−1 20 Exh. valve cage, nut to waisted stud M110x6 1000 (160_) Oil
21 Exhaust valve cage, waisted stud M110x6 no additional

lubricant required
2751−2 22 Exhaust valve, head screw for M12 120 Oil

measuring cone − piston
23 Exhaust valve, nut to waisted stud to M24 435 Oil

upper housing − valve cage
3
3103 * 24 Flywheel, nut to coupling bolt M56 20_ MOLYKOTE G
* 25 Crankshaft division, nut to coupling M85x4 50_ MOLYKOTE G

bolt
3114 * 26 Crankshaft − propeller shaft, nut to M85x4 50_ MOLYKOTE G
coupling bolt
3130−2 27 Crankshaft − counterweight, nut to M85x4 35_ MOLYKOTE G

coupling bolt
* 28 Crankshaft − vibration damper, nut M85x4 40_ MOLYKOTE G
to coupling bolt (standard flange)
2 Tightening torque


1 2 3
[bar] [Nm] [_; mm]
3146−1 29 Axial damper − bedplate, fixing bolt M36 (2270) 50_ MOLYKOTE G
3303−1 30 Connecting rod, stud for top end M76x6 1000 Oil
bearing 1st step 600 bar (gap = 0)
2nd step 1000 bar
Check: 1st step to 2nd step (35_)
31 Connecting rod, stud for bottom end M100x6 1000 Oil

bearing 1ststep 600 bar (gap = 0)
2nd step 1000 bar
Check: 1st step to 2nd step (50_)
3403−1 32 Piston rod − crosshead, waisted stud M64 30_ MOLYKOTE G
3403−3 33 Piston rod − piston crown, nut to M48x3 1000 115_ MOLYKOTE G
waisted stud
34 Spraying plate − piston rod, waisted M16 1st step 30 Nm Oil
screw 1st step to 2nd step 40_
4
4103−2 35 Intermediate wheel bearing, waisted M36 55_ MOLYKOTE G
screw
36 Intermediate wheel bearing, waisted M36 60_ MOLYKOTE G

screw
37 Gear rim − hub of intermediate M42x3 75_ see details in
4103−2
wheel, screwed connection
(nut secured with LOCTITE No. 262)
4103−3 38 Gear wheel on crankshaft, waisted M48x3 Elongation 1.85 ± 0.08mm see details in
4103−3
stud (spare wheel)
39 Gear wheel on crankshaft, nut to M42x3 (4400) 70_ no additional
lubricant required
waisted bolt to flanged connection
(secured with LOCTITE No. 262)
5
5552−1 40 Servo oil pump, screw M24 600 Oil
5552−2 41 Supply unit, nut to waisted bolt M42 1000 Oil
42 Supply unit, waisted bolt M42 140 Oil
2 Tightening torque


1 2 3
[bar] [Nm] [_; mm]
5552−4 43 Supply unit − housing of intermediate M16 170 Oil

wheel, screw
44 Supply unit − housing of intermediate M36 (2100) 47_ Oil
wheel, screw
45 Bearing cover of intermediate wheel M56 1000 Oil
to camshaft, nut to waisted bolt
46 Bearing cover of intermediate wheel M56 320 Oil
to camshaft, waisted bolt
5552−5 47 Camshaft wheel, nut to waisted bolt M42 1000 Oil
48 Camshaft wheel, waisted bolt M42 140 Oil
5553 * 49 Supply unit − support, waisted screw M42x4.5 (2650) 55_ Oil
5556−1 50 Fuel pump cover − upper housing, M27 480 Never-Seez

NSBT-8
screw
51 Fuel pump − supply unit, screw M30 (1250) 64_ Never-Seez
NSBT-8
52 Fuel pump cover − fuel pipe, screw M12 70 Never-Seez

NSBT-8
5562 * 53 Non-return valve M36x2 450 Never-Seez

NSBT-8
* 54 Nipple M36x2 400 Never-Seez

NSBT-8
* 55 Screw plug M27x2 300 Never-Seez
NSBT-8
* 56 Transition nipple to pressure M27x2 300 Never-Seez
NSBT-8
transmitter
* 57 Pressure transmitter M14x1.5 25 Never-Seez
NSBT-8
* 58 Cover − fuel rail, screw M16x100 150 Never-Seez
NSBT-8
* 59 Valve block − cover, screw M16 150 Never-Seez
NSBT-8
* 60 Stop valve in valve block, screw M10 35 Never-Seez
NSBT-8
* 61 Non-return valve G ¾” 80 Oil
* 62 Drain screw M20x2 200 Never-Seez

NSBT-8
2 Tightening torque


1 2 3
[bar] [Nm] [_; mm]
5564 * 63 Fuel quantity sensor − fuel quantity M8 20 Never-Seez

NSBT-8
housing, screw
* 64 Fuel quantity housing − intermediate M10 25 Never-Seez

NSBT-8
flange, screw
* 65 Fuel quantity sensor − fuel quantity M12 75 Never-Seez

NSBT-8
housing, screw
* 66 Flange − injection control block, M14 145 Never-Seez

NSBT-8
screw
5564−1 67 Injection control unit − fuel pipe, M16 110 Never-Seez

NSBT-8
screw
68 Pre-control valve, screw M4 2.5 Never-Seez
NSBT-8
69 Injection control unit − connection M42x2 700 Never-Seez
NSBT-8
piece
70 Connecting nipple M42x2 350 Never-Seez
NSBT-8
5566 * 71 Valve block, screw M10 35 Oil
* 72 Valve block − pressure reducing M24x1.5 60 Oil

valve
* 73 Drain screw M24x2 200 Oil
* 74 Transmitter G ¼” 25 Oil
* 76 Shut-off valve − valve block, screw M18x1.5 70 Oil
* 77 Nipple M30x2 200 Oil
5571 * 78 Shut-off valve − valve block, screw M18x1.5 70 Oil
* 80 Distributor block − press. relief valve M22x1.5 80 Oil
* 81 Distributor block − press. relief valve M28x1.5 120 Oil
* 82 Non-return valve G 1” 160 Oil
2 Tightening torque


1 2 3
[bar] [Nm] [_; mm]
5610 * 84 Pressure transmitter G ¼” 25 Oil
* 85 Screw plug G ¼” 25 Oil
* 86 Valve block − servo oil rail, screw M20 260 Oil
* 88 Waisted screws to flanges M16 170 Oil
* 89 Stop valve on valve block, screw M16 130 Oil
5612−1 90 Pre-control valve, screw M4 2.5 Oil
91 Exhaust valve control unit − servo oil M20 170 Oil

rail, screw
8
8447 * 92 Stop valve in valve block, screw M16 130 Oil
8447−1 93 Servo oil piping, screw M16 170 Oil
94 Spindle to shut-off valve M30x2 200 Oil
8733−1 95 Fuel pressure piping, screw M12 40 Never-Seez

NSBT-8
8750−2 96 Pressure control valve, screw M16 190 Never-Seez

NSBT-8
8750 * 97 Flange and end flange, screw M16 190 Never-Seez
NSBT-8
* 98 Stop valve in end flange, screw M10 35 Never-Seez

NSBT-8
* 99 Flange with relief valve, screws M16 190 Never-Seez

NSBT-8
* 100 Flange of intermediate fuel M16 190 Never-Seez

NSBT-8
accumulator, screw
* 101 Nipple M26x1.5 100 Never-Seez

NSBT-8
8751−1 102 Relief valve M30x2 300 Never-Seez

NSBT-8
8752−1 103 Fuel pressure piping, screw M12 60 Never-Seez

NSBT-8
2 Tightening torque


1 2 3
[bar] [Nm] [_; mm]
8752−1 104 Spindle to shut-off valve M20 100 Never-Seez
NSBT-8
9
9923 * 105 Connecting unit, adjusting disc − M10 35 MOLYKOTE G
coupling disc, screw
9223−1 106 nut to waisted screw M16 140 MOLYKOTE G
107 Shaft nut M40x1.5 25 MOLYKOTE G
108 Shaft nut M35x1.5 25 MOLYKOTE G
109 Screw to shaft encoder − bearing M8 16 MOLYKOTE G
housing
110 Screw to distance piece M12 60 MOLYKOTE G
111 Screw to connecting unit − driving M12 60 MOLYKOTE G
wheel
112 Screw to spring tens. − coupling disc M12 60 MOLYKOTE G
113 Screw to spring tensioner M10 35 MOLYKOTE G
9314 * 114 Clamping nut to oil mist detector G ¾” 15 Oil
* 115 Screws for opening head of oil mist 5 Oil
detector
* Tools
116 Screw plug 94585 M36x2 270 Never-Seez
NSBT-8
6606−1 117 Lifting device 94660, screw M30 500 no additional

lubricant required
94690−94692 for rail unit transport

* 118 Lifting support, screw M20 450 no additional
lubricant required
* 119 Lifting tool, screw M24 800 no additional

lubricant required
2 Tightening torque

LIFTING GEAR FOR ENGINE STAY LIFTING DEVICE FOR

CYLINDER LINER (FRICTION TYPE) COOLER ELEMENT
117
9
6
10
15
13 12
33
11 34
32
40
30
31
3
115
114
015.180/07

21
20
36
35 4
38 5 37
39
28
25
27
26
24
29
8 − 10 CYL.
ENGINES
015.185/07
1 2

INDICATOR
VALVE
14 23
22
STARTING
VALVE 95
19
18
16
95
69
17
99 I
100 101 104
I II
94 92
50
52
102 97 96 51
42
42
II 41
41
47
48
97 98
43
44 015.186/07

DISTRIBUTOR BLOCK TO
CONTROL OIL PUMP (RAIL UNIT)
81 78 93
103
I I
93
II II
103
79 80
93
I-I II - II 41
45
42 46
49
82 83
015.187/07

FUEL RAIL
I
68 104
60
FREE END
59
IV CONTROL OIL
I SUPPLY
VI
58 72 71 77 58 71
5−7 CYL.
I ENGINES
VI
55 54 53
III - III IV - IV 76
75 61
5−10 CYL.
ENGINES
VI
73
57 56 75
I 116
63 64 65 66 67
62
CONTROL OIL
SUPPLY
III III
015.188/07
74 73 70

SERVO OIL RAIL
I
88
88 86
II
II
85 84
90 91
87
015.189/07
89 94

CRANK ANGLE SENSOR UNIT
I
108
106 I-I
I
010.293/02
111 107 109

008.566/01
CONNECTING UNIT TO CRANK

ANGLE SENSOR UNIT
B
105
110 113 112

B
008.750/01
008.567/01

TOOL FOR RAIL UNIT

TRANSPORT
118
119
015.190/07

Tightening Values of Standard Screwed Connections
1. Standard screws
This table is valid for all screws that are not considered in 0352−1.
It is recommended to lubricate the threads for screws which come into contact with
hot parts like exhaust pipings, expansion pieces, etc. with a heat-resisting lubri-
cant, e.g. THREAD GARD or Never-Seez NSBT-8, etc.
Attention! These tightening instructions are valid only if:
− screws are made of the 8.8 material
− threads have been lubricated with oil
Standard thread Fine thread Tightening torque [Nm]

M8 M8 x 1 20
M10 M10 x 1.25 40
M12 M12 x 1.25 70
M14 M14 x 1.5 110
M16 M16 x 1.5 170
M18 M18 x 1.5 250
M20 M20 x 1.5 350
M22 M22 x 1.5 450
M24 M24 x 2 600
M27 M27 x 2 900
M30 M30 x 2 1200
M33 M33 x 2 1600
M36 M36 x 3 2100
M39 M39 x 3 2500
M42 M42 x 3 2900
M45 M45 x 3 3300
M48 M48 x 3 3700
M52 M52 x 3 4100
M56 M56 x 4 4600
M60 M60 x 4 5200
Wärtsilä Switzerland Ltd 1/ 2 2010−01

Tightening Values of Standard Screwed Connections
2. Waisted studs
Waisted studs must be tightened according to the values in the following diagram.
D Before fitting a waisted stud clean its thread and corresponding tap hole. The
sealing faces must be degreased (e.g. using white spirit) and subsequently
primed.
D Screw in the waisted stud without lubricant on the thread right to the bottom of
the tap hole, and tighten. Always utilize a stud driver or two nuts.
Tools like a pipe wrench etc. which would damage the stud shank must never be
used.
D For the protection of the waisted stud in the cylinder jacket and cylinder cover,
fill the annular space above the thread with a non-hardening jointing com-
pound (see 2751−1).
TIGHTENING TORQUE FOR WAISTED STUDS
3500
3000 400
TIGHTENING TORQUE [Nm]
2500
300
2000
1500 200
1000
100
500
001.769/97
0 0
10 20 30 40 50 60 70 80 90 100 110 120 10 20 30 40 50 60
THREAD DIAMETER [mm]

Masses (Weights)
Individual Components per Piece in kg
Group Component Execution kg

1
1134 Main bearing shell 295
1137 Main bearing cover 772−778
1138 Jack bolt 142
1224 Thrust bearing pad 156
1717 Casing, upper part free end 796

Casing, lower part free end 1082
1719 End casing driving end 680
1720 Oil baffle, upper part 569

Oil baffle, lower part 234
1903 Tie rod complete 1156

Tie rod nut 35
Intermediate ring for tie rod nut 25−38
2
2106 Waisted stud with nut in cylinder jacket 137
2120 Supporting ring 2550
2124 Cylinder liner 7070
2130 Water guide jacket 503
2303 Piston rod gland complete 323
2708 Waisted stud with nut for valve cage 88

Cylinder cover without accessories 4912
Cylinder cover with valves and water complete 7345
guide jacket
2722 Injection valve complete 23.6
2728 Starting valve complete 82
2740 Relief valve complete 5.4
2751 Exhaust valve complete 1612
2754 Exhaust valve spindle 181


3
3122 Flywheel light 4500−6230
Flywheel heavy 11 730−25 200
3122 Counterweight 460−1620
3140 Axial damper cylinder 2-part 1592
3206 Turning gear with planetary gear 1500
3303 Connecting rod complete 5923

Waisted stud with nut for bottom end 66
bearing
Waisted stud with nut for top end 28
bearing
3306 Connecting rod shank 4150
3309 Lower bearing half for bottom end complete 773

bearing with waisted studs
3310 Bearing shell for bottom end bearing 85
3312 Upper bearing half for top end bearing 726
3315 Bearing shell for top end bearing 130
3326 Crosshead 3175

Crosshead with guide shoes complete 4546
Guide shoe complete 620
3403 Piston with piston rod complete 4183

Piston crown 1056
Piston skirt 199
Piston rod 2648
Spraying plate with oil pipe 172
3603 Toggle lever to crosshead lubrication complete 196

and piston cooling
4
4106 Gear wheel on crankshaft 1-part 2031
Gear wheel on crankshaft 2-part, complete 3226
4108 Intermediate wheel with bearing pin for complete 3234

camshaft drive
Bearing pair for intermediate wheel 324
4120 Intermediate wheel with shaft to supply 1472

unit
4325 Shut-off for starting air 331


5
5550 Driving wheel to supply unit 570
5551 Servo oil pump to supply unit Dynex 227
5552 Gear wheel with shaft to driving wheel complete 934

Gear wheel on shaft to driving wheel 387
Camshaft with cams and gear wheels complete 2586
Camshaft 725
Cam 150
5556 Fuel pump complete 408
5564 Injection control unit complete 207
5572 Control oil pump complete 195
5612 Exhaust valve control unit complete 130

6
6506 Turbocharger TPL80−B 6540
Turbocharger MET83SE or II 6700
6545 Auxiliary blower with electric motor complete 1340−1380

Electric motor 590−630
6606 Scavenge air cooler GEA190/48/24/4 3980

Tube stack to main cooler 2550 − 3550
Tube stack to pre-stage 250
Connection chamber 210
Connecting bend 130
6708 Water separator 650

8
8138 Expansion piece between exhaust 80
manifolds and before turbocharger
8139 Expansion piece after exhaust valve 107

Dimensions
O-rings and Round Rubber Rings
Group Place of application Thick- Inner ∅

ness
[mm] [mm]
1903 Tie rod 5.33 120.02
2106 Relief valve for cylinder jacket type 224EVT 8 210

Cylinder jacket − division 9 540
Cylinder liner
2124 Cylinder liner − water guide jacket 9 1160
Cylinder liner − water guide jacket 9 1220
Cylinder liner − supporting ring 20 990
Cylinder liner − cylinder jacket 20 970
2136 Lubricating quill (bush) 3.53 36.09
2138 Lubricating quill (bush) (Pulse Jet lubrication) 5.33 69.22

Lubricating quill (bush) (Pulse Feed lubrication) 3.53 36.09
Piston rod gland

2303 Housing − cylinder jacket 6.99 633.48
Ring 2-part − cylinder jacket 6.99 430.66
Cylinder cover
2708 Cylinder cover − water guide jacket 9 1220
Cylinder cover − water guide jacket 9 1090
2722 Injection valve / spring tensioner 3.53 36.09
Starting valve
2728 Housing − cylinder cover 6.99 132.72
Connection pipe 1.78 14
5/2-way valve − cover 2 12
2740 Relief valve for cylinder cover 5.33 40.64
Exhaust valve
2751 Valve cage − cylinder cover 6.99 658.88
Valve seat − cylinder cover 6.99 557.68
Valve seat − valve cage 6.99 417.96
Housing − valve cage 6.99 227.97
Housing − upper housing 6.99 240.67
Damper − housing 5.33 69.22
Guide bush − valve cage 5.33 113.67
Piston − valve spindle 5.33 85.09
Housing − valve stroke sensor 3.53 28.17
Vibration damper
3130 Intermediate piece − vibration damper 9 1060
Piston
3403 Piston − oil pipe 6.99 142.24
Piston − spraying plate 9 540

Dimensions: O-rings and Round Rubber Rings

ness
[mm] [mm]
Shut-off valve for starting air

4325 Housing − valve guide 6.99 215.27
Cover − liner bush 6.99 117.17
Housing − valve block 3.53 56.74
Valve block − housing 2.62 13.94
Pressure switch − valve block 1.78 6.07
Double check valve − valve block 2 10
Control air supply unit A

4605 Pressure reducing valve − corner union 2.4 20.30
Valve body − pressure transmitter 1.78 6.86
Supply unit
5551 Flange − servo oil pump 3.53 202.79
5552 Spray nozzle − housing 3.53 28.17

Spray nozzle − housing 3.53 18.64
5554 Pump support − housing 3.53 202.79
Fuel pump
5556 Lower housing − housing of supply unit 6.99 227.97
Upper housing − lower housing 6.99 227.97
Valve block − upper housing 5.33 158.12
Valve block − pump cover 5.33 158.12
Connection pin − lower spring carrier 2.62 15.54
Adapter piece − lower and upper housing 3.53 9.12
Pump cover − flange 5.33 59.69
Guide pin − lower housing 3.53 37. 69
Flange − upper housing 1.78 34. 65
Fuel rail
5562 Spindle guide − valve block 3.53 32.92
Drain screw − valve block 1.78 12.42
Injection control unit

5564 Fuel quantity piston − sensor 3.53 40.87
Fuel quantity piston housing − fuel quantity piston 3.53 40.87
Pre-control valve − valve unit 1.78 5.28
Control oil supply

5566 Drain screw − valve block 2.62 15.54
Non-return valve 1.5 16
Stop valve − valve block 1.78 14
Stop valve spindle − screw plug 1.78 9.25


ness
[mm] [mm]
Control oil pump rail unit

5571 Stop valve − distributor block 1.78 14
Stop valve spindle − screw plug 1.78 9.25
Drain screw − distributor block 2.62 15.54
Non-return valve 1.5 16
Blind flange − distributor block 3.53 50.39
Piping flange − distributor block 2.62 32.99
Piping flange − distributor block 3.53 44.04
Servo oil rail

5610 Cover − pressure retaining valve 5.33 75.57
Pressure retaining valve − oil pipe 5.33 132.72
Valve − valve block 2.62 29.82
Drain screw − valve block 1.78 12.42
Exhaust valve control unit

5612 Servo oil rail − valve control block 3.53 40.87
Spring housing − valve control block 2.62 56.82
Spring housing − cover 2.62 56.82
Valve control block − pre-control valve 1.78 5.28
Underslung
6509 Sealing of water separator with round rubber cord ∅4
(developed lengths 4372 and 6328 mm)
Cylinder lubricating pump

7206 Flange − oil inlet pipe 3.53 40.87
Inlet pipe control oil pump

8446 Flange − valve block 3.53 50.39
Flange − inlet pipe control oil pump 3.53 56.74
Servo oil piping

8447 Servo oil piping − collector block 3.53 47.22
Servo oil piping − servo oil pump 3.53 37.69
Flange − collector block 3.53 47.22
Drain screw − collector block 2.62 15.54
Servo oil piping

8453 Flange − servo oil piping 5.33 75.57
Flange − distributor block 5.33 85.09
8460 Hydraulic piping for exhaust valve 5.33 94.67
8704 Fuel pressure retaining valve 2.62 15.54
Fuel pressure piping

8733 Connection piece − injection control unit 2.62 37.77
Flange − connection piece 3.53 37.69
Flange − pressure piping 3.53 32.92
Flange − pressure piping (star tube) 3.53 31.34


ness
[mm] [mm]
Intermediate fuel accumulator

8750 Flange − fuel pressure pipe 3.53 40.87
Flange − intermediate fuel accumulator 5.33 59.69
Intermediate fuel accumulator − end flange 5.33 148.49
Shut-off valve − end flange 3.53 32.92
Fuel pressure control valve (3.06)

Intermediate piece − end flange 3.53 50.39
Intermediate piece − fuel pressure control valve 3.53 32.92
Cylinder − cover 1.78 20.35
Cylinder − cover 1.78 6.07
Cover − valve body 2.62 113.97
Piston − cover 2.62 18.72
Piston − cover 2.62 15.54
Valve tip − piston 1.78 6.07
3/2-way valve − valve body 2 10
Slide − valve body 2.62 3.63
Fuel pressure control valve 3.53 18.64
Fuel pressure piping

8752 Flange − fuel pressure piping 5.33 46.99
Flange − distributor block 5.33 66.04
Flange − intermediate piece 5.33 66.04
Flange − end flange / intermediate fuel accumulator 5.33 66.04
Crank angle sensor drive

9223 Retaining ring − housing 3.53 72.62
Measuring instruments
9258 Pressure switch and transmitter 1.78 6.07
Tools
9434 94349: Pressure testing device for piston 6.99 304.17
9455 94430: Device for cutting out / in of a fuel pump 2.62 34.59

Dimensions
Piston and Rod Seal Rings
Group Place of application Ring Dimension [mm]

type
4325 Shut-off valve for starting air − valve PSR 190 x 184 x 5.8
Shut-off valve for starting air, cover − flange RSR 30 x 33 x 2.8
5556 Fuel pump, flange − regulating (toothed) rack RSR 24 x 26 x 1.8
Fuel pump, lower housing − guide piston RSR 70 x 3.53
Tools
9408−10 94424: Hydr. jacking tool PSR 65 x 61 x 3.8
Piston Seal Ring (PSR) Rod Seal Ring (RSR)

Nominal dimension o∅ x i∅ x b Nominal dimension i∅ x o∅ x b
Cylinder Bush
O-ring
b Seal ring
Seal ring
O-ring
Piston Rod
i∅ o∅ i∅ o∅

Dimensions: Rod Seal Rings
Group Place of application Ring Dimension [mm]

type
2751 Exhaust valve guide RSR 100.1 x 85 x 6.1
Rod Seal Ring (RSR)

Nominal dimension da x di x b
Bush
O-ring
Seal ring
Rod
00.7384 di da
da = Groove diameter
di = Rod diameter
b = Groove width

Tool Place of application of pre-tensioning Part Back-up ring O-ring

No. jack (slotted)
Dimension [mm]
o∅ x i∅ x t i∅ x s
Jack bolt to main bearing piston 120 x 110.6 x 1.7 110.49 x 5.33
94145 Foundation bolt and engine stay piston 135 x 125.6 x 1.7 123.19 x 5.33
cylinder 104.4 x 95 x 1.7 94.62 x 5.33
94215a Cylinder cover stud piston 235 x 222.8 x 2.5 215.27 x 6.99
cylinder 149.4 x 140 x 1.7 139.07 x 5.33
94252 Waisted stud to valve cage piston 265 x 252.8 x 2.5 253.37 x 6.99
cylinder 149.4 x 140 x 1.7 139.07 x 5.33
94314 Waisted stud to bottom end bearing piston 215 x 202.8 x 2.5 202.57 x 6.99
cylinder 162.2 x 150 x 2.5 148.59 x 6.99
94315 Waisted stud to top end bearing piston 175 x 162.8 x 2.5 158.12 x 6.99
cylinder 127.2 x 115 x 2.5 113.67 x 6.99
94556 Waisted bolt to bearing of intermediate shaft piston 137.8 x 150 x 2.5 6.99 x 135.89
to supply unit cylinder 85 x 94.4 x 1.7 5.33 x 85.09
O-ring Back-up ring t
o∅ i∅
o∅ i∅
002.696/98

Tool Place of application of pre-tensioning Part Back-up ring O-ring

No. jack (un-slotted)
Dimension [mm]
94180 Tie rod piston 330 x 317.8 x 2.5 316.87 x 6.99
cylinder 222.2 x 210 x 2.5 202.57 x 6.99
94346 Waisted stud to piston crown piston 158.2 x 146 x 2.5 91.44 x 5.33
cylinder 264 x 251.8 x 2.5 78.97 x 3.53
94557 Gear wheel and waisted bolt of bearing to piston 115 x 105.6 x 1.7 104.14 x 5.33
camshaft cylinder 76.2 x 70 x 1.4 69.44 x 3.53
94595 Jack for jacking-out of jammed pump piston 112 x 102.6 x 4.7 100.97 x 5.33
plunger
O-ring Back-up ring t
o∅ i∅
o∅ i∅
011.032/03

Group Place of application Part Back-up ring O-ring

(un-slotted)
Dimension [mm]
8750 Intermediate fuel accumulator: Relief valve 75 x 69.6 x 1.4 66.27 x 3.53
O-ring Back-up ring

t
A∅ I∅
A∅ I∅
014.687/06

Maintenance Schedule
Inspection and Overhaul Intervals (Guidelines)
Group Component Work to be carried out Intervals

0
Lubricating oil − Laboratory analysis 3000 Op. h (operating
hours)
Cooling water − Determine quality and concentration of inhibitor weekly

(follow instructions of inhibitor manufacturer)
1
1112−1 Bedplate − Check pre-tension of foundation bolts, 12 000 Op. h
first time after 1500 Op. h
Crankcase − Visual examination 1500−3000 Op. h

100 Op. h after overhaul works
1132−2 Main bearing − Remove bearing cover for inspection, according to

random inspection every 12 000 Op. h classification society
− Remove bearing shell for inspection acc. to class. society
1203−1 Thrust bearing − Check axial and radial clearances 6000−8000 Op. h
− Check bottom drain for free passage 6000−8000 Op. h
1224−1 − Remove thrust bearing pads for inspection acc. to class. society
1715−2 Hydraulic engine − Check pre-tension of waisted studs, 6000−8000 Op. h

stays first time after sea trial
1903−1 Tie rod − Check pre-tension, if necessary re-tension 24 000−30 000 Op. h
first time after one year
2
2124−1 Cylinder liner − Establish wear in bore (in fitted condition) at every piston removal
2124−2 − Remove cylinder liner as required
− Replace O-rings at every removal
− Replace (soft iron) joint ring between cylinder liner at every piston removal
and cylinder cover
− Water guide jacket, replace O-rings at every piston removal
− Check condition of antipolishing ring at every piston removal
2124−3 − Grind off wear ridge in bore at every piston removal

− Refinish lubricating grooves as required
− Clean scavenge ports and refinish their edges as required
2136−1 Lubricating quill − Check function and tightness at every piston removal
and accumulator
− Check function of non-return valves at every liner removal
− Replace O-rings at every liner removal

− Random check of diaphragm to accumulator 6000 Op. h

2138−1 Lubricating quill − Check function and tightness at every piston removal
(Pulse lubrication)
− Check function of non-return valves at every liner removal
− Replace O-rings at every liner removal
2303−1 Piston rod gland − Clean rings, establish wear at every piston removal
2708−1 Cylinder cover − Check combustion space for damage and wear at every piston removal
2722−1 Injection valve − Check externally for tightness before starting engine
after a longer standstill
− Check spray pattern, opening pressure, tightness 3000 Op. h

condition of nozzle tip, readjust opening pressure
(life time of nozzle tip about 6000 Op. h)
2728−1 Starting valve − Check piping before the valve during operation, weekly
if piping is too hot, dismantle starting valve
− Remove and dismantle one starting valve at 6000−8000 Op. h

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

if necessary tighten nut
− Solenoid valve, random functional check 6000 Op. h

overhaul 18 000 Op. h
2745−1 Relief valve to − Check blow-off pressure as required

cylinder cover
2751−1 Exhaust valve − General inspection of valve housing, valve at every piston removal
to spindle and valve seat
(without dismantling of exhaust valve)
2751−4 − Check condition and wear of valve spindle 24 000−36 000 Op. h
(if necessary regrind seat by machining)
− Check piston seal ring / air spring & rod seal ring / 24 000−36 000 Op. h
guide bush
− Check condition and wear of valve seat 24 000−36 000 Op. h

(if necessary regrind seat by machining)
− Random check of valve drive, outside and 18 000 Op. h

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

measuring cone
3
3103−1 Crankshaft − Measure crank deflection according to
classification society
− Always in case of grounding of the ship as well as
before and after every docking

3130−1 Torsional − Take a silicon oil sample from viscous vibration first time after 15 000 −
vibration damper damper (based on results of 1st sample, interval 18 000 Op. h
for taking further samples will be decided)
3130−2 − Inspection interval and dismantling of vibration acc. to instructions of

damper damper manufacturer
3146−1 Axial damper − Dismantling and inspection 36 000−48 000 Op. h
3206−1 Turning gear − Inspection interval acc. to instructions of

turn. gear manufacturer
− Re-lubrication of tooth flanks of pinion & flywheel,
depending on visual inspections, however every
2000 Op. h of diesel engine
− Check screwed connections, 12 000 Op. h

first time after one year (if necessary retighten)
Connecting rod − Check bearing clearances (see 0330−1) 6000−8000 Op. h

bearings
3303−2 − Inspect bottom end bearing 30 000−36 000 Op. h or

(life time of shell 60 000−72 000 Op. h) acc. to class. society
3303−3 − Inspect top end bearing 30 000−36 000 Op. h or

acc. to class. society
3326−1 Guide shoe, − Check clearances 6000−8000 Op. h

crosshead pin
3326−2 − Remove crosshead as required
3403−1 Piston − Remove, clean and measure ring grooves 18 000−36 000 Op. H
(cylinder liner with antipolishing ring and chrome- (condition based)
ceramic piston rings)
− Check tightness on piston in situ and with running after refitting

oil pump, visual check through scavenge ports
3403−3 − Dismantling and assembling (open cooling space as required

& clean same, min. one piston every three years)
3403−4 − Check condition of the piston top surface at every piston removal
− Visual check through scavenge ports to piston, 500−1000 Op. h

piston rings and cylinder liner
(rotate crankshaft with turning gear)
Piston underside − Check condition of space and clean it as required 1500−3000 Op. h
− Check drains for free passage 1500−3000 Op. h
3425−1 Piston rings − Measure thickness of chrome-ceramic layer 1500−2000 Op. H

− Replace piston rings based on remaining coating 18 000−30 000 Op. H
thickness (condition based)


4
Start interlock − Check electric and pneumatic interlocks quarterly
(see Operating Manual 4003−1)
4103−1 Driving wheels − Check condition of teeth 6000−8000 Op. h
− Check running clearance and backlash of teeth 6000−8000 Op. h
Starting air − Vent after each manoeuvring

shut-off valve period
4325−1 − Dismantle, clean and check 24 000−36 000 Op. h

(particularly seat, springs and seal rings)
− Overhaul common start valve 18 000 Op. h
5
Control air filter − Drain filter weekly
− Clean filter 6000 Op. h
5552−1 Supply unit − Replace servo oil pump either with new one or a 24 000 Op. h
pump overhauled by a Wärtsilä workshop
− Check pinion and driving wheels to servo oil 3000 Op. h

pump drive
− Check bearing bushes to pinion 24 000 Op. h
5552−2 − Camshaft, check running surface of cams, 3000 Op. h

rollers & roller guides (first time after 500 Op. h)
− Camshaft, check bearing clearances at random 12 000 Op. h
− Camshaft, check thrust bearing clearances 36 000 Op. h
5556−1 Fuel pump − Replace O-rings in valve block 18 000 Op. h
− Random visual check of plunger & cylinder, 18 000 Op. h

roller and roller guide
5564−1 Injection control − Replace unit (incl. rail valves) either with new 24 000−36 000 Op. h
unit one or a unit overhauled by a Wärtsilä workshop
− Replace filter before pre-control valve (control 18 000 Op. h

oil)
5571 Control oil pump − Check coupling, adjust working pressure 18 000 Op. h
according to instruction of manufacturer
− Replace ball-bearing on electric motor 36 000 Op. h
− Replace pump element on HP piston pumps 36 000 Op. h

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


5610 Servo oil rail − Replace hoses 18 000−30 000 Op. h
5610−1 Pressure − Checking gas (nitrogen) pre-charge pressure:

reducing valve the same criteria apply as specified for 7218−1
5612−1 Exhaust valve − Random check of piston and slide rod 18 000 Op. h
control unit
− Replace rail valve (pre-control valve) 30 000−36 000 Op. h
− Replace filter (control oil) 18 000 Op. h
5801−1 Regulating − Check for free movement, lubricate all movable 3000 Op. h
linkage parts
6
6420−1 Scavenge air − Check and clean air flaps 4000−6000 Op. h
receiver
− Clean receiver 4000−6000 Op. h
− Check water drain pipings for free passage 1500−3000 Op. h
Exhaust gas − Wash-cleaning of blower in service (see Operating Manual)

turbocharger
− Wash-cleaning or dry cleaning of turbine in (see Operating Manual)

service
Air filter − Check filter half yearly
− Cleaning of filter at a p increase of 50% as required

compared to the shop test value at same engine
load
6545−1 Auxiliary blower − Clean impeller and casing 24 000−36 000 Op. h
− Replace ball-bearing 24 000−36 000 Op. h
6606−1 Scavenge air − Cleaning of scavenge air cooler (air side) in as required
cooler service at the beginning weekly, later at a p
(pressure drop through SAC) increase of 50%
compared to the shop test value at same engine
load
− Check condensate collector through sight glass daily

− Check condensate collector for free passage 1500−3000 Op. h

− Check scavenge air cooler sealing quarterly
− Vent daily
− Remove scavenge air cooler for general overhaul as required

6708−1 Water separator − Check condensate collector through sight glass daily
− Check condensate collector for free passage 1500−3000 Op. h

− Check water separator elements (if necessary 1500−3000 Op. h

clean them)
− Remove water separator for general overhaul as required
7
Cylinder − Drain and wash out casing, 18 000−24 000 Op. h
lubricating pump first time after 1000 Op. h according to instruction
of pump manufacturer
7218−1 Lubricating pump − General maintenance works according to instructions

and accumulator of equipment
(Pulse lubrication) manufacturer
− Checking gas (nitrogen) pre-charge pressure:

CLU4 min. 20 bar / max. 25 bar
CLU4−C min. 30 bar / max. 35 bar
directly after installation of a new accumulator −>
then at least once in first week after start-up −>
afterwards −> every three months
8
8135−1 Exhaust Waste − During a longer operation period at low engine
Gate (LLT) load, manually open butterfly valve at least once
per week (see Operating Manual 8135−1)
− General inspection according to instruction
of valve manufacturer
Servo oil − Follow manufacturer’s instructions

automatic filter
Starting air − Drain (de-water) before and after every

piping manoeuvring period
Pressure gauges − Compare and calibrate according to master 6000−8000 Op.h

and pyrometers instruments
Fuel and − Clean or replace filter elements as required

lubricating oil (depending on make, follow manufacturer’s in-
filters structions)
Pipe holders − Check tightness of fastenings periodically, if as required

necessary retighten screws
(first time after 100 Op.h, then half yearly)

8447 Collector block − Replace safety valve (servo oil) 36 000 Op.h
Servo oil system − Check spindle of shut-off valve for free 6000 Op.h
movement
8447−1 Servo oil piping − Regrind sealing faces as required
8460−1 Hydraulic piping − Regrind sealing faces as required

to exhaust valve
8733−1 Fuel pressure − Regrind sealing faces as required

piping (on
cylinder cover)
8744 Supply unit fuel − Check regularly for free passage at least once a 6000 Op.h
drain piping year
8750−1 Relief valve − Function check on test bench 18 000 Op.h

(fuel overpressure
safety valve)
8750−2 Fuel pressure − Check shut-down function 3000 Op. h

control valve (see Operating Manual 4003−1)
(PCV)
− Function check 6000 Op. h

− General overhaul only necessary when

PCV fails
− Replace filter (control oil) 18 000 Op. h
8752−1 Fuel pressure − Regrind sealing faces as required

piping
9
9223−1 Crank angle − Check tension visually 3000 Op.h
sensor unit Check cracks and wear of tooted belt visually
Visual lubricating oil check
− Replace toothed belt 24 000 Op.h
− Overhaul drive (ball bearing, sealing ring etc.) 48 000 Op.h

and check shaft eccentricity of CAS drive
− Check shaft eccentricity of CAS drive at every CAS exchange
− Replace crank angle sensor 48 000 Op.h

(only if new soft belt is
applied from beginning)
Oil mist detector − Follow manufacturer’s instructions half yearly
WECS electronic − Replace FCM−20, ACM−20 modules 36 000−50 000 Op. h

components (see Operating Manual 4002−4)
− Check cabling quarterly

The indicated maintenance intervals must be taken as guidance and may vary
depending on the installation. The proper intervals are subject to the points men-
tioned below. Experience will show whether these intervals can be extended or
must be shortened.
− Environmental and operating conditions
− Heavy fuel oil and lubricating oil qualities (see Operating Manual 0710−1 and
0750−1)
− Engine load
− Fuel, lubricating oil and cooling water care (see Operating Manual 0720−1
and 0760−1)
− Overhaul according to Maintenance Manual
− Genuine spare parts used
− Engine monitoring
− Engines according to specifications of Wärtsilä Switzerland Ltd.
On the engine sectional drawings 0803−1, those parts are marked with group
numbers, as they are found in the Maintenance Manual.
Group numbers exist of the following engine components, although these parts
are not marked on the sectional drawings:
Engine component Group No.
− Engine stays with hydraulic engine stays . . . . . . . . . . . . . . . . . . . . . 1715−2

− Regulating linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5801−1
Engine Control System WECS
Control works in the WECS (Wärtsilä Engine Control System) are described in the
following groups of the Operating Manual:
− Regular checks and recommendations . . . . . . . . . . . . . . . . . . . . . . 4002−4
− Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4003−1

Engine Cross Section and Longitudinal Section
Cross Section:
2722−1
8733−1
2728−1
8460−1
5612−1
5564−1 6545−1
8447−1
6420−1
8752−1
8752−1
6606−1
5556−1
5556−2
5552−1
to
5552−6
6708−1
4103−1 to 4103−3 3301−1
1112−1
014.266/06

Engine Cross Section and Longitudinal Section
Longitudinal Section:
2751−1
to
2751−4
2708−1 to 2708−3
2124−1
2136−1 to
2138−1 2124−3
1903−1
3403−1
to
3403−4
4325−1
2303−1
3326−1
3326−2
3303−1
to
3303−4
1132−1
1132−2
3146−1
9223−1
1203−1 3103−1
1224−1 3130−1
3130−2
014.267/06

Bedplate and Tie Rod Group 1

Bedplate and Thrust Bearing: Checking the Foundation Bolts . . . . . . . . . . . . . . . . . 1112−1/A1
Main Bearing
− Loosening and Tensioning of Jack Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−1/A1
− Removal and Fitting of a Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132−2/A1
Thrust Bearing
− Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203−1/A1
− Removal and Fitting the Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224−1/A1
Hydraulic Engine Stays: Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A2

Tie Rod: Checking the Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . 1903−1/A1
Wärtsilä Switzerland Ltd 1/ 3 RT−flex84T−D / MM / 2008

Bedplate and Thrust Bearing
Checking the Foundation Bolts
Tools: Key to Illustrations:

1 Feeler gauge 94122 1 Pin 11 Chock
1 Pre-tensioning jack 94145 2 Vent screw 12 Ship’s foundation plate
1 HP oil pump 94931 3 Cylinder 13, 13a Conical socket
1 Pressure gauge 94932 4 Piston 14 Special round nut
1 Pressure gauge 94932a 5 Sealing ring
1 Hydr. distributor 94934a 6 Bedplate
1 Plug piece 94934e 7 Nut EV Relief valve
1 HP hose 94935 8 Foundation bolt KO Slot
1 HP hose 94935a 9, 9a Bush RS Round bar
10 Sleeve SA Gap
1. General
The pre-tension of the foundation bolts must be checked at longer intervals e.g.
during overhauls (see 0380−1).
In the area of the thrust bearing the bedplate may be fastened with foundation bolts
8, bushes 9 and sleeves 10 (Fig. ’A’).
The remaining area is fastened with foundation bolts 8 and bushes 9a, however
without sleeves 10 (Fig. ’B’).
Remark: Pay attention to General Application Instructions 9403−4 for hydraulic
pre-tensioning jacks.
A B
7
8
9 6 9a
10 11
12
13 13a
14
006.131/10

2. Checking the pre-tension
⇒ Clean the threads of the foundation bolts and the seating surfaces. Subse-
quently apply MOLYKOTE G paste to the threads.
⇒ Place pre-tensioning jack 94145 on foundation bolt 8 to be checked, and
screw it completely down with vent screw 2 open until there is only little or no
clearance at ’x’.
⇒ Connect the pre-tensioning jack with HP oil pump 94931, whereby one side of
hydr. distributor 94934a must be closed with plug piece 94934e.
⇒ Shut relief valve ’EV’ at the HP oil pump. Actuate HP oil pump till oil flows
bubble-free at vent screw 2.
⇒ Close vent screw, tension the foundation bolt with 1000 bar and keep pres-
sure constant.
D Attention should be paid to ensure that pin 1 always protrudes slightly
compared with piston 4 on the pre-tensioning jack!
Check with feeler gauge through slot ’KO’ if there is any clearance between nut 7
CHECK and its seating.
⇒ If there is no clearance, this means that the tightening condition of the founda-
tion bolt has remained unchanged since the last check. The pressure can be
released to zero with relief valve ’EV’ and the pre-tensioning jack removed.
Should a clearance be found, nut 6 must be tightened down onto its seating
with round bar ’RS’ while the pressure is kept at 1000 bar (check with feeler
gauge). Subsequently lower the pressure to zero.
C
94935a 94932a
94934e
2 94934a
1
x 94935
3 94932
5
7
4 RS
KO
EV 94931
9, 9a
8
014.295/06
Remark: If the foundation bolts have completely loosened and have to be ten-
sioned again, then all foundation bolts have to be pre-tensioned first with 600 bar
(1st step) and subsequently tensioned with 1000 bar (2nd step).
2010−01 2/ 3 Wärtsilä Switzerland Ltd

3. Loosening the foundation bolts
⇒ First screw down pre-tensioning jack 94145 as for checking the pre-tension,
then turn back by ½ turn (gap ’SA’).
⇒ Connect the pre-tensioning jack with HP oil pump 94931, whereby one side of
hydr. distributor 94934a must be closed with plug piece 94934e.
⇒ Shut relief valve ’EV’ at the HP oil pump. Actuate HP oil pump till oil flows
bubble-free at vent screw 2.
⇒ Close vent screw 2 and pump until a pressure of 1020 bar has been reached.
⇒ Turn back nut 7 by one turn, and release the pressure to zero.
Remove the pre-tensioning jack.
D
94935a 94932a
94934e
2 94934a
1
4 94935
3
94932
5
SA
EV 94931
9, 9a
8
014.297/06
4. Tensioning the foundation bolts
D Tensioning of the foundation bolts must be carried out in two steps without ex-
ception, for both metal & synthetic chocks, i.e. tension all foundation bolts first
with 600 bar (1st step), then finish tensioning with 1000 bar (2nd step).
D Tensioning must be carried out as described in ’Checking of the pre-tension’.

Main Bearing
Loosening and Tensioning of Jack Bolts

1 Special feeler gauge 94123 1 Bearing cover 11 Spot face
1 Depth gauge 94126 2 Bearing shell 12 Piston seal ring
2 Connection pieces 94427 3 Bearing girder 13 Locking wire
1 Pressure gauge 94932a 4 Jack bolt 14 Screw plug
1 Hydr. distributor 94934a 5 Column center piece
1 HP hose 94935 6 Vent valve
2 HP hoses 94935a 7 Locking wire DR Pressure space
1 Hydraulic unit 94942 8 Set screw RC Eye bolt
1 Open end spanner AF95 9 Cylinder RS Round bar
10 Nut SE Rope
1. General
Attention! Loosening and tensioning of jack bolts must only be undertaken when
the tie rods are tensioned as specified in 1903−1.
2. Preparatory works for loosening
⇒ Before loosening jack bolts 4 secure these with rope ’SE’ and eye bolt ’RC’
against falling outward.
⇒ Remove locking wire 13.
⇒ Remove screw plugs 14, screw and firmly tighten Connection pieces 94427 in
their place.
A SE
5
94427 RC
14
9
13
4
13
4
2
014.781/06 3
014.780/06

Main Bearing: Loosening and Tensioning of Jack Bolts
3. Loosening the jack bolts
⇒ Remove locking wire 7.

⇒ Open vent screws 6 by approx. two turns.
⇒ Join both Connection pieces 94427 to hydraulic unit 94942 as shown in Fig.
’B’.
⇒ Actuate the hydraulic unit till bubble-free oil flows out through the vent screws.
Close vent screws.
⇒ Actuate the hydraulic unit up to approx. 1120 bar and screw back nuts 10 by
approx. two turns.
⇒ Release pressure to zero and remove both Connection pieces.
⇒ Screw both nuts 10 sufficiently back to be able to remove the jack bolts from
their seats.
⇒ Close oil inlet holes again with screw plugs 14 to prevent the entry of foreign
matters (dirt).
6
SE
7
DR 94427
12
8
RS
10
94935a
11
014.784/06
94932a
94934a
94942 94935
014.782/06

Main Bearing: Loosening and Tensioning of Jack Bolts
4. Preparatory works for tensioning
⇒ Clean the seating surfaces on the bearing cover and column center piece 5.
⇒ Place the jack bolts and turn their cylinders 9 to such a position that the Con-
nection pieces can be fitted and then tighten nuts 10 with round bar ’RS’, how-
ever without any extension.
⇒ Establish distances ’a1’ and ’a2’ with depth gauge 94126. The difference be-
tween the two distances may not exceed 0.3 mm. If necessary bring bear-
ing cover 1 to the right position by slightly loosening nut 10 of the jack bolt on
which side distance ’a’ is less and tighten the nut of the other jack bolt while
holding the latter in its spot face 11 firmly with an open end spanner.
⇒ When the difference between distances ’a1’ and ’a2’ is within 0.3 mm, tighten
both nuts with round bar ’RS’ until fully seated.
5. Tensioning the jack bolts
⇒ Fit and then join both Connection pieces 94427 to hydraulic unit 94942 as
shown in Fig. ’B’.
⇒ Open vent screws 6 by approx. two turns.
⇒ Actuate the hydraulic unit till bubble-free oil flows out through the vent screws.
Close vent screws.
⇒ Actuate the hydraulic unit till a pressure of 1100 bar. Both gauges should indi-
cate the same oil pressure.
C ⇒ Keep pressure constant and tight-

en both nuts 10 using round bar ’RS’
till fully seated on cylinders 9 (check
seating with feeler gauge).
⇒ Release pressure to zero at the hy-
9 draulic unit and measure again dis-
10 tances ’a1’ and ’a2’. Should the dif-
ference exceed 0.3 mm, loosen
jack bolts, adjust bearing cover cor-
respondingly and repeat the tension-
ing procedure.
⇒ Remove Connection pieces and refit
screw plugs 14 (Fig. ’A’).
⇒ Secure vent valves 6 and set screws
8 together with locking wire 7 (Fig.
’B’).
a2
a1
⇒ Secure nuts 10 with locking wire 13

(Fig. ’A’).
Finally check the bearing clearance by
CHECK means of special feeler gauge 94123
014.784/06
(see Clearance Table 0330−1).

Main Bearing
Removal and Fitting of a Main Bearing

1 Assembly template 94107 1 Crankshaft
1 Lifting tool 94116 2 (Main) bearing cover
2 Roller supports 94117 3 (Main) bearing shell
1 Turning-out device 94118 4 Locating pin
1 Lifting yoke 94119 5 Groove
2 Ropes with shackle (300 mm) 94120b 6 Cylindrical pin
1 Rope with shackle (1200 mm) 94120c 7 Nut
1 Rope with shackle (1500 mm) 94120d 8 Waisted bolt
1 Rope with shackle (1800 mm) 94120e 9 Bearing girder
1 Rope with shackle (2000 mm) 94120f 10, 10a Suspension eye
1 Rope with shackle (2300 mm) 94120g 11 Flywheel
1 Rope with shackle (2800 mm) 94120i 12 Protection
1 Rope with shackle (3000 mm) 94120k 13 Guide shoe
1 Rope with shackle (3500 mm) 94120l 14 Eye bolt (M30)
1 Rope with shackle (4000 mm) 94120m 15 Spur-geared chain block
1 Rope with 2 shackles (1000 mm) 94120q 16 Jack bolt
1 Special feeler gauge 94123 17 Jack
1 Support 94141
2 Ground plates 94141a
1 Working platform 94142
1 HP oil pump 94931
1 Hydr. distributor 94934a
1 HP hose 94935 H1... Lifting tackles
2 HP hoses 94935a HZ Lifting tackle
2 Hydraulic jacks 94936 RC Eye bolt
Overview
1. View of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/20
2. Removal of bearing cover No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 2/20
3. Removal of bearing cover No. 2 . . . . . . . . . . . . . . . . . . . . . . . . 4/20
4. Removal of normal bearing cover . . . . . . . . . . . . . . . . . . . . . . 7/20
5. Removal of bearing cover at free end . . . . . . . . . . . . . . . . . . 10/20
6. Removal of bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/20
7. Fitting of bearing shell and bearing cover . . . . . . . . . . . . . . 19/20
Remark: Pay attention to:

− General Guidelines for Lifting Tools 0012−1.
− Utilization of Working Platform 3301−1.
Attention: The minimum lifting capacity must be 2000 kg for the required lift-
ing tools and ropes.

1. View of main bearings
Remark: Although all main bearings are the same, the main bearings between No.
2 and the end bearing at the free end are described as ’normal bearing’ in the in-
struction on hand.
16
8
7 2
1
6
4
3
001.311/97
MAIN BEARING NO. 1 MAIN BEARING WITH

WITH WAISTED BOLTS JACK BOLTS
2. Removal of bearing cover No. 1
⇒ Turn the corresponding crank to exhaust side approx. 100_ after T.D.C.
⇒ Remove upper part of oil baffle at the driving end.
⇒ Loosen nuts 7 for waisted bolts 8 (Fig. ’A’) with an impact ring spanner and a
hammer.

B
⇒ Screw eye bolt ’RC’ into bearing
cover 2.
⇒ Fasten roller support 94117 to col-
HZ H1
umn plate using screw M30x60 and
10 10a washer ∅68 mm underneath as
shown in the detail.
⇒ Connect rope 94120c with eye bolt
’RC’ and lifting tackle ’HZ’ (fitted to
the outer suspension eye 10) via roll-
er support.
⇒ Lift bearing cover over the waisted
bolts.
⇒ Fasten lifting tackle H1 to inner sus-
RC pension eye 10a.
2
⇒ Connect rope 94120b with eye bolt
94117 94120c ’RC’ and lifting tackle H1 (view I).
017.862/08
⇒ Pull bearing cover towards flywheel

I
together with lifting tackles H1 and
014.967/07 ’HZ’.
⇒ Remove lifting tackle ’HZ’ and rope
94120c.
⇒ Move bearing cover by means of a
further lifting tackle H2 towards fuel
side as shown in view I.
H2 H1 10a
10
HZ
94120b
94120c
RC
2
014.967/07

3. Removal of bearing cover No. 2
⇒ Turn the corresponding crank horizontally to exhaust side.

⇒ Install working platform 94142.
⇒ Remove toggle lever for crosshead lubrication and piston cooling.
⇒ Loosen and remove jack bolts (see 1132−1).
⇒ Fasten roller support 94117 to column plate.
⇒ Provide an edge protection 12 on the crank web.
⇒ Screw eye bolt ’RC’ into bearing cover 2.
⇒ Connect rope 94120e with eye bolt ’RC’ and lifting tackle ’HZ’ via the roller
support.
⇒ Lift bearing cover carefully as much as possible.
⇒ Screw two eye bolts ’RC’ (M20) laterally into the bearing cover.
C
I-I
I
94117 RC
HZ 2
RC
94142
12
2
014.968/07

⇒ Screw eye bolt 14 into guide shoe 13.

⇒ Connect rope 94120q with eye bolts ’RC’ and lifting tackle H1.
⇒ Lift bearing cover 2 over the crank web with ropes 94120q and 94120e and
then pull it towards the center of the cylinder.
I I-I
13
14 H1
94120e
H1 HZ
94120e
94120q
RC
014.969/07

⇒ Connect rope 94120g with lifting tackle H3 and eye bolt ’RC’ on bearing cover
2.
⇒ Pull bearing cover with rope 94120g towards fuel side and place it on working
platform 94142.
⇒ Remove ropes 94120q and 94120e.
E I I-I
H3 H1
H
RC
94120g
1
94120e 94120g
94120q 94142
014.970/07
014.970/07
HZ
F ⇒ Connect rope 94120i with eye bolt
’RC’ and lifting tackle ’HZ’.
⇒ Lift bearing cover out of crankcase
94120i using ropes 94120g and 94120i.
H3
⇒ Remove rope 94120i.
⇒ Move bearing cover a way by means
of spur-geared chain block 15.
15
94120g 014.971/07

4. Removal of normal bearing cover
⇒ Turn the corresponding crank horizontally to exhaust side.

⇒ Remove toggle lever for crosshead lubrication and piston cooling.
⇒ Loosen nuts 7 for waisted bolts 8 (Fig. ’A’) with an impact ring spanner and a
hammer.
⇒ Fasten a roller support 94117 each to guide shoes 13 using screw M30x60
and washer ∅68 mm between tool and guide shoe as shown in the detail.
⇒ Screw eye bolt ’RC’ into the bearing cover.
⇒ Connect rope 94120f with eye bolt ’RC’ and lifting tackle ’HZ’ via the corre-
sponding roller support.
⇒ Connect rope 94120k−m (ropes 94120k, I or 94120m have to be used de-
pending on the position of the guide shoe) with lifting tackle H1 and eye bolt
’RC’ via the corresponding roller support.
⇒ Provide an edge protection 12 on the crank web.
⇒ Lift bearing cover carefully over the crank web with ropes 94120k−m and
94120f.
⇒ Remove rope 94120k−m.
I I-I
13
94117
017.862/08
94120 k−m
13
H1 HZ
HZ 94120f
94117
94120f
RC
94142
2 12
014.972/07

⇒ Screw eye bolts ’RC’ (M20) laterally into bearing cover 2.

⇒ Screw eye bolts 14 into guide shoes 13.
⇒ Connect rope 94120q with eye bolts ’RC’ and lifting tackle ’HZ’.
⇒ Pull bearing cover with ropes 94120f and 94120q towards the center of the
cylinder.
I I-I
13
14
94120f 94120f
HZ
2
94120q
RC
014.973/07
I

⇒ Connect rope 94120g with lifting tackle H3 and eye bolt ’RC’ on bearing cover.
⇒ Pull bearing cover with rope 94120g towards fuel side and place it on working
platform 94142.
⇒ Remove ropes 94120q and 94120f.
I
I I-I
H3
94120f 94120f
RC
94120g
94120g
94120q
94142
014.974/07
I 014.974/07
K
HZ ⇒ Connect rope 94120i with eye bolt
’RC’ and lifting tackle ’HZ’.
⇒ Lift bearing cover out of crankcase
H3 using ropes 94120g and 94120i.
94120i
94120g RC
014.975/07

5. Removal of bearing cover at free end
D The removal of the bearing cover at the free end is carried out as described for
Fig. ’G’ to ’K’.
HZ
94120i
H3
94120g
13
14
94120e
H1
12
94120q
RC
014.976/07

6. Removal of bearing shells
Never remove two neighbouring bearing shells at the same time.
D The same lifting tackles are used for the removal of the corresponding bearing
shells as for the removal of the corresponding bearing covers.
D For the removal of bearing shells No. 1 and 2 the flywheel must also be
pressed up with the additional hydraulic jack 17. To protect the flywheel tooth-
ing, put a copper or aluminium plate between the hydraulic jack and the fly-
wheel (Fig. ’R’).
M I 6.1 Fitting the hydraulic jacks

⇒ Turn crankshaft 1 to exhaust side
approx. 90_ after T.D.C.
⇒ Put support 94141 on two bearing
girders 9 parallel to the engine axis.
⇒ Place hydraulic jacks 94936 on sup-
port 94141.
94936
⇒ Connect the hydraulic jacks with HP
94141a hoses 94935 and 94935a, as well as
hydr. distributor 94934a to HP oil
94141 pump 94931.
9 Remark: Depending on hydraulic jacks

94936, ground plates 94141a must be
017.893/08 placed onto support 94141 in order to
I reach the height necessary to lift the
crankshaft.
I-I
94942
94931
94935
94934a
94935a 94936
94141a
94141

6.2 Lifting the crankshaft

N
⇒ Using hydraulic jacks 94936 and lift
the crankshaft at the main bearing to
be removed by value ’x’ = 0.4 −0.5
mm.
Attention! Lift the crankshaft max. to the
point where the neighbouring main bear-
ings show vertically no clearance any
1
more between the bearing cover and
crankshaft.
3
x
Check this procedure with a dial gauge

CHECK
installed above the crankshaft, and verify
9 the bearing clearance at the neighbouring
004.844/98
main bearings using special feeler gauge
94123.
6.3 Turning out the bearing shells
Main bearing No. 1, see Fig. ’Q’:

D The same ropes and arrangement are used for turning out and lifting of the
bearing shell.
Main bearing No. 2, see Fig. ’S’:

End bearing, see Fig. ’T’:
bearing shells, however, rope 94120d must be replaced by rope 94120e.
Normal bearing, see Fig. ’O’:

bearing shells, however, rope 94120f must be replaced by rope 94120g.
D The turning-out procedure is the same for all bearing shells as described for
Fig. ’O’.

6.4 Turning out the bearing shell of a normal bearing

⇒ Fasten turning-out device 94118 on the joint face of the bearing shell utilizing
its proper screws (view III).
⇒ Lead both ropes of turning-out device along the lateral edges of bearing shell
3 to the other side and connect them with lifting yoke 94119 (see view II).
Remark: By means of a wire attached to the ropes they can be pulled below the
bearing journal to the other side. This may be of help primarily for bearings No. 1, 2
and end bearing.
⇒ With ropes 94120k−m and 94120g connected to lifting tackles H1 and ’HZ’ pull
bearing shell slowly out from the bearing girder till both ends of the bearing
shell are free (no meshing).
⇒ Remove lifting yoke 94119 and rope 94120g.
O
I I-I
94117 94117
HZ
H1
94117 HZ
94120g
94120g
94120k
to m
94120k−m
94119
014.977/07
014.977/07
I III II
94120k−m 94120g
94118 94119
3
014.977/07
014.977/07

6.5 Removal of bearing shell of a normal bearing

⇒ Fasten lifting tool 94116 onto bearing shell 3 and connect it with ropes
94120k−m and 94120f as shown in view II, and lift the bearing shell carefully
over the crank web.
⇒ Loosen and remove ropes 94120k−m.
⇒ Connect lifting tackle H1 directly to lifting tool and pull bearing shell together
with rope 94120f towards the center of the cylinder.
⇒ Connect rope 94120g with lifting tackle H3 and lifting tool, and then pull bea-
ring shell towards fuel side (view I-I).
The further procedure is carried out as shown in Fig. ’K’ for the removal of the bea-
ring cover.
P
I I-I
H3
94120k−m
H1 H3
94120f 94120g
II
014.978/07
014.978/07
I II
94116
3
014.978/07

6.6 Turning out the bearing shell No. 1

⇒ Connect rope 94120c to lifting tackle ’HZ’ (fitted to the outer suspension eye
10) and lifting yoke 94119 via roller support 94117.
⇒ Fasten turning-out device 94118 on the joint face of the bearing shell as de-
scribed and shown under paragraph 6.4 and connect it to lifting yoke 94119.
⇒ Turn bearing shell slowly out from the bearing girder till both ends of the bea-
ring shell are free (no meshing).
⇒ Remove lifting yoke 94119.
10 HZ
94117
94120c
94119
94118
014.979/07

R
6.7 Removal of bearing shell No. 1
I ⇒ Fasten lifting tool 94116 onto bearing
HZ H1 shell 3 (see detail in Fig. ’P’).
⇒ Connect rope 94120c with lifting tool
and lifting tackle ’HZ’ via roller sup-
port 94117 and lift bearing shell.
⇒ Connect lifting tackle H1 with lifting
tool and swing bearing shell together
with rope 94120b towards flywheel
11.
94120c
⇒ Pull bearing shell out behind the fly-
94116
3 wheel as shown in view I-I.
The further procedure is carried out as de-
scribed for Fig. ’B’.
11
014.980/07
17
I
I-I
H2 H1
HZ
94120b
94120c
94116
3
014.980/07

6.8 Removal of bearing shell No. 2

⇒ Fasten lifting tool 94116 onto bearing shell 3 (see detail in Fig. ’P’).
⇒ Connect rope 94120d with lifting tool and lifting tackle ’HZ’ via roller support
94117.
⇒ Connect lifting tackle H1 with lifting tool and pull bearing shell towards the cen-
ter of the cylinder.
The further procedure is carried out analogously as shown in Fig. ’E’ and ’F’ (Re-
moval of bearing cover).
I I-I
H1
13
HZ
94117
94120d
94116
014.981/07 014.981/07

6.9 Removal of end bearing

⇒ Fasten lifting tool 94116 onto the bearing shell 3 (see detail in Fig. ’P’).
⇒ Connect rope 94120d with lifting tool and lifting tackle ’HZ’ via roller support
94117.
⇒ Connect lifting tackle H1 with lifting tool and pull bearing shell towards the cen-
ter of the cylinder.
⇒ Connect rope 94120g with lifting tackle H3 and lifting tool, and then pull bea-
ring shell towards fuel side (view I-I).
The further procedure is carried out analogously as shown in Fig. ’K’ (Removal of
bearing cover).
I I-I
H3
H3
H1
H1
94120d
94120g
94116
014.982/07 014.982/0

7. Fitting of bearing shells and bearing covers
D All bearing covers are marked DRIVING END on their faces. Therefore, they
must be fitted correspondingly.
D Bearing shell and bearing cover should be fitted into the bearing girder in their
original positions.
D The oil bore in the bearing girder must be clean and without particles of white
metal.
D Crankshaft journal, girder bore for bearing and all parts to be fitted must be
clean and undamaged!
Remark: Apply LOCTITE type A to cylindrical pins 6 and fit them into bearing shell
3. The location of the cylindrical pins must be properly adjusted with assembly tem-
plate 94107 as shown in Fig. ’U’.
3 94107
6 6
004.769/00
The fitting of bearing shell and bearing cover is carried out analogously but in re-
verse sequence to the removal.
⇒ Immediately before fitting (turning in) bearing shell 3 apply a very thin lay-
er of MOLYKOTE paste G to the back of it.
⇒ The crankshaft journal and the running surface of the bearing shell must be
thoroughly lubricated with clean engine oil.

7.1 Turning in the bearing shell

(see Fig. below as an example for a normal bearing)
⇒ Connect ropes 94120k−m and 94120g with
lifting yoke 94119.
⇒ Lead both ropes of turning-out device 94118
V below the crankshaft journal to the exhaust
side and connect them with the lifting yoke.
D To prevent the bearing shell from gliding
jerkily and jamming, hold it and guide it
slowly into the bearing girder at the ends of
the ropes.
⇒ Pay attention that locating pins 4 catch
groove 5 of the bearing shell (Fig. ’A’). Both
joint faces of the bearing shell must show
the same distance to the upper edge of the
bedplate (measure with depth gauge).
⇒ Turn the bearing shell completely into the
94120g 94120k−m bearing girder.
94119 ⇒ Release the pressure at the HP oil pump

and fit bearing cover. The latter can be fitted
by means of lifting tackles and ropes as de-
scribed for the removal, but in reverse se-
quence.
END OF
ROPE ⇒ Tighten the jack bolts following the instruc-
94118 tions in 1132−1.
⇒ Nuts 7 for waisted bolts 8 (Fig. ’A’) must be
tightened equally by an angle of 40_ with an
impact ring spanner and a hammer.
014.983/07
D After tightening the waisted or jack bolts, the positional tolerance of the bea-
ring cover must not exceed 0.3 mm (see 0330−1 ’Crankshaft and main bea-
ring’).
D Always fit toggle lever to crosshead lubrication and piston cooling in
such a way that its curvature stands upwards.
⇒ Remove all the tools from the engine.
If the crank deflection is measured before fitting the bearing cover, take care that
the bearing shell does not turn. In this case, block the latter with a piece of wood.
The bearing clearances and the crank deflection must be measured after a new
CHECK bearing shell has been fitted and the bearing cover has been tightened (see
0330−1 and 3103−1).
After assembly, check if lubricating oil is supplied to the bearing with the oil pump in
operation!

Thrust Bearing
Checking the Axial Clearance

1 Inside micrometer 94101 1 Coupling flange 7 Thrust bearing pads
1 Feeler gauge 94238 2 Oil baffle, upper part ASTERN
1 Dial gauge with magnetic base 3 Oil baffle, lower part 7a Thrust bearing pads
4, 4a Holder AHEAD
5 Thrust flange 8 Cover
6 Crankshaft
1. Measuring method 1
The total displacement which results from pushing the crankshaft axially both
ways until it contacts the thrust bearing pads AHEAD and ASTERN, is measured
with a dial gauge. This is then checked against the figure marked on the sheet
’Check Dimensions’ in the engine documents supplied (see also Clearance Table
0330−1 ’Crankshaft and main bearing’).
An increase compared with the nominal figure signifies wear of the thrust bearing
pads.
2. Measuring method 2
⇒ Displace the crankshaft axially until it rests on the engine side thrust bearing
pads (AHEAD) and then fix it in this position.
⇒ Measure the distance between the coupling flange and the upper part of the
oil baffle with the inside micrometer 94101 at the position indicated (see Fig.
’B’). The amount by which distance ’X’ is smaller than that given on the sheet
’Check Dimensions’ corresponds to the wear of the engine side thrust bearing
pads (AHEAD).
⇒ Displace the crankshaft axially until it rests on the thrust bearing pads for
ASTERN. Determine the total axial clearance with the inside micrometer.
Remark: After major works have been carried out in the thrust bearing space dis-
mantle cover 8 for a check-up on the thrust bearing housing. Remove any foreign
matters through the opening.

Thrust Bearing: Checking the Axial Clearance
2
5
4a
6 4
THRUST
8 7a 7
3
014.162/06
CHECK HOLE FOR

FREE PASSAGE EVERY
6000−8000 OP. HOURS
014.794/06
B
I
I-I
2 I
3
X
2 1 94101
014.795/06

Thrust Bearing
Removal and Fitting the Thrust Bearing Pads

1 Turning-out device 94155 1 Thrust bearing flange 7 Bearing cover
for 1-part gear wheel 2, 2a Thrust bearing pads 8 Oil baffle, upper part
1 Turning-out device 94155a 3 Gear wheel 9 Casing
for 2-part gear wheel 4 Holder 10 Waisted stud
1 Eye bolt M16 5 Screw w. distance sleeve 11 Oil piping
6 Screw 12 Temp. sensor bore
1. Removal
⇒ Remove casings 9 and oil piping 11.

⇒ Loosen both holders 4 above thrust bearing pads 2 or 2a to be removed.
⇒ Remove temperature sensors from their bores 12 (Fig. ’A’) before turning out
thrust bearing pads on engine side.
⇒ Fasten turning-out device 94155 or 94155a respectively to the 1-part or 2-part
gear wheel as illustrated on Fig. ’B’ or ’C’.
Attention! Turning-out device 94155 for the 1-part gear wheel must under no cir-
cumstances be fitted onto the 2-part gear wheel.
⇒ The crankshaft is then to be turned with the turning gear until an eye bolt M16
can be screwed into a pad which can then be lifted up and removed one by
one.
Remark: When only a few thrust bearing pads of a row are to be removed the
crankshaft is located in its axial position by the remaining pads. When all thrust
bearing pads must be removed then the crankshaft must be prevented from sliding
axially. Therefore, insert a piece of hardwood of the same thickness in place of the
thrust bearing pad.

11
9
4 5
6
12
2, 2a
014.702/06
2. Fitting
D Make absolutely sure that all the thrust bearing pads are meticulously clean
and smeared with fresh engine oil; the thrust bearing pads must all be re-
placed in their original position. Note also numbering of the individual pads!
D For fitting the thrust bearing pads tool 94155 or 94155a respectively can also
be utilized. Note in this respect that the first pad, when pushed in, rests against
the tool. The following thrust bearing pads can then be fitted one after the
other while simultaneously turning the crankshaft. The thrust bearing pads
should slide in without effort to their end position.
With all the thrust bearing pads in position, the distances from the outermost pads
CHECK on fuel side and exhaust side to the upper edge of the bedplate must be equal to be
able refitting holders 4. Subsequently check the clearance between holder and
thrust bearing pads 2 and 2a (see Clearance Table 0330−1 ’Crankshaft and thrust
bearing’).
D Prior to fitting screws 5 and 6 clean threads, tap holes and coat screw threads
with LOCTITE No. 222.
Attention! After fitting the thrust bearing pads immediately remove tool 94155 or
94155a respectively.
Remark: When fitting new or remetalled thrust bearing pads, care must be taken
that their thickness (final dimension) corresponds exactly with the neighbouring
pads.
When replacing a complete row of new or remetalled thrust bearing pads the clear-
ance must be adjusted to the original values (see Clearance Table 0330−1 ’Crank-
shaft and thrust bearing’ and 1203−1).

FASTENING TURNING-OUT DEVICE 94155

TO THE 1-PART GEAR WHEEL
II - II B
I-I
II
94155
4
8 II
4 3
7 1
1
2
2a, 2
2a
94155
001.146/97
3
001.146/97

FASTENING TURNING-OUT DEVICE 94155a

TO THE 2-PART GEAR WHEEL
II - II C
I-I
II
94155a
4
8 II
4 1
7 3
10
1
2
2a, 2
2a
001.143/97
3
94155a
001.143/97

ARRANGEMENT OF THRUST BEARING PADS

FOR CLOCKWISE ROTATING ENGINES WITH
FIXED PITCH PROPELLER
ASTERN AHEAD
12
014.796/06
SUPPORT SURFACE
VIEW FROM DRIVING END VIEW FROM DRIVING END

PADS AT DRIVING END PADS ON ENGINE SIDE
DRIVING END ENGINE SIDE
PROPELLER THRUST PROPELLER THRUST

ASTERN AHEAD
008.989/01
PADS FOR ASTERN PADS FOR AHEAD
SUPPORT SURFACES

Hydraulic Engine Stays
Checking the Oil Pressure
Key to Illustrations:
1 Hydraulic engine stays 5 Ball valve
2 Hydraulic cylinder 6 Plug 3/8“ NPT
3 Bladder accumulator 7 Pressure gauge
4 Rod
1. General
Two hydraulic type stays 1 are installed each on the exhaust side and fuel side of
the engine.
The oil pressures on the pressure gauges of the hydraulic cylinders must be
CHECK checked and compared with each other at regular intervals.
If one of the hydraulic cylinders shows a pressure below 30 bar, which could be
caused by defective O-rings, leaking valves or screwed connections, the opposite
hydraulic cylinder must also be released of its pressure till 30 bar.
The defective engine stays must be repaired at the first opportunity. Afterwards the
oil pressure must be readjusted to the required value on all the engine stays,
whereby the detailed instructions of the respective maker must be considered.
I I
1 FREE END 1
1 1
EXHAUST
SIDE
1 1
014.766/06
II
II 7
SHIP SIDE
004.078/98
4 6 5 2

Tie Rod
Checking the Pre-tension and Tensioning the Tie Rods

1 Feeler gauge 94122 1 Cylinder jacket 13 Column
2 Pre-tensioning jacks 94180 2 Upper intermediate ring 14 Bearing girder
1 Pressure gauge 94932a 3 Upper tie rod nut 15 Lower intermediate ring
1 Hydr. distributor 94934a 4 Cylinder 16 Lower tie rod nut
1 HP hose 94935 5 Piston 17 Bush
2 HP hoses 94935a 6 Round nut 18 O-ring
1 Hydraulic unit 94942 7 Vent screw
8 Tie rod AN Drain slot
9 Screw BN Limiting groove
10 Protection cover KO Slot
11 Bore for solvent RS Round bar
12 Clamp screw SA Gap
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
2. Checking the pre-tension of tie rods . . . . . . . . . . . . . . . . . . . . . 1/5
3. Loosening and tensioning the tie rods . . . . . . . . . . . . . . . . . . . 3/5
1. General
We recommend that about one year after commissioning the engine all tie rods are
checked for their correct pre-tensioning and if necessary to tension them to the
specified value. Later it is sufficient to make random checks during major over-
hauls, or the pre-tension of all tie rods has to be checked within four years.
Remark: For such checks it is not required to loosen the jack bolts of the main
bearings nor the clamp screws 12 (Fig. ’D’).
Pay attention to General Application Instructions 9403−4 for hydraulic pre-ten-
sioning jacks.
2. Checking the pre-tension of tie rods
⇒ Remove protection cover 10 from all tie rods and clean the seating surface of
upper intermediate ring 2.
⇒ Screw both pre-tensioning jacks 94180 onto two tie rods lying opposite each
other.
⇒ Turn the pre-tensioning jack so that the holes in tie rod nuts 3 are accessible.
⇒ Open vent screws 7.
⇒ Tighten round nuts 6 until there is only little or no clearance at ’x’ (Fig. ’A’).
⇒ Connect both pre-tensioning jacks with hydraulic unit 94942 according to
Fig. ’A’.
⇒ Actuate the hydraulic unit until bubble-free oil flows out through the vent
screws.
Remark: Hydraulic oil flowing out can be drained into a container by means of
hoses which are put over the vent screws.
⇒ Close the vent screws, operate the hydraulic unit up to 1000 bar and maintain
the pressure constant.
Never move the piston 5 of the pre-tensioning jack further up than to the red limit-
ing groove ’BN’ (Fig. A).

A 94935a
8 6 7
SA
x x
5
4 94932a
BN 94934a
11 94935
RS
3
KO
2
014.797/06
94942
PRE-TENSIONING JACK PRE-TENSIONING JACK
PLACED FOR TENSIONING PLACED FOR LOOSENING
Using feeler gauge 94122 inserted through slot ’KO’, check whether tie rod nut 3
CHECK rests on upper intermediate ring 2 without any clearance.
⇒ If any clearance does exist, tighten the tie rod nut with round bar ’RS’ until it
rests firmly on the upper intermediate ring (check with feeler gauge). Subse-
quently release the pressure to ’0’ at the hydraulic unit. If no clearance exists,
the pressure can immediately be released and the pre-tensioning jacks re-
moved. Check all the tie rods in this manner and, wherever necessary, tighten
the tie rod nut.
⇒ Protect the tie rod threads against corrosion by coating them with non-acidic
grease after checking has been completed. Fit and fasten the protection cov-
er.
Remark: If a tie rod nut 3 is blocked/seized it may be attempted to press in oil or
solvent through bore 11 (#/8” NPT) with the pre-tensioning jacks placed and pres-
surized so that the tie rods are lifted. At the same time insert a brass or copper bar
into a hole in the tie rod nut through the slotted aperture of cylinder 4 and first loos-
en, then tighten the nut with several heavy hammer blows. Make sure, however,
that the edge of the hole is not seriously deformed or it will be impossible to remove
the pre-tensioning jack. Seal off bore 11.

3. Loosening and tensioning the tie rods
Should tie rods have to be removed or fitted, the following principles have to be
observed:
⇒ Remove clamp screws 12 (Fig. ’D’).
D Tensioning has to be carried out in one procedure. The sequence is shown in
Fig. ’B’, i.e. in pairs, first tie rods a/a, then b/b, etc.
Never move piston 5 of the pre-tensioning jack further up than to the red limiting
groove ’BN’ (Fig. A).
D If the tie rods have been newly tightened, then the jack bolts of the main bear-
ings also have to be checked for correct pre-tensioning (see 1132−1).
3.1 Loosening
The procedure for loosening the tie rods is the same as the one described in sec-
tion 2 ’Checking the pre-tension’, except that round nuts 6 must be turned back by
four turns after being completely screwed down the pre-tensioning jacks (gap ’SA’
in (Fig. ’A’). At this starting point connect the jacks with hydraulic unit 94942 and
operate it until a pressure of about 1030 bar is reached.
⇒ Turn the tie rod nuts 3 up until they fully seat on the pistons of the pre-tension-
ing jacks and then screw back them by approx. ½ turn with round bar ’RS’.
⇒ Release pressure to ’0’ and remove the pre-tensioning jacks.
3.2 Tensioning
Preliminary works:
D Clamp screws 12 must not be tightened up.
D Lower tie rod nut 16 is screwed on.
⇒ Clean the seating surface for upper intermediate ring 2 and upper nut 3 and
smear them with MOLYKOTE paste G.
⇒ Smear the tie rod thread for upper nut lavishly with MOLYKOTE paste G and
screw the nut on (check for easy threading).
⇒ Screw eye bolt into the tie rod and lift carefully until the lower tie rod nut rests
snugly against the bearing girder 14.
Risk of accident! Use a manual ratchet hooked onto the crane, with which the tie
rod can be lifted manually until the lower nut is snug on its seating, as with the crane
alone the landing of the nut cannot easily be felt and the rope might break.
⇒ In this position tighten the upper tie rod nut with round bar ’RS’ until firmly
seated on the upper intermediate ring, and separate the manual ratchet the
from the tie rod.
There must now be no clearance between bearing girder and lower tie rod nut and
CHECK the latter must be flush with the tie rod end (Fig. ’D’).
⇒ Place pre-tensioning jacks 94180 onto the tie rods a/a.
⇒ Turn the pre-tensioning jacks so that the holes in tie rod nuts 3 are accessible.
⇒ Tighten round nuts 6 until there is only little or no clearance at ’x’ (Fig. ’A’).

Tensioning in one procedure:

⇒ Connect the pre-tensioning jacks with the hydraulic unit 94942 (see Fig. ’A’).
⇒ Actuate the hydraulic unit until bubble-free oil flows out through the vent
screws 7. Close the vent screws.
⇒ Raise the pressure to 100 bar, keep it constant and firmly tighten the two up-
per tie rod nuts 3 with the round bar ’RS’.
⇒ Measure and record the distance ’L’ (the measurements can be taken directly
on the mounted pre-tensioning jacks, i.e. from the top edge of the tie rod 8 to
the cylinder 4).
⇒ Subsequently tension the tie rods with 1000 bar, keep it constant and firmly
tighten the two upper tie rod nuts 3 with the round bar ’RS’.
Never move pistons 5 of the pre-tensioning jacks further up than to the red limiting
grooves ’BN’ (Fig. ’A’).
⇒ Measure again the distance ’L’ and record it as ’L1’.
The tie rods are correctly tensioned with 1000 bar when the following reference
value of a total elongation L (’L1’−’L’) is measured:
L = 17.0 ... 19.0 mm
⇒ Release the pressure to ’0’ bar.
⇒ Proceed in the same way by following the required sequence for all tie rods
b/b, c/c, d/d ect.
⇒ After completing the tensioning, smear the protruding thread portions of all the
tie rods lavishly with an acid-free grease and fit protection cover 10 (Fig ’D’).
B C
TIE ROD
ELONGATION
DRAWN FOR 6 CYLINDERS

L
DRIVING END
FREE END
L1
L
SEQUENCE
4
RS
3
011.665/04 8
DRAWN FOR 8 CYLINDERS
011.663/04

D
IV
9
IV
III - III
8
10
1
12
II 11
3
17
2
13
1
8
II
17
III III
12
I
8
14
14
18
15
AN
16
I
011.665/04
FLUSH

Cylinder Liner and Cylinder Cover Group 2
Cylinder Liner
− Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−1/A1
− Removing the Wear Ridge, Re-dressing Scavenge Ports
and Lubricating Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124−3/A1
Lubricating Quills
− and Accumulators: Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2136−1/A1
− with Pulse Jet Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A1
− with Pulse Feed Lubrication: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . 2138−1/A2
Piston Rod Gland: Dismantling and Assembling, Measuring the Wear . . . . . . . . . 2303−1/A1
Cylinder Cover
− Removal and Fitting of Cylinder Cover and Water Guide Jacket . . . . . . . . . . . . 2708−1/A1
− Loosening and Tensioning of Cylinder Cover Waisted Studs . . . . . . . . . . . . . . . 2708−2/A1
− Machining of Sealing Face for Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708−3/A1
Injection valve: Checking, Dismantling, Assembling and Adjusting . . . . . . . . . . . . . 2722−1/A1

Starting Valve: Removal, Fitting and Dismantling, Grinding-in & Assembling . . . . 2728−1/A1
Relief Valve for Cylinder Cover: Checking Blow-off Pressure . . . . . . . . . . . . . . . . . 2745−1/A1
Exhaust Valve
− Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs . . . . . . . . . 2751−1/A1
− Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751−3/A1
− Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . 2751−4/A1
Wärtsilä Switzerland Ltd 1/ 1 RT−flex84T−D / MM / 2010−01

Cylinder Liner
Measuring Bore Wear

1 Inside micrometer 94101 1 Cylinder liner
1 Ladder 94224 2 Antipolishing ring
1 Measuring gauge 94225 ST Setting screw
SETTING SCREW ’ST’ DRAWN FOR COM-

PRESSION SHIM THICKNESS = 0 mm.
ST
⇒ The cylinder liner wear is to be determined af-
94225 ter every piston removal with the cylinder liner
in situ.
⇒ To permit comparisons with previous mea-
sures always carry out measuring in the same
place and note down the values in a log.
006.125/99
⇒ Always use the properly adjusted measuring
gauge 94225.
Check setting screw ’ST’. Its lower pro-
CHECK truding length must correspond to the
2 mean thickness of the built-in compres-
sion shims. This ensures that the topmost
1 measuring point is located between the top
ring wear ridge and the antipolishing ring.
The unrun position must be thoroughly
cleaned from any deposits or lacquer before
measurement.
⇒ Hook the measuring gauge over the top face
of the cylinder liner.
94101
⇒ The measurements have to be taken in longi-
tudinal and transversal directions to the en-
gine axis by putting the inside micrometer
94101 into the holes provided in the measur-
ing gauge.
For maximum permissible inside diameter re-
CHECK fer to Clearance Table 0330−1 ’Cylinder liner’.
⇒ The ridge at the top of the cylinder bore has to
be removed carefully without damaging the
running surface for the piston rings (see
2124−3).
⇒ Remove the lower part of the measuring
gauge 94225 for measuring the cylinder liner
with piston in situ. Turn piston to B.D.C.
014.808/06

Cylinder Liner
Removal and Fitting

1 Lifting gear 94202 1 Screw 11 Antipolishing ring
2 Distance plates 94202d 2 Water guide jacket 12, 12a O-ring
2 Brackets (reduced height) 94203a 3 Supporting ring 13, 13a O-ring
2 Suspension straps 94206 4 Cylinder liner 14 O-ring
2 Special screws 94207 5 Cylinder jacket 15 O-ring
4 Suspension straps 94208 6 Allen screw
1 Lifting hook 94209 7 Centring pin
1 HP oil pump 94931 8 Centring pin AF Seating surface
1 Pressure gauge 94932 9 Cylinder cover EV Relief valve
1 Pressure gauge 94932a 10 Screw HU Wooden underlay
1 HP hose 94935
2 HP hoses 94935a
2 Hydr. jacks 94936
Overview
1. Preparations for removal of cylinder liner . . . . . . . . . . . . . . . . 1/7
2. Removal of cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/7
3. Removal of jammed cylinder liner . . . . . . . . . . . . . . . . . . . . . . . 3/7
4. Removal and fitting of antipolishing ring . . . . . . . . . . . . . . . . 4/7
5. Removal and fitting of supporting ring . . . . . . . . . . . . . . . . . . 4/7
6. Preparations for fitting cylinder liner . . . . . . . . . . . . . . . . . . . . 6/7
7. Fitting cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/7
8. Laying down and raising cylinder liner . . . . . . . . . . . . . . . . . . 7/7
1. Preparations for removal of cylinder liner
⇒ Drain cylinder cooling water from the respective cylinder and remove cylinder
cover (see 2708−1).
⇒ Remove piston together with piston rod gland (see 3403−1 and 2303−1).
⇒ Loosen and remove screws 1 which fasten supporting ring 3 to cylinder liner
4 (Fig. ’F’).
⇒ Separate all piping connections for cylinder oil from the lubricating quills. All
passages and lubricating quills as well as their protecting bushes must
be removed whenever a cylinder liner is being pulled out (see 2136−1 or
2138−1).

− General Application Instructions 9403−4 for hydraulic pre-tensioning jacks.

Cylinder Liner: Removal and Fitting
2. Removal of cylinder liner
A cylinder liner can be removed normally by crane and lifting gear, whereby the
following must be observed:
2.1 Placing lifting gear

⇒ Place lifting gear 94202 with the lightly fastened suspension straps 94206
onto cylinder liner 4.
⇒ Loosen screws 10 correspondingly so that suspension straps can be fastened
to cylinder liner with special screws 94207. Hand-tighten the latter with
approx. 30 Nm.
⇒ Equally screw in the four screws 10 till the suspension straps touche the spe-
cial screws. Hand-tighten screws 10 with approx. 30 Nm.
Remark: Subsequently length ’x’ of the thread screwed-in should be min. 1.2-fold
of the thread diameter.
⇒ Pull cylinder liner fully out by means of the crane.
A
94202
10
x
94206
94202d
94207
4
009.001/01

3. Removal of jammed cylinder liner
If a cylinder liner jam in the cylinder jacket bore, proceed as follows:

⇒ Place both brackets 94203a at the bottom of cylinder jacket 5 as shown in Fig.
’B’. Thereby the bigger end of the brackets must point towards fuel side.
⇒ Place both hydr. jacks 94936 on the brackets and push them against the cylin-
der liner.
⇒ Connect the hydr. jacks to HP oil pump 94931.
⇒ Close relief valve ’EV’ at the HP oil pump, and jack out the cylinder liner of its
guide portion by slowly pumping.
B I I
4
5
FUEL SIDE
94935a 94936 94203a
I-I
94932a
94934a
94932
019.267/10
94931 EV 94935 94935a 94936 94203a

4. Removal and fitting of antipolishing ring
⇒ Four suspension straps 94208 are provided for removing and fitting antipol-
ishing ring 11 as shown in Fig. ’C’.
D The latter can be moved with the aid of lifting hook 94209 connected to the
suspension straps and the crane.
⇒ Before fitting, clean the seating surfaces on the antipolishing ring and cylinder
liner.
⇒ Smear the antipolishing ring lightly with oil.
C 94209
94208
4
11
012.073/04
5. Removal and fitting of supporting ring
5.1 Removal
Supporting ring 3 (Fig. ’D’ and ’F’) is fastened with three Allen screws 6 to cylinder
jacket 5 and located on fuel side by centring pin 7. For the removal of the support-
ing ring the three Allen screws 6 can be used as jacking screws (see Fig. ’E’).
5.2 Fitting
⇒ The sealing surfaces on supporting ring and cylinder jacket must be cleaned
and then smeared with a non-hardening sealing compound (e.g. silicone).
⇒ Place supporting ring.
⇒ Apply LOCTITE 264 to screws 6 and tighten them with a torque of 150 Nm.
D E
3 3 3
7 6 6
5 5
5
004.087/98

I
F I-I
8
9
III 13a
2
13 1
8 1
8 I
4
III
AF
3 II
3
4
II - II
9
2 1
14
EXHAUST SIDE
15
IV 4
1 1
4 IV
FUEL SIDE
3
3
3
4
12a
12
014.809/06

6. Preparations for fitting cylinder liner
⇒ Clean all guide areas and sealing surfaces on cylinder liner 4, cylinder jacket 5
and on supporting ring 3.
⇒ Place O-rings 12 and 12a of the specified quality and dimension into the
grooves on the cylinder liner.
⇒ Smear O-rings and guide areas of cylinder liner, cylinder jacket and support-
ing ring with lubricating oil.
⇒ Clean seating surfaces ’AF’ of supporting ring 3 and cylinder liner 4 carefully
(Fig. ’F’ section I-I).
7. Fitting cylinder liner
⇒ Mount lifting gear 94202 according to Fig. ’A’.

⇒ Move the cylinder liner hanging on the crane above the supporting ring 3.
⇒ Lower the cylinder liner and apply a non-hardening sealing compound to the
seating surfaces ’AF’ (Fig. ’F’ section I-I).
⇒ Turn cylinder liner and align the centring pin 8 with the centring holes of the
supporting ring and cylinder liner. Lower cylinder liner.
⇒ Fit screws 1 and tighten them firmly for locking the cylinder liner onto the sup-
porting ring (Fig. ’F’ section II-II).

8. Laying down and raising cylinder liner
⇒ Place lifting gear 94202 as described in paragraph 2.1.

⇒ Connect rope ’a’ (lifting capacity 8000 kg) with crane and lifting gear. Lay
down the cylinder liner as shown in Fig. ’G’ to ’I’ and secure it against rolling
away.
Risk of accident! Laying down and raising a cylinder liner must not be done
in any other way than as shown in the figures, i.e. in longitudinal direction of
lifting gear 94202!
Never lay down a cylinder liner with fitted insulation bandage!
An insulation bandage can easily be removed from the cylinder liner disengaging
the tension springs by means of tool 94345e.
D Raising the cylinder liner is carried out in reversed sequence.
G H
a
94202
I
012.066/04
HU HU HU

Cylinder Liner
Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports

1 Wear ridge grinding device 94299 1 Roller support 10 Carbide milling cutter
2 Holder 11 Cylinder liner
3 Holder 12 Uppermost piston ring
4 Spacer roller
5 Pipe (column)
6 Grinder SI Scavenge port
7 Air hose SN Lubricating grooves
8 Hose oiler SN1 Lubricating bores
9 Thread nozzle (with CLU−3 only)
1. General
Due to wear in the cylinder liner a ridge is formed on top to where the piston rings do
not reach. By that also the lubricating grooves in the cylinder liner lose their depth,
and the corner radii of the scavenge port edges become smaller.
After every piston removal measure the bore of the cylinder liner (see 2124−1) and
remedy any irregularities. For that the following points are of importance:
D Protect the space below the cylinder liner from falling particles.
D After completing the reconditioning clean the bore of the cylinder liner thor-
oughly (particularly the lubricating grooves).
D Remove waste particles which may have passed into the scavenge space
through the ports.
D Actuate the cylinder lubrication until oil flows from all the lubricating points,
thereby flushing away any metal dust.
2. Removing the wear ridge
When grinding away the wear ridge take greatest care not to damage the running
surface. The machining of the wear ridge has to be carried out as shown in Fig. ’B’.
Therefore, always use wear ridge grinding device 94299 for carrying out this work.
3. Re-dressing the lubricating grooves
If the depth of the lubricating grooves has worn to less than 1.5 mm re-dress them
to their original depth and slightly round their edges with an oil stone (see Fig. ’A’).
4. Re-dressing the edges on the scavenge ports
The shape of the scavenge ports shown in Fig. ’A’ corresponds to new cylinder lin-
ers. When reconditioning (depending on the degree of wear or damage) aim at
matching these shapes. Take care not to damage the running surface in the cylin-
der liner bore! Polish (round) the passages into the running surface with emery
cloth.

Cylinder Liner: Re-dressing Lubricating Grooves and Scavenge Ports
II
A
II
I-I
SN
SN1
I EDGES ROUNDED OFF

FUEL SIDE
003.267/00
II-II
II
SI
II
014.810/06a
011.350/04

Cylinder Liner: Removing the Wear Ridge
94299
11
5
10
11
2
3
T.D.C.
2 −3 mm
6
12 1 mm
4
009.004/01
7 8 9

Lubricating Quills and Accumulators
Function Check
1 Accumulator cylinder 14 Steel ball
2 Spring 15 Non-return valve housing
3 Accumulator piston 16 Washer
4 Cap nut 17 Screw
5 Diaphragm 18 Support ring
6 Accumulator casing 19 Flange
7 Cap nut 20 Joint
8 Backing screw 21 Protecting bush
9 Copper sealing rings 22 O-ring
10 Cylinder liner
11 Lubricating quill
12 Passage for lubricating quill DF Sealing surface
13 Filling pin LB Leak oil bore
A LB
1
2
20 19 3
4
5
6
14
15
8
7
12 16 17 11 9 9
014.771/06
DF 10 22 21 13 18
1. General
1.1 Function check

Actuate the cylinder lubricating pump until oil emerges from all the lubricating
points in the bore of the corresponding cylinder liner. Note that on cylinder liners
with two rows of lubricating grooves (Multi-Level Lubrication) the oil delivery for
upper and lower row of lubricating grooves may be differently set (correct setting is
recorded on the acceptance records). Whatever the settings, make sure that on all
the lubricating points of the same row of lubricating grooves the oil outflow quantity
is equal.

Lubricating Quills and Accumulators: Function Check
1.2 Check of accumulator

During a major overhaul check at random several accumulators or if there are oil
leakages through bores ’LB’ (Fig. ’A’), open the relevant accumulators. Check the
condition of the diaphragms and defective or brittle ones must be replaced. Do not
use any sharp-edged objects for fitting new diaphragms!
1.3 Check of non-return valve

The non-return valve must also be checked for correct functioning. Therefore, the
complete lubricating quill and accumulator must be removed.
If compressed air is blown into X ⇒ no air must emerge from Y.
CHECK If compressed air is blown into Y ⇒ air must emerge from X.
014.253/06
2. Removing and fitting
⇒ If a non-return valve has to be replaced, remove backing screw 8 together with

filling pin 13.
⇒ After fitting the new part tighten the backing screw with 50 Nm and lock it with a
centre punch.
⇒ Before removing a cylinder liner 10, the passages for lubricating quills 12 and
protecting bushes 21 must be first disconnected.
Attention! The flange 19 must never be removed before the cylinder cooling water
has been drained.
D If only the passage for lubricating quill 12 has to be removed, with cylinder lin-
er fitted, then the protecting bush may remain in place.
D When refitting the passage for lubricating quill take care that sealing surface
’DF’ between cylinder liner and passage for lubricating quill is absolutely
clean. Sealing surface ’DF’ must seal metallically and the use of gaskets is
prohibited!
Remark: The design of the lubricating quills for the upper and the lower row of lu-
bricating grooves is the same.
Non-return valves are only supplied complete with filling pin as replacement parts.

Lubricating Quills
Removal and Fitting with Pulse Jet Lubrication
Tool: Key to Illustrations:

1 Tool box 94720 1 Supporting ring 17 Guide piece
with fittings for charging 2 Cylinder liner 18 Compression spring
accumulator 3 Lubricating quill 19 4/2-way solenoid valve
4 Protecting bush 20 Sink plunger
5 Flange 21 Pin (tool)
6 Flange ring 22 Allen screw
7 Joint 23 Allen screw
8 Housing for lubricating quill 24 Screw-in union
9 Clamping part 25 Union nut
10 Non-return valve 26 Union nut
11 Joint disc 27 Cylinder lubricating oil pipe
12 Nozzle tip 28 O-ring
13 Spring dowel pin
14 Guide bush AF Seating surface
15 Valve spindle BO Bore
16 Self-locking nut DF Sealing surface
1. General
If only lubricating quills 3 must be removed, protecting bushes 4, flanges 5 and 6

remains in place. Therefore, the cylinder cooling water must not be drained.
In order to remove a cylinder liner 2 however, lubricating quills 3 and protecting
bushes 4 must be dismantled.
Prior to the removal, the cylinder cooling water must be drained on the relevant
cylinder (see 2708−1 ’Removal of cylinder cover’).
2. Removal of the cylinder lubricating oil pipe
A ⇒ Loosen union nut 26 of the angle union.

⇒ Hold the position of screw-in union 24 with an
open-end spanner while loosening union nut 25.
⇒ Separate cylinder lubricating oil pipe 27 and pro-
tect it against damaging and entering of any dirt.
24 25
26
27
015.434/07
018.315/09

Lubricating Quills: Removal and Fitting with Pulse Jet Lubrication
3. Removal of the lubricating quill and protecting bush
⇒ Separate cylinder lubricating oil pipe 27 as mentioned in section 2.

⇒ Loosen Allen screws 23 and remove flange ring 6.
⇒ Remove flange 5 together with protecting bush 4 with two jacking screws
M8x30 from the bore of supporting ring 1.
⇒ Loosen Allen screw 22 and remove lubricating quill 3.
Attention! Allen screws 23 and flange 5 must never be removed before the cylin-
der cooling water has been drained.
B
I-I
5 DF
DF BO AF I
23
22
TOP
015.435/07
6
I
28 7 1 4 28 2

4. Disassemble the lubricating quill
⇒ Unscrew clamping part 9 from the housing of the lubricating quill 8.

⇒ Remove non-return valve 10 together with two joint discs 11.
⇒ Push nozzle tip 12 out of the housing of the lubricating quill.
5. Assemble the lubricating quill
⇒ Prior to assembly of the lubricating quill clean all relevant parts and check the
spray holes of the nozzle tip.
⇒ Assemble the nozzle tip. Special care must be taken to align the guideway of
nozzle tip 12 to spring dowel pin 13 (see detail II‐II in Fig. ’C’).
⇒ Assemble non-return valve 10 with two new joint discs 11.
⇒ Fit clamping part 9 and tighten it with 15 Nm, however the thread M20x1.5
must be oiled beforehand.
Remark: If not absolutely necessary non-return valve 10 should not be dis-
mantled.
Check if guide piece 17 of the non-return valve is moving free.
CHECK
When assembling housing 8 its milled surfaces must be aligned vertically.
C
I-I
II I
II TOP
I
9 8
015.436/07
II - II 13 12
11 10 11

6. Non-return valve
Non-return valve 10 should only be dismantled if absolutely necessary. Subse-

quently, however, a new self-locking 16 nut must be used and distance x = 1±0.1
mm adjusted accordingly.
D I-I
16 17 18
I
I
14 15
x = 1$0.1 mm 015.437/07
7. Fitting of the lubricating quill
⇒ Clean the bore ‘BO’, the seating surface ‘AF’ and the sealing surface ‘DF’ as
shown in Fig. ’B’ on each lubricating quill.
⇒ Apply oil to the thread of the Allen screws 22.
⇒ Assemble lubricating quill 3 and tighten screws 22 with a torque of 10 Nm
equally.
Remark: The lubricating quills can not be mounted the wrong way, because of the
asymmetrical arrangement of the screw holes of Allen screws 22.
⇒ Apply MOLYKOTE paste G to both sides of joint 7 before assembling the joint
to the cleaned bore of supporting ring 1.
⇒ Install two new O-rings 28 at protecting bush 4. Apply oil to the O-rings before
mounting them.
⇒ Slide flange 5 over the protecting bush 4 with the two O-rings 28 (see Fig. ’B’).
⇒ Mount flange 5 together with protecting bush 4 to the cleaned bore of cylinder
liner 2.
⇒ Mount flange ring 6 with the four Allen screws 23 and tighten them equally.
⇒ Connect cylinder lubricating oil pipe 27 and tighten the angle union. Hold the
position of screw-in union 24 with an open-end spanner while tightening union
nut 25.
Attention! After completing maintenance works the correct position of the stop
valve in the lubricating oil pipe to the exhaust valve must be checked, as well as the
flow direction of the non-return valve, if this has been dismantled (see also Operat-
ing Manual 7218−1 ’Additional lubrication of exhaust valve spindle’).

8. Venting of the cylinder lubricating system
After assembly of the lubricating quills, a function control of the lubricating system
must be carried out. Prior to the function control, all single cylinder lubricating oil
pipes 27 must be vented at the connection of screw-in union 24 and union nut 25.
⇒ Select the respective cylinder number on the context MANUAL LUBRICA-
TION ON CYLINDER shown on the operator interface or manually operate
the 4/2 way solenoid valve 19 as shown in Fig. ’E’.
⇒ Hold the position of screw-in union 24 with an open-end spanner while loosen-
ing union nut 25 by about 1 to 2 turns.
⇒ Push with pin 21 (diameter 3.5 mm) on top of sink plunger 20 of the 4/2-way
solenoid valve. This must be repeated until the cylinder lubricating oil is flow-
ing bubble-free out of the loosened connection.
Remark: As described above the lubricating module can also be operated with the
operator interface of the control system.
Further information and adjustments about the lubricating pumps are given in the
Operating Manual 7218−1.
⇒ Hold the position of the screw-in union 24 with an open-end spanner while
tightening the union nut 25.
D If all cylinder lubricating oil pipes are vented and afterwards properly tightened
again, actuate the cylinder lubrication module until bubble-free cylinder oil
emerges from all lubricating points in the respective cylinder liner. This visual
inspection of the lubrication process is carried out through the scavenge ports
at piston underside and the piston is therefore at T.D.C. position.
D If there are signs of irregularities with nozzle tips 12, they must be replaced!
19 20 21
015.438/07

Lubricating Quill
Removal and Fitting with Pulse Feed Lubrication

1 Tool box 94720c 1 Cylinder liner 19 Pin (tool)
with fittings for 2 Lubricating pump 20 Shut-off valve servo oil
charging accumulator 3 Accumulator 21 Venting valve servo oil
1 HP oil pump 94931 4 Supporting ring 22 Venting valve lube oil
1 Hydr. distributor 94934h 5 Lubricating quill 23 O-ring
(with pr. gauge 0...25 bar) 6 Non-return valve 24 Steel ball
1 Connection nipple (G¼”) 94934i 7 Screw-in union 25 Spring
1 HP hose 94935 8 Bush 26 Screw-in union
9, 9a Flange 27 Filling pin − long
10 Seal version
11 Screw 28 Filling pin − short
12 Adjustable angle union version
13 Pipe bracket
14 Lubricating oil pipe DF Sealing surface
15 Cu gasket OZ Oil supply
16 Stop valve SE Servo oil inlet
17 4/2-way solenoid valve SR Servo oil return
18 Sink plunger SS Servo oil to next lubr. pump
1. General
If only the lubricating quill must be removed, with cylinder liner in situ, then bush 8,
flanges 9 and 9a may remain in place. Therefore, the cylinder cooling water must
not be drained.
In order to remove a cylinder liner 1 or supporting ring 4 however, all lubricating
quills and bushes must be dismantled, whereby the cylinder cooling water
must be drained on the relevant cylinder (see 2708−1 ’Removal of cylinder
cover’).
Remark: For the handling of stop valve 16 see detailed instructions in the Operat-
ing Manual 7218−1.
A
1
16
11
4
12
14
13 015.434/07
019 003/09
Wärtsilä Switzerland Ltd 1/ 5 CLU4−C / 2014-07

Lubricating Quill with Pulse Feed Lubrication
2. Removal and fitting of lubricating quill
⇒ Loosen lower union nut of adjustable angle union 12 and pipe bracket 13 (Fig.
’A’). Separate lubricating oil pipe 14 and protect it against any damages and
entering of dirt.
⇒ Remove lubricating quill , if necessary also bush 8.
D When refitting the lubricating quill take care that sealing surface ’DF’ is abso-
lutely clean, as it seals metallically. Therefore, do not use any gaskets be-
tween cylinder liner 1 and lubricating quill 5!
D Replace seal 10, Cu gasket 15 and fit new O-rings 23.
D Oil and tighten lubricating quill 5 with a torque of 30 Nm.
9 9a
15
12
DF
14
WCH02749
5 23 8 10 6 11 7
2014-07 / CLU4−C 2/ 5 Wärtsilä Switzerland Ltd

3. Non-return valve
134.5
C
7 24 25 26 27
95
WCH02716
7 24 25 26 28
3.1 Checking a non-return valve

For judging the proper functioning of the non-return valve an opening pressure test
(opening pressure test) must be carried out.
During testing the lubricating quill should be kept in horizontal position and an oil
with a viscosity of either SAE 50 at 40_C (approx. 200 cSt) or SAE 30 at 25_C
(approx. 190 cSt) must be used.

3.2 Test procedure

D Instead of screw-in union, fit connection nipple 94934i into screwed union 6.
⇒ Connect and vent the lubricating quill as shown below.
⇒ Vent the lubricating quill.
⇒ Apply a pressure of 2 bar and increase slowly untill the non-return valve
opens.
⇒ Note down the opening pressure.
Remark: The opening (cracking) pressure should be at least 2.5 bar for correct
functioning.
94934i
D
WCH02716
7 26
001.547/97
94931 94934h 94935
2014-07 / CLU4−C 4/ 5 Wärtsilä Switzerland Ltd

4. Venting of the cylinder lubricating system
A function control must be carried out after every assembly of the lubricating quills
and tightening lubricating oil pipes 14 and pipe brackets 13. The lubricating oil
pipes must be vented at screw-in union 12 and its nut.
⇒ Select the respective cylinder number on context MANUAL LUBRICATION
ON CYLINDER shown on the operator interface or manually operate 4/2-way
solenoid valve 17.
⇒ Hold the position of the angle union with an open-end spanner while loosening
its nut by approx. two turns.
⇒ Push with pin 19 (diameter 3.5 mm) on top of sink plunger 18 of the 4/2-way
solenoid valve. This must be repeated until the cylinder lubricating oil is flow-
ing bubble-free out of the loosened connection.
Remark: As described above the lubricating module can also be operated with the
operator interface of the control system. Further information and adjustments
about the lubricating pumps are given in the Operating Manual 7218−1.
Venting valve 22 to lubricating pump 2 may be opened by max. three turns only.
⇒ Hold the position of the angle union with an open-end spanner while tighten-
ing its nut.
D If all cylinder lubricating oil pipes are vented and afterwards properly tightened
again, actuate the cylinder lubrication module until bubble-free cylinder oil
emerges from all lubricating points in the respective cylinder liner. This visual
inspection of the lubrication process is carried out through the scavenge ports
at piston underside and the piston is therefore at T.D.C. position.
TO LUBRICATING
QUILLS
E
SR
SE
21
17
OZ
SS
3 019.125/10 019.002/09
2 22
20 18 19

Intentionally blank
Piston Rod Gland
Dismantling and Assembling, Measuring the Wear

1 Dismantling device 94344 1 Housing (2-part) 12 Cylinder cover stud
(recommended special tool) 2 Scraper ring 13 Screw
2 Distance holders 94345 3 Sealing ring 13a Fitted bolt
1 Clamp ring (2-part) 94345b 4 Sealing ring 14 Locking plate
1 Gauge 94345c 5 Ring support 15 Screw
2 Spring assembly tools 94345e 6 Scraper ring 16 Cylindrical pin
4 Distance pieces 94345f 7 Locating pin 17 2-part ring
1 Piston supporting device 94350 7a Locating pin 18 Cylinder jacket
8 Tension spring 19 Hinged cover
9 Tension spring 20 Piston rod
10 Screw 21 O-ring
11 Screw 22 O-ring
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/9
2. Removing, dismantling and assembling (variant 1) . . . . . . . 2/9
2.1 Removing a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/9
2.2 Dismantling a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/9
2.3 Assembling a gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/9
3. Removing, dismantling and assembling (variant 2) . . . . . . . 7/9
1. General
The removal of the piston rod gland (hereafter called gland) can be carried out in
two different ways, i.e. removing the gland together with the piston (variant 1) or
removing the gland downwards into the crankcase leaving the piston in situ and
using the dismantling device 94344 (variant 2).
On every piston overhaul, the gland must also be dismantled and inspected. Ex-
cessively worn or damaged parts are to be replaced.
It is important that the gland be in perfect condition when assembled. A possible
earlier than planned inspection of the gland with a piston in situ can only be carried
out under difficult conditions and with the help of the dismantling device 94344.

Piston Rod Gland: Dismantling and Assembling, Measuring the Wear
2. Removing, dismantling and assembling (variant 1)
2.1 Removing a gland

A ⇒ For removing the gland, both distance holders
94345 are to be screwed on the foot of piston rod
17 20 (Fig. ’A’).
⇒ Unscrew the four outer screws 15 to 2-part ring
17 (Fig. ’B’).
94345
20 Attention! For reasons of safety, the eight inner
screws 10 to 2-part ring 17 are to be loosened and
removed after dismantling the gland (Fig. ’B’).
⇒ Remove the gland including the piston (see
3403−1 ’Removal of a piston’).
12
011.405/04
2.2 Dismantling a gland

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

0330−1 ’Piston rod gland’. Parts which are beyond the admissible tolerance
must be replaced.
D If necessary remove scraper rings 6 from ring supports 5 and replace them
with new ones.
D Defective tension springs 8, 9 and O-rings 21, 22 have to be replaced with
new ones.

B I-I II
20
1
22 10 17 15
16
18
21
13a 13
II
FUEL SIDE
11
13a
16
I
17
10
14
15
011.451/04

11 mm
94345f
2
3 009.655/02
4
3
4
19 mm
94345f
009.654/02
19 94345b
11 mm
94345b
94345f
009.655/02
011.468/04
94345
20
014.739/06
2.3 Assembling a gland

⇒ Place the piston in piston supporting device 94350, its hinged covers 19 must
be folded down.
⇒ Attach clamp ring (2-part) 94345b − resting on the hinged cover − to piston
rod.
⇒ Place the three parts of a ring support 5 on the clamp ring with scraper rings 6
fitted. Distribute the distances evenly.
⇒ Use assembly tool 94345e (see 9403−5) for fitting tension spring 9.
⇒ Place two distance pieces 94345f (11 mm) on ring support 5 and fit another
ring support with scraper ring 6 and tension spring 9 as described above.
D The height of distance pieces 94345f corresponds to the respective web
height of the ring grooves in 2-part housing 1.

2 8
GROOVE a
7
2 7a
3
4 GROOVE b
3
4 GROOVE c
5
GROOVES
d−i
9
1
6
18
011.485/04
⇒ After assembly of the ring supports for grooves ’d’ − ’i’ (Fig. ’D’), place two dis-
tance pieces 94345f (19 mm) on the uppermost ring support 5 and fit sealing
rings 3, 4 and tension spring 8 for groove ’c’.
D Take care that one segment is always provided with two horizontal locating
pins 7a lying side by side on sealing ring 4. These locating pins must fit into the
corresponding bores in sealing ring 3. Remove possibly existing vertical locat-
ing pins 7.
The remaining three segments are provided only with one horizontal locating
pin each.
⇒ Place two distance pieces 94345f (19 mm) on the assembled sealing ring 3
and fit again sealing rings 3, 4 and scraper ring 2 with tension spring 8 for
groove ’b’.
D Proceed in the same way as mentioned above for sealing rings 3 and 4, how-
ever, a vertical locating pin 7 in sealing ring 3 must fit into the respective recess
in scraper ring 2.
No vertical locating pin may be fitted in the scraper ring.
⇒ Place two distance pieces 94345f (11 mm) on the assembled scraper ring 2
and fit the two uppermost scraper rings 2 with tension springs 8 for groove ’a’.
No vertical locating pin may be fitted in the uppermost scraper ring.

⇒ Remove all distance pieces 94345f and clamp ring 94345b.

Check the proper position of all rings with gauge 94345c resting on hinged cover
CHECK 19.
⇒ Smear piston rod as well as all rings with bearing oil.
⇒ Push both housing halves 1 on hinged covers 19 over the ring pairs against
the piston rod, then screw them together with screws 13 and fitted bolts 13b
according Fig. ’B’.
⇒ Place O-rings 21 and 22.
⇒ Place 2-part ring 17 on the housing and locate it by means of cylindrical pin 16
(Fig. ’B’).
⇒ Fit screws 10 and 11 with locking plates 14.
⇒ Just before the gland is fitted with the piston, apply lubricating oil to the re-
spective bores in the cylinder jacket as well as to the gland housing in the re-
gion of the O-rings.
D When fitting the gland into the cylinder jacket distance holders 94345 must be
mounted on the piston rod foot (Fig. ’C’).
D For fitting the gland in the cylinder jacket see also 3403−1.
94350
94345c
19
014.741/06

3. Removing, dismantling and assembling (variant 2)
For removing the gland with piston in situ using dismantling device 94344 (Fig. ’F’)
the following procedure should be observed:
⇒ Turn the piston to B.D.C.
⇒ Dismantling device 94344 (2-part) with its supports as shown in Fig. ’F’ is to be
set on the guide shoes, and both halves of the dismantling device are to be
screwed together.
⇒ Loosen and remove the four outer screws 15 from 2-part ring 17.
II - II
II II
20
17
15
I I
20
94344
014.767/06

⇒ Turn the piston with the mounted dismantling device carefully to T.D.C. until
the 2-part ring is pushed a little upwards (Fig. ’G’).
⇒ Loosen and remove the eight inner screws 10.
⇒ Clamp 2-part clamp ring 94345b to piston rod 20 lying on housing 1.
I
94345b
1
II II 17
I
94344
II - II
10
014.768/06

H
⇒ Turn the piston slowly to B.D.C.
17 again and pay attention that the
18 gland slides out of the gland bore in
the cylinder jacket without jamming.
2-part ring 17 remains on cylinder
jacket 18.
94345b I
II II
I
94344
014.769/06
014.769/06
D The same procedure as mentioned

in the previous section (variant 1) is
to be applied here for dismantling
II - II and assembling a gland, with the
exception that the dismantling and
1 assembling is carried out using dis-
mantling device 94344 instead of
piston supporting device 94350.
Attention should be paid that the gland
CHECK
slides into the bore of the cylinder jacket
without jamming when assembling it
using dismantling device 94344 and the
94344 turning gear.
⇒ Fit 2-part ring 17 in T.D.C. (Fig. ’B’)
screw in and tighten screws 10 and
lock these.
⇒ Turn the piston to B.D.C. and re-
move dismantling device 94344.
1 Subsequently screw in and tighten
014.769/06 screws 15.

Cylinder Cover
Removal and Fitting of Cylinder Cover and Water Guide Jacket

1 Suspension device 94265 1 Cylinder cover 10 Allen screw
2 Spec. (nut) eye bolts 94265a 2 Nut 11 Screw M20x200
3 Protection caps 94265b 2a Cylinder cover stud 12 Platform support
1 Cradle 94266 3 Cyl. cooling water outlet 13 Fixing screw
4 Leak oil drain 14 Plug
5 Exhaust valve cage 15 Control box
5a Stud to exhaust valve cage 16 Fuel pressure piping
6 Connection for valve 17 O-ring
shank lubrication 18 O-ring
7 Hydraulic piping
8 Air inlet for air spring DB Through hole
9 Water guide jacket RC Eye bolt
Overview
1. Removal of cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/6
2. Transport of cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/6
3. Fitting of cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/6
4. Removal of water guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . . 4/6
5. Fitting of water guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/6
1. Removal of cylinder cover
A
⇒ Drain the cylinder cooling water from the affected
cylinder, i.e. first shut the valves for cylinder cooling
water inlet and outlet at the supporting ring on the
exhaust side and above the cylinder cover respec-
tively.
7
⇒ Open drain cock to the respective cylinder. This
cock is situated on the exhaust side below the cock
for cylinder cooling water inlet.
⇒ Then open the vent valve in the cylinder cooling wa-
ter outlet pipe of the respective cylinder!
16
⇒ Disconnect all the connections to the cylinder cover
and to the exhaust valve as well as the expansion
piece between exhaust valve and exhaust manifold
(see 2751−1).
⇒ Remove hydraulic piping 7 (see 8460−1).
⇒ Remove fuel pressure piping 16 (see 8733−1).
15
⇒ Disconnect plugs 14 from control box 15.
14 ⇒ Clean all the thread protrusions on the cylinder cov-
er studs.
⇒ Loosen the nuts of the cylinder cover studs (see
2708−2).
014.812/06

2. Transport of cylinder cover
⇒ Screw spec. eye bolts 94265a to suspension device 94265 onto the studs 5a
of the exhaust valve cage. Insert the two hooks of the suspension device into
the spec. eye bolts.
⇒ Lift cylinder cover 1 together with water guide jacket 9 and exhaust valve cage
5 by means of the crane (Fig. ’C’).
Remark: Removing and transporting the cylinder cover is the same with exhaust
valve cage 5 in situ or removed from the cylinder cover.
B C
94265
94265a
5a
1
94265b
9
2a
003.307/00 008.328/01

3. Fitting of cylinder cover
Before placing the cylinder cover in position the following points must be taken
care of:
D The compression space must be absolutely free of foreign particles or dirt.
D The seating surfaces on cylinder cover and cylinder liner must be clean and
undamaged.
D A new soft iron joint ring 2 mm thick must be placed on the cylinder liner in such
a way that it lies flat all over.
D The inner surface of water guide jacket 9 which is screw fastened to the cylin-
der cover as well as the respective guide surface at the collar of the cylinder
liner must be clean and smeared with bearing oil.
D Place new O-rings into the grooves of the cylinder liner and smear these with
bearing oil.
D The threads of the cylinder cover studs must be clean and smeared with MO-
LYKOTE paste.
D Place three protection caps 94265b on cylinder cover waisted studs (Fig. ’C’).
When these conditions are all met, lower the cylinder cover, attached to suspen-
sion device 94265 or 94265c, slowly over the cylinder cover studs, whereby a cen-
tring pin assures the correct position (see 2124−2).
⇒ Screw all nuts by hand onto the cylinder cover studs, paying attention to easy
turning.
⇒ Pre-tension the studs with hydraulic pre-tensioning device 94215 in accor-
dance with 2708−2.
⇒ Reconnect all connections to cylinder cover and exhaust valve.
⇒ Finally shut drain and vent cock, and reopen the cocks for cooling water inlet
and outlet.
Remark: Concerning the fitting of the expansion piece between exhaust valve and
exhaust manifold see 2751−1.
D
1 8
5a
3
RC
FUEL SIDE
7 4
5
6
2
2a
014.813/06

4. Removal of water guide jacket
4.1 Assembly of the cradle

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

D The cylinder cover can be placed on
F I cradle 94266 with exhaust valve in situ.
⇒ Turn fixing screws 13 fully back.
5
⇒ Place cylinder cover 1 on the cradle.
I
1
94266
13
94266
5
1
014.814.06

4.3 Removal of water guide jacket

⇒ Turn all fixing screws 13 till the stop at water guide jacket 9 (Fig. ’G’).
⇒ Remove Allen screws 10.
⇒ Turn fixing screws 13 equally back till the water guide jacket rests on the hold-
ers of the cradle (Fig. ’H’).
Remark: If the water guide jacket should not come loose of the cylinder cover, the
previously removed Allen screws 10 are used as withdrawing screws, which are
turned into tape holes ’GL’.
⇒ Lift and remove the cylinder cover with the crane.
⇒ Lift and remove the water guide jacket with the crane.
G H GL
1 1
10
9
13
94266
014.817/06

5. Fitting of water guide jacket
⇒ Clean all the sealing faces and ring grooves.

⇒ Fit new O-rings in the cylinder cover and oil them slightly.
⇒ Turn fixing screws 13 fully back.
⇒ Place water guide jacket on the cradle.
⇒ Lower and align cylinder cover above water guide jacket in such a way that
tape holes ’GL’ and through holes ’DB’ in water guide jacket 9 are in line.
Remark: In order to facilitate the alignment, two threaded rods (M24 x approx. 300
mm) can be provided in the tape holes ’GL’.
⇒ Lower the cylinder cover onto the water guide jacket.
⇒ Screw in fixing screws 13 equally till the water guide jacket rests on the cylin-
der cover (Fig. ’K’).
⇒ Screw in and tighten the Allen screws.
1 K
I
GL 1
DB 10
17
18
13
94266
014.818/06

Cylinder Cover
Loosening and Tensioning of Cylinder Cover Waisted Studs

1 Hydr. tensioning device 94215 1 Cylinder cover stud
consisting of: 2 Nut
2 Device halves each with 3 Vent screw
4 pre-tensioning jacks LEFT 94215a 4 Piston
4 pre-tensioning jacks RIGHT 94215a1 5 Round nut
8 HP hoses 94215b 6 Pin MO Emplacement for round
1 Suspension device 94215c 7 Sealing ring nuts 5 when not in use
2 Piston reset devices 94215d 8 Sealing ring RO Emplacement for round
1 Pressure gauge 94932a 9 Cylinder LEFT bars ’RS’ when not in use
1 Hydr. distributor 94934a 10 Cylinder RIGHT RS Round bar
1 HP hose 94935
2 HP hoses 94935a
1 Hydraulic unit 94942
1. General

Should a cylinder cover stud have to be replaced, please observe the indication in
2751−1.
2. Set-up of pre-tensioning jacks
⇒ Remove expansion piece between valve cage / exhaust pipe (see 2751−1).
⇒ Remove the fuel pressure pipes from the injection valves.
⇒ Clean the threads of all cylinder cover studs 1 (Fig. ’C’) as well as the area
around nuts 2.
⇒ Mount two device halves of pre-tensioning device 94215 over the cylinder
cover studs and rest them on the cylinder cover.
I
A
94215c
MO
RS 94215b
RO
94215d
014.815/06
94215a 94215a1

B
⇒ Open vent screws 3 (Fig. ‘C’) of all pre-ten-
sioning jacks.
⇒ Connect the device halves to hydraulic unit
94942 as shown in Fig. ’B’.
⇒ Press pistons 4 of all pre-tensioning jacks
94215a, 94215a1 downwards upon cylinders
9 and 10, either by screwing on round nuts 5
(Fig. ‘C’) or without round nuts by using piston
reset devices 94215d (Fig. ‘D’).
When the pistons are resting on the cylinders
CHECK
there should be little or no clearance at ‘x’.
⇒ After using the piston reset device screw
round nuts 5 until they sit firmly on piston 4.
Remark: For loosening the waisted studs screw
back the round nuts by about two turns.
94932a
For tensioning the waisted studs the round nuts
94934a must lie on piston 4.
94935a 94935a
94935
94942
014.816/06
C D 94215d
5 1 3 6 RS
x
x
4 4
7 9, 10 9, 10
8 RS
003.306/00

3. Loosening
⇒ Set-up of the pre-tensioning jacks as mentioned in section 2.

⇒ Start up hydraulic unit 94942.
⇒ Close vent screws 3 on the jacks as soon as oil flows bubble-free.
⇒ Actuate hydraulic unit until a pressure of 1020 bar is indicated on its pressure
gauge and on pressure gauge 94932a.
D Attention should be paid to ensure that pins 6 always protrude slightly
compared with pistons 4 on the pre-tensioning jacks.
⇒ Turn all nuts 2 upwards till the stop, using round bar ’RS’. Store round bar ’RS’
in emplacement ’RO’ while not in use (see Fig. ’A’).
⇒ Release pressure to zero.
⇒ Disconnect and remove HP hoses 94935a from both device halves.
⇒ Unscrew round nuts 5 and remove them together with the pre-tensioning
jacks.
4. Tensioning
⇒ Smear threads and seating surface of nuts 2 with oil.

Tighten all nuts down with round bar ’RS’ till fully seated (check with feeler gauge).
CHECK
⇒ Mark position of all nuts, with a line on nuts and cylinder cover, with a felt-tip
pen (this will serve for a later check).
⇒ Set-up of the pre-tensioning jacks as mentioned in section 2.
⇒ Start up hydraulic unit 94942.
⇒ Shut vent screws 3 on the pre-tensioning jacks as soon as oil flows bubble-
free.
⇒ Actuate hydraulic unit until a pressure of 1000 bar is indicated on its pressure
gauge and on pressure gauge 94932a.
compared with pistons 4 on the pre-tensioning jacks.
While keeping this pressure constant tighten all nuts 2 with round bar ’RS’ till fully
CHECK seated on the cylinder cover (check seating with feeler gauge), verify while tight-
ening that all nuts can be turned by about the same angle of 350_.

D Where it is found that a nut can be turned considerably less than the others, it
must be assumed that the respective cylinder cover stud has become insuffi-
ciently tensioned.
Possible causes:
− Sealing rings 7 and 8 defective (Fig. ’C’).
− Piston 4 jams.
− Connection piece of HP hoses 94215b leaky or incorrectly connected.
D Repeat tensioning procedure after the cylinder cover studs have been loos-
ened again.
⇒ When all nuts have been tightened by practically the same angle, release the
oil pressure to zero.
⇒ Disconnect and remove HP hoses 94935a from both device halves.
⇒ Unscrew round nuts 5 and remove them together with the pre-tensioning
jacks.
Verify by the previously applied marks that all nuts have been turned equally by an
CHECK angle of about 350_.

Cylinder Cover
Machining of Sealing Face for Injection Valve

1 Overhauling device 94270 1 Cylinder cover 6 Centring mandril
1 Ring spanner AF 24 2 Milling cutter holder 7 Screw
3 Guide flange
4 Setscrews
5 Profiling cutter * Depository for screw
1. General
The seat sealing face in the cylinder cover must be clean and undamaged as the
sealing is metallic.
Should any blow-by of combustion gases have been noticed during engine opera-
tion, the spring packets with their screws of the injection valve are not, under any
circumstances, to be tightened further as a counter measure.
2. Machining of sealing face
* 2 3 7
Dirty or slightly damaged sealing faces can be re-condi-

tioned on the spot by using overhauling device 94270.
⇒ Carefully insert the profiling cutter, bolted to the mill-
ing cutter holder, into the hole in the cylinder cover.
⇒ Fasten guide flange 3 with screws 7.
When the tool is being used, the centring mandril on
the profiling cutter on the one hand and the guide
flange on the other, give the tool the necessary sta-
bility and direction.
⇒ Cutting is done by pressing down lightly with the
hand on the milling cutter holder at the same time as
turning the hexagon evenly with the other hand us-
ing the ring spanner.
Try to remove as little material as possible but suffi-
cient, however, to obtain the desired standard for
the seating area.
1 D Putting some sticky grease on the profiling cutter
will prevent any foreign matter from entering the
4 combustion chamber during overhaul.
6 009.013/01

Injection Valve
Checking, Dismantling, Assembling and Adjusting with OBEL Test Bench

1 Protection cap 94271 1 Injection valve 16 Snap ring
1 OBEL test bench 94272 2 Allen screw 17 Dowel pin
1 Connection piece 94272b 3 Spring guide 18 Dowel pin
4 Cup spring (spring packet) 19 Cylinder cover
5 Nozzle holder 20 Support
6 Collar nut 21 HP hose
7 Spring tensioner 22 Receiver
8 Nozzle tip 23 Dowel pin
9 Tappet carrier 24 Spring cage
10 Tappet 25 Circlip
11 Retaining nut 26 Shim ring
12 Compression spring 27 Shim
13 Nozzle needle 28 O-ring
14 Nozzle body
15 Retaining sleeve LF Leakage fuel
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8
2. Checking an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/8
3. Judging an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8
4. Dismantling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . 4/8
5. Assembling an injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . 4/8
6. Adjusting the opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . 6/8
7. Replacing a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/8
8. Assembling a spring cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/8
9. Fitting an injection valve in cylinder cover . . . . . . . . . . . . . . . 7/8
10. Protecting a nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/8
11. Storage and handling of injection valve . . . . . . . . . . . . . . . . . . 8/8
1. General
For checking, dismantling, assembling and adjusting the injection valve, test
bench 94272 as well as test & calibration fluid has to be used (e.g. Shell Calibration
Fluid S.9365) complying with the data according to the following table:
Physical characteristics for test & calibration fluid:
Kinematic Viscosity ASTM D445

at 40 _C mm2/s 2.6
Density at 15 _C kg/m3 ISO 12185 827
Pour Point _C ISO 3016 −27
Remark: Clean diesel oil (gas oil) can be used if no calibration fluid is available.
The use however is not recommended, if the injection valve will be stored and not
directly installed on the engine (corrosion reasons).
On some injection valves the leakage flow amount might be bigger than on others.
In case of the test bench flow is not sufficient to open the nozzle needle, a clean
additive-type crankcase (system) oil of the SAE 30 viscosity grade (for additional
data see 0750−1 ’System oil’ in the Operating Manual) can be used for testing
instead of the above mentioned fluids.

Injection Valve: Checking, Dismantling, Assembling and Adjusting with OBEL Test Bench
2. Checking an injection valve
Before commissioning the instructions and directions of the test bench manufac-
turer must be observed.
From time to time check the pressure gauges of the test bench with a master pres-
CHECK sure gauge and adjust them if necessary.
Remark: The work station must be clean; welding and grinding should not be done
nearby!
⇒ Remove combustion residues and clean nozzle tip externally with a brass
wire brush.
⇒ Place injection valve 1 with nozzle tip pointing downwards into support 20 of
test bench 94272 and fasten it with two Allen screws 2 and spring cages 24.
⇒ Tighten HP hose 21 of test bench with connecting piece 94272b.
⇒ Start the test bench following the proper manufacturer’s instructions.
⇒ Bring the injection valve to spray with a few short pump jerks, and then ob-
serve at what pressure the injection valve opens, applying slow, equal pump
jerks.
Danger of injuries! Never hold fingers or hands directly before the spray holes of
the nozzle tip!
A
21
94272b
I
2
24
1
20
22
94272
I
94272b
2
24
017.670/08
017.086/08

3. Judging an injection valve
For correct functioning and for a reuse of an injection valve observe the following
points:
D Spray pattern: Fuel will spray mainly from the holes in the first level of the
nozzle tip at the specified opening pressure. No fuel should drip from nozzle
tip when injection is finished.
D For new injection valves the opening pressure is 375 ±5 bar.
On used injection valves a pressure reduction of 30 bar may be acceptable.

Should a readjustment of the opening pressure be necessary, see section
’Adjusting the opening pressure’.
D In order to test tightness between the nozzle needle and needle seat, keep the
pressure in the test bench constant at approx. 20 bar below the opening pres-
sure. During a time period of 30 seconds no ’dripping’ should occur at the
nozzle tip.
D The spray holes of nozzle tip 8 must not be flushed out unduly.
⇒ Injection valves which do not spray efficiently must be dismantled as
described in section 4. Often, a thorough cleaning suffices to make them fully
functional.
Remark: Nozzle tips with flushed out spray holes must be replaced by new ones.
Nozzle holder 5 and nozzle body 14 (Fig. ’B’) with poor sealing faces must either be
replaced or reconditioned by the manufacturer or an authorized company.

4. Dismantling an injection valve
⇒ Remove receiver 22.

⇒ Screw down the injection valve on support 20 of test bench 94272, as men-
tioned, however without connecting HP hose 21 to the injection valve.
⇒ Loosen collar nut 6 and unscrew spring tensioner 7 until the compression
spring 12 is completely released (Fig. ‘B’).
⇒ Turn valve holder through 180_ into vertical position.
⇒ Place the special tool of the test bench onto retaining nut 11 and loosen it with
the press of the test bench.
Note test bench manufacturer’s application instruction!
⇒ Remove retaining nut 11, nozzle tip 8, retaining sleeve 15, nozzle body 14 and
nozzle needle 13.
Examine all parts for their condition.
CHECK
Remark: If only a nozzle tip 8 has to be replaced, see section 7.
Never interchange nozzle needle 13 and nozzle body 14! Each nozzle needle
belongs to its mated nozzle body into which it has been individually fitted with
greatest precision.
5. Assembling an injection valve
To assemble an injection valve, follow generally the reverse sequence of the dis-
mantling process, but note also the following points:
⇒ To clean injection valve parts, use only clean diesel oil (gas oil) or fresh kero-
sene, and dry compressed air.
⇒ The fitting position of nozzle tip 8, nozzle body 14 and nozzle holder 5 is given
by dowel pins 17 and 18 (Fig. ’B’).
⇒ Make sure that the sealing faces are in perfect condition and that no lubricant
is applied.
⇒ Fit the nozzle tip in accordance with section 7.
D If tappet 10, compression spring 12 and spring tensioner 7 with collar nut 6 are
already fitted, the spring tensioner must be screwed by approx. one turn only,
in order to prevent the compression spring from being under tension in any
case, otherwise nozzle body 14 does not lie flat on nozzle holder 5 during as-
sembly.
⇒ Apply a layer of Never-Seez NSBT-8 to the thread and the seating surface of
retaining nut 11.
⇒ First tighten retaining nut 11 to 100 Nm using a torque wrench. Starting from
this position, tighten the retaining nut by a further angle of 30_ by means of the
hydraulic tightening (or loosening) device of the test bench.
D Repeat the tightening procedure on the initial assembly.
D An angle of 30_ corresponds to 20.4 mm on the circumference relating to a nut
diameter of 78 mm.
After assembling the injection valve must be checked and judged according to sec-
CHECK tions 2 and 3.

I-I II - II
2 B
7
3
4 6
x1
24
5 28 23
12
19
9
10
11
18
13
14
16
15 17
DESIGNATION
OF NOZZLE TIP
MANUFACTRER x ID‐NO. x
I EXECUTION x CHARG. NO.
I
LF
II
014.117/06
II

6. Adjusting the opening pressure
⇒ Install the injection valve in the test bench as described in section 2.

⇒ The opening pressure of the injection valve (see setting table) can be set by
adjusting spring tensioner 7.
⇒ For readjusting the opening pressure, compression spring 12 must first be
completely released by means of spring tensioner 7.
⇒ Then operate the valve test bench and tighten the spring tensioner simulta-
neously until the required opening pressure is reached.
⇒ Check the injection valve as described in section 2.
⇒ After adjusting the opening pressure, tighten collar nut 6.
Remark: An opening pressure of 375 bar corresponds with reference dimen-
sion ’x1’ = 50.5 mm .
7. Replacing a nozzle tip
Ensure that always specified nozzle tips are used in accordance with the IMO
technical file of the engine or the shoptest protocol.
If the nozzle tip 8 should be dismantled only, it is sufficient to remove the retaining
sleeve 15.
SCREW DRIVER 7.1 Removal

⇒ Using two screw drivers inserted between both re-
cesses in retaining nut 11, press snap ring 16 out of
8 the groove in the retaining nut, whereby the retain-
ing sleeve can be withdrawn.
Watch that the snap ring does not jump off unex-
pectedly.
17
⇒ Remove nozzle tip.
15 7.2 Fitting
16
For fitting it is advantageous to clamp the injection
valve on its flange into a vice (nozzle body 14 pointing
11
14 upwards), and then proceed as follows:
⇒ Clean all parts with clean diesel oil or kerosine and
blow them out with compressed air.
⇒ Place nozzle tip on the nozzle body whereby the
position is assured by dowel pin 17.
⇒ Put retaining sleeve 15 over the nozzle tip, and
press snap ring 16 into the groove of the retaining
nut by means of the screw drivers.
After replacing a nozzle tip the injection valve must be
5 checked and judged according to sections 2 and 3.
004.072/98

8. Assembling a spring cage
x
− Cup springs 4 are fitted in spring cage 24.
− The spring packet consists of three packs com-
25 posed of three cup springs which are arranged as
3 shown in Fig. ‘D’.
4 In order to maintain an equal contact force when screw-
ing down the injection valve, distance ’x’ must be
adjusted to 1.6 ± 0.1 mm with shims 27 .
26
27
24
011.473/04
9. Fitting an injection valve in cylinder cover
Clean the seating surface of the injection valve in the cylinder cover and check for
CHECK damages.
If necessary recondition the seating surface using the special tool supplied with the
tools set (see 2708−3).
The sealing must be metal-to-metal, i.e. no joint must be put in between.
⇒ Place the injection valve carefully in the cylinder cover 19. Dowel pin 23 as-
sures the correct position.
FLUSH
E 2 10.1 Screwing down the injection valve
3
⇒ Apply Never-Seez NSBT-8 to the threads and the
24
seating surfaces of Allen screws 2.
4
⇒ Fit and equally tighten Allen screws 2 until spring
guides 3 are flush with spring cages 24.
23
19
011.472/04

10. Protecting a nozzle tip
Remark: To protect the nozzle tip integrated in the injection valve against damage,
always fit protection cap 94271 for transport, storage, etc.
94271
11. Storage and handling of injection valve
Store an injection valve in a dry place but not in a place contaminated with exhaust
gases or any other corrosive atmosphere. Keep the injection valve in its original
packing. Handle with care when preparing for use and avoid any hard contact
against other objects.
Attention! Do not open vacuum packed injection valve before the installation on
the engine.
For cleaning use white spirit, e.g. Shellsol TD, Shellsol T or Solvent FP68. Always
wear gloves and safety goggles with closed side frame!

Starting Valve
Removal, Fitting and Dismantling, Grinding-in and Assembling

2 Jacking screws 1 Nut 12 Control valve
2 Cover 13 Connecting pipe
3 Ring 14 Piston ring
4 Casing 15 Spindle guide
5 Cylinder cover 16, 17 O-rings
6 Self-locking nut 17 Solenoid
7 Piston 18 Nut with locking washer
8 Valve spindle
9 Allen screw CA Control air pipe
10 Compression spring (from starting air pipe)
11 Joint ring RC Eye bolt
1. General
Should functional difficulties occur with the starting valves when starting, or should
a starting air pipe near to the connection become noticeably hotter in operation
than on the neighbouring cylinders, then the starting valve must be dismantled and
reconditioned at the very next opportunity.
If no such difficulties occur it is recommended to dismantle yearly at random one
starting valve for a thorough check and to overhaul the other starting valves in fre-
quencies determined by such checking.
Periodical venting of the starting air manifold under higher pressure must be
CHECK provided as mentioned in the Operating Manual 0320−1. In addition, regular
checks must be carried out to make sure, that nut 18 on solenoid 17 is tight (see
also Maintenance Schedule 0380−1).
2. Removal from the cylinder cover
⇒ Loosen pipes for control air ’CA’.

⇒ Loosen and remove all four nuts 1.
⇒ Loosen and remove Allen screws 9. Screw jacking screws into the threaded
holes in casing 4 and by tightening them jack the complete starting valve from
the bore in cylinder cover 5.
⇒ Reinsert both Allen screws 9 for removing the complete valve.
⇒ Suspended by eye bolts ’RC’ lift the valve off the cylinder cover.
D When the removal is carried out with the cylinder cover fitted on the engine,
the vacated opening must be immediately covered by suitable means to pre-
vent the possibility of foreign particles entering the combustion space.
3. Dismantling a starting valve
D Lift cover 2 with mounted control valve 12 off casing 4. Take care that during
lifting, the cover does not get jammed, whereby connecting pipe 13 risks be-
ing damaged.
⇒ Remove ring 3 from casing 4.
⇒ For further dismantling clamp the valve on the milled faces below the valve
spindle head (spanner purchase) in a vice.

Starting Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling
⇒ Loosen self-locking nut 6 with a socket spanner, and remove it.

⇒ Pull piston 7 and compression spring 10 from casing 4.
⇒ Lift casing up over valve spindle 8.
4. Grinding-in
D Slightly damaged seat faces may be ground in (lapped) manually.

D Badly worn seat faces must first be machined and then ground in (lapped)
manually.
Remark: The valve spindle has an angle of 61_, however, the valve seat angle
amounts to 60_.
5. Assembling
Assemble the valve in reverse sequence to the dismantling.

⇒ Clean all parts and smear them lightly with oil.
⇒ Apply MOLYKOTE paste G to the thread of valve spindle 8, however not in the
area of the locking ring of the self-locking nut 6.
⇒ Tighten the not greased, clean self-locking nut with 800 Nm or by a tightening
angle of 55_.
⇒ Place new, lightly oiled, O-rings 16 and 17 into the groove in casing 4 and con-
necting pipe 13 respectively.
After completing the assembly (without cover 2) check the easy movement of the
CHECK valve spindle by moderately tapping the upper end of the valve spindle several
times with a lead block in an axial direction; the valve spindle must jump every time
back on the seat.
If the valve seat have been ground/machined several times, check the clearance
’x’ (see figure) with a depth gauge from the upper edge of ring 3 onto the piston 7.
Clearance ’x’ must be minimum 1 mm.
⇒ Fit cover 2 and tighten it with Allen screws 9. Take care that when assembling
cover 2, connecting pipe 13 does not interfere.
6. Fitting in the cylinder cover
⇒ Place a new joint ring 11 on the shoulder of the bore in cylinder cover 5.
⇒ Smear bore in cylinder cover lightly with oil and fit the assembled starting
valve.
⇒ Apply Never-Seez NSBT-8 to the threads of nuts 1, fit and tighten them cross-
wise through an angle of 90_.

Starting Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling
I-I II - II
II
RC
12 17
18
1
2 CA
6
3
X
14 I IV I
7
14 4 III
IV
5
16
8
III
10
15
III - III IV - IV
11 9
13
17
4
014.772/06
005.224/89 005.224/89

Relief Valve for Cylinder Cover
Checking Blow-off Pressure

1 OBEL test bench 94272 1 Cylinder cover 10 Receiver
1 Valve holder 94272c 2 Relief valve 11 Gasket
1 HP oil pump 94931 3 Indicator valve 12 Gasket
2 Hydr. distributors 94934a 4 Adapter piece
1 HP hose 94935 5 Protection plate
6 Flange EV Relief valve
7 Adapter MD Metallic sealing
8 Sleeve RB Relief bore from
9 Allen screw compression chamber
1. General
Each cylinder cover is provided with an indicator valve combined, depending on

Class requirements, with a relief valve, which is connected by relief bore ’RB’ to the
compression chamber. An inadmissible high pressure peak in the compression
chamber opens the valve and the over-pressure is immediately reduced.
A relief valve which has blown off or valves leaking during engine operation
must be replaced at the first opportunity (with engine stopped only).
A relief valve can not be repaired nor adjusted any more after having blown-
off!
Relief valves require no maintenance, however they should be checked in general
at every major engine overhaul. Basically leaking or damaged valves should be
returned to the manufacturer for inspection and repair.
BLOW-OFF PRESSURE
STAMPED IN
A
2
5
12
11
4
3 12
9
6
7
MD
8
1
RB
017.671/08

Relief Valve: Checking Blow-off Pressure
2. Checking blow-off pressure
For checking relief valve 2 use test bench 94272 and diesel oil or a thin-bodied oil
as test medium.
Remark: Pay attention to the manufacturer’s detailed instructions and working
specifications of the test bench.
If necessary, a relief valve must be replaced completely and set according to the
following table:
Firing pressure Blow-off pressure

[bar] [bar]
140−143 200
144−147 205
148−1511) 210
152−155 220
156−160 225
1) Firing pressure range for RT−flex84T−D and RTA84T−D engines
94935
94934a
94272c
2
10
017.670/08
013.484/05
94272
94931 EV 013.486/05
3. Fitting the relief valve
⇒ Apply Never-Seez NSBT-8 to the thread of relief valve 2 and fit it with new gas-
ket 10.
⇒ Always properly close indicator valve 3 so that no gas escapes and then
screw on its cap.
Remark: If indicator valves leak for a long period the seats will become damaged.
Early replacement of a leaking indicator valve will allow easy repair. All threads and
internal parts must also be smeared with Never-Seez NSBT-8.

Exhaust Valve
Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs

1 Dismantling tool 94008a−M90 1 Waisted stud 9 Cylinder
1 Pre-tensioning jacks 94252 2 Nut 10 Expansion piece
1 Valve protector 94262 3 Vent screw 11 Protection pipe
1 Suspension device 94265 4 Piston 12 Valve cage
2 Lifting lugs 94811 5 Round nut 13 Valve spindle
1 Pressure gauge 94932a 6 Pin
1 Hydr. distributor 94934a 7 Sealing ring KO Slot
1 HP hose 94935 8 Sealing ring RS Round bar
2 HP hoses 94935a
1. General
Prior to the removal of an exhaust valve, drain first the cylinder cooling water from
the respective cylinder (see 2708−1), and close the air inlet to the air spring at the
control air supply (see 0520−1 in the Operating Manual).
The exhaust valve can be removed from the cylinder cover or transported as whole
unit (without cylinder cover) with suspension device 94265.
The valve cage must be suspended as shown in Fig. ’A’.
D If the exhaust valve is not to be dismantled at site immediately, mount the
valve protector 94262 (Fig. ’B’).
A 94265
12
13
94262
008.330/01 003.352/00

2. Removal
⇒ Remove all connected pipes. Removal of hydraulic piping see 8460−1.

⇒ Expansion piece 10 (Fig. ’C’) has to be removed with the aid of lifting lug 94811
and suspension device 94265. Therefore, two screws of each suspension
strap have to be screwed into the expansion piece flange. After removing the
connecting screws from the expansion piece flanges the expansion piece can
be taken out in the engine longitudinal direction.
94265
10
94811
I
12
94811 94811 I I-I
10
014.773/06
11
5 1 3 6
D ⇒ Clean the threads of waisted studs 1 of the valve
cage as well as the area around nuts 2 (Fig. ’D’).
RS
x
⇒ Place pre-tensioning jacks 94252 onto waisted

studs 1 which have to be loosened (arrangement
4 according to Fig. ’E’).
7
8 ⇒ Open vent screws 3 of the pre-tensioning jacks.
⇒ Screw round nuts 5 onto waisted studs 1 until there
2 is no or very little clearance at ’x’.
RS
9
KO ⇒ Subsequently slacken round nuts by approx. one
turn (for loosening only).
008.331/01

94252
E
94935a
94932a
94934a
94935 94935a
014.774/06
94252
94942
⇒ Connect pre-tensioning jacks 94252 with hydraulic unit 94942 as shown in

Fig. ’E’.
Verify the oil level in the hydraulic unit.
CHECK
⇒ Actuate hydraulic unit.

⇒ Close vent screws 3 on the pre-tensioning jacks as soon as oil flows bubble-
free.
⇒ Actuate hydraulic unit till a pressure of 1020 bar is indicated on pressure
gauge 94932a and on the pressure gauge at the hydraulic unit.
compared with pistons 4 on the pre-tensioning jacks!
⇒ Turn all nuts 2 upwards till the stop, using round bar ’RS’.
⇒ Release pressure to zero at the hydraulic unit and remove the pre-tensioning
jacks.
⇒ Unscrew round nuts 5 from the waisted studs.
⇒ Suspend the hooks of suspension device 94265 (Fig. ’A’) into the eye bolts of
valve gage 12 and pull the complete exhaust valve out of the cylinder cover.

3. Fitting
D Before fitting the exhaust valve into the cylinder cover, the sealing surfaces
must be checked for cleanliness and possible damage.
D Make sure that the soft iron gasket of 2 mm thickness lies flat in its recess in
the cylinder cover.
⇒ Fit new O-rings and oil these slightly.
⇒ Fit the complete exhaust valve suspended on the suspension device, taking
care not to damage the thread of the waisted studs.
D The correct position of the exhaust valve cage is determined by the cylindrical
dowel pin set in the cylinder cover.
⇒ Smear thread of waisted stud lightly with oil.
Fit nuts 2 and tighten them firmly with round bar ’RS’ till fully seated before mount-
CHECK ing the pre-tensioning jacks (check seating with feeler gauge).
⇒ Mark position of the nuts on a corner and their position on valve cage 12 with a
felt-tip pen (for later checks).
⇒ Place pre-tensioning jacks 94252 onto waisted studs 1 (Fig. ’D’) which have to
be loosened (arrangement according to Fig. ’E’).
⇒ Open vent screws 3 of the pre-tensioning jacks.
⇒ Screw round nuts 5 onto waisted studs 1 until there is no or very little clear-
ance at ’x’.
⇒ Connect pre-tensioning jacks 94252 with hydraulic unit 94942 as shown in
Fig. ’E’.
Verify the oil level in the hydraulic unit.
CHECK
⇒ Actuate hydraulic unit.

⇒ Close vent screws 3 on the pre-tensioning jacks as soon as oil flows bubble-
free.
⇒ Slowly raise the pressure to 1000 bar.
Keep this pressure constant and tighten nuts 2 with round bar ’RS’ till firmly seated
CHECK on exhaust valve cage 12 (check seating with a feeler gauge through the slot ’KO’).
After tightening the nuts ascertain that these have been turned by approx. the
same angle of 160_.
If bigger differences occure the tensioning procedure must be repeated.
⇒ Release pressure to zero and remove both pre-tensioning jacks.
Remark: When fitting expansion piece 10 smear its flange surfaces and connect-
ing screws lightly with a heat resisting lubricant. The expansion piece has to be
fitted in such a way that protection pipe 11 of the expansion piece comes to lie in
flow direction i.e. on the valve cage side as shown in Fig. ’C’.

4. Replacement of waisted studs
When fitting a new waisted stud (in the following text called stud for short) of the
cylinder cover, exhaust valve cage or starting valve, the instructions hereafter
must be strictly observed.
Before fitting the stud, clean and degrease the joint surface respectively sealing
face.
If recommended by the jointing compound manufacturer, apply an adhesive prim-
er in order to improve the adhesion on the joint surface.
Do not apply adhesive primer and any lubricant to the thread!
⇒ Screw in the stud right to the bottom and until it rests on its seating surface and
tighten it according to instructions 0352−2 using always a stud driver or two
counter locked nuts. Tool 94008a−M90 must be used for the cylinder cover
stud.
Tools like pipe wrenches or multigrip tongs, etc. which would cause damages to
the shank of the stud must never be used!
⇒ Fill the annular space completely up to the rim with jointing compound.
4.1 Studs fitted in cylinder jacket and cylinder cover
F
JOINTING G
COMPOUND
ANNULAR SEALING
SPACE SURFACE
1
94008a−M90
CYLINDER
COVER STUD
WCH00836
003.465/00

4.2 Recommended jointing compound and adhesive primers
Jointing Hardener Adhesive Manufacturer

compound primer
Elastosil RT 622 B G 790 Wacker-Chemie Gmbh
RT 622 A Geschäftsbereich Silicone
Hanns-Seidel-Platz 4
D-81737 München
Silcoset Silcoset Silcoset Primer AMBERSIL LTD
105 RTV Curing Agent A Wylds Rd
Bridgwater
Somerset
TA6 4DD
Uk-Great Britain
Remark: Mixing and applying of the jointing compounds must be done according
to the instruction of the respective manufacturer.
Products of other manufacturers are also allowed when fulfilling the below specifi-
cation:
− Containing no acid, e.g. no acetic acid.
− Resistant to oil, marine diesel oil, heavy fuel oil and water at a permanent tem-
perature of approximately 100 _C.
− Short age hardening time, i.e. at least 24 hours under ISO standard reference
conditions.
− Well flowing to properly fill out the annular space, in order to avoid the creation
of any hollow space.
− Good adhesion on adhesive-primed metallic surface.
− Easy to prepare and combine.
− None or only minimal surface shrinkage.
− The jointing compound must remain elastic, as a cylinder cover stud may be
removed at any given time.

Exhaust Valve
Dismantling and Assembling

1 Depth gauge 94124 1 Valve cage 24 Throttle
1 Retaining screw 94259 2 Lower housing 25 Screw plug
2 Jack screws 94263 3 Head screw 26 Valve seat
1 Torque wrench 4 Nut 27 Rod seal ring
5 Upper housing 28 Non-return valve
6 Outside piston 29 Air pipe
7 Inside piston 30 Double nipple
8 Thrust piece 31 Valve stroke sensor
9 Valve spindle 32 Screw
10 Screw plug 33 Transmitter housing
11 Piston guide 34 Spring
12 Waisted bolt 35 Distance ring
13 Screw 36 Damper
14 Measuring cone 37 Shim
15 Head screw 38−46 O-rings
16 Valve cotter
17 Piston BO Bore
18 Piston seal ring HU Wooden underlay
19 Disc spring OB Oil bore
20 Distance ring OB1 Oil bath for valve
21 Head screw spindle lubrication
22 Guide bush RC Eye bolt
23 Filter VW Maximum exhaust
valve stroke
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/9
2. Dismantling of exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/9
3. Assembling of exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/9
4. Blocking of exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/9
RC
A 1. General
36
5 There are in minimum two complete exhaust
valves on board, as recommended by the Interna-
4 tional Association of Classification Societies
(IACS). Therefore, they must be used as a re-
2 placement in any case of difficulties appeared
during operation.
3 Defective exhaust valves may, however, only be
1 repaired or reconditioned by qualified personnel
or a Wärtsilä Switzerland Ltd. authorized repair
workshop.
For inspection and overhaul intervals see Mainte-
nance Schedule 0380−1.
Remark: Pay attention to General Guidelines for
Lifting Tools 0012−1.
017.603/08

Exhaust Valve: Dismantling and Assembling
23 24 25
B
RC
36
46 37
5
6 7 36
8
4
11 BO
2
15 40
12
14
16
41
17 18
19 20
27 21
42
43 2
OB1
20 1
22 22
9
014.223/06
44
45
26
016.632/08

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

Attention! During dismantling and assembling, the activity area has to be clean
and as dust-free as possible (grinding dust etc.), and performing electric welding
must absolutely be omitted near or on the engine.
⇒ Place the exhaust valve on wooden underlay ’HU’ in vertical position.
⇒ Loosen and remove all nuts 4 (Fig. ’A’).
⇒ Lift the upper valve drive and remove it using eye bolt ’RC’.
⇒ Loosen screws 32 and remove housing 33, valve stroke sensor 31, spring 34
and distance ring 35.
⇒ Remove O-ring 39.
⇒ Loosen and remove all head screws 3.
⇒ Lift lower housing 2 and remove it.
2.2 Dismantling of valve spindle
⇒ Loosen head screws 15 and remove them together with measuring cone 14.
⇒ Push piston 17 away from valve cotters 16, then remove the latter.
⇒ Withdraw the piston from the valve spindle.
⇒ Remove disc springs 19.
⇒ Carefully lift valve cage 1 by means of the engine room crane. Ensure that the
valve spindle always stands on the wooden underlay while the valve cage is
sliding out.
9
C
15
14
16
18
17
40
19
HU
014.753/06

2.3 Removal of guide bush

⇒ Undo head screws 21, remove them together with distance ring 20 and rod
seal ring 27.
⇒ Screw both jack screws 94263 into the flange of guide bush 22 until the latter
can be lifted off.
Check and measure inner diameter of the guide bush according to Clearance Tabl-
CHECK e 0330−1 ’Exhaust Valve’.
D 94263
21 27 20 E
1 1
43
22
2.4 Fitting of guide bush

⇒ Clean the bore in valve cage 1 concerned and guide bush 22.
Check oil bores ’OB’ in guide bush and valve cage for free passage.
CHECK
⇒ Replace O-ring 43.

⇒ Oil guide bush and press it into the valve cage 1 up to the stop using jack
screws 94263.
94263
F
OB
43
22
014.792/06

3. Assembling of exhaust valve
Assembling is carried out analogously to dismantling but in reverse sequence.

Check the dimensions of valve spindle 9 with Clearance Table 0330−1 ’Exhaust
CHECK Valve’.
The condition of piston seal ring 18 (Fig. ’B’) is to be examined on every occasion,
at the latest, however, on the occasion of an overhaul of the exhaust valve accord-
ing to the maintenance schedule. A damaged piston seal ring must be replaced in
any case.
Heat new piston seal rings in boiling water before fitting them. When fitting proceed
with care, to avoid their damage; do not use any sharp edged utensils for assis-
tance.
⇒ Check all O-rings of the dismantled parts for damage and replace them if nec-
essary.
Remark: If an exhaust valve is to be fitted with a new seat or spindle, the seats
must be checked according to the instructions given in 2751−3.
3.1 Fitting of valve spindle

⇒ Apply oil to the valve spindle and fit it.
⇒ Apply oil to a new rod seal ring 27, fit it with distance ring 20 and tighten the
latter with head screws 21.
Remark: Always fit rod seal ring and distance ring only after fitting the valve
spindle, otherwise the rod seal ring might be damaged.
20
G
21 27
HU
014.760/06

3.2 Assembling of valve drive

⇒ Push valve spindle 9 against the valve seat and fit disc springs 19 as shown in
Fig. ’C’.
⇒ Fit piston 17 with O-ring 40, valve cotters 16 and measuring cone 14.
⇒ Apply oil to the threads of head screws 15. Fit and tighten them equally up to a
torque of 120 Nm.
D After tightening all screws 15 check them repeatedly for correct torque load,
since valve cotters 16 embed during the tightening process.
⇒ Bring the valve cage to vertical position.
D In this position fill oil bath ’OB1’ liberally with system oil (Fig. ’B’).
⇒ Fit lower housing 2.
⇒ Fit and tighten head screws 3.
⇒ Fit upper valve drive.
⇒ Apply oil to the threads and turn nuts 4 onto waisted bolts 12 and tighten them
crosswise in equal steps with a torque of 435 Nm.
36
12
2
15
16
014.762/06

3.3 Setting of damper

Setting of damper 36 (Fig. ’B’) is necessary only after a valve spindle or valve seat
has been replaced, and after one of the valve seating faces has been ground. Set-
ting is to be carried out, after assembling of the exhaust valve as shown in Fig. ’I’.
Check bores ’BO’ (Fig. ’B’) in the damper for free passage.
CHECK
3.4 Determining of total thickness ’h’ of the shims

⇒ Remove damper 36.
⇒ Determine with depth gauge 94124 measure ’H’ from the seating surface of
the damper to the bottom of the damper bore in inside piston 7; for this the
exhaust valve must be closed (check with feeler gauge whether the valve
plate lies against the valve seat without clearance).
D The total thickness ’h’ of shims 37 assigned to measure ’H’ is shown in the
following formula:
h = 156 − H $0.50 mm
⇒ Fit damper 36 and shims 37 with determined total thickness.
Single shim rings of 1 mm are available.
94124
37
h
H ± 0.5
014.791/06

3.5 Assembling of valve stroke sensor

⇒ Oil O-ring 39 and insert it into the corresponding groove in lower housing 2.
⇒ Fit valve stroke sensor 31 in such a way that spring 34 presses distance ring
35 against the collar of the valve stroke sensor.
⇒ Push valve stroke sensor together with housing 33 into the exhaust valve
housing and tighten screws 32.
II
K
2
39 34
31
32
I-I 35 33
I I
10 014.762/06
II
016.632/08
3.6 Checking filter

⇒ Remove screw plug 25 (detail in Fig. ’B’). Loosen filter 23 together with throttle
24 and check them for fouling.
(Tightening torque of throttle approx. 4 Nm with oiled thread).
3.7 Checking non-return valve
D In order to remove non-return valve 28 unscrew air pipe 29 & double nipple 30.
⇒ Undo the non-return valve.
Check the non-return valve for its proper function.
CHECK
28 26
L
AIR
INLET
014.793/06
30 29

4. Blocking of exhaust valve
In case of an emergency, i.e. with water leakages into the combustion chamber the
exhaust valve can be blocked in open position by means of thrust pin 94259. The
latter must also be fitted if an exhaust valve is jammed in the open position (see
0520−1 in the Operating Manual).
⇒ Remove screw plug 10 (Fig. ’K’) from lower housing 2 and screw in retaining
screw 94259 instead.
⇒ After screwing in the retaining screw reopen the shut-off valve to the air spring
supply. This locks valve spindle 9 in OPEN position.
94259
2
016.627/08
014.285/06
VW

Exhaust Valve
Replacing and Grinding the Valve Seat

1 Feeler gauge 94122 1 Valve seat AF Seating face
1 Valve seat fitting and dismantling device 94261 2 Valve cage HA Hammer
1 Gauge 94279 3 O-ring RC Eye bolt
1 Valve grinding device 94291
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
2. Removing the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
3. Fitting the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/5
4. Grinding the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/5
5. Checking the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/5
1. General
Valve seats of which the seat surfaces are badly damaged, or on which the wear
limit has been reached through frequent grinding, must be replaced.
The most advantageous position for replacing the valve seat is to bring the valve
cage in a vertical position as shown in Fig. ’A’.
Remark: When the valve seat must be removed with the valve cage in the inverted
upside down position, it must be suspended on the engine room crane slightly
above a wooden underlay. Device 94261 can then be attached from below and the
valve seat carefully withdrawn until it drops caused by its own weight (107 kg).
Therefore, the valve seat must be properly secured with additional wooden under-
lays. The distance to the wooden underlay is to be kept as small as possible to
avoid any accidents or damage.
2. Removing the valve seat
⇒ Fit both pairs of ring halves of the valve seat fitting and dismantling device
94261 into the groove on the circumference of valve cage 2 and valve seat 1
respectively.
⇒ With the aid of the three jack screws of the valve seat fitting and dismantling
device, the valve seat can be pressed out of its seating in the valve cage.
D Should a valve seat be removed for any reason, it must be reground by means
of valve grinding device 94291 before refitting.
94261
000.211/93

Exhaust Valve: Replacing and Grinding the Valve Seat
3. Fitting the valve seat
⇒ Place valve cage vertically.

⇒ Clean bore as well as seating shoulder at ’AF’ meticulously.
⇒ Smear the bore into which the valve seat has to fit with oil, or lubricants such
as THREAD GARD, LOCTITE, ANTI-SEIZE COMPOUND etc.
⇒ Smear new O-ring 3 of original specification with the same lubricant.
⇒ Push valve seat as far as possible into the bore, then mount valve seat fitting
and dismantling device 94261 and by equal tightening of the jack screws
press the valve seat down till fully seated.
Through the control openings in the valve seat fitting and dismantling device check
CHECK with feeler gauge 94122 all around the circumference that no clearance remains at
’AF’.
B
1
94261
94122
94261
2
000.250/93
3 AF

4. Grinding the valve seat
Grinding in valve seats using the valve spindle with grinding paste must be avoided
as a matter of principle!
Therefore, always use the valve grinding device 94291 for grinding in the valve
seats in the following cases:
− When new or reconditioned valve spindles are fitted.
− When the seat surface on the valve seat is badly damaged (impacts, corro-
sion scars).
94291
016.773/08

Remark: Regarding the operation of the grinding machine refer to the operating
instructions of the respective manufacturer.
D The grinding must produce an even and smooth surface.
Valve seat angle = 30_ + 02’

The grinding allowance on the valve seat is maximum 3 mm. The wear condition
CHECK can be checked efficiently with gauge 94279 in combination with feeler gauge
94122. Possible burn scars at the inside of the valve seat must not exceed 13 mm.
The depth of the burn scars can also be verified with the gauge 94279 as shown in
Fig. ‘D’.
D Valve seats which exceed the above mentioned values must be replaced.
94279
003.458/00
max. 13 mm

5. Checking the valve seat
E RC HA CHECK
After grinding it is necessary to check whether the new or
reground valve makes correct contact with the valve
seat. For this the spindle head seat face is spread with a
thin coating of blueing paste, then inserted vertically into
the guide bush.
Remark: The angle difference is chosen such that in the
hot operating condition the valves makes contact by
50 −100% from the outer edge (Fig. ’F’). The blueing
check should show that the cold valve makes contact
only from inside around the whole circumference. The
angle difference can be checked at gap ’S’ on the outer
edge with a feeler gauge (Fig. ’G’).
003.457/00 ⇒ The blueing on the valve seat must be checked by
tapping the valve head three or four times with a
hammer on a wooden block! (Fig. ’E’).
Do not rotate the valve spindle on the valve seat
face, as this risks seizure of the seating.
F
30 _ + 2’
0
50−100%
003.456/00
S = 0.14 − 0.18 mm
003.455/00

Exhaust Valve
Grinding the Seating Surface on the Valve Head
Tools:
1 Feeler gauge 94122
1 Valve grinding device 94291
1 Gauge 94292
1. General
Grinding in a valve together with its valve seat with grinding paste is not permitted.
Valves which have had the seating surfaces badly damaged by pitting or corrosion
have to be reground by machine. It is strongly recommended that a suitable grind-
ing machine 94291 be made available.
Remark: A valve spindle with missing rotation wing may not be reground. The
wing hub must be shrink-fitted on the valve shaft by heating it to 480 _C. Grinding
may first begin after the whole unit has cooled down.
The machines from the makers HUNGER and CHRIS - MARINE are well proven
for valve grinding and can also be ordered directly from Wärtsilä Switzerland Ltd,
Winterthur.
2. Grinding the seating surface
SEATING SURFACE
ANGLE ON VALVE
+20’
a = 30 _ +18’
A D Only as little material as necessary should be

ground off the valve seating surface to provide a
clean and smooth finished surface.
Only grind with cooling (wet).
a
D 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 vibra-
tion from running machinery or engines, etc. If
necessary the grinding machine should be stood
on a rubber mat.
Remark: For the application of the grinding device re-
fer to the operating instructions.
94291
016.744/08

Exhaust Valve: Grinding the Seating Surface on the Valve Head
The wear condition can be checked at any time with gauge 94292 and feeler gauge
CHECK 94122.
D Where the precise angle required has been obtained during grinding, a check
with marking blue with the valve on the reground valve seat in the valve cage
will show only a line contact or a very narrow band (extent of contact) starting
from the smaller diameter as shown in Fig. ’B’.
See also remarks in 2751−3 regarding the valve behaviour at running temper-
ature.
D A maximum of 3 mm may be ground off the valve seating surface. Valve
plates, where the seat surface has been ground back by more than 3 mm can
be reconditioned by build-up welding.
D On engines with arduous operating conditions, corrosion may form at the

bottom of the valve plate, after a longer operating time. Exhaust valves can be
reconditioned if the loss of material on the valve plate is less than or equal to
12 mm.
Exhaust valves cannot be reconditioned anymore, when the loss of material is
more than 12 mm, but can be kept in operation up to 25 mm loss of material.
Remark: Reconditioning of exhaust valves may, however, only be carried out by a
Wärtsilä Switzerland Ltd authorized repair workshop.
max. 3 mm
94292
max. 12 mm 003.454/00

Crankshaft, Connecting Rod and Piston Group 3

Crankshaft: Measuring Crank Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103−1/A1
Vibration Damper
− Taking a Silicone Fluid Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−1/A1
− Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130−2/A1
Axial Damper: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3146−1/A1

Turning Gear: Checking the Toothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3206−1/A1
Crankcase: Utilization of Working Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301−1/A1
Connecting Rod
− Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . 3303−1/A1
− Inspection, Removal and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . 3303−2/A1
− Inspection, Removal and Fitting of Top End Bearing with Piston in Situ . . . . . . 3303−3/A1
− Inspection, Removal and Fitting of Top End Bearing with Piston Removed . . . 3303−3/A2
− Removal and Fitting with Piston in Situ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−4/A1
− Removal and Fitting with Piston Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303−4/A2
Crosshead
− Checking the Clearances and Fitting the Guide Shoes . . . . . . . . . . . . . . . . . . . . 3326−1/A1
− Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326−2/A1
Piston
− Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403−2/A1
− Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403−4/A1
Piston Rings: Checking Wear of Piston Rings and Ring Grooves . . . . . . . . . . . . . . 3425−1/A1

Crankshaft
Measuring Crank Deflection

1 Crankshaft checking equipment 94305 1 Flywheel
(dial gauge) 2 Pinion
1. General
Regular crankweb deflection measurements according to the intervals defined by

the class rules are sufficient. Detailed alignment measurements might become ne-
cessary only in case of abnormalities, like
− significant change of crankweb deflection measurement results compared to
the set of previous measurements.
− bearing temperature alarms or bearing damage.
− after replacing main bearing shells and again after approx. 100 service hours.
− in case the ship has touched ground.
In any such cases it is recommended to contact Wärtsilä for support.
The checking equipment 94305 is clamped between the crank webs into the pro-
vided center punch marks. When turning the crankshaft, the change in distance
between the crank webs can be read from the dial gauge as it indicates any open-
ing or closing up. The smaller the variation the better the alignment of the crank-
shaft. Thereby, however, the function of the checking equipment, i.e. the sign on
dial gauge “+” (standard) or “−” must be taken into consideration.
2. Conditions for measuring
D Indicator valves must be open.

D The ship must be floating freely and lying in the water as horizontal as
possible.
D The crankshaft must rest perfectly on all the main bearings.
A
2.1 Influences on measuring
D Engine cold or at service temperature.
D The difference in temperature between the lubricating oil
sump tank and the seawater.
1 D Loaded condition of the ship (draught).
D Strong sunshine.
2 It is recommended to include these data in the records.
3. Measuring procedure
Despite the ordinary rotation direction of the engine, the

crankshaft must always be turned in such a manner that
flywheel 1 and pinion 2 of the turning gear are rotating as
017.943/08
indicated by the arrows.
TURNING GEAR
ON FUEL SIDE

3.1 Setting the checking equipment

With the running gear in situ, the crank to be measured has to be turned corre-
spondingly after B.D.C. The checking equipment can now be clamped next to the
connecting rod into the provided center punch marks.
⇒ Pretension the dial gauge of checking equipment 94305 and turn the latter
around its own axis for its proper settling.
⇒ Dial gauge must not deviate more than 0.01 mm. Set subsequently dial gauge
to zero.
⇒ Turn crankshaft by means of turning gear, reading the dial gauge in the shown
crank positions at B.D.C. − EXHAUST SIDE − T.D.C. − FUEL SIDE − B.D.C
and noting down the values.
D The last value at B.D.C. is for checking. With correctly carried out measuring
procedure it should be again nearly zero. If it deviates more than 0.06 mm
from the first reading, then the measuring must be repeated.
B VIEW FROM
DRIVING END
COUNTERCLOCK-
WISE ROTATION
EXHAUST SIDE T.D.C. FUEL SIDE
B.D.C. B.D.C.
CRANK DEFLECTION
SIGN ON DIAL GAUGE
94305
+ −
OR
− +
APPROX. 18 mm
CENTER PUNCH MARK

FOR DIAL GAUGE 94305

4. Judging the measuring
STROKE
94305
B.D.C
D
T.D.C
The difference between the indicated values shows the amount of crank deflection
during one revolution (Fig. ’B’).
Where values are measured which lie above the maximum permissible limits, the
cause has to be found and the necessary remedial measures taken (defective
main bearing, engine stay altered due to hull deformation, loose holding-down
bolts, defective propeller shaft bearings or checking equipment 94305, etc.).
The limits are valid for any condition of ship service after ship delivery, i.e.:
− The ship’s draught and trim are within the limits for normal operation.
− The engine is stopped and hot or cold.
− In case of measurements at cold engine condition, any tank heating which is
arranged close or below the main engine as well as the pre-heater of the main
lubricating oil separator have to be out of operation at least 8 hours prior to the
measurement.
Normal ship service: Crankweb deflection limits [mm]
Vertical Horizontal
Cylinder No. 1 Cylinder No. 2 Last cylinder All cylinders

(Driving end) to penultimate (Free end)
cylinder
1) 2)
0.83 0.59 0.59 0.59 0.27

−0.83 −0.59 −0.59 −0.83 −0.27
1) For engine without torsional vibration damper or front disc or free end PTO.
2) For engine with torsional vibration damper or front disc or free end PTO.
Contact Wärtsilä Switzerland, if the final measurements exceed the limits given in
the above table.

Vibration Damper
Taking a Silicone Fluid Sample
1 Casing trough 7 Crankshaft
2 Casing cover 8 Cap nut
3 Screw plug
4 O-ring
5 Sealing ring KS Secured by centre punch mark
6 Coupling bolt PB Sample container
1. General
Viscous vibration dampers manufactured by Hasse & Wrede, Metaldyne Interna-

tional UK, STE Schwingungstechnik and Geislinger can be mounted at the free
end of the crankshaft and in case of RTA engines as well at the free end of the cam-
shaft.
The service life of a vibration damper is largely dependent on the speed range in
which the engine is run. Wear of the inner parts as well as changes in the silicone
oil properties can reduce the effectiveness of the damper. By periodic examination
of the silicone oil the makers of the vibration damper can draw conclusions on its
condition.
The silicone oil must be examined for the first time after about 15 000−18 000 oper-
ating hours. Future intervals for examinations depend on the result of these first
findings.
Special sample containers ’PB’ (Fig. ’B’) can be obtained from the vibration
damper makers.
A Remark: Before taking a sample, or be-

fore working on a vibration damper, al-
ways follow first the instructions of the
vibration damper manufacturer.
In casing trough 1 and casing cover 2, two
oil sampling holes are carefully closed
and sealed with screw plugs 3.
FREE END
1
2
3 3
014.886/06
4 4

2. Preparation for taking a silicone fluid sample
⇒ Remove the casing of the vibration damper.

⇒ Turn the crankshaft in such a way that both screw plugs 3 of the vibration
damper are positioned horizontally to each other, whenever possible. If in this
position the screw plugs cannot be loosened , then the vertical position can
also be chosen.
⇒ Before removing the screw plug, carefully clean the area around it.
D Leave the damper in the mentioned position for at least two hours.
(If the oil sample is to be withdrawn from a removed vibration damper the
same conditions apply as regards the positions and the waiting time).
⇒ Using a flat caulker, hammer back the squeezed material in the corresponding
slot, which serves as locking means of screw plug 3.
⇒ Loosen the screw plug, but do not unscrew it yet, it must still seal.
3. Taking the sample
Prepare sample container ’PB’, i.e. remove both cap nuts 8 and examine the bore
CHECK which must be meticulously clean.
Remark: Two different threads are used for the sample bores of the ’Simpson In-
ternational’ and STE vibration dampers. Therefore, the ends of the sample con-
tainer are provided with different threads.
⇒ Remove the previously loosened screw plug 3, and screw in the sample con-
tainer ’PB’ instead.
⇒ After fully screwing in the sample container, screw it back by one turn to pre-
vent it from touching the flywheel inside the vibration damper.
⇒ Wait until the silicon fluid appears at the open end of the sample container.
Depending on the viscosity of the fluid, this may take some seconds only, or
much longer.
⇒ As soon as the silicon fluid flows out of the sample container, close its open
end with the respective cap nut.
⇒ Unscrew the sample container from the vibration damper housing (taking care
not to let escape the fluid), then immediately set in screw plug 3 with a new
O-ring 4 or sealing ring 5. (Avoid any leaking of silicon fluid.)
⇒ Screw the second cap nut on the sample container and tighten it moderately.
⇒ For the different vibration dampers tighten screw plugs 3 as follows:
− Metaldyne International with 25 Nm
− Hasse & Wrede with 20 Nm
− STE with 15 Nm (M10) or 45 Nm (M16)
⇒ Finally secure the screw plugs with centre punch mark ’KS’ (Fig. ’B’).

B SAMPLE CONTAINERS
Metaldyne
and STE
8 3/8”BSF (M16)
HASSE & WREDE
M10x1
PB
PB
M10x1
8 5/16”BSF (M10)
007.964/97
3 3
5 4
KS
KS
If a sample is not obtained by the method described, proceed as follows:

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

The filled sample container has to be labelled and depending on the manufacturer
sent to one of the following addresses for examination:
Hasse & Wrede
Georg-Knorr-Strasse 4
D-12681 Berlin
Germany
Tel: +49 30 93 92 3135
Fax: +49 30 70 09 0835
Remark: Samples taken on dampers manufactured by STE Schwingungstechnik
have to be sent to Hasse & Wrede.
Metaldyne International UK Ltd

131 Parkinson Lane
GB-Halifax HX1 3RD
United Kingdom
Tel: +44 1422 357 234
Fax: +44 1422 354 432
Geislinger GmbH
Hallwanger Landesstrasse 3
A-5300 Hallwang / Salzburg
Austria
Tel: +43 662 66 999 0
Fax: +43 662 66 999 40
The label must contain the following information:

D Engine type
D Engine No.
D Number of operating hours of the vibration damper
D Ship name
D Shipyard and hull number
D Manufacturing serial number of damper (see manufacturing plate or stamped
marks)
D Damper location (crankshaft or camshaft)

Vibration Damper
Inspection (GEISLINGER Vibration Damper)
1 Damper casing 6 Coupling bolt
2 Vent nozzles 7 Coupling disc
3 Sealing rings (crank angle sensor unit)
4 Oil supply piping 8 Vibration damper
5 Crankshaft 9 Sealing ring
1. General
Depending on the design execution of an engine, a vibration damper of GEIS-

LINGER make may be mounted at the free end of the crankshaft.
The service life of a vibration damper depends largely on the speed range in which
the engine is operated. Water, in particular sea-water, in the lubricating oil leads to
increased wear and loss of damping action.
2. Check
D The engine filters should regularly be checked for steel or bronze chippings. If
such chippings are found also in the damper housing, the damper supplier is
to be informed accordingly.
Until the reasons for such findings are not clarified and rectified, it is not allowed to
put the damper back into service.
D Should the oil pressure drop below 1 bar, it may not be corrected by adjust-
ment of the adjustable throttle in the supply piping. Instead, the cause of the
pressure drop must be investigated (defective oil supply piping 4).
Attention! If the oil supply to the damper is interrupted, the engine must be
stopped immediately, otherwise the damper may be seriously damaged. The oil
supply has to be reestablished before restarting the engine.
D Should damage be noticed on the engine bearings which is due to water con-
tamination of the lubricating oil, then the vibration damper must also be in-
spected for possible damage at the very earliest opportunity.
D To check the inner spring tips and groove flanks the inspection cover on the
face of damper casing 1 (Fig. ’B’) can be removed (with stopped engine). For
wear limits refer to the manual of the damper manufacturer.
D Dismantling of a vibration damper should only take place if there is a reason-
able suspicion that the damper is damaged or wear rates have exceeded their
limits. In this case contact the damper manufacturer for further instructions.
Attention! Adjustments on the vibration damper may only be carried out by a spe-
cialist, with simultaneous torsional vibration measurements.
Prior to removing a vibration damper and balance weight mark their positions with
reference to the crankshaft.
D For tightening values of coupling bolts 6 see 0352−1.
Remark: For the test run after the first commissioning, as well as the normal
checking and servicing intervals, refer to the manual of the damper manufacturer.
Contact address for GEISLINGER vibration dampers:
Geislinger GmbH
A-5300 Hallwang / Salzburg
Austria

Inspection (GEISLINGER Vibration Damper)
A B
8
8
1
2
9
OIL SUPPLY
FREE
END
011.669/04 014.819/06

Axial Damper
1 Upper part of cylinder 15 Oil inlet pipe
2 Lower part of cylinder 16 Main bearing cover
3 Screw 17 Crankshaft
4 Screw 18 Main bearing shell
5 Screw 19 Jack bolt
6 Large seal ring 20 Upper casing
7 Small seal ring 21 Screw
8 Self-locking nut 22 Piping for damper
9 Allen screw monitoring
10 Throttling valve 23 Vent piping
11 Spindle 24 Support
12 Locking screw
with locking plate
13 Locking plate H1 Lifting tackle
14 Diaphragm RC Eye bolt
1. Preparation
Remark: Pay attention to General Guidelines for Lifting Tools 0012−1.
When seal ring 6 or 7 has to be removed from axial damper, proceed as follows:
⇒ Switch off the bearing oil pump.
⇒ Remove vent piping 23.
⇒ Unscrew and remove the oil inlet pipes 15 and the piping for damper monitor-
ing 22 internally and externally from the upper casing 20. Take care that no dirt
enters the oil pipe!
⇒ Remove the upper casing 20.
A
23
15
22
20
015.093/07

Axial Damper: Dismantling and Assembling
2. Dismantling
⇒ Loosen screws 21 and remove throttling valve 10.

⇒ Pull out both taper pins locating the upper and lower parts of cylinder 1 and 2
by means of the withdrawing device which is part of the standard tools. For
this purpose the taper pins have been provided with a thread of M20.
⇒ Loosen and remove all screws 5 and 3.
⇒ Loosen all screws 4 to the upper part of cylinder 1 and pull them out as far as
possible on engines provided with vibration damper; on other engines, how-
ever, the screws can be removed completely.
10
B 14
I-I
I
11
21 19 10
15
16
6
5
1
4
17 7 7
18
009.019/01
009.020/01

C I
24 H2
H1
RC
1
014.775/07
I-I
H1 H2
3. Removal of upper part of cylinder
⇒ Screw two eye bolts ’RC’ into upper part of cylinder

1.
⇒ Fasten lifting tackle H1 to support 24 and connect it
to eye bolts ’RC’ by means of ropes.
⇒ Carefully lift upper part of cylinder.
Attention! When lifting upper part of cylinder, make sure
that it slides out of seal rings 6 and 7 without jam-
ming, as otherwise the seal rings risk being damaged.
1
6 ⇒ The upper part of the cylinder can be pulled to the
side using an other lifting tackle H2.
7
015.094/07

D For removal of two-part seal rings 6 and 7, loosen

first self-locking nuts 8 and remove Allen screws 9.
9
The sealing rings can then be turned out of their
grooves in the lower part of cylinder 2 without any
8 problems.
6 (7)
003 718/95
4. Checking the throttling valve
11
E 12
13
x
D When overhauling the axial damper check also the

condition of throttling valve 10. The spindle position
10 has been locked by locking screw 12 and a locking
plate 13.
Changing the position of the throttling valve is forbidden.
D For pre-setting spindle 11 has to be turned back by

about four turns starting from the closed position.
D This adjustment must be verified on the basis of
vibration measurements during sea trial; otherwise
the spindle must be readjusted. The final adjust-
14 ment has to be engraved in the name plate fitted to
the upper part of cylinder 1.
004.156/99
If it becomes necessary to unscrew or replace a spindle for any reason, then the
distance ’x’ must be measured first (Fig. E’). The spindle has to be adjusted to the
same distance on reassembling.
The spindle must not be turned back by more than 16 turns , that corresponds to a
stroke of x = 48 mm.
D When the above check brings to light any defect of throttling valve 10 then dia-
phragms 14 (Fig. ’B’) screwed into the throttling valve must also be checked
for possible damage and replaced if necessary.
Attention! The engine must not be operated with spindle 11 removed or with the
oil supply to the axial damper interrupted!

5. Assembling
Remark: The seal rings normally have no signs of wear, therefore no dimension
due to wear is indicated. However, worn or damaged seal rings 6 and 7 due to con-
tamination must be replaced. See also 3146−1 ’Monitoring system’ in the Operat-
ing Manual.
D The seal rings are fastened by two Allen screws 9 and self-locking nuts 8. Im-
mediately before fitting the seal rings smear them with clean engine oil.
D Newly fitted seal rings must allow radial movement when fitted.
D The assembling of the axial damper is done analogously to dismantling but in
reverse sequence. Pay the utmost attention when lowering upper part of cylin-
der 1 into place, to prevent seal rings 6 and 7 from being damaged.
D Before tightening screws 3 as well as 4 and 5 fit the taper pins for the upper
part and lower part of the cylinder.
Remark: Apply MOLYKOTE and tighten screw 4 between axial damper and bed-
plate with a tightening angle of 50_ (see also 0352−1).

Turning Gear
Checking the Toothing
Key to Illustration:
1 Turning gear
2 Pinion
3 Toothing of flywheel
1. General
Before putting the turning gear into operation, the condition of the tooth flanks, i.e.
the lubricant of pinion 2 and toothing of flywheel 3 must always be checked. See
also 0750−1 in the Operating Manual.
For maintenance of the turning gear the instructions recommended by the
manufacturer must be followed.
1
3
017.943/08

Turning Gear: Checking the Toothing
2. Checking the toothing
2.1 Application instruction

The lubricant needs to be spread evenly in a very thin layer over the tooth flanks
of pinion 2 and flywheel 3 in order to prevent it from being thrown off at full engine
speed.
Brand Application picture Remark

1 LE 5182 Apply lubricant in a zig-
PYROSHIELD zag line to provide a thin
layer of lubricant over
the entire gear tooth sur-
face.
2 Klüberfluid In order to reach a very

C−F 3 ULTRA thin shiny layer of lubri-
cant, it is recommended
to warm up Klüberfluid
to approx. 35 _C in a
small tin which is put into
warm water.
2.2 Re-lubrication intervals

According to visual inspection results, when hardly any lubricant is left any more on
the highest loaded tooth flank areas, i.e. before the tooth flanks nearly run dry:
Approximately every 2000 operating hours of the diesel engine, or more fre-
quently, as required.
2.3 Recommended suppliers

1 Lubrication Engineers Inc.
300 Bailey Avenue
Forth Worth, TX
USA
http://www.lelubricants.com/
Email: info@le-inc.com
2 Klüber Lubrication München KG

Geisenhausenerstrasse 7
81379 München
Germany
http://www.klueber.com
Email: info@klueber.com

Crankcase
Utilization of Working Platform

2 Working platforms, 94142 1 Engine longitudinal beam
consisting of 3 grids each 2 Crank web
3 Working supports 94143 3 Step
4 Strap
1. General
To avoid accidents, grids of working platform 94142 and working supports 94143
should be used for inspections or work in the crankcase. The grids must always be
fitted in such a way that their U-profiles come to lie between engine longitudinal
beam 1 and that the opposite end rests on crank web 2 as shown in Fig. ’A’.
Working support 94143 can be fitted between the columns at the desired height,
on steps 3. These are safeguarded against falling down by shoving straps 4
against the steps.
Never rotate crankshaft while grids or working supports are in position.
I-I I
A
3
94143
94143
3 4
FUEL SIDE
94142
94142
1
1
009.340/02 009.341/02

Connecting Rod
Loosening and Tensioning the Connecting Rod Studs

1 Feeler gauge 94122 1 Connecting rod stud 8 Bottom end bearing
2 Pre-tensioning jacks 94314 2 Nut 9 Top end bearing
2 Pre-tensioning jacks 94315 3 Pin
1 Pressure gauge 94932a 4 Vent screw
1 Hydr. distributor 94934a 5 Piston KO Slot
1 HP hose 94935 6 Cylinder RS Round bar
2 HP hoses 94935a 7 Sealing ring SA Gap
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
2. Loosening the stud of bottom end bearing . . . . . . . . . . . . . . . 2/5
3. Tensioning the stud of bottom end bearing . . . . . . . . . . . . . . 3/5
4. Loosening the stud of top end bearing . . . . . . . . . . . . . . . . . . 4/5
5. Tensioning the stud of top end bearing . . . . . . . . . . . . . . . . . . 5/5
1. General
⇒ For loosening and tensioning clean the threads of connecting rod studs 1 and
the area around nuts 2 and lubricate the threads.
Check that the nuts turn freely on the threads.
CHECK Always check the oil level before using the hydraulic unit.

Attention! Never turn the crankshaft as long as the pre-tensioning jacks are
mounted on the connecting rod studs!
4
3
x
7
5
6
2
RS
SA KO
1
011.359/03 011.360/03
PRE-TENSIONING JACK PRE-TENSIONING JACK

PLACED FOR LOOSENING PLACED FOR TENSIONING

2. Loosening the connecting rod stud of bottom end bearing
B ⇒ Place pre-tensioning jacks 94314 on con-

necting rod studs 1 (Fig. ’B’) and completely
screw them on with opened vent screw 4
(Fig. ’A’).
⇒ The pre-tensioning jacks are to be loosened
94314 by about ½ turn (gap ’SA’ in Fig. ’A’).
⇒ Connect the pre-tensioning jacks with hy-
draulic unit 94942 as shown in Fig. ’B’.
1 ⇒ Actuate hydraulic unit.
8 ⇒ Close vent screws 4 on the pre-tensioning

jacks as soon as oil flows bubble-free.
⇒ Actuate hydraulic unit till a pressure of 1020
bar is indicated on pressure gauge 94932a
and on the pressure gauge at the hydraulic
unit.
D Attention should be paid to ensure that pins
3 always protrude slightly compared with
94935a 94932a 94935a pistons 5 on the pre-tensioning jacks!
94934a ⇒ Turn back nuts 2 by one turn, using round
bar ’RS’.
⇒ Release pressure to zero at the hydraulic
94935
unit and then remove pre-tensioning jacks.
94942
015.095/07

3. Tensioning the connecting rod stud of bottom end bearing
D Consider the previously mentioned directions.

⇒ Tighten the nuts first with round bar ’RS’ by hand with a smart jerk.
Check whether the nuts rest flush on the connecting rod shank.
CHECK
⇒ Equally distribute the clearance between the bearing halves (bearing projec-
tion).
⇒ Screw pre-tensioning jacks 94314 onto connecting rod studs 1 until these rest
against the connecting rod shank. Moreover, open slightly vent screws 4 so
that pistons 5 can slide back to their initial position, i.e. there is no or little clear-
ance at ’x’ (Fig. ’A’).
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’B’.
⇒ Actuate the hydraulic unit and set pressure to 600 bar (1st step) and keep
pressure constant.
⇒ Start up hydraulic unit till bubble-free oil flows out through vent screws 4. Shut
the vent screws.
Tighten the nuts with round bar ’RS’ and check with the feeler gauge through slot
CHECK ’KO’ (Fig. ’A’) that no clearance remains between nut and supporting surface.
Check with the feeler gauge that no clearance remains between bearing cover and
connecting rod shank.
(Should clearance remain, loosen the fastening and compare the bearing projec-
tion with the nominal value as indicated in 3303−2).
Fig. ’a’
⇒ After tensioning to the 1st step mark the position of
the nuts against connecting rod as shown in Fig. ’a’.
⇒ Raise the pressure to 1000 bar (2nd step) and keep
constant.
Tighten nuts down and check correct seating with the
CHECK
feeler gauge.
Check from the markings applied by how much the nuts
y were turned after pre-tightening (1st step).
x Tightening angle to be about 50_ (Fig. ’b’).
⇒ Should considerable differences to these nominal
Fig. ’b’ values be encountered then repeat the tensioning
process.
⇒ Release pressure to zero at the hydraulic unit and
then remove pre-tensioning jacks.
Finally check the vertical bearing clearance (see Clear-
CHECK
y ance Table 0330−1 ’Top and bottom end bearings to con-
necting rod’).
98.7700
TIGHTENING x
ANGLE

4. Loosening the connecting rod stud of top end bearing
C
I-I
a Remark: For loosening the studs always follow

b the sequence shown in Fig. ’C’ i.e. a + a and
b + b.
94315 ⇒ Place pre-tensioning jacks 94315 diago-
b
a nally on connecting rod studs 1 (Fig. ’C’) and
completely screw them on with opened vent
screw 4 (Fig. ’A’).
by about ½ turn (gap ’SA’ in Fig. ’A’).
⇒ Connect the pre-tensioning jacks with hy-
draulic unit 94942 as shown in Fig. ’C’.
9 ⇒ Actuate hydraulic unit.
1 ⇒ Close vent screws 4 on the pre-tensioning

jacks as soon as oil flows bubble-free.
⇒ Actuate hydraulic unit till a pressure of 1020
bar is indicated on pressure gauge 94932a
and on the pressure gauge at the hydraulic
unit.
D Attention should be paid to ensure that pins
3 always protrude slightly compared with
I
I
pistons 5 on the pre-tensioning jacks!
94935a 94932a 94935a
⇒ Turn back nuts 2 by one turn, using round
94934a bar ’RS’.
⇒ Release pressure to zero at the hydraulic
94935
unit and then remove pre-tensioning jacks.
⇒ Proceed in the same manner for the second
pair of connecting rod studs.
94942
015.096/07

5. Tensioning the connecting rod stud of top end bearing
Remark: For tensioning the studs always follow the sequence shown in Fig. ’C’
i.e. a + a and b + b for each step.
D Consider the previously mentioned directions.
⇒ Tighten the nuts first with round bar ’RS’ by hand with a smart jerk.
Check whether the nuts rest flush on the bearing cover.
CHECK
⇒ Equally distribute the clearance between the bearing halves (bearing projec-
tion).
⇒ Screw pre-tensioning jacks 94315 diagonally onto two connecting rod studs 1
until these rest against the bearing cover. Moreover, open slightly vent screws
4 so that pistons 5 can slide back to their initial position, i.e. there is no or little
clearance at ’x’ (Fig. ’A’).
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’C’.
⇒ Start up hydraulic unit till bubble-free oil flows out through vent screws 4. Shut
the vent screws.
⇒ Actuate the hydraulic unit and set pressure to 600 bar (1st step) and keep
pressure constant.
Tighten the nuts with round bar ’RS’ and check with the feeler gauge through slot
CHECK ’KO’ (Fig. ’A’) that no clearance remains between nut and supporting surface.
Check with the feeler gauge that no clearance remains between bearing cover and
connecting rod shank.
(Should clearance remain, loosen the fastening and compare the bearing projec-
tion with the nominal value as indicated in 3303−3).
Fig. ’a’ ⇒ Proceed in the same manner for the second pair of
connecting rod studs.
⇒ After tensioning to the 1st step mark the position of
the nuts against bearing cover as shown in Fig. ’a’.
⇒ Raise the pressure to 1000 bar (2nd step) and keep
constant.
Tighten nuts down and check correct seating with the
CHECK
y feeler gauge.
Check from the markings applied by how much the nuts
x were turned after pre-tightening (1st step).
Tightening angle to be about 35_ (Fig. ’b’).
Fig. ’b’ Should considerable differences to these nominal val-
ues be encountered then repeat the tensioning process.
⇒ Release pressure to zero at the hydraulic unit and
remove pre-tensioning jacks.
Finally check the vertical bearing clearance (see Clear-
CHECK
ance Table 0330−1 ’Top and bottom end bearings to con-
y necting rod’).
98.7700
x
TIGHTENING
ANGLE

Connecting Rod
Inspection, Removal and Fitting of Bottom End Bearing

1 Working platform 94142 1 Connecting rod stud 8 Bearing shell
4 Retaining pins 94323 2 Nut 9 Allen screw
3 Crank 10 Strap
4 Toggle lever
5 Bearing cover HZ Lifting tackle
6 Connecting rod H1 ... Lifting tackles
7 Guide way RC Rye bolt
1. Inspection and removal
⇒ Turn crank 3 of cylinder concerned to about 70° before T.D.C. (Fig. ’A’).
D Loosening of connecting rod studs 1 must be carried out according to 3303−1.
Attention! Never turn the crankshaft as long as the pre-tensioning jacks are
mounted on the connecting rod studs!
1.1 Lowering of bearing cover

⇒ Fit an eye bolt ’RC’ (M24) on each side of bearing cover 5 immediately below
the bearing division.
⇒ Connect lifting tackles H1 and H2 (lifting capacity 1000 kg each) with the eye
bolts fastening bearing cover according to Fig. ’B’.
⇒ Remove nuts 2.
⇒ Carefully lower the bearing cover while taking care that the threads of the con-
necting rod studs as well as the surface of the crankpin are not damaged.
⇒ Remove rope ’a’ and lifting tackle H2.
A B
H1
H2
b a
1
RC RC
5
3
015.106/07

1.2 Removal of bearing cover

⇒ Fasten lifting tackle H2 to the lower suspension eye and connect it with eye
bolt ’RC’ as shown in Fig. ’C’.
⇒ Turn bearing cover 5 to fuel side by means of lifting tackles H1, H2 (Fig. ’D’).
⇒ Remove lifting tackle H2 and eye bolt ’RC’.
⇒ Turn crank by approximately 30° towards exhaust side (Fig. ’E’).
⇒ Lift bearing cover up to the column opening.
C D
H1 H1
H2
H2
RC
RC
015.107/07

⇒ Connect lifting tackle ’HZ’ with the corresponding strap 10 and eye bolt ’RC’.
⇒ Remove bearing cover 5 from the crankcase as shown in Fig. ’F’ or ’G’.
F G
10 HZ
10
HZ
RC
RC
5
5
015.108/07
REMOVAL OF BEARING COVER REMOVAL OF BEARING COVER

OUTSIDE THE AREA OF SUPPLY UNIT BELOW SUPPLY UNIT

1.3 Inspection of bearing shell

H D Bearing cover 5 must be lowered (see para-
graph 1.1).
⇒ Loosen and remove the screws fastening
toggle lever 4 of piston cooling and cross-
HZ 94323 head lubrication and separate toggle lever
7 from connecting rod 6. Suspend toggle lever
4
with lifting tackle ’HZ’ inside the crankcase as
6 shown in Fig. ’H’.
⇒ Turn the crankshaft to T.D.C.
H3 c
⇒ Insert four retaining pins 94323 into the bores
of guide ways 7.
x
x ⇒ Carefully turn crankshaft towards fuel side till
3
the guide shoes come to rest on the retaining
pins.
If, however, not all retaining pins touch the
guide shoes, turn them such that their eccen-
trics contact the guide shoes.
⇒ Secure the connecting rod with lifting tackle
H3 and rope ’c’ (lifting capacity 500 kg each)
5 on fuel side.
⇒ Carefully turn down the crankshaft to fuel
side, following with the connecting rod bot-
tom by pulling it with the lifting tackle H3 just
as far as to keep always a distance ’x’ be-
tween the connecting rod bearing and the
crank 3.
I
1.4 Removal of bearing shell

H4 Bearing cover 5 may not be in the crankcase
any more (see paragraph 1.2).
H5 ⇒ Turn crank 3 downwards.

d
e
⇒ Screw two eye bolts ’RC’ (M8) each into the
RC
front faces of bearing shell 8.
94142
⇒ Connect lifting tackles H4 and H5 to eye bolts
’RC’ using ropes ’d’ and ’e’ and tighten lightly.
015.109/07

K ⇒ Undo Allen screw 9 (Fig. ’L’).

⇒ Lower bearing shell 8 using lifting tackles H4
and H5.
H4
L
H5
009.031/01
⇒ Screw two eye bolts ’RC’ (M8) each into the

front faces of the bearing shell.
⇒ Connect lifting tackle H6 with the correspond-
ing strap 10 and eye bolt ’RC’ (M8).
⇒ Remove bearing shell from the crankcase as
shown in Fig. ’M’ or ’N’.
M N
H4 H4
10 H6
10
H6
H5 H5
015.110/07


2. Fitting
The fitting of bearing shell 8 and bearing cover 5 is carried out analogous to remov-
al but in reverse sequence.
D The running surfaces have to be lavishly smeared with clean bearing oil.
D Tensioning of connecting rod studs must be carried out according to 3303−1.
Attention! Always fit toggle lever 4 in such a way that its curvature stands up-
wards.
After completing the work all retaining pins 94323 must be removed without fail.
3. Fitting of a bearing shell
D For fitting a bearing shell to the bottom end bearing, the surface of the crank-
pin must be in perfect condition.
D While fitting a bearing shell pay attention to prevent dirt or foreign particles
from entering between the shell rear surface and its seating! The contact sur-
faces of the shell rear side and the bearing bore must be free from any dam-
age. Immediately before inserting the bearing shells they have to be wiped
with a slightly oily hand, so that a trace of oil is on them.
D The bearing shell should be placed in the connecting rod head such that it pro-
trudes by the same distance at both ends of the separating face.
This protrusion is a must and under no circumstances may the separating
face of the bearing shell be filed to reduce it!
Protrusion of a new
x1
bottom end bearing shell:

x1 + x2 = approx. 0.64 − 0.72 mm
x2
008.458/01
Remark: Above measuring checks must be carried out when fitting new bearing
shells. For this the bearing shells are placed in position the bearing cover fitted and
the nuts tightened by hand with a round bar.
Prior to final assembly smear the running surfaces lavishly with clean bearing oil.
Should, however, the engine have to be frequently turned after the fitting of the
bearing, or should a re-start of the engine not be immediately planned, then
instead of bearing oil a mixture of 2/3 steam-engine cylinder oil and 1/3 normal bea-
ring oil should be used. Special oils suited to this purpose are also available from
reliable suppliers.
In order to further reduce the risk of dry running on newly fitted bearing shells, the
latter can be post-lubricated by means of a lubricating pump (see 3303−3).

Connecting Rod
Inspection, Removal and Fitting of Top End Bearing with Piston in Situ

1 Working platform 94142 1 Crankshaft 13 Guide segment
4 Retaining pins 94323 2 Toggle lever 14 Bolt with nut
2 Suspension straps 94333a 3 Connecting rod 15 Supporting sheet
2 Wire rope slings with hooks 94333b 4 Guide way 16 Piston rod foot
2 Eye bolts 94333c 5 Crosshead pin 17 Platform
1 Connecting flange 94336 6 Nut
7 Connecting rod stud
8 Cylindrical pin DL Oil pressure pipe
9 Bearing shell HZ Lifting tackle
10 Allen screw H1... Lifting tackles
11 Bearing cover OP Lubricating pump
12 Guide shoe RC Eye bolt
Overview
1. Inspection of bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/7
2. Removal of bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/7
3. Fitting the bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/7
4. Removal of bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/7
5. Fitting the bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/7
1. Inspection of bearing shell

⇒ Turn crank of the corresponding cyl-

HZ inder to B.D.C.
2 ⇒ Install working platform 94142.
⇒ Undo the screws fastening toggle le-
ver 2 of the crosshead lubrication and
piston cooling, and separate the
toggle lever from connecting rod 3.
⇒ Suspend toggle lever with lifting
94142 tackle ’HZ’ inside the crankcase.
⇒ Remove the working platform from
the crankcase.
015.102/07

⇒ Turn crank of corresponding cylinder

H2 to about 120° after T.D.C.
2 ⇒ Loosen and remove all nuts 6 of con-
necting rod studs 7 to top end bearing
as instructed in 3303−1.
⇒ Remove working platform 94142.
C
H2 ⇒ Turn crank to T.D.C.
12 ⇒ Place four retaining pins 94323 into
H1 b 94323 the guide ways 4 and turn down the
a crankshaft towards exhaust side until
4
the guide shoes 12 rest on the retain-
RC ing pins.
⇒ Secure connecting rod with lifting
tackles H1, H2 and ropes ’a’, ’b’ (lift-
ing capacity 5000 kg each).
⇒ Carefully turn crank to exhaust side
following with connecting rod using
lifting tackles H1 and H2.
D Take care that cylindrical pins 8
(Fig. ’G’) and connecting rod studs
7 slide out through the bores with-
out jamming!
Risk of accident! The piston may not be
removed in this position without securing
015.103/07 the bearing cover against falling down.

2. Removal of bearing shell
⇒ Swing out and lower connecting rod

till it contacts the side member of the
column opening as shown in Fig. ’D’
(place protection underneath).
⇒ Unscrew Allen screws 10 (Fig. ’G’).
⇒ Fit two eye bolts ’RC’ (M8) into the
front faces of the bearing shell 9.
a
RC
PROTECTION
2.1 Removal of bearing shell below

supply unit
⇒ Connect lifting tackle H4 and rope ’c’
H4 (lifting capacity 500 kg each) with the
H3 eye bolts fitted in the bearing shell.
⇒ Connect lifting tackle H3 (lifting ca-
pacity 500 kg) with ropes ’c’.
a
c ⇒ Remove the bearing shell from the
c connecting rod using lifting tackles H3
and H4.
015.104/07

2.2 Removal of bearing shell outside

the area of supply unit
H4
⇒ Connect lifting tackle H4 and rope ’c’
(lifting capacity 500 kg each) with the
eye bolts fitted in the bearing shell.
H3 ⇒ Connect lifting tackle H3 (lifting ca-
pacity 500 kg) with ropes ’c’.
c a ⇒ Remove the bearing shell from the
c connecting rod using lifting tackles H3
and H4.
015.105/07
11
10
13
13 7
9
015.170/07

3. Fitting the bearing shell
The fitting of bearing shell 9 and bearing cover 11 is carried out analogously but in
reverse sequence to the removal, whereby the following points require special
attention:
Check whether the surface of the crosshead pin is in perfect condition before fitting
CHECK the bearing shell.
age. Immediately before inserting the bearing shell they have to be wiped with
a slightly oily hand, so that a trace of oil is on them.
trudes by the same distance at both ends of the separating face (Fig. ’H’).
bearing, or should a restart of the engine not be immediately planned, then instead
of bearing oil a mixture of 2/3 steam-engine cylinder oil and 1/3 normal bearing oil
should be used. Special oils suited to this purpose are also available from reliable
suppliers.
D The tensioning of the connecting rod studs must be carried out as instructed in
3303−1.
D When fitting the bearing shell, as well as the crosshead pin, pay attention not
to damage the white metal of the two guide segments 13 (Fig. ’G’).
Attention! Always fit toggle lever 2 in such a way that its curvature stands upwards
(Fig. ’A’).

3.1 Fitting a new top end bearing shell

⇒ Proceed as described in section 3, however protru-
1 sion x1 + x2 must be measured prior to tension con-
x1
necting rod studs 7.
3.1.2 Measuring the protrusion

x2
⇒ Hand-tighten nuts 6 (Fig. ’G’) with a round bar and
3 measure the protrusion (of a new bearing shell):
x1 + x2 = approx. 0.58 − 0.66 mm
015.171/07
3.2 Post lubrication of connecting rod bearing

In order to further reduce the risk of dry running on newly fitted bearing shells, a
connecting flange 94336 can be fitted after removing the oil pressure pipe ’DL’ to
the crosshead bearing as shown in Fig. ’I’. The connecting flange has to be con-
nected via an oil pressure hose to a lubricating pump ’OP’.
The pump has to be filled with the mentioned oil mixture (steam-engine cylinder oil)
or special oil. The lubricating pump has to be operated from time to time, until oil is
pouring out from the bearing side faces. Before the engine is put back into opera-
tion, the oil pressure pipe ’DL’ must be refitted. The remainder of the above men-
tioned special oil or oil mixture may remain in the engine oil system.
I
94336 2
DL
FUEL SIDE
OP
009.036/01

4. Removal of bearing cover
When a bearing cover 11 has to be removed with piston in situ, proceed as follows:
⇒ Loosen all four nuts 6 (Fig. ’G’) to connecting rod studs 7 of the top end bearing
as instructed in 3303−1, then remove the nuts.
⇒ Remove the four waisted screws for the connection of crosshead pin 5 and
piston rod foot 16 (see also 3403−1).
⇒ Screw down both suspension straps 94333a (Fig. ’K’ and ’L’) onto the piston
rod foot.
⇒ Fit two eye bolts 94333c into the underside of the cylinder jacket.
⇒ Turn crank of the corresponding cylinder towards T.D.C. until both wire ropes
94333b can be attached to the eye bolts and the two suspension straps.
⇒ Turn crankshaft slowly towards B.D.C. and take care that piston rod foot 16
slide out through crosshead pin 5 without jamming.
⇒ The bearing cover can now be inspected or if necessary be removed as
instructed in 3303−3/A2, section 4.
For the removal of bearing cover 11 toggle lever 2 must be dismantled.
5. Fitting the bearing cover
The fitting of bearing cover 11 is carried out analogously but in reverse sequence to
the removal, whereby the following points require special attention:
D Tightening of nuts 6 (Fig. ’H’), see 3303−1.
D Tightening of the nuts for the connection of crosshead pin 5 and piston rod foot
16, see 3403−1.
K L
94333c
I 94333b
94333a
16
12
16
5
001.312/97 001.312/97

Connecting Rod
Inspection, Removal and Fitting of Top End Bearing with Piston Removed

1 Working platform 94142 1 Crankshaft 14 Bolt with nut
4 Retaining pins 94323 2 Toggle lever 15 Piston rod foot
1 Lifting plate 94324 3 Connecting rod 16 Waisted stud
1 Connecting flange 94336 4 Guide way 17 Waisted screw
5 Crosshead pin 18 Platform
6 Nut 19 Spur-geared chain block
7 Connecting rod stud
8 Cylindrical pin
9 Bearing shell DL Oil pressure pipe
10 Allen screw HZ Lifting tackle
11 Bearing cover H1... Lifting tackles
12 Guide shoe OP Lubricating pump
13 Guide segment RC Eye bolt
Overview
1. Inspection of bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8
2. Removal of bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8
3. Fitting the bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8
4. Removal of bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/8
5. Fitting the bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/8
1. Inspection of bearing shell


inder to about 120° after T.D.C.
⇒ Loosen and remove all nuts 6 of con-
6
94142
015.097/07

B ⇒ Screw eye bolts ’RC’ (M48) into con-

necting rod head on both sides.
⇒ Connect lifting tackles H1 and H2 (lift-
ing capacity 5000 kg each) with eye
bolts and column straps as shown
Fig. ’B’.
⇒ Fasten lifting plate 94324 with waist-
ed screws 17 to crosshead pin 5 pro-
vided for screwed connection piston
rod / crosshead pin.
I
H1 H2 ⇒ Connect lifting tackle ’HZ’ (lifting ca-
pacity 7000 kg) to lifting plate 94324
and engine crane.
Risk of accident! For safety reasons the
RC RC crosshead shall not be lifted directly with
the engine crane, but with the lifting tackle
connected between!
HZ
17
94324
C 5
12
⇒ Lift crosshead up over the bores pro-
94323 vided for retaining pins in the guide
4 ways.
⇒ Place four retaining pins 94323 into
guide ways 4, and pay attention to de-
H1 H2 tail in Fig. ’C’!
⇒ Lower crosshead onto retaining pins.
⇒ Turn retaining pins so that their ec-
centrics contact the guide shoes 12.
015.098/07

2. Removal of bearing shell
D
⇒ Loosen the screws fastening toggle
lever 2 of the crosshead lubrication
and piston cooling, and separate the
HZ
⇒ Suspend toggle lever with lifting
2
tackle ’HZ’ inside the crankcase.
H2
⇒ By means of lifting tackles H1 and H2
(Fig. ’C’) swing connecting rod to fuel
side ensuring that it can not tilting
back to exhaust side.
⇒ Remove lifting tackle H1 and swing
connecting rod in that position as
shown in Fig. ’D’.
2.1 Removal of bearing shell below

supply unit
⇒ Fit two eye bolts M8 each into the
H4 front faces of the bearing shell.
H3 ⇒ Loosen Allen screws 10 (Fig. ’G’).
⇒ Place lifting tackle H4 and connect
rope ’c’ (lifting capacity 500 kg each)
c with the eye bolts fitted in the bearing
c shell.
⇒ Place lifting tackle H3 and connect it
(lifting capacity 500 kg) with ropes ’c’.
⇒ Lift the bearing shell out of the crank-
case using lifting tackles H3 and H4.
015.099/07

F
2.2 Removal of bearing shell outside
the area of supply unit
⇒ Fit two eye bolts M8 each into the
H4 front faces of the bearing shell.
⇒ Loosen Allen screws 10 (Fig. ’G’).
rope ’c’ (lifting capacity 500 kg each)
H3
with the eye bolts fitted in the bearing
shell.
c
c rope ’d’ (lifting capacity 500 kg each)
with the eye bolts fitted in the bearing
shell.
⇒ Lift the bearing shell out of the crank-
case using lifting tackles H3 and H4.
015.169/07
11
10
13
13 7
9
015.170/07

3. Fitting the bearing shell
The fitting of bearing shell 9 and bearing cover 11 is carried out analogously but in
attention:
Check whether the surface of the crosshead pin is in perfect condition before fitting
CHECK the bearing shell.
age. Immediately before inserting the bearing shell they have to be wiped with
a slightly oily hand, so that a trace of oil is on them.
trudes by the same distance at both ends of the separating face (Fig. ’H’).
bearing, or should a restart of the engine not be immediately planned, then instead
of bearing oil a mixture of 2/3 steam-engine cylinder oil and 1/3 normal bearing oil
should be used. Special oils suited to this purpose are also available from reliable
suppliers.
D The tensioning of the connecting rod studs must be carried out as instructed in
3303−1.
D When fitting the bearing shell, as well as the crosshead pin, pay attention not
to damage the white metal of the two guide segments 13 (Fig. ’G’).
(Fig. ’A’).

3.1 Fitting a new top end bearing shell

⇒ Proceed as described in section 3, however protru-
1 sion x1 + x2 must be measured prior to tension con-
x1
necting rod studs 7.
3.1.2 Measuring the protrusion

x2
⇒ Hand-tighten nuts 6 (Fig. ’G’) with a round bar and
3 measure the protrusion (of a new bearing shell):
x1 + x2 = approx. 0.58 − 0.66 mm
015.171/07
3.2 Post lubrication of connecting rod bearing

In order to further reduce the risk of dry running on newly fitted bearing shells, a
connecting flange 94336 can be fitted after removing the oil pressure pipe ’DL’ to
the crosshead bearing as shown in Fig. ’I’. The connecting flange has to be con-
nected via an oil pressure hose to a lubricating pump ’OP’.
The pump has to be filled with the mentioned oil mixture (steam-engine cylinder oil)
or special oil. The lubricating pump has to be operated from time to time, until oil is
pouring out from the bearing side faces. Before the engine is put back into opera-
tion, the oil pressure pipe ’DL’ must be refitted. The remainder of the above men-
tioned special oil or oil mixture may remain in the engine oil system.
I
94336 2
DL
FUEL SIDE
OP
009.036/01

4. Removal of bearing cover

HZ HZ inder to about 120° after T.D.C.
b a
11 as instructed in 3303−1.
RC
⇒ Remove working platform 94142 and
turn crank to B.D.C.
94142
⇒ Undo the screws fastening toggle le-
ver 2 of the crosshead lubrication and
piston cooling, and separate the
⇒ Screw eye bolts ’RC’ into bearing
cover 11.
⇒ Connect lifting tackle ’HZ’ and ropes
’a’, ’b’ (lifting capacity 1000 kg each)
with eye bolts ’RC’.
⇒ Lift bearing cover over the crosshead

pin.
⇒ Protect the crosshead pin against dirt
b a and damage.
⇒ Pull bearing cover to fuel side and
H1 then lower it as much as possible.
⇒ Fasten lifting tackle H1 and connect it
RC
with rope ’c’ to eye bolt ’RC’.
⇒ Tighten lifting tackle H1 and remove
rope ’b’.
015.100/07

⇒ Connect lifting tackle H1 with eye bolt ’RC’.

⇒ Remove bearing cover 11 from the crankcase as shown in Fig. ’M’ or ’N’.
M N
HZ HZ
H2 H2
b b
H1 H1
015.101/07

5. Fitting the bearing cover
The fitting of bearing cover 11 is carried out analogously but in reverse sequence to
the removal, whereby the following points require special attention:
D Before fitting smear the running surfaces lavishly with clean bearing oil.
D Tightening of nuts 6, see 3303−1.
(Fig. ’A’).

Connecting Rod
Removal and Fitting with Piston in Situ

4 Retaining pins 94323 1 Crank 9 Upper nut piece
1 Holder 94331 2 Top end bearing 10 Yoke
1 Connecting element 94331a 3 Connecting rod 11 Threaded rod
4 Piston
5 Suspension beam
6 Spur-geared chain block H1... Lifting tackles
7 Lifting lug HZ Lifting tackle
8 Lower nut piece RC Eye bolt
1. General
D The bearing cover for the bottom end bearing must be removed (see 3303−2).
D Prepare the top end bearing as instructed in 3303−3/A1 ’Inspection of bearing
shell’, however toggle lever must be removed from the crankcase in B.D.C.

2. Removal
A 2.1 Fitting the holder 94331

⇒ Fasten holder 94331 to the connect-
ing rod foot as shown in view I.
4 ⇒ Fit lifting lug 7 on lower nut piece 8
2 and tighten it with a torque of 700 Nm.
H2
H1 b a ⇒ Remove rope ’b’.
94323
Risk of accident! The piston may not be
removed in this position without securing
3 the bearing cover against falling down.
I
I
7
8 8
11 11
3
015.037/07
9
94331
10
015.037/07

Connecting Rod: Removal and Fitting with Piston in Situ
⇒ Swing connecting rod downwards to

H1 a H2 the column opening by means of lift-
b ing tackles H1, H2 and remove rope
’b’ on halfway.
015.038/07
⇒ Carefully turn the crankshaft and

H1 H2 guide the connecting rod head out of
the crankcase following with lifting
5 a tackle H2 at the same time.
b
H3 ⇒ Sling rope ’b’ around the connecting
rod shaft and tighten it.
c
RC ⇒ Remove rope ’a’.
⇒ Attach lifting tackle H3 to suspension
beam 5 and connect it with rope ’c’
(lifting capacity 5000 kg each) to eye
bolt ’RC’.
⇒ Remove rope ’b’.
015.039/07

⇒ Carefully turn crankshaft to about 45°

before T.D.C.
⇒ Attach lifting tackle H4 (lifting capacity
5
5000 kg) to suspension beam 5.
H4
⇒ Sling rope ’d’ (lifting capacity 5000
c kg) around the connecting rod shaft,
d connect it with lifting tackle H4 (lifting
capacity 5000 kg each) and tighten
the latter.
⇒ Remove rope ’c’.
015.040/07
⇒ Screw eye bolt ’RC’ into the connect-

H2 ing rod foot.
⇒ Attach lifting tackle H2 and connect it
to eye bolt ’RC’ by means of rope ’e’
H4 e (lifting capacity 5000 kg each) and
6 RC tighten it.
d 9 ⇒ Suspend spur-geared chain block 6

(lifting capacity 5000 kg) instead of
10
the removed lifting tackle H4 and rope
8 ’c’ (Fig. ’D’).
⇒ Undo lower nut piece 8.
⇒ Loosen yoke 10 from upper nut piece
9 and remove it as shown in Fig. ’F’.
015.041/07

F
⇒ Fasten connecting element 94331a
to upper nut piece 9.
H2
H4 e
6 I
d
10 I
RC
11 9 94331a
015.042/07
015.042/07
701.015.042
701.015.042

H2 pacity 5000 kg) to connecting ele-
ment 94331a as shon in Fig. ’H’ and
tighten it.
e ⇒ Remove lifting tackle H2.
H5
015.043/07

⇒ Connect lifting tackle ’HZ’ (lifting ca-

pacity 5000 kg) to eye bolt ’RC’ and
tighten it.
⇒ Sling rope ’f’ around the connecting
rod shaft, connect it to spur-geared
H4 RC
H5 chain block 6 and tighten it.
6
⇒ Remove rope ’d’.
d
f
015.044/07
HZ
⇒ Connect rope ’d’ to lifting lug 7.
H4
⇒ Remove the connecting rod from the
crankpin by means of lifting tackle
PROTECTION and spur-geared chain block.
H5
d ⇒ Protect the crankpin against dirt and
7 damage.
015.045/07

HZ ⇒ Move connecting rod in engine longi-

tudinal direction with spur-geared
chain block 6, and turning it slowly by
means of lifting tackle ’HZ’.
⇒ Remove lifting tackle ’HZ’.
H5
d
015.046/07 ⇒ Remove connecting rod from the

crankcase following with spur-
geared chain block 6 in longitudinal
direction and slowly turning it by
means of lifting tackle H5 (Fig. ’L’ and
’M’).
⇒ Remove lifting tackle H5.
L M
H4
H5
6
d
015.047/07

⇒ Move the connecting rod till it hangs

parallel to engine longitudinal direc-
H4 tion.
015.048/07
3. Fitting
Fitting the connecting rod is carried out analogously to the removal but in reverse
sequence, whereby attention must be paid to instructions 3303−1 to 3303−3.
For the assembly bearings and bearing pins must be in perfect condition. They
must be smeared lavishly with fresh bearing oil.
Attention! Always fit toggle lever in such a way that its curvature stands upwards.
After completing the work retaining pins 94323 and all other tools must be removed
immediately from the crankcase.

Connecting Rod
Removal and Fitting with Piston Removed

1 Working platform 94142 1 Crank 11 Spur-geared chain block
4 Retaining pins 94323 2 Top end bearing 12 Lifting lug
1 Lifting plate 94324 3 Connecting rod 13 Lower nut piece
1 Holder 94331 4 Toggle lever 14 Upper nut piece
1 Connecting element 94331a 5 Waisted screw 15 Yoke
6 Crosshead pin 16 Threaded rod
7 Nut
8 Guide way H1... Lifting tackles
9 Guide shoe HZ Lifting tackle
10 Suspension beam RC Eye bolt
1. General
D The bearing cover for the bottom end bearing must be removed (see 3303−2).
D Holder 94331 must be installed as instructed in 3303−4/A1 ’Fitting the holder’.

2. Removal
⇒ Remove toggle lever 4.

A ⇒ Fasten lifting plate 94324 onto the
crosshead pin 6 using waisted
screws 5 provided for screwed con-
nection piston rod / crosshead pin.
4 I
94142
I
5
94324
6
94331
015.049/07

Connecting Rod: Removal and Fitting with Piston Removed

inder to about 120° after T.D.C.
necting rod studs to top end bearing 2
7
94142
015.050/07
⇒ Turn crank to B.D.C.

H1
H2 ⇒ Screw in eye bolts ’RC’ (M48) on ei-
ther side of the connecting rod head.
b a
HZ ⇒ Connect lifting tackles H1 and H2 (lift-
ing capacity 5000 kg each) with eye
bolts and column straps as shown
Fig. ’C’.
RC
RC
⇒ Connect lifting tackle ’HZ’ (lifting ca-
pacity 7000 kg) to lifting plate 94324
and engine crane.
Risk of accident! For safety reasons the
crosshead shall not be lifted directly with
the engine crane, but with the lifting tackle
connected between!
015.051/07

9
⇒ Lift crosshead up over the bores pro-
94323 vided for retaining pins in the guide
ways.
8
⇒ Place four retaining pins 94323 into
guide ways 8, and pay attention to de-
tail in Fig. ’D’!
⇒ Lower crosshead onto retaining pins.
⇒ Turn retaining pins so that their ec-
centrics contact the guide shoes 9.
015.052/07
⇒ Turn crankshaft and at the same time

H1 H2 swing connecting rod downwards to
b a
the column opening by means of lift-
ing tackles H1, H2 and remove rope
’b’ on halfway.
015.053/07

H1
⇒ Carefully turn the crankshaft and

H2 guide the connecting rod head out of
10 H3
the crankcase following with lifting
b a tackle H2 at the same time.
⇒ Sling rope ’b’ around the connecting
rod shaft and tighten it.
c
RC ⇒ Remove rope ’a’.
⇒ Attach lifting tackle H3 to suspension
beam 10 and connect it with rope ’c’
(lifting capacity 5000 kg each) to eye
bolt ’RC’.
⇒ Remove rope ’b’.
015.054/07
⇒ Carefully turn crankshaft to about 45°

before T.D.C.
10 H4
⇒ Attach lifting tackle H4 (lifting capacity
5000 kg) to suspension beam 10.
⇒ Sling rope ’d’ (lifting capacity 5000
c kg) around the connecting rod shaft,
d connect it with lifting tackle H4 and
tighten the latter.
⇒ Remove rope ’c’.
015.055/07

⇒ Screw eye bolt ’RC’ into the connect-

ing rod foot.
H4 H2
⇒ Attach lifting tackle H2 and connect it
to eye bolt ’RC’ by means of rope ’e’
e RC (lifting capacity 5000 kg each) and
11 tighten it.
14
⇒ Suspend spur-geared chain block 11
d 15
(lifting capacity 5000 kg) instead of
the removed lifting tackle H4 and rope
’c’ (Fig. ’D’).
13
⇒ Undo lower nut piece 13.
⇒ Loosen yoke 15 from upper nut piece
14 and remove it as shown in Fig. ’F’.
015.056/07
⇒ Fasten connecting element 94331a

to upper nut piece 14.
H4 H2
e
11 I
d
15 16 3 RC 14 94331a
015.057/07


pacity 5000 kg) to connecting ele-
H2
ment 94331a as shon in Fig. ’K’ and
tighten it.
e ⇒ Remove lifting tackle H2.
H5
015.058/07
HZ ⇒ Connect lifting tackle ’HZ’ (lifting ca-

pacity 5000 kg) to eye bolt ’RC’ and
H4 tighten it.
⇒ Sling rope ’f’ around the connecting
RC rod shaft, connect it to spur-geared
11 H5 chain block 11 and tighten it.
d ⇒ Remove rope ’d’.
f
015.059/07

HZ
⇒ Connect rope ’d’ to lifting lug 12.
H4
⇒ Move the connecting rod from the
crankpin by means of lifting tackle
PROTECTION and spur-geared chain block.
H5
d ⇒ Protect the crankpin against dirt and
12 damage.
015.060/07
HZ ⇒ Move connecting rod in engine longi-

tudinal direction with spur-geared
H4 chain block 11, and turning it slowly
by means of the lifting tackles.
⇒ Remove lifting tackle ’HZ’.
11 H5
d
015.061/07

⇒ Remove connecting rod from the crankcase following with spur-geared chain
block 11 in longitudinal direction and slowly turning it by means of lifting tackle
H5 (Fig. ’O’ and ’P’).
⇒ Remove lifting tackle H5.
O P
H4
11 H5
d
015.062/07 015.062/07
⇒ Move the connecting rod till it hangs

parallel to engine longitudinal direc-
tion.
H4
3. Fitting
11 Fitting the connecting rod is carried out

analogously to the removal but in reverse
sequence, whereby attention must be
paid to instructions 3303−1 to 3303−3.
3
For the assembly bearings and bearing
pins must be in perfect condition. They
must be smeared lavishly with fresh bear-
ing oil.
Attention! Always fit toggle lever in such
a way that its curvature stands upwards.
After completing the work all tools must be
015.117/07 removed immediately from the crank-
case.

Crosshead
Checking the Clearances and Fitting the Guide Shoes

1 Feeler gauge 94238 1 Crosshead pin
2 Guide shoe
3 Retaining cover
4 Guide way in engine column
5 Top end bearing
of connecting rod
6 Guide rail
1. General
On the occasion of an overhaul or when a crosshead has been removed, the op-
portunity should be taken to measure the various running clearances and to
compare them with the values found in the Clearance Table 0330−1 ’Crosshead
Guide’, so that possible wear may be discovered.
1
2 2
3
014.719/06
4 6 3 1
FUEL SIDE

Checking the Clearances and Fitting the Guide Shoes
2. Checking the clearances
Clearance 1 Clearance between guide shoes and guide ways:

The corresponding crankpin must stand in such a position
that guide shoes 2 lie on guide ways 4 on fuel or exhaust
side.
Clearance 1 is valid over the whole guide way length and
is measured according to the position as shown in Fig. ’B’.
Clearance 2 Radial clearance between crosshead pin and
guide shoe:
This clearance is very difficult to establish inside the en-
gine. It is therefore best to measure and calculate this
clearance on the removed crosshead. For this the pin di-
ameter and the bore in the guide shoe have to be mea-
sured with micrometers.
Clearance 3 Lateral clearance of crosshead between the columns:
The clearance is measured in every position of the cross-
head. The complete crosshead must be pressed axially to
a side with suitable hardwood wedges or similar aids. The
pressure must be exerted onto guide shoe 2 and not onto
crosshead pin 1.
Clearance 4 Lateral clearance between guide shoe and
crosshead pin:
Push the corresponding guide shoe to the stop of retaining
cover 3 in the above mentioned position of the crosshead.
90° BEFORE OR
1 AFTER T.D.C.
013.784/06

Crosshead
Removal and Fitting of a Crosshead Pin

1 Lifting plate 94324 1 Crank 9 Jack bolt
2 Connecting rod 10 Crank web
3 Crosshead pin 11 Bearing cover
4 Guide rail 12 Spur-geared chain block
5 Spring dowel pin
6 Retaining cover
7 Guide shoe HZ Lifting tackle
8 Neighbouring cylinder H1... Lifting tackles
1. General
If a crosshead pin has to be removed, the following works must first be carried out
on the cylinder concerned:
D Pulling out piston (see 3403−1).
D Removing toggle lever to crosshead lubrication and piston cooling.
D Removing jack bolts to both main bearings (see 1132−1).
D Removing bearing cover to top end bearing (see 3303−3/A2).

2. Removal
A
D Turn crankshaft to such a position, that crank
94324 1 of the neighbouring cylinder stands at 90_
or at 270_ after T.D.C. respectively. The cor-
rect crank position (ideal position) of the
neighbouring cylinder 8 is shown in the table
Fig. ’B’. This ideal position of the crank is im-
portant to ensure the accessibility for the re-
HZ moval of the respective crosshead.
⇒ Fasten lifting plate 94324 onto the crosshead
pin (see 3303−3/A2).
⇒ Screw two eye bolts into the connecting rod
2
head and secure connecting rod 2 with ropes
and lifting tackle (see 3303−3).
⇒ Lift the crosshead with the crane until it is fully
clear of the connecting rod top end bearing.
⇒ Connecting rod 2 can now be rested in the
crankcase towards exhaust side and de-
pending on crank position, it must be secured
with lifting tackle ’HZ’.
015.084/07

Table with ideal crank positions of neighbouring cylinders:
B
5 CYL. CRANK ANGLE
ENGINE NEIGHBOURING CYL. AFTER T. D. C.
1 2 270_
2 1 90_
3 2 90_
4 3 90_
5 4 90_
6 CYL. CRANK ANGLE

ENGINE NEIGHBOURING CYL. AFTER T.D.C.
1 2 270_
2 1 90_
3 2 90_
4 3 270_
5 4 90_
6 5 90_
7 CYL. CRANK ANGLE

1 2 270_
2 1 90_
3 2 90_
4 5 90_
5 4 270_
6 5 90_
7 6 90_
8 CYL. CRANK ANGLE

1 2 270_
2 1 90_
3 2 90_
4 5 90_
5 6 90_
6 5 270_
7 6 90_
8 7 90_
9 CYL. CRANK ANGLE

1 2 90_
2 3 90_
3 4 270_
4 3 90_
5 4 90_
6 5 90_
7 8 90_
8 9 90_
015.085/07
9 8 270_

⇒ Lower the crosshead pin on the crane as far as possible (Fig. ’C’).
⇒ Disassemble guide rail 4 and retaining cover 6 on the side of neighbouring
cylinder 8 (in ideal position), however spring dowel pin 5 should not be re-
moved (Fig. ’E’).
⇒ Secure guide shoe 7 with lifting tackle H1, H2 and ropes (lifting capacity 1000
kg each), see also Fig. ’G’ view I.
C D
H1 H2
9 3
7 7
1
8
015.086/07
3 6
7
015.081/07
FUEL SIDE
4 5

⇒ Pull the crosshead as far as possible in axial direction towards neighbouring

cylinder 8 using a lifting tackle.
⇒ Dismantle guide shoe and place it on crank web 10 (Fig. ’F’).
⇒ Remove the second retaining cover, however do not remove the guide rail.
⇒ Dismantle guide shoe and place it onto bearing cover 11.
⇒ Turn crosshead by 90_.
F G
H1 H2 I
3
7 7
7
11
10
I
11
H2 H2
H1 7
H1
10
015.087/07

⇒ Lower the crosshead with an other lifting tackle to fuel side as shown in Fig. ’H’
to ’K’).
⇒ Remove the crosshead from the crankcase by means of spur-geared chain
block 12 (lifting capacity 5000 kg) as shown in Fig. ’I’ to ’L’).
REMOVAL OUTSIDE OF
H AREA OF SUPPLY UNIT I
12
REMOVAL BELOW
K SUPPLY UNIT L
12
015.088/07

4. Fitting
Fitting procedure is analogous to the removal, but in reverse sequence.

D Fit only crosshead pins which have a perfect, undamaged running sur-
face.
D Before fitting the crosshead pin clean all guide and bearing surfaces carefully
and smear them lavishly with bearing oil.
D Lock screws to retaining covers 6 and guide rails 4.
Attention! Always fit toggle lever to crosshead lubrication and piston cooling in
such a way that its curvature stands upwards.
After completing the work check that all tools and foreign bodies are removed from
CHECK the crankcase, and that all the screwed fastenings are tightened to specification
and locked accordingly.
Check crosshead clearances according to Clearance Table 0330−1 ’Crosshead
Guide’.
Check with lubricating oil pump running that crosshead and connecting rod bottom
end bearings are lavishly supplied with oil.

Piston
Removal and Fitting

1 Piston ring expander 94338 1 Piston rod 8 Piston rod gland
1 Suspension device 94341 2 Crosshead pin 9 Screw connection
1 Insertion funnel 94342a(b) 3 Waisted screw 10 Waisted stud
2 Distance holders 94345 3a Locking element 11 Piston skirt
1 Cover plate 94345d 3b Screw 12 Cylinder liner
1 Tap 94348 4 Centring pin
1 Piston supporting device 94350 5 Platform support
6 Support
7 Hinged cover
1. General

D 2124−3 ’Removing wear ridge’ in cylinder liner at every piston removal.
D 2708−1 ’Removal of cylinder cover’ and draining cylinder cooling water.
The piston may not be transported with built-on piston rod gland (gland for short).
Attention! The supporting device 94350 can be used for piston overhauling
work at calm sea only, however, in no case this may serve as storage place
during the voyage!
Moreover, always consider, that the passage between engine and supporting de-
vice is limited (e.g. as possible escape route) on the platform.
2. Removal
⇒ Loosen screws 3b and remove them with locking

A elements 3a. Loosen screwed connection piston
rod 1 / crosshead pin 2 and remove waisted
screws 3.
⇒ Screw fasten both distance holders 94345 onto
the piston rod foot.
I-I
1
I I 3
3a
94345
2 3b
014.945/06
014.945/06

Piston: Removal and Fitting
Remark: Loosen and remove all screws for the screwing gland / cylinder jacket
(see 2303−1).
Remove antipolishing ring as described in 2124−2.
⇒ Turn the crank to T.D.C. whereby the gland is pushed out of its seating in the
cylinder jacket by distance holders 94345 (Fig. ’B’).
⇒ Use tap 94348 to clean threaded holes of combustion residue in the piston
crown.
⇒ Mount suspension device 94341 to the piston crown.
D Before pulling the piston out, the crosshead pin and the top end bearing must
be protected, so that entry of dirt into the top end bearing is absolutely pre-
vented.
⇒ Fasten piston supporting device 94350 to platform supports 5, designed for
this on the cylinder cover platform.
⇒ Pull the piston by crane out of cylinder liner 12.
⇒ Loosen screw connection 9, push supports 6 completely outwards and turn up
the hinged covers 7.
⇒ Lower the piston into the supporting device until the piston rod foot protrudes
below the supporting device.
⇒ Turn the two hinged covers 7 down and lower the piston until gland 8 rests on
the two hinged covers. Push the two supports 6 together and firmly tighten
screw connections 9.
⇒ Lower the piston further until the piston rod head rests on the support 6.
Risk of accident! Fasten cover plate 94345d provisionally onto the gland bore in
the cylinder jacket.
B C
94341
94350
5
94345 10
6
9
8
014.946/07

3. Fitting the piston
Prior to fitting the piston, the following works must be carried out:
⇒ Remove the piston rings with ring expander 94338 (see 3425−1) and clean
piston exterior thoroughly. (Use no tool which could scratch or otherwise dam-
age the surface!).
Determine the height of the piston ring grooves (see Clearance Table 0330−1
CHECK ’Piston and piston rings’).
⇒ Clean piston rings and measure them.
Remarks: For refitting of used and new piston rings, follow strictly instructions in
3425−1.
D When refitting used piston rings be sure to fit them in the same grooves
as before.
D Fit the piston rings in such a manner that their marking TOP is on top.
Check the piston top surface (see 3403−4).
CHECK Measure bore of cylinder liner (see 2124−1) and carry out any needed recondition-
ing to lubricating grooves and scavenge ports (see 2124−3).
⇒ Actuate the cylinder lubrication till oil flows from all the lubricating points.
D Gland and both distance holders 94345 must be mounted on the piston rod
(see 2303−1).
D Suspension device 94341 must be fastened to the top of the piston crown.
Remarks: 2-part insertion funnel 94342b has the advantage that a half can be re-
moved, if required.
⇒ Insertion funnel 94342a/b for the piston rings must be placed on cylinder liner
12 and fitted as shown in Fig. ’E’.
⇒ Smear the piston rings, piston skirt, piston rod and running surface in cylinder
liner lavishly with a bearing oil.
94342a(b)
12
014.948/07

⇒ Turn corresponding crank to B.D.C.

⇒ Slowly lower the piston into the cylinder liner until
the lowest piston ring is at the level of insertion fun-
nel 94342a(b).
⇒ Arrange the piston rings so that their gaps alter-
nate by 180_ to each other.
F ⇒ Remove cover plate 94345d.

⇒ Lower the piston further and direct the gland into its
seating bore in the cylinder jacket (see also
2303−1).
⇒ Slowly lower the piston further until its piston rod
94342a(b) foot has arrived just above the crosshead pin.
While one person directs the further lowering of the
piston from the top, another directs the piston rod
progress from the engine interior and how it must
be turned to guide the piston rod foot, without jam-
ming, into the centring pins 4 (Fig. ’A’) in the cross-
head pin.
⇒ Place piston on crosshead and remove distance
holders 94345.
⇒ Apply MOLYKOTE paste G to the thread and seat-
ing surface of waisted screws 3.
⇒ Fit and hand-tighten the waisted screws. Mark
their head positions with felt marker against piston
94345
rod foot (initial position).
⇒ With the ring spanner and hammer tighten waisted
screws alternately in small steps until the tighten-
ing angle has reached 30_. Apply the locking ele-
ments 3a.
⇒ Complete the gland and firmly tighten all screws
fastening the gland housing.
⇒ Turn piston to T.D.C. and remove suspension de-
vice and insertion funnel.
014.949/07
D Refit antipolishing ring as described in 2124−2.
4. Leak test
A leak test must be carried out after every fitting of a piston in the cylinder. For this,
start the bearing lubrication pump and set the bearing lubricating pressure. Check
through the scavenge space on the fuel side in the cylinder jacket (piston under-
side) whether cylinder liner running surface and piston rod remain dry.
Any increase in the dirty oil level in the scavenge air space may be caused by a
faulty O-ring in the piston.

Piston
Changing the Compression Shims

1 Propping device consisting of: 94347 1 Gland housing, 2-part 4 Crosshead pin
2 segments 2 Piston rod 5 Piston
for changing compression shim 3 Piston rod foot 6 Compression shim
2 Eye bolts M16
1. Fitting and removing compression shim
⇒ Loosen locking elements and screw fas-

tenings of the piston rod foot 3 and
crosshead pin 4 (see 3403−1).
5 ⇒ Open the door to the piston underside of
the corresponding cylinder on fuel side.
94347
⇒ Place both supporting sheets of prop-
ping device 94347 onto the flange of the
I I gland housing 1, and push these as far
1 as possible to the piston rod.
⇒ Turn the piston downwards until it rests
fully on both supporting sheets. Check!
⇒ Carefully turn crank forward and take
care that the two centring pins in the
crosshead pin 4 do not jam in the piston
rod foot.
⇒ Loosen the two screws fastening the
2
compression shim 6 and remove them.
⇒ Remove the compression shim with the
aid of the two eye bolts.
3
D For fitting new compression shims pro-
6 ceed in reverse sequence to the remov-
4 al.
Remark: If the new compression shim is
014.963/07
thicker than the old one, it must absolutely
be remembered to grind off the wear ridge
in the cylinder liner (see 2124−3).
I-I
94347

Piston
1 Suspension device 94341 1 Piston crown 13 Locating pin

4 Pre-tensioning jacks 94346 2 Spraying plate with oil pipe 14 Locating pin
1 Piston supporting device 94350 2a Nozzle to spraying plate 15 Waisted screw
2 Jacking screws 94363 3 Vent screw 16 O-ring
2 Jacking screws 94364 4 Piston 17 O-ring
1 Hydr. distributor 94934a 5 Cylinder 18 O-ring
1 Connection block 94934c 6 Nut
1 Plug piece 94934e 7 Waisted stud
1 HP hose 94935 8 Piston rod BN Limiting groove
2 HP hoses 94935a 9 Piston skirt EV Relief valve
4 HP hoses 94935b 10 Rubbing ring KO Slot
1 Hydraulic unit 94942 11 Centring pin RS Round bar
1 Torque wrench 12 Elastic screw SA Gap
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/6
2. Loosening the waisted studs of piston crown . . . . . . . . . . . . 2/6
3. Tensioning the waisted studs of piston crown . . . . . . . . . . . 3/6
4. Dismantling of a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/6
5. Assembling of a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/6
1. General
Should the dismantling of a piston become necessary (cleaning the cooling cham-
ber, reconditioning the ring grooves etc.), then this can be carried out as described
below. For this purpose the piston is to be placed in the piston supporting device
94350 according to 3403−1.
Attention! When dismantling or assembling a piston take particular care that the
nozzles to spraying plate 2a (Fig. ’G’) are not damaged. In the other case, they
must be replaced.


Piston: Dismantling and Assembling
2. Loosening the waisted studs of piston crown
A
⇒ Clean the threads of waisted studs 7 and the
area around nuts 6 (Fig. ’G’).
⇒ Place the four pre-tensioning jacks 94346
crosswise on the waisted studs, as shown in
Fig. ’C’, and completely screw them on with
94346 opened vent screws 3 until there is only little
3 or no clearance at ’x’ (Fig. ’B’).
by approx. ½ turn (gap ’SA’ in Fig. ’B’).
I I ⇒ Connect all pre-tensioning jacks to hydraulic
unit 94942 as shown in Fig. ’A’.
⇒ Start up the hydraulic unit.
⇒ Close vent screws 3 of the pre-tensioning
jacks as soon as oil flows out bubble-free.
⇒ Operate the hydraulic unit till a pressure of
about 1030 bar is reached.
⇒ Unscrew nuts 6 by one turn (Fig. ’B’).
Never move piston 4 of the pre-tensioning jacks
further up than to the red limiting grooves ’BN’
(Fig. ’B’).
⇒ Release the pressure to zero.
⇒ Remove the pre-tensioning jacks.
⇒ The same procedure is to be applied cross-
wise according to the sequence in Fig. ’C’ for
loosening the waisted studs b−b / b−b.
⇒ Only two pre-tensioning jacks are used to
I-I loosen the remaining waisted studs c−c. For
this case, disconnect the hose 94935a from
Hydr. distributor 94934a on one side. Place
94934c the plug piece 94934e in the position of the
94935a removed hose.
94935b
94346
94934e 94932a
94934a
017.878/08
94935 94942

3. Tensioning the waisted studs of piston crown
PRE-TENSIONING JACK PLACED FOR

TENSIONING LOOSENING
B ⇒ Clean the threads of waisted studs 7

and the area around nuts 6.
3 ⇒ Apply MOLYKOTE G paste to the
threads of waisted studs and screw
on the nuts.
BN
⇒ Tighten the nuts with round bar ’RS’
by hand.
x
CHECK Using a feeler gauge, check whether the

4 nuts rest without clearance.
7
5 ⇒ Mark the position of nuts to seating
surface with a felt tipped pen (Fig.
RS ’a’).
6 KO
⇒ Place the four pre-tensioning jacks
94346 crosswise on the waisted
SA
studs as shown in Fig. ’C’, and com-
pletely screw them on with opened
vent screws 3 until there is only little
or no clearance at ’x’.
KO
⇒ Connect the pre-tensioning jacks to
the hydraulic unit 94942 as shown in
C Fig. ’A’.
TENSIONING ⇒ Start up hydraulic unit.
SEQUENCE ⇒ Close vent screws 3 of the pre-tensioning jacks as
soon as oil flows out bubble-free.
⇒ Operate the hydraulic unit till a pressure of 1000 bar
is reached.
Fig. ’a’
Never move piston 4 of the pre-tensioning jacks further
up than to the red limiting grooves ’BN’ (Fig. ’B’).
⇒ Keep the pressure of 1000 bar constant and tighten
nuts 6 with round bar ’RS’ till firmly seated.
After tensioning the nuts, check their seatings with a
CHECK
feeler gauge through slot ’KO’.
y ⇒ Always the same procedure is to be applied cross-
x wise according to the sequence in Fig. ’C’ for ten-
Fig. ’b’ sioning the remaining waisted studs.
y ⇒ Remove pre-tensioning jacks.
After tensioning the nuts, check if these have been

CHECK
TIGHTENING 011.675/04
turned by about the same angle, i.e. approx. 115_
ANGLE compared with the marks previously made (Fig. ’b’).
x

4. Dismantling of a piston
⇒ Insert both jacking screws 94363 into the two opposite bores for centring pins
11 in the piston rod head (Fig. ’G’), and drive them in till they press against the
centring pins (Fig. ’E’).
⇒ Equally tighten the two jacking screws in small steps, till the piston crown is
separated from the piston rod.
⇒ Lift piston crown 1 by crane and take particular care not to damage nozzles 2a
of spraying plate 2.
⇒ Remove both jacking screws from the piston rod head.
Following the removal of piston crown separate piston skirt 9 from piston rod 8 as
described below:
⇒ Loosen and remove both elastic screws 12 (Fig. ’G’).
⇒ Using two jacking screws 94364 (Fig. ’F’) the piston skirt can be separated
from the piston rod.
D While raising the piston skirt pay attention that locating pin 13 does not jam.
D
For the removal of spraying plate with oil pipe 2 (Fig. ’G’)
loosen and remove first waisted screws 15 with locking
plates. The spraying plate with oil pipe can then be pulled
as a complete unit from piston rod 8.
94341
Attention! Do not damage nozzles to spraying plate 2a!
1
2a
E F
8
SEPARATING OF SEPARATING OF
PISTON CROWN PISTON SKIRT
1 94364
2 2 9
9
11
8 8
94363
014.966/07

I-I
G
1
2a
15
II II
16 9
13
10
17 II - II
2
14
6 V
7
V IV
I
IV
I
FUEL SIDE
17
IV - IV
1
III
III
11
8
9
6 V
1
7
12
9
8
WCH00842

5. Assembling of a piston
For assembling the piston the following points must be observed:

D Damaged spraying nozzles 2a must not be reused. New ones must be fitted
with liquid securing agent LOCTITE No. 0640. Pay attention to the different
diameters of the spraying nozzles.
D Whenever possible always use the new O-rings, they must conform in dimen-
sions and quality to our specifications (see 0370−1).
D All cylindrical guide portions and O-rings must be smeared with oil before
the assembly.
Pre-tighten waisted screws 15 (lubricated with oil) with 30 Nm using a torque
CHECK wrench, subsequently tighten to an angle of 40_ and finally secure them with lock-
ing plates.
D Attention must be paid to locating pin 13 when assembling piston skirt 9 with
piston rod 8.
⇒ Insert and tighten both elastic screws 12.
D For the assembly of piston crown 1 with piston rod 8 make sure that the two
centring pins 11, serving also as guides, mate with the corresponding bores in
the piston skirt 9 and the piston rod.
D Tension waisted studs 7 according to section 3.
H
Ğ 2.3 mm Ğ 2.8 mm Ğ 2.3 mm
2a
WCH00843

Piston
Checking Piston Top Surface
Tools:
1 Feeler gauge 94122
1 Template 94366
1 Template 94366a
Every time a piston is pulled the piston top surface contour must be checked with
CHECK the checking template 94366 and with feeler gauge 94122. The template is placed
on the topmost piston ring and rotated around the piston axis (see Fig. ’A’).
D Where burn scars are only slight it is sufficient to grind them over and to
smooth sharp-edged zones with emery cloth. Where, however, burn scars ex-
ceed x = 10 mm the original material thickness must be restored by surface
welding. This entails the removal of the piston crown.
Before re-starting the engine, the reason for such heavy burns should be estab-
lished. The causes must be remedied.
Causes of heavy burn scars may be:
− Poor combustion
− Worn nozzles
A
− Heavy local carbon deposits on top of the piston
94366 crown etc.
PISTON RING
003.321/00
94366a The template 94366a should be used if the shape of

the crown top of a piston in situ has to be checked.
As shown in Fig. ’B’, the template is to be pushed
through one of the scavenge ports of the cylinder lin-
er and placed on top of the piston crown.
x 003.321/00

Piston Rings
Checking Wear of Piston Rings and Ring Grooves
Tools: Key to Illustration:

1 Inside micrometer 94101 1 Piston ring
1 Feeler gauge 94122 2 Cylinder liner
1 Piston ring tensioning device 94338 3 Piston head
4 Claw
1 Equipment case 94356
with instruments for
measuring chrome layers
1 Micrometer (0−30 mm)
1 Calliper gauge 94357
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/7
2. Determine wear rate of piston rings . . . . . . . . . . . . . . . . . . . . . 1/7
3. Measuring piston ring grooves . . . . . . . . . . . . . . . . . . . . . . . . . . 4/7
4. Removing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/7
5. Fitting piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/7
6. Storage and handling of piston rings . . . . . . . . . . . . . . . . . . . . 7/7
1. General
For judging and evaluating the condition of cylinder liner, piston and piston rings
the following guidelines serve for a condition-based Maintenance for piston and
cylinder liner overhaul.
Wear rates strongly depend on operational factors, such as fuel in use, engine load
profile, ambient conditions etc.
By visual inspections, critical conditions of cylinder liners and piston rings can be
detected at an early stage. Further information to monitor the cylinder liner and pis-
ton ring conditions are given in the Operating Manual 0750−1 Lubricating Oils.
The information regarding measuring piston ring grooves helps to define if the
wear on piston ring grooves is within the given limits or if the piston head must be
reconditioned. For the maximum wear data see Clearance Table 0330−1 ’Piston
and Piston Rings’.
2. Determine wear rate of piston rings
Measure the thickness of the chrome-ceramic coating of the piston rings as sched-
uled in 0380−1 to determine the wear rate and the remaining life time of the piston
rings.
Remark: See suppliers operation manual for the usage of layer measurement tool
94356.

Piston: Checking Wear of Piston Rings and Ring Grooves
2.1 Measure coating thickness with piston in situ (through scavenge ports)
Before each measurement the layer measurement tool 94356 must be calibrated.
Use the delivered calibration foils and the bare top flank of a spare top piston ring
as base material for proper setting.
⇒ Clean piston ring running surface at reachable measuring points P1 to P9.
⇒ Press the sensor of the layer measurement tool against the piston ring surface
at middle of ring height.
⇒ Measure the layer thickness and note the output value.
MEASURING POINTS
A ON PISTON RING
MINIMUM RECOMMENDED
P9 P1 P9 P1
1 94356
P7 P3
2
WCH01145 P5 P5
2.2 Wear rate

The chrome-ceramic coating is a lifetime coating. However, the actual wear de-
pends on operating conditions. When during a piston underside inspection a pis-
ton ring with a partially worn chrome-ceramic coating is found, we recommend
overhauling the unit at next opportunity (Fig. ’B’).
With regular done measuring you can determine the specific wear rate for each
piston ring.
The piston rings can still be used, if the remaining chrome-ceramic coating is
above the following limits:
− Uppermost piston ring ’a’ > 0.05 mm
− Lower piston rings ’b’ and ’c’ > 0.02 mm
Below those minimal coating thicknesses, a piston ring replacement must be
planned.
PARTIALLY WORN CC-COATING

2.3 Lifetime calculation

Calculate the wear rate and the remaining lifetime of a piston ring.
Use the formula below to calculate the wear rate:
WR = (D1−D2) x 1000
T2−T1
WR = Wear rate [mm/1000 h]

T2 = Actual running hours [h]
T1 = Running hours at previous measurement [h]
D2 = Actual coating thickness [mm]
D1 = Coating thickness at previous measurement [mm]
Example for wear rate calculation:
D1 D2 T1 T2 WR
0.382 0.367 0 (new) 1500 0.01
0.351 0.340 3500 5000 0.0073
Use the formula below to calculate the remaining piston ring lifetime according to
the latest condition setting:
LT = (D2− Dmin) x 1000

WR
LT = Remaining lifetime [h]

D2 = Actual coating thickness [mm]
Dmin = Minimal coating thickness [mm] (see chapter 2.2)
WR = Calculated wear rate [mm/1000 h]
Example for remaining lifetime calculation:
D1 D2 Dmin T1 T2 WR LT
0.382 0.367 0.05 0 (new) 1500 0.01 31700
0.351 0.340 0.05 3500 5000 0.007333 39545

3. Measuring piston ring grooves
Check all dimensions and record them (see Clearance Table 0330−1 ’Piston and
CHECK piston rings’). These records are important for later evaluation of the running gear.
They should encompass all dimensions, the date of overhaul and operating hours
of the various components and of the engine itself.
3.1 Measurement with piston in situ (through scavenge ports)
The measurement of the piston ring clearance has to be carried out at two to four
free positions around the complete circumference of the piston head. The number
of measurement points depends on the accessibility.
Make sure that feeler gauge 94122 is pushed into the piston ring groove until it
touches the inner diameter of the groove, i.e. at point A. If there is a wear step on
the chromium layer, the feeler gauge can be pushed only to that point (C3).
Remark: Also consider the deposits in the piston ring groove and/or on the piston
ring top face.
⇒ Move piston 3 down (C1) by means of the turning gear.
⇒ Make sure that the total clearance is measured:
First measure the clearance ’x1’at point A.
⇒ Afterwards repeat the measurement at the same circumferential position and
measure the clearance ’x2’.
The sum of both values will give the total piston ring clearance.
Remark: The reason for this split measuring principle is that the piston rings might
be in a tilted position and thus not fully pushed-up and tight to the upper face of the
piston ring groove (C2).
The maximum clearance is at point A. For the maximum wear data see Clearance
Table 0330−1 ’Piston and Piston Rings’.
If the clearance at point A exceeds the permitted value, the piston rings have to be
replaced and the piston head has to be reconditioned.
For reconditioning of piston crowns please contact your nearest Wärtsilä Service
Center.
C PISTON MOVED
DOWN (C1) (C2)
x2
3 3
x1
1 1
1
A
3
94122
WCH02244
POSSIBLE WEAR
WEAR STEP ON SHAPE ON GROOVE
CHROMIUM LAYER (C3)
1
3 WCH02244

3.2 Measurement with piston removed from cylinder liner

The measurement of the piston ring clearance has to be carried out on at least four
positions around the complete circumference of the piston head.
⇒ Remove the piston rings as described in section 4.
⇒ Clean the piston ring grooves.
Measuring method with calliper gauge:
⇒ Measure the groove height with calliper gauge 94357 at point A and B.
D
3
B
A
WCH02244
94357
POSSIBLE WEAR
SHAPE ON GROOVE
Measuring method with a piece of a piston ring:

⇒ Measure the thickness of piece of a piston ring (1).
⇒ Place piece of piston ring into the piston ring groove.
⇒ Measure gap ’x2’ between the face of piston ring and groove with feeler gauge
94122.
⇒ Evaluate the piston ring clearance with the following data:
CL = GH − RT (mm)
− CL = CLearance
− GH = Measured piston ring Groove Height (mm)
− RT = Nominal piston Ring Thickness (mm)
E
x2
3
(1)
94122
WCH02244
If the clearance at point A and/or B exceeds the permitted value, the piston head
has to be reconditioned. For the maximum wear data see Clearance Table 0330−1
’Piston and Piston Rings’.
A piston head with clearances close to the maximum value may not be further used
as the expected remaining lifetime is too short.

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

5. Fitting piston rings
D When reusing piston rings, only rings in perfect condition may be fitted, how-
ever in the same position and groove as removed.
D Always fit piston ring with the marking TOP upwards
(when the piston is assembled the piston rings must be turned such that the
ring gaps are staggered by 180_).
D The chromium plating thickness of a new CC coated piston ring should be
measured and recorded to monitor the wear rate over time.
Remark: New piston rings have to be run-in according to the relevant indications in
the Operating Manual 0410−1.
Standard piston ring arrangement:
Ring type Coating / material Application
Uppermost piston ring ’a’

1 x SCP1CC20_Straight Cut chrome-ceramic for new and fully
coated honed cylinder liners
as well as for used
Piston rings ’b’, ’c’ and ’d’ cylinder liners in
3 x SCP2CC20_Straight Cut chrome-ceramic good conditions
coated
G
TOP
CHROMIUM a r 2.0
PLATING
TOP
CHROMIUM b r 2.0
PLATING TOP
CHROMIUM c r 2.0
PLATING
TOP
CHROMIUM d r 2.0
PLATING
017.684/08
6. Storage and handling of piston rings
Store the piston rings in a dry place but not in a place contaminated with exhaust
gases or any other corrosive atmosphere. Lay the piston rings horizontally on a flat
surface, keeping them in their original packing. Handle with care when preparing
for use and avoid any hard contact against other objects.

Driving Wheels and Shut-off Valve for Starting Air Group 4
Driving Wheels
− Checking the Running and Backlash Clearances and Condition of Teeth . . . . 4103−1/A1
− Removal and Fitting of Intermediate Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−2/A1
− Replacing the Gear Wheel on Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103−3/A1
Shut-off Valve for Starting Air: Cleaning and Function Check . . . . . . . . . . . . . . . . . 4325−1/A1
Wärtsilä Switzerland Ltd 1/ 2 RT−flex84T−D / MM / 2008

Driving Wheels
Checking the Running and Backlash Clearances and Condition of Teeth

1 Feeler gauge 94122 0−6 Tooth profile
1 Micrometer a, b, c Lead wires
1 Dial gauge TF Driving flanks
1 Lead wire Ø 1.5 mm
1. General
Gear wheels of new engines have to be checked visually during the running-in pe-
riod after about 1−2 operating hours. The same applies to old engines which have
been equipped with new gear wheels.
2. Check
⇒ Rotate crankshaft with the turning gear until all the teeth have been inspected.
⇒ Check with running lubricating oil pump, whether all the spray nozzles are de-
livering oil freely.
⇒ Check whether all the screws are correctly locked, and whether any irregulari-
ties can be detected.
⇒ After the running-in period check the gear wheels periodically every three
months in the manner described above. Should in this time faults appear, then
these can in certain cases be remedied by an experienced engineer.
D Should noises be heard in the region of the gear train, search for its cause.
Replace defective gear wheels as soon as ever possible, to prevent damage
to the mating gear wheels.
D When the gear wheels have run well for an initial running period of 6000−8000
hours the above-mentioned inspection may be carried out annually.
D For the checking of clearances and tooth impressions the tie rods and the
waisted studs of the main bearings must be tightened.
3. Checking the gear tooth backlash
Information concerning the gear tooth backlash values can be found in the table of
clearances (see 0330−1). The backlash can be determined in several ways. De-
pending on the possibilities, the following methods of measurement can be used:
3.1 With feeler gauge 94122

Measure the gap between the teeth flanks by using different thicknesses of feel-
ers. Repeat the measurement at a minimum of four points on the circumference of
the gear wheel.
3.2 With dial gauge

Mount the dial gauge in such a way that the turning movement can be read off in
mm. The gear wheel is turned in such a way that the tooth profile of one tooth
moves from one side to the other. When using this method of measuring care must
be taken since the drive wheel must not be allowed to turn.

Checking the Running and Backlash Clearances as well as Condition of the Teeth
A 15 mm
=
= 3.3 Measuring tooth backlash with lead wire
15 mm
b1 D Use a fresh piece of lead wire Pb 99.9 fine of
1.5 mm diameter for each measurement.
b3 D Always use lead wires of the same diameter
and quality.
a1
7 ⇒ Place lead wire pieces a, b, c of about 200 mm
a3 length around the tooth profile and attach
b them with scotch tape (see Fig. ’A’ and ’B’).
c ⇒ Number the tooth profiles in accordance with
000.653/93 a Fig. ’B’.
⇒ Turn the lead wires only once through the
teeth meshing.
LEAD WIRE Ø 1.5 mm D Lead wire ’c’ (Fig. ’A’) serves to verify total
tooth backlash ’f’ (Fig. ’C’).
B With lead wires ’a’ and ’b’ (Fig. ’A’) the tooth
profile parallelity is checked.
0 D Total tooth backlash ’f’ (Fig. ’C’) composes of
1
f1 and f2 (thickness of lead wire):
2 f = f1 + f2
3
D Obliquity ’Df’ is calculated from the difference
4 in thickness of the squashed lead wires along
5 driving flanks TF (Fig. ’A’):
6 Df = a1 − b1 or a3 − b3 etc.
... D The admissible deviation of tooth profile pa-
rallelity amounts to max. 0.2o/oo across the
...
... width of the tooth.
000.653/93
C 4. Checking the running performance
To enable judging the running performance of

the gear train after re-commissioning, three
f1 teeth each of the gear wheels are smeared
with a thin coat of oil resisting marking blue
f2
(ink) equally spread. This check is necessary
in order to verify the mating appearance of the
teeth.
One brand of oil resisting marking blue is, for
example, Dykem Layout Red Dx-296.
TF
c
000.653/93

Driving Wheels
Removal and Fitting of Intermediate Wheel

1 Feeler gauge 94122 1 Intermediate wheel 12 Bearing journal
6 Adjusting devices 94410 2 Cover 13 Locking strap
Withdrawing device 3 Cover 14 Double column
for taper pins 4 Suspension beam 15 Wheel hub
5 Support 16 Gear rim
6 Gear wheel on crankshaft 17 Lubricating oil pipe
7, 7a Waisted screws 18 Self-locking nut
8 Cover
9 Screw plug for taper pin
9a Screw plug H1... Lifting tackles
10 Taper pin HZ Lifting tackle
11 Bearing RC Eye bolt
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/5
3. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/5
4. Adjustment of the intermediate wheel . . . . . . . . . . . . . . . . . . . 4/5
5. Replacement of a gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/5
1. General
D The turning gear must be engaged.

Risk of accident! Precautions must be taken that, while removal work is in prog-
ress, the running gear can on no account be put into motion.
701.015.118
015.118/07

2. Removal
⇒ Screw eye bolt ’RC’ into support 5.

B
⇒ Connect lifting tackle ’HZ’ to eye bolt ’RC’ and
cover 3.
⇒ Fasten lifting tackle H1 (lifting capacity 4000
kg) to suspension beam 4 and connect it to
cover 3.
2
⇒ Loosen and remove the cover.
H2
⇒ Remove lubricating oil pipes 17 to intermedi-
ate wheel 1, where necessary.
5
a ⇒ Fasten lifting tackle H2 (lifting capacity 4000
I kg) to cover 2.
a ⇒ Connect one rope ’a’ (lifting capacity 4000 kg)
3 with intermediate wheel and lifting tackle H2.
⇒ Pull wire rope ’a’ taut.
I H1
4
RC
015.119/07
HZ
015.119/07
II - II
C
⇒ Loosen and remove waisted screws 7, 7a on

14 both sides of taper pins 10.
13 13 ⇒ Remove screw plugs 9 and then loosen taper

11 pins 10 for the bearing location using a with-
17 drawing device.
⇒ Loosen the remaining waisted screws and
remove them together with covers 8.
12
I
8 I
8 III - III
7 II
7a
III
015.120/07 10 9
IV
III IV - IV
II
16 9a
IV

⇒ Lower intermediate wheel 1 completely onto

the gear wheel on crankshaft 6 by means of
rope ’a’, and turn it out to exhaust side while
following up with rope ’b’.
H2 ⇒ When the intermediate wheel is in position as

shown in Fig. ’D’, attach it to lifting tackle H3
a and rope ’b’ as well as to lifting tackle H1 and
H3 b H1
rope ’c’ (ropes and lifting tackles with lifting
c
capacity 4000 kg).
⇒ Remove rope ’a’.
1
⇒ Lift the intermediate wheel out of the double
column with ropes ’b’ and ’c’.
6 D After having removed locking straps 13 with
screws and locking plates, bearings 11 can
015.121/07 be pulled off bearing journal 12 (Fig. ’C’).
3. Fitting
Fitting the intermediate wheel is carried out analogously to the removal but in
reverse sequence, whereby attention must be paid as follows:
Remark: When fitting bearings 11 they must first be lavishly smeared with bearing
oil. Both bearings are basically equal, they may, however, only be refitted in their
original place, as their position has been dowelled with taper pins 10 when building
the engine.
D Fit intermediate wheel so that marking DRIVING END appears when viewed
from the driving end of the engine.
D Intermediate wheel may be fitted arbitrarily with respect to the tooth position.
⇒ Before the final assembly of the intermediate wheel, apply a non-hardening
sealing compound on the joint face of covers 8; afterwards fit it with three
waisted screws 7, 7a (lubricated with MOLYKOTE G paste) on double column
14.
⇒ Tighten the waisted screws only as much as bearings 11 can still be moved.
⇒ Align the bearings so that the bores of the pinholes in the double column cor-
respond exactly with those in the bearings.
⇒ Drive home the taper pins to both of the bearings, using a copper rod and a
hammer.

⇒ Screw in the remaining waisted screws, tighten all slightly and evenly by hand
using a wrench and mark them with a line in this position.
⇒ Tighten waisted screws crosswise until the following angles are obtained:
− 60° for waisted screws 7
− 55° for waisted screws 7a.
As a safeguard check the tooth backlash between the gear wheels (see also Clear-
CHECK ance Table 0330−1 ’Driving Wheels for Supply Unit’).
⇒ Fit screw plugs 9 with LOCTITE No. 0222 and screw them in till the stop at the
taper pins.
⇒ Lock all waisted screws 7, 7a in pairs with locking wire.
4. Adjustment of the intermediate wheel
Should it be necessary to replace one bearing 11, the opposite bearing must be
replaced at the same time, as new bearings are always manufactured in pairs.
When fitting them an exact adjustment of the intermediate wheel is essential.
D For a readjustment of the intermediate wheel, adjusting devices 94410 must
be used as shown in Fig. ’E’, however screw plugs 9a (Fig. ’C’) must first be
removed.
After a readjustment of the intermediate wheel the tooth backlash (see Clearance
CHECK Table 0330−1 ’Driving Wheels for Supply Unit’), as well as the tooth flank contact
pattern have to be checked (see 4103−1).
D If a readjustment of the bearings is required, the pin holes pre-bored in the
column must be used.
D After removing the adjusting devices, screw plugs 9a must be refitted and se-
cured applying LOCTITE 0222.
14
I 11 II
7a 7
8 8
I II
94410a 94410
015.122/07

5. Replacement of a gear rim
D The replacement of a damaged 2-part gear wheel may only be done in ex-
change for a complete gear wheel i.e. gear rim 16 must be screw fastened to
wheel hub 15 and the bearing journal fitted.
D This is necessary as the final machining of the gear teeth has been carried out
in this mounted condition at the maker’s works and guarantees the required
perfect true running of the complete gear wheel.
For this reason a split design gear wheel may only be installed if the final
machining of the teeth had been carried out with assembled hub / gear
rim.
After the final machining of the teeth the gear rim may not be separated from the
wheel hub.
D Should the damage be limited to the toothing (gear rim), then the hub may be
reused, provided a new rim, on which the teeth are not finish-machined, is
fitted to the hub, screw-fastened and dowelled. Then its teeth can be finish-
machined.
D Apply LOCTITE 262 and then tighten self-locking nuts 18 until an angle of 75_
is obtained.
015.123/07
15
18
16

Driving Wheels
Replacing the Gear Wheel on Crankshaft

1 Feeler gauge 94122 1 Gear wheel 8 Self-locking nut
1 Hydraulic tightening device 94412 2 Crankshaft flange 9 Dowel pin
consisting of: 3 Waisted stud 10 Column
1 Clamping fork with extension 94412a 4 Castle nut 11 Screw
1 Extension 94412b 5 Base
1 Retaining device 94412c 6 Flange screw
1 Hydraulic ram 94412d 7 Distance sleeve EV Relief valve
1 Forked piece 94412e
1 Retaining wrench 94412f
1 Impact ring spanner 94412g
1 HP oil pump 94931
1 Pressure gauge 94932
1 Pressure gauge 94932a
1 Plug piece 94934e
1 HP hose 94935
1 HP hose 94935a
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/9
2. Preparing the assembly of the gear wheel . . . . . . . . . . . . . . . 2/9
3. Assembly of the gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/9
6
1
4
5
3
9 9
5
4
001.173/97

Replacing the Gear Wheel on the Crankshaft
1. General
Usually, the gear wheel on the crankshaft (from now on referred to as gear wheel)
is executed in one part and fitted as such on the crankshaft. If a damaged gear
wheel in the engine is to be replaced, it must be separated into two halves for dis-
mantling. In order to avoid damages, especially to the crankshaft, please ob-
tain the necessary instructions and recommendations for executing such disman-
tling work from the engine supplier or from Wärtsilä Switzerland Ltd.
For dismantling as well as for assembling a new gear wheel, dismount the inter-
mediate wheel (4103−2) to the supply unit drive.
The spare gear wheel is designed in two parts and must be fitted as described be-
low.
Remark: When ordering a two-part spare wheel, please indicate the engine type,
the engine No., as well as the engine supplier. This data is necessary because the
centring diameter of the crankshaft is registered for mounting the gear wheel, and
the center hole of the two-part spare wheel is manufactured according to these di-
mensions.
2. Preparing the assembly of the gear wheel
DRIVING END
B CHECK
The undersize of center hole ‘d’ (Fig. ‘A’) on two-part
gear wheel 1 with regard to the corresponding centring
diameter of the crankshaft has to be checked and re-
corded beforehand. For measuring, the crankshaft, the
gear wheel, and the measuring instrument must have
the same temperature.
The undersize of the center hole with respect to the cen-
DEGREASE tring diameter must be 0.05−0.14 mm.
2
D If the undersize is not within the mentioned toler-
ance, the gear wheel must not be assembled, but
1 the center hole of the gear wheel has to be given an
appropriate aftertreatment (remachine / possibly
000.697/98
bore and flame-spray, and machine to obtain the
correct diameter).
MIDDLE OF ENGINE D Check whether there is a mark on crankshaft flange
2 for fitting the gear wheel. For the assembly, the
DRIVING END
gear wheel partition must coincide with this mark.

The designation DRIVING END, which is located on
the front of the gear wheel, must be on the side of
the flywheel!
DEGREASE 2
1
000.697/98

D Before assembling, the centring diameter of the crankshaft flange as well as

the centre hole of the gear wheel with the corresponding flange faces must be
well cleaned and degreased (Fig. ‘B’). Do not use neither oil nor MOLYKOTE.
All surfaces must be in faultless condition.
Remark: The assembly of the gear wheel must be carried out carefully, since rela-
tively small faults could have a negative influence on the operating performance of
all gear wheels of the drive.
3. Assembly of the gear wheel
The connection consists of four waisted studs 3, each of them comprising two
castle nuts 4 and bases 5 (Fig. ‘C’).
C ⇒ Before assembling the gear wheel halves, fit two

waisted studs crosswise into each half.
4
⇒ Fasten a base 5 and a castle nut 4 on either side
MOLYKOTE 5
of each waisted stud.
3 The projection ‘X’ of the waisted stud with respect
to the castle nut must be 4 mm.
9 ⇒ Before fitting the castle nut, degrease the thread
and apply LOCTITE 262 to it.
LOCTITE 262 ⇒ In addition, secure the castle nut with a split pin to
DEGREASE 1 prevent it from slipping when tightening the waist-
SPLINT PIN 5 ed studs afterwards.
4 D Wait one or two days before tightening the waisted
studs in order to ensure thorough curing of the
LOCTITE.
X
001.168/97
Remark: The castle nut secured with LOCTITE and a

split pin must be fitted in such a way that the waisted stud
can be tensioned together with the castle nut opposite,
as shown in Fig. ‘I’ and ‘K’.
3.1 Work sequence

⇒ Turn the crankshaft so that the mark on the crank-
shaft flange is approximately horizontal with re-
D gard to the crankshaft centre line.
⇒ Put one gear wheel half with two pre-assembled
waisted studs 3 on the centring diameter of the
6 crankshaft flange in such a way that the joint face
1 of the gear wheel coincides with the mark on the
crankshaft flange. The designation DRIVING END
3 located on the front of the gear wheel must be on
the side of the flywheel.
001.167/97
⇒ Insert flange screws 6 (Fig. ‘D’) each in the centre
and at both ends of the gear wheel half and tighten
them temporarily.

E
3
6
⇒ Turn the gear wheel half to the bottom (Fig. ‘E’) and
1 place the second gear wheel half, which is also pro-
vided with two pre-assembled waisted studs 3, on
the top (Fig. ‘G’).
001.167/97
D Check the correct diameter tolerance by measuring
the size of the gap between both gear wheel halves.
For that the gap must be closed on the opposite side
(Fig. ‘F’).
F
GAP 0
Gap ‘j’ must be 0.16 mm−0.44 mm. If the dimension is

j
CHECK
not within the mentioned tolerance, the gear wheel must
not be assembled, but the center hole has to be given an
appropriate re-machining (see ’Preparing the assembly
of the gear wheel’).
⇒ After measuring, align the gaps between the wheel
001.166/97 halves and slightly tighten castle nuts 4 of waisted
studs 3 (Fig. ‘C’).
⇒ Also insert a flange screw 6 in the centre of upper
gear wheel half and tighten it temporarily (Fig. ‘G’).
G 6
⇒ Remove flange screws 6 from each end of the lower
1 gear wheel half so that there are now only two flange
screws 6, each of them tightened temporarily in the
centres of the upper and the lower gear wheel half
(Fig. ‘H’).
CHECK There must be no clearance on the seating surfaces be-

001.166/97
tween the gear wheel and the crankshaft flange − check!

⇒ For fitting the four remaining castle nuts 4 belonging
to waisted studs 3 (Fig. ‘C’), apply MOLYKOTE
6 paste G to the threads and the seating surfaces.
H Tighten only the castle nuts treated with MOLYKO-
TE paste G. Use retaining wrench 94412f (Fig. ‘K’ or
’M’) for holding up the castle nuts opposite which
3 have already been fitted and secured with LOCTITE
1 and a split pin.
⇒ Tighten the four castle nuts 4 of waisted studs 3
crosswise by means of hydraulic tightening device
94412 (Fig. ‘I’ and ‘K’ or ’L’ and ’M’), measuring and
6
001.166/97
recording the length of the waisted studs before-
hand.

⇒ Loosen and remove the jack bolts of the corresponding main bearing, see
1132−1.
⇒ Fasten retaining device 94412c to the column using screws 11 as shown in
Fig. ’L’ to ’M’.
⇒ Depending on the place of use, fit clamping fork with extension 94412a or ex-
tension 94412b as shown in Fig. ‘I’ and ’M’, and connect the hydraulic ram
94412d to the forked piece 94412e and the impact ring spanner 94412g.
⇒ For tightening, connect the hydraulic ram together with both HP hoses
94935a and 94935 and hydr. distributor 94934a to HP oil pump 94931, plug-
ging one of the openings at the connection piece with plug piece 94934e.
⇒ Close relief valve ‘EV’ and actuate the HP oil pump.
The waisted studs are correctly pretensioned if an extension of L 1.85± 0.08
CHECK mm is measured.
Check: there must be no gap in the gear wheel partition.
⇒ If the split pin for securing the castle nut cannot be fitted, turn the castle nut
only so far as to allow the split pin to be fitted.
⇒ After the check mentioned above has been carried out, dismantle both flange
screws 6 which have been temporarily fitted beforehand (Fig. ‘H’).
Degrease the threads of all flange screws 6 and their self-locking nuts 8 and then
apply LOCTITE 262 to them; do not use MOLYKOTE!
⇒ Fit all flange screws 6 with distance sleeves 7 and self-locking nuts 8 (Fig. ‘I’).
Afterwards, tighten them crosswise and evenly distributed over the circumfer-
ence with an angle of 70_.
⇒ Refit and tension the jack bolts, see 1132−1.
After fitting the gear wheel on the crankshaft and assembling the intermediate
CHECK wheel, check the correct positioning of the driving wheels (see 4103−2).
Check all driving wheels as specified in 4103−1 after assembling them.

I
II - II
94412c
94412b
94412a
94412d
94412g
8
6
7
015.089/07

I-I
K
II
94412c
11
94412b
III
94935a
3
94412e
MOLYKOTE LOCTITE 262
III - III
1
1
3
III
94932a
94934e
94934a
94412f 4 2
94935
015.092/07
II
94932 EV 94931

II - II
L
I
94412c 94412c
94412b
94412d
94412e
94412g
8
6
7
015.091/07

I-I
M
II
94412c
11
94412b
III
94935a
3
94412e
MOLYKOTE LOCTITE 262

III - III
1
1
3
III
94932a
94934e
94934a
94412f 4 2
94935
015.090/07
II
94932 EV 94931

Shut-off Valve for Starting Air
Cleaning and Function Check
1 Valve seat 18 Spindle
2 Cover 19 Spindle guide
3 Spring 20 Handwheel
4 Valve 21 Locking lever
5 Valve seat 22 Common start valve
6 Valve guide 23 O-ring
7 Spring 24 O-ring
8 Valve body
9 Control valve DT* To instrument panel and
10 Piston seal ring pressure transmitter PT4301C
11 Piston EB Equalizing bore
12 Valve EV* To venting valve 2.21
13 Screw plug SL* Control air
14 Spring TV* To (drain and) test valve 2.06
15 Screw plug
16 Liner bush * See Control Diagram 4003−2
17 Screw in the Operating Manual
1. General
The shut-off valve must be dismantled, cleaned and inspected according to Main-
tenance Schedule 0380−1.
Remark: To avoid accumulation of water in the main starting air piping open for a
short time water drain pipe on the main starting air piping after each starting opera-
tion.
Risk of accident! Before starting work on the shut-off valve for starting air it is es-
sential to manually close the stop valves on the starting air receivers.
The turning gear must be engaged.
The venting valve 2.21 to connection ’EV’ as well as the valve 2.27 must be open
for venting and draining the main starting air piping on the engine (see Control Dia-
gram 4003−2 in the Operating Manual).
2. Dismantling and assembly
2.1 Dismantling
⇒ If the valve seat 1 is to be grind in, first loosen the screws to cover 2.
⇒ Withdraw spring 3 together with valve 4 and spindle 18 as an unit.
⇒ Unscrew spindle guide 19 and remove the valve from the spindle.
⇒ If valve seat 5 of the non-return valve is to be grind in, then the shut-off valve
must be completely dismantled.
⇒ After dismantling valve guide 6 and spring 7 remove valve body 8 of the non-
return valve.
D When the above mentioned items are being checked, control valve 9 has also
to be dismantled and cleaned.

Shut-off Valve for Starting Air: Cleaning and Function Check
2.2 Assembly
⇒ Before reassembling all items replace corroded springs by new ones.
⇒ Replace damaged or much worn piston seal ring 10.
⇒ Check equalizing bores ’EB’ for free passage.
⇒ Before reassembling spindle 18, the threads in valve 4 and spindle guide 19
are to be thoroughly degreased and then smeared with LOCTITE. Insert the
spindle and fully tighten the spindle guide.
⇒ For the assembly smear all the parts lightly with MOLYKOTE paste.
Check to ascertain that clearance ’S’ between piston 11 and valve 12 of control
CHECK valve 9 amounts to about 1 mm.
24 6 17
7
8
13
5
1
EB
EV
S1
DT
10
4
19
16
3 23
15
9
TV 14
12
2
S
I 11
21
I 22
SL 018.954/09
18
20
014.350/06 014.860/06

3. Function check
After completing the assembly carry out a function check, for which the following
precautions have to be taken:
3.1 Initial position

D The stop valves of the starting air receivers must still be closed.
D Screw plug 13 of the shut-off valve has to be removed.
D Shut-off valve for starting air is in position CLOSED (closed by hand).
D Venting valve 2.21 to connection ’EV’ must be closed.
D The engine has to be completely assembled, ready to start and the turn-
ing gear must be in the disengaged position.
D The area of flywheel, propeller shaft and propeller must be free of persons or
objects.
D During the functional check the reversing must remain in position STOP and
START may not be actuated under any circumstances.
3.2 Tightness
⇒ Close venting valve 2.27 in the main starting pipe.
⇒ Open the stop valve of a starting air receiver slowly.
Check whether the automatic shut-off valve is airtight, i.e. verify that no air escapes
CHECK from the bore of screw plug 14.
3.3 Manual opening

⇒ Open the shut-off valve slowly with the help of handwheel 20 till locking lever
21 is in the position OPENED (by hand). The discharging air at the bore for
screw plug 13 indicates that valve 4 of the shut-off valve and valve body 8 of
the non-return valve are open.
Risk of accident! Great care must be taken for this operation. To prevent acci-
dents from compressed air suddenly escaping out of the bore for screw plug 13 a
sufficient distance has to be kept.
3.4 Automatic closing

⇒ Turn handwheel 20 to position CLOSED till locking lever 21 engages in posi-
tion AUTOMATIC.
D In this position the shut-off valve should, through the spring resistance, be au-
tomatically closed. No more air should come out at the bore for screw plug 13.
D In this position the valve closes positively only if there is a clearance ’S1’ (in
new condition min. 2 mm − max. 5 mm) between spindle 18 and spindle guide
19.

By turning the spindle carefully to position OPENED, the contact with spindle guide
CHECK 19 can be felt. The clearance ’S1’ can thus be determined externally and it shall be
min. 2 mm corresponding to 1/3 turn of the spindle.
D Should virtually no clearance exist after frequent reconditioning of valve seat
and valve, these parts have to be replaced during the next overhaul.
3.5 Automatic opening

D Locking lever 21 is in position AUTOMATIC.
D By opening test valve 2.06, which is fitted in piping ’TV’, the same effect is ob-
tained as when actuating control valve 9.
D Upon opening test valve 2.06 the shut-off valve opens automatically. The air
now escaping at the bore for screw plug 13 indicates that valve 4 of the shut-
off valve and valve body 8 of the non-return valve have opened.
Risk of accident! Great care must be taken for this operation. To prevent acci-
dents from compressed air suddenly escaping out of the bore for screw plug 13 a
sufficient distance has to be kept to the shut-off valve.
D After shutting test valve 2.06 no air must escape from bore for screw plug 13.
⇒ After completing these checks fit and tighten screw plug 13, and close the
shut-off valve with handwheel 20 to position CLOSED (by hand).

Supply Unit, Injection and Exhaust Valve Control Group 5
Supply Unit
− Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive . . . . . . . . . 5552−1/A1
− Removal and Fitting of Camshaft and Bearing Shells . . . . . . . . . . . . . . . . . . . . . 5552−2/A1
− Removing and Fitting the Fuel Cams with Conical Bushes . . . . . . . . . . . . . . . . 5552−3/A1
− Removal and Fitting of Intermediate Wheel to Camshaft . . . . . . . . . . . . . . . . . . 5552−4/A1
− Removal and Fitting of Gear Wheel on Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 5552−5/A1
− Lubrication of Supply Unit During Maintenance Works . . . . . . . . . . . . . . . . . . . . 5552−6/A1
Fuel pump
− Removal, Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−1/A1
− Removal of a Jammed Pump Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5556−2/A1

− Checking the Gas Pre-charge Pressure (with Lubricating Pump CLU4) . . . . . 5610−1/A1
− Checking the Gas Pre-charge Pressure (with Lubrication Pump CLU4−C) . . . 5610−1/A2
Injection Control Unit: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5564−1/A1

Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling . . . . . 5612−1/A1
Regulating Linkage: Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5801−1/A1

Supply Unit
Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive

1 Device 94561 1 Servo oil pump 20 Guide
1 Lifting plate 94435 2 Pin 21 Flange
3 Screw 22 Screw
4 Pump support 23 Flange
5 Snap ring 24 Screw
6 Pinion 25 Wing nut
7 Shaft 26 Shut-off valve
8 Gear wheel 27 Collector block
9 Intermediate wheel 28 Screw
10 Bearing bush 29 Drain screw
11 Housing 30 Screw
12 Spray nozzle 31 Inspection cover
13 Spray nozzle 32 O-ring
14 Screw 33 O-ring
15 Screw 34 O-ring
16 Cover
17 Guide bush HZ Lifting tackle
18 Stop rod MA Mark
19 Foot RC Eye bolt
1. General
Concerning the maintenance of the servo oil pump observe the instructions from
the manufacturer. The servo oil pump drive must be checked in accordance with
the Maintenance Schedule 0380−1 ’Supply Unit’.
2. Removal of servo oil pump
⇒ Stop the engine.

A
⇒ Shut stop valve before automatic filter
(see 5551−1 in the Operating Manual).
⇒ Remove the casing as far as necessary.
⇒ Disconnect the electrical connections
27
from servo oil pump 1 to be removed.
⇒ Open drain screw 29 (Fig. ’I’).
1 ⇒ Remove the corresponding pipings.
30 ⇒ Close shut-off valves 26 to collector
block 27 (Fig. ’I’).
⇒ Connect servo oil pump 1 (227 kg) with
a lifting tackle, loosen and remove it in
horizontal direction.
31
94435
701.014.885
014.885/06

B
10 11 6 10 5 MA
2.1 Removal of pinion
Device 94561 is used for removing pinion 6
3 as shown in Fig. ’F’ and its application is
4 illustrated in Fig. ’C’ to ’F’.
7 ⇒ Withdraw and remove shaft 7.
34 ⇒ Remove screws 3 and fit threaded rods

M16 instead.
⇒ Withdraw pump support 4 from housing
11 using two screws 3 and then remove
014.880/06 the pump support.
C
RC
⇒ Fit guide bush 17 as shown in Fig. ’C’.

⇒ Fit eye bolts ’RC’.
17
014.880/06
⇒ Turn stop rod 18 till its foot 19 pointing

D vertically downwards.
⇒ Turn guide 20 till its mark TOP pointing
upwards.
⇒ Insert stop rod as shown in Fig. ’D’.
I
I-I
I 11
18
18
20
014.880/06
19 20
014.474/06

⇒ Turn stop rod 18 till its mark TOP pointing upwards (view I).
⇒ Fasten flanges 23 to flange 21 by means of screws 24.
⇒ Push flange 21 (mark TOP pointing upwards) over stop rod 18 to guide bush
17 and fasten it by means of screws 22.
⇒ Fit and tighten wing nut 25 to the stop rod.
⇒ Connect lifting tackle ’HZ’ with eye bolt ’RC’ and remove pinion 6 (see Fig. ’F’).
E
11 RC
22
I
I
25 014.473/06
23 18
24
21
17
014.475/06
HZ
RC
94561
6 014.467/06

3. Spray nozzles
Two spray nozzles 12 are provided for each pinion; they are located in such a man-
ner that oil is sprayed between pinion 6 and gear wheel 8.
The tap holes in the housing of the supply unit are properly arranged ensuring cor-
rect fitting of the spray nozzles.
The spray nozzles can be removed each time the engine and the lubricating pump
are stopped.
3.1 Removal of spray nozzles

− Spray nozzle 12 can be removed after loosening screw 14.
− Spray nozzle 13 for intermediate wheel 9 can only be unscrewed after remov-
al of cover 16 (Fig. ’H’).
D For the removal of cover 16 see 5552−2.
Check spray nozzles for free passage.
CHECK
6 8 12
I-I
4
2
2
4
I
II
I
II - II
33
32
23
12 14
014.881/06
II

H I-I
I
16
014.882/06
9
13 15
4. Fitting
I
Fitting is carried out analogously to the remov-
al but in reverse sequence, whereby attention
27 must be paid to the following:
D O-rings 32 and 33 of spray nozzles 12
26 (Fig. ’G’) must be replaced.
29 D Screws 15 for fastening spray nozzles 13
(Fig. ’H’) must be secured with LOCTITE
0243.
D O-rings 34 in pump support 4 must be re-
placed by new ones.
1
Remark: Bores for bearing bushes 10 in hous-
30 ing 11 and pump support 4 are machined to-
gether and marked accordingly. Therefore,
never interchange the pump supports and take
special care of marks ’MA’ on assembly!
D Apply oil to screws 30 and tighten them
with a torque of 600 Nm.
During fitting the clearances are to be deter-
CHECK
mined in accordance with Clearance Table
0330−1 ’Supply Unit’.
⇒ Open shut-off valves 26 and tighten their
014.939/06 spindles with 200 Nm.

Supply Unit
Removal and Fitting of Camshaft and Bearing Shells

Devices 94430 1 Servo oil pump 17 Lower bearing shell
(depending on number of cylinders) 2 Cover 17a Upper bearing shell
1 Lifting support 94553b 3 Fuel pump 18 Gear wheel
1 Fork lever consisting of: 94554 4 Spur-geared chain block 19 Push rod
1 Face plate 94554a 5 Cover 20 Nut
1 Rocker arm 94554b 6, 6a Waisted bolt 21, 21a Bolt
1 Nut 94554c 7, 7a Nut 22 Guide
1 Bolt 94554d 8 Vent screw 23 Dowel pin
1 Web 94554e 9 Cylinder 24 Flange
2 Pre-tensioning jacks 94557 10 Piston 25 Distance plate
2 Sleeves 94558 11 Housing
1 Socket wrench 94559 12 Bearing cover
2 Round bars 94560 13 Dowel pin BN Limiting groove
2 Supports 94566 14 Camshaft BO Bore
2 Tension nuts 94566a 15 Thrust bearing ring half HK Wooden wedge
1 Assembly template 94567 16 Screw SA Gap
1 Pipe 94567a
1 Pressure gauge 94932
1 HP hose 94935
2 HP hoses 94935a
Overview
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/14
2. Removal of camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . 3/14
3. Removal of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/14
4. Fitting of bearings and camshaft . . . . . . . . . . . . . . . . . . . . . . 11/14
1. Preparation
⇒ Stop the engine and main lubricating pump.

⇒ Remove the casing plates from servo oil pumps.
⇒ Cut out fuel pumps 3 (Fig. ’A’) by means of devices 94430 (see 5556−2 in the
Operating Manual).
⇒ Remove servo oil pump 1 which is placed in front of camshaft wheel and the
corresponding pinion (see 5552−1).


Supply Unit: Removal and Fitting of Camshaft and Bearing Shells
1.1 Removal of cover 5

⇒ Remove cover 2.
3 ⇒ Install flange 24 to lifting support

94553b.
⇒ Connect spur-geared chain block 4
1 with lifting support 94553b as shown in
Fig. ’B’.
⇒ Fasten lifting support 94553b to cover
5.
⇒ Remove cover 5.
015.080/07
5 2
4 I
5
94553b 94553b
24
5
014.094/06
014.889/07

2. Removal of bearing shells
2.1 Loosening and removal of waisted bolts 6

Remark: Always two waisted bolts can be loosened at the same time.
⇒ Clean the threads of waisted bolts 6 and the area around nuts 7 and oil the
threads.
⇒ Put sleeves 94558 over the nuts.
⇒ With vent screws 8 open, screw pre-tensioning jacks 94557 on waisted bolts 6
till they seat on the sleeves and there is little or no clearance at ’x’.
⇒ Then unscrew the pre-tensioning jacks by 1½ turns (gap ’SA’ in Fig. ’C’).
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’C’.
⇒ Actuate hydraulic unit, and close vent screws as soon as oil flows bubble-free.
⇒ Operate hydraulic unit till a pressure of approx. 1020 bar is reached.
Pistons 10 of the pre-tensioning jacks must never exceed the red limiting grooves
’BN’.
⇒ Turn back nuts 7 with round bar 94560 till they are almost touching the pistons
of the pre-tensioning jacks.
⇒ Release pressure to zero and remove the pre-tensioning jacks and sleeves.
⇒ Remove the nuts and waisted bolts.
94932
C
94935a
94557
6
94935a 11
8 10 94934a 13
x
BN 14
SA
9
94558
6
7
11
94560
94935 94942
014.891/07

2.2 Loosening of waisted bolts 6a

⇒ With vent screws 8 open, screw pre-tensioning jacks 94557 on waisted bolts
6a till they seat on bearing cover 12 and there is little or no clearance at ’x’ (Fig.
’D’).
D Till the removal of pre-tensioning jacks the further procedure is the same as
described in paragraph 2.1.
D Nuts 7a are turned out with socket wrench 94559 as shown in Fig. ’E’.
Remark: For safety reasons do not unscrew nuts 7a before the corresponding
bearing cover will be removed!
9 10
x D E
12
13 13
8 BN SA
7a
6a
94557
94935a
94932
I
94934a 94559 12
I 014.892/07
I-I
94942 94935
94560
7a

2.3 Numbering of bearings

Bearing No. 1 is designed as thrust bearing.
Remark: All bearing covers 12 are machined together with housing 11, therefore
never interchange them! They must be marked accordingly before their removal.
3 2 1 12
11
12 12
015.077/07

2.4 Removal of bearing shells

Start with the removal of bearing No. 1 (Fig. ’F’). The other bearing covers may
be removed after the respective bearing shells have been removed and support
94566 has been installed.
2.4.1 Removal of bearing covers

⇒ Install distance plate 25 to lifting support 94553b.
⇒ Fasten lifting support to bearing cover.
D For bearing covers 12 the removal procedure is the same as described for
cover 5 in paragraph 1.1.
I II
94553b 13
12
II
I 23 25
014.893/07
015.078/07

H
2.4.2 Removal of bearing shell No. 1
⇒ Move camshaft 14 till there is a clearance on
both sides of thrust bearing ring halves 15.
⇒ Push thrust bearing ring halves out and re-
move them.
18 I
18
3 2 11
I 14
15 15
14 17a
015.076/07
2.4.3 Turning out the bearing shells

⇒ Loosen screw 16 so far till web 94554e is fastened only.
⇒ Push fork lever 94554 over waisted bolt 6a and fasten it with nut 94554c as
shown in Fig. ’I’.
I
I-I
I
94554
3 2
94554b
16
94554e
94554c
014.894/07
I
94554a 6a 94554d

K
⇒ Place assembly template 94567 on lower
bearing shell 17, so that its pin fits into the cor-
responding bore of the bearing shell.
14
⇒ Put pipe 94567a on the assembly template
17a and pull it in arrow direction, push camshaft
14 up by tightening screw 16 till the bearing
shells can be turned at the same time.
94567 17
⇒ Turn lower bearing shell 17 upwards as far as
possible.
94567a
16
L
⇒ Insert pipe 94567a into the other pin and turn
lower bearing shell upwards till assembly
template stops at housing 11.
11 ⇒ Remove assembly template.
94567
94567a
M
⇒ Turn screw 16 out of gear with face plate
94554a, lift and remove rocker arm 94554b.
⇒ Remove lower bearing shell.
17a
Remark: Lower bearing shells 17 which are
reused must be marked properly with the
bearing number and LOWER in order to fit
these in the same place as before.
⇒ Remove face plate 94554a.
16
94554e 94554b 94555a 011.858/04

3. Removal of camshaft
⇒ Push support 94566 over waisted bolt 6a and fasten it with tension nut 94566a
as shown in Fig. ’N’.
Attention! Heads of bolts 21 and 21a must point towards the free end when fitting
support 94566 as shown in Fig. ’N’.
⇒ By means of turning nut 20, extend push rod 19 till it touches camshaft 14.
I
I-I
14
3 2 19
21a
21
20 94566a 94566 6a
015.075/07
I
O
⇒ Screw the bearing cover and bearing shell

down to bearing No. 3 as described in para-
graph 2.4.3.
⇒ Fit support 94566 and extend push rod 19
as described for Fig. ’N’.
⇒ Remove the bearing covers and lower bear-
ing shells 17 from the remaining bearings.
2
014.895/07

⇒ Equally retract push rods 19 till camshaft 14

is seated horizontally on supports 94566.
94430 Take care that rear bearing shells do not fall
out.
⇒ Secure the camshaft with wooden wedge
14 ’HK’.
19
94566
HK
⇒ Pull out bolt 21 and lift push rod 19 together

with guide 22.
⇒ Reinsert the bolt and put the guide on it as
shown in Fig. ’Q’.
⇒ Remove the push rod from the guide.
22
21
19
HK
011.865/04

⇒ Pull out bolt 21a. Lift and remove

guide 22.
94430 ⇒ Reinsert the bolt.
⇒ Remove wooden wedge ’HK’ (Fig. ’R’)
and roll camshaft 14 till the stop.
⇒ Upper bearing shells 17a can now be
removed.
17a
Remark: Upper bearing shells 17a which
are reused must be marked properly with
the bearing number in order to fit these in
the same place as before.
22 21a
011.868/04
4. Fitting of bearings and camshaft
The fitting of bearings and camshaft is carried out analogously but in reverse se-
quence to the removal, whereby the following points require special attention:
The camshaft can be installed in every position, however:
D all parts to be fitted must be clean and undamaged!
D for the assembly smear bearing shells, thrust bearing ring halves and cam-
shaft with oil.
D take care of the designations of reused bearing shells.
D fit bearing shells, so that their bores provided for dowel pins 23 in the bearing
covers point to the same side (Fig. ’G’).
Align bearing shells laterally and their mating surfaces with housing 11.
D fit lower bearing shell 17 laterally aligned with upper bearing shell 17a.
D take care of the bearing cover numberings and meshing of dowel pins 13 and
23 (Fig. ’G’).
D apply oil to the threads of nuts 7, 7a and tighten nuts 7a with socket wrench
94559 till there is no clearance at ’y’ (Fig. ’S’).

4.1 Tensioning of waisted bolts 6a

6a till they seat on the sleeves and there is little or no clearance at ’x’.
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’S’.
⇒ Operate hydraulic unit till a pressure of 1000 bar is reached.
’BN’.
⇒ Keep pressure constant and tighten nuts 7a with round bar 94560 till firmly
seated.
⇒ Release pressure to zero and remove the pre-tensioning jacks.
9 10
S x
T
12
8 BN 7a
7a 6a
94557
94559
94935a I
94934a
y
I 014.896/07
I-I
94942 94935
94560
7a

4.2 Tensioning of waisted bolts 6

⇒ Clean and oil the threads of waisted bolts 6.
⇒ Fit and tighten the waisted bolts.
⇒ Clean the area around nuts 7.
⇒ Screw on and tighten the nuts by hand with round bar 94560.
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’U’.
⇒ Operate the hydraulic unit till a pressure of 1000 bar is reached.
’BN’.
⇒ Keep pressure constant and tighten nuts 7 with round bar 94560 till firmly
seated.
94932
U
94935a
94557
6
94935a 11
94934a
13
8 10 14
x
BN
9
94558 94935
6
7
014.897/07
11 94942
94560

4.3 Final assembly

Determine radial and axial clearances, see clearance table 0330−1 ’Supply Unit’.
CHECK
⇒ Apply sealing compound to sealing faces of covers 4, 5 and fit the latter.
⇒ Fit servo oil pumps (see 5552−1).
⇒ Install all pipings.
⇒ Cut in the fuel pumps and remove tools 94430 (see 5556−2 in the Operating
Manual).
After assembly, turn the engine and check if lubricating oil is supplied to all lubricat-
CHECK ing points and bearings with the oil pump in operation!

Supply Unit
Removing and Fitting the Fuel Cams with Conical Bushes

1 Hydr. jacking tool 94424 1 Camshaft
1 Adapter piece 94426a 2 Fuel cam
Cam adjusting gear 94562 3 Washer
consisting of: 4 Fitted bolt
1 Angle rail 94562a 5 Camshaft wheel
1 Guide tube 94562e 6 Screw M8x20
1 Positioning unit 94562f 7 Conical bush
1 Distance holder 94563 8 Screw
1 Distance holder 94563a 9 Vent screw
1 HP oil pump 94931 10 Ring piece
1 Pressure gauge 94932(a) 11 Piston supporting plate
1 Hydr. distributor 94934a 12 Piston
1 Plug piece 94934e 13 Shaft
2 HP hoses 94935 14 Driving wheel for servo oil pumps
1 HP hose 94935a
1 Hydraulic unit 94942 EV Relief valve
GL Taphole
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/7
2. Removing the 2-part fuel cam . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/7
3. Fitting the 2-part fuel cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/7
1. General
The following instructions apply to supply units which are providing 2-part fuel
cams, i.e. with conical bushes (bush for short).
The camshaft must be removed from the supply unit for removing and fitting the
fuel cams and gear wheels on the camshaft (see 5552−2). To be able to work ap-
propriately, it is recommended to put the camshaft on suitable pedestals.
Prior to fitting the fuel cams, it must be ensured that the fuel cams, bushes and
camshaft are absolutely clean and in perfect condition.
HP oil pump 94931 and hydraulic unit 94942 have to be filled with engine oil having
a viscosity of SAE30 to SAE40 before starting them up. In exceptional cases hy-
draulic unit 94942 may be filled with cylinder lubricating oil.

Supply Unit: Removing and Fitting the Fuel Cams with Conical Bushes
2. Removing the fuel cam
⇒ Screw adapter piece 94426 into fuel cam 2 to be removed and connect it to
hydraulic unit 94942.
⇒ Push hydr. jacking tool 94424 on fuel cam and fasten it using six screws 8
(evenly tighten screws slightly by hand only).
⇒ Connect the hydr. jacking tool to HP oil pump 94931, however one side of
hydr. distributor 94934a must be plugged with plug piece 94934e.
⇒ Close relief valve ’EV’ and open vent screw 9.
⇒ Actuate HP oil pump 94931 and close the vent screw as soon as oil flows
bubble-free, and continue pumping till all pistons 12 are drawn out.
⇒ Evenly tighten screws 8.
Danger of accident! The following order of actuating HP oil pump and hydraulic
unit must be followed!
The oil pressure in the hydr. jacking tool 94424 may not exceed 250 bar.
⇒ Actuate HP oil pump 94931 till the pressure in the hydr. jacking tool reaches
approx. 90 bar.
⇒ Actuate hydraulic unit 94942 till oil is squeezing out on the whole circumfer-
ence between bush 7 and fuel cam 2. While keeping the hydraulic unit run-
ning, the oil pressure in the hydr. jacking tool may slowly be reduced with relief
valve ’EV’ at HP oil pump 94931, whereupon the fuel cam will loosen.
⇒ Dismantle all tools and remove bush and fuel cam.
A
12 11 2 1
I 10
94424 9 8
I
94426a 7
94935
94935a
94932
94934a
94942
94932a
94931 EV 94935 014.906/08
94934e

3. Fitting the fuel cam
3.1 Numbering, distances and positioning angle of fuel cam

D The numbering starts with fuel cam No. 1 , which is next to the camshaft
wheel 5.
D Setting the distances of the fuel cams to each other is carried out with the aid
of distance holders 94563 and 94563a.
− Distance ’x1’ = 365 ± 0.1 mm
− Distance ’x2’ = 200 ± 0.1 mm
D Setting the positioning angles of the fuel cams to each other is carried out with
the aid of cam adjusting gear 94562, i.e. angle rail 94562a, guide tube 94562e
and positioning unit 94562f.
The appropriate tool is delivered for each engine.
D The positioning angles of the fuel cams to the camshaft wheel is undefined.
D All fuel cams are identical.
Remark: A fuel cam 2 and its bush 7 (Fig. ’A’) form one unit and must not be inter-
changed! If necessary, both parts must therefore be replaced at the same time;
moreover they are only supplied together.
1
94563a 94563 2
94564 94562
GL
2 1
x2 x1

3.2 Fitting the fuel cam No. 1

⇒ Put distance holder 94563 onto the camshaft and push it against the camshaft
flange.
⇒ Push fuel cam 2 together with bush 7 onto the oiled camshaft till the bush rests
on the distance holder.
⇒ Push hydr. jacking tool 94424 on bush 7 and fasten it to the fuel cam using six
screws 8 (evenly tighten screws slightly by hand only).
⇒ Open vent screw 9 and relief valve ’EV’.
⇒ Tighten screws 8 evenly by hand till ring piece 10 rests on piston supporting
plate 11.
⇒ Close relief valve ’EV’.
⇒ Screw adapter piece 94426a into fuel cam 2 and connect it to hydraulic unit
94942.
I 12 11 2 94563
10
94424 9 8
I
94426a 7
94935 014.909/08
94935a
94932
94934a
94942
94932a
94931 EV 94935
94934e

⇒ Actuate HP oil pump 94931 till oil flows bubble-free at vent screw 9; then close
the latter.
⇒ Actuate hydraulic unit 94942, and when oil is squeezing out on the whole cir-
cumference between bush 7 and fuel cam 2, operate also the HP oil pump.
⇒ Pull the fuel cam onto the bush by means of the HP oil pump while keeping the
hydraulic unit running. During this process pay attention that oil is continuous-
ly squeezing out between bush and fuel cam.
Attention! The oil pressure in hydr. jacking tool 94424 may not exceed 250 bar.
⇒ When fuel cam 2, is flush with piston supporting plate 11, release the pressure
to zero at the hydraulic unit and approx. 30 seconds later also at the HP oil
pump.
⇒ Remove all tools.
Remark: Mark camshaft together with bush and fuel cam by means of a non-
washable colour in order to ascertain a possible deviation of the marks, i.e. twisting
of the parts.
D
14
11 2 94563
I
94424 9
94426a 7
94935 014.901/08
94935a
94932
94934a
94942
94932a
94931 EV 94935
94934e

3.3 Fitting the fuel cams

3.3.1 Preparation
⇒ Fasten angle rail 94562a with fitted bolts 4 and washer 3; and guide tube
94562e at 25° mark with screws 8 to fuel cam No. 1 .
⇒ Push bush 7 together with fuel cam No. 2 onto the oiled camshaft.
⇒ Fit positioning unit 94562f with its shaft 13 into one of the three tapholes on the
relevant side of fuel cam No. 2 .
⇒ Put distance holder 94563a onto the camshaft and push it against fuel cam
No. 1 .
⇒ Push and turn the bush with fuel cam so that shaft 13 meshes in guide tube
94562e.
I-I
E
4
94424 94563a 94562
III
I 94563a 8
94426
94562a
14
III
2 1
3, 4
x1
I
III - III
x2
017.855/08
94562f 13 94562e 94562a
⇒ Push bush 7 together with fuel cam 2 till the bush rests on distance holder
94563a (Fig. ’E’).
⇒ Push hydr. jacking tool 94424 on bush 7 and fasten it to the fuel cam using six
screws 8 (evenly tighten screws slightly by hand only).
⇒ Open vent screw 9 and relief valve ’EV’.
⇒ Tighten screws 8 evenly by hand till ring piece 10 rests on piston supporting
plate 11.
⇒ Screw adapter piece 94426a into fuel cam 2 and connect it to hydraulic unit
94942 as shown in Fig. ’C’.

3.3.2 Fitting the fuel cam

⇒ Actuate HP oil pump 94931 till oil flows bubble-free at vent screw 9; then close
the latter.
⇒ Actuate hydraulic unit 94942, and when oil is squeezing out on the whole cir-
cumference between bush 7 and fuel cam 2, operate also the HP oil pump.
⇒ Pull the fuel cam onto the bush by means of the HP oil pump while keeping the
hydraulic unit running. During this process pay attention that oil is continuous-
ly squeezing out between bush and fuel cam.
Attention! The oil pressure in hydr. jacking tool 94424 may not exceed 250 bar.
⇒ When fuel cam 2 is flush with piston supporting plate 11, release the pressure
to zero at the hydraulic unit and approx. 30 seconds later also at the HP oil
pump.
⇒ Remove shaft 13 from positioning unit 94562f and subsequently remove the
angle rail.
⇒ Remove all remaining tools.
Remark: Mark camshaft together with bush and fuel cam by means of a non-
washable colour in order to ascertain a possible deviation of the marks, i.e. twisting
of the parts.
BEFORE DRAWING UP AFTER DRAWING UP
94424 2
8
7
94563a
10 12 11 2

Supply Unit
Removal and Fitting of Intermediate Wheel to Camshaft

1 Feeler gauge 94122 1 Intermediate wheel 18 Pin
2 Pre-tensioning jacks 94556 2 Housing 19 Bearing cover
1 Assembly template 94567 3 Intermediate shaft 20 Jack
1 Pipe 94567a 4 Cover 21 Lower bearing shell
1 Rail 94571 5 Screw plug 21a Upper bearing shell
2 Screws 94571a 6 Screw 22 Locating pin
2 Washers 94571b 7 Spray nozzle 23 Locating pin
1 Carriage 94571c 8 Housing 24 Thrust bearing ring halves
8 Screws 94571d 9 Screw 25 Bearing pin
1 Support (left) 94571e 10 Bush
1 Support (right) 94571f 11 Screw AF Seating face
1 Pressure gauge 94932a 12 Securing bolt BO Bore
1 Hydr. distributor 94934a 13 Waisted bolt HU Wooden underlay
1 HP hose 94935 14 Nut RC Eye bolt M10
2 HP hoses 94935a 15 Vent screw RS Round bar
1 Hydraulic unit 94942 16 Cylinder SA Gap
17 Piston ZA Pin
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/10
2. Removal of housing with intermediate wheel . . . . . . . . . . . . 2/10
3. Removal of bearing shell and intermediate wheel . . . . . . . 7/10
4. Fitting bearing shell and intermediate wheel . . . . . . . . . . . . 8/10
5. Fitting housing with intermediate wheel . . . . . . . . . . . . . . . 10/10
1. General
Removing intermediate wheel 1 is only possible after the camshaft has been re-
moved too (see 5552−2).
The intermediate wheel must be removed together with its housing from the supply
unit.
011.926/04

Supply Unit: Removal and Fitting of Intermediate Wheel to Camshaft
2. Removal of housing with intermediate wheel
⇒ Remove the cover 4 and the screw plugs 5 (Fig. ’B’).

⇒ Loosen the screws 6 and remove the nozzle 7 (Fig. ’C’).
⇒ Connect the rail 94571 to ropes ’a’, ’b’ and the lifting tackles. Rope ’b’ is guided
through the opening, which appears after the cover 4 is removed.
5 5
b
a
2
94571
6 I
7 014.571/06a

⇒ Instead of screw plugs 5 (Fig. ’B’), put the screws 94571a and washers
94571b into the housing 8 and attach them to rail 94571.
⇒ Remove rope ’a’ and ’b’.
⇒ Attach the carriage 94571c to the rail 94571 as shown in Fig. ’D’.
⇒ Move the carriage 94571c along the rail 94571 into the tightening position
(Fig. ’D’ and ’E’).
Risk of accident! Make sure that the bolt 12 is installed in the rail.
D
b
a
8 I-I
94571a
I-I 94571b
12
8
94571
94571d
94571c
⇒ Use the screws 94571d to hold the

carriage 94571c sufficiently in position
E on the housing 2 (see Fig. ’E’). Do not
tighten the screws too much.
⇒ Remove the screws 9 and the bushes
10.
⇒ Loosen the screws 11.
I
2 10 2
11
014.572/06a

94571f
94571e
014.571/06a
⇒ Use the bolts from the supply unit cover to attach the supports 94571f and
94571e to the supply unit (Fig. ’F’).
⇒ Fully tighten the screws 94571d on the carriage 94571c to lift up the intermedi-
ate wheel and the housing (Fig. ’G’).
8
I-I
I-I
8
I 94571d
94571
94571c
1

⇒ Pull the housing 2 and the intermediate wheel 1 back until the securing bolt 12
as shown in Fig. ’H’.
⇒ Connect the rope ’c’ (lifting capacity 3000 kg) through the holes in the housing
2 and intermediate wheel 1 with the lifting tackle and tighten rope.
⇒ Loosen the securing bolt 12, then remove the housing and the intermediate
wheel and place them on wooden underlays ’HU’ as shown in Fig. ’I’.
Remark: Wooden underlays ’HU’ must be high enough so that a jack can be un-
derlaid afterward as shown in Fig. ’L’.
H
c
12
014.573/06a

2.3 Loosening waisted bolts

13 until they seat on bearing cover 19 and there is little or no clearance at ’x’.
⇒ Unscrew the pre-tensioning jacks by ¾ turns (gap ’SA’ in Fig. ’I’).
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’I’.
⇒ Operate hydraulic unit until a pressure of approx. 1030 bar is reached.
⇒ Turn back nuts 14 with round bar ’RS’ until they are almost touching the pis-
tons of the pre-tensioning jacks.
⇒ Release pressure to zero and remove the pre-tensioning jacks and nuts.
18 15
I
x
17
16
94932a 94934a 13
14 RS
19
SA
94935a
94556
94935
HU
94942
011.936/04

K
RC
19
23 22 3. Removal of bearing shells
Remark: All bearing covers 19 are machined

together with housing 2, therefore never inter-
change them! They must be marked accord-
ingly before their removal.
⇒ Fit eye bolt ’RC’ into bearing cover 19, lift
and remove the latter by means of the
crane.
BEARING DIVISION
I
L
94567a
1
94567 In order to be able to remove bearing shells 21
21
and 21a, jack 20 with a protection (Al or Cu
25 plate) is used to lift intermediate wheel 1 as
shown in Fig. ’L’.
⇒ Lift intermediate wheel as much as neces-
sary until a clearance of approx. 0.10 mm
around bearing pin 25 can be measured
with feeler gauge 94122.
21a 2 ⇒ Place assembly template 94567 on upper
bearing shell 21a, so that its pin ’ZA’ fits
into the corresponding bore of the bearing
shell.
⇒ Insert pipe 94567a into the other pin and
turn assembly template in arrow direction
until it stops at housing 2.
I 20 PROTECTION D Remove assembly template and upper
bearing shell.
⇒ Lift and remove the intermediate wheel.
011.937/04
ZA

I
M
⇒ Dismantle thrust bearing ring halves 24.

⇒ Remove lower bearing shells 21 and mark
them.
011.938/04
24 BO 21 AF
4. Fitting bearing shell and intermediate wheel
The fitting of bearing shells intermediate shaft is carried out analogously but in
attention:
D All parts to be fitted must be clean and undamaged!
D For the assembly smear bearing shells and thrust bearing ring halves with oil.
D Take care of the designations of reused bearing shells.
D Fit bearing shells, so that their bores ’BO’ provided for locating pins 22 in the
bearing covers (Fig. ’L’) point to the same side (Fig. ’M’).
Moreover align bearing shells laterally (they must not protrude in any case!)
with seating faces ’AF’ of thrust bearing ring halves 24.
D Take care of the designations and meshing of locating pins 22 and 23 when
fitting the bearing covers.
⇒ Apply oil to the threads of nuts 14 and tighten them with round bar ’RS’ until
there is no clearance at ’y’ (Fig. ’N’).
D Carry out tensioning of waisted bolts 13 as described in paragraph 4.1.
After tensioning of waisted bolts determine radial and axial clearances, see clear-
CHECK ance table 0330−1 ’Supply Unit’.

4.1 Tensioning waisted bolts

13 until they seat on bearing cover 19 and there is little or no clearance at ’x’.
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’N’.
⇒ Operate hydraulic unit until a pressure of approx. 1000 bar is reached.
⇒ Keep pressure constant and tighten nuts 14 with round bar ’RS’ until firmly
seated.
Using feeler gauge inserted through slot ’KO’ (Fig. ’N’), check whether the nuts rest
CHECK on bearing cover without any clearance.
⇒ Release pressure to zero and remove the pre-tensioning jacks.
18 15
x
N
17
16
94932a 94934a 13
14 RS
19
KO
94935a
949556 14
94935
y
HU
94942
011.939/04

5. Fitting housing with intermediate wheel
The fitting of housing with intermediate wheel is carried out analogously but in
reverse sequence to the removal.
Fastening housing 2 to housing 8 is carried out as follows:
⇒ Apply oil to the threads of screws 9 and 11.
⇒ Fit screws 9 and bush 10.
⇒ Tighten screws 9 until housing 2 seats on housing 8.
⇒ Fit and tighten screws 11 with a torque of 170 Nm using a torque wrench.
⇒ Lightly tighten screws 9 manually in small steps using a wrench. Starting from
this position, tighten the screws by a further angle of 47_.
Check tooth backlash, see clearance table 0330−1 ’Driving Wheels for Supply
CHECK Unit’.
8
I
2 10
11
6
7 I
014.574/06a
5.1 Fitting spray nozzle

Check spray nozzle 7 for free passage!
CHECK
D Screws 6 must be secured with LOCTITE 0243!

Supply Unit
Removal and Fitting of Gear Wheel on Camshaft

2 Pre-tensioning jacks 94557 1 Camshaft 10 Nut
2 Sleeves 94558 2 Fuel cam 11 Withdrawing screw
1 Round bar 94560 3 Vent screw 12 Spacer
1 Pressure gauge 94932a 4 Cylinder
1 Hydr. distributor 94934a 5 Piston
2 Connecting elements 94934d 6 Shaft BN Limiting groove
1 HP hose 94935 7 Gear wheel HU Wooden underlay
2 HP hoses 94935a 8 Camshaft wheel EC Eye bolt
1 Hydraulic unit 94942 9 Waisted bolt SA Gap
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
2. Removal of camshaft wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/5
3. Fitting the camshaft wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/5
1. General
First the camshaft must be removed from the supply unit for dismantling camshaft
wheel 8 (see 5552−2), and subsequently if necessary waisted bolts 9 loosened
and shaft 6 with gear wheel 7 taken off.
1 2 9 10 8 6 7 014.915/07

Supply Unit: Removal and Fitting of Gear Wheel on Camshaft
2. Removal of camshaft wheel
2.1 Loosening the waisted bolts

⇒ Clean the threads of waisted bolts 9 and the areas around nuts 10 and oil the
threads.
⇒ Unscrew the pre-tensioning jacks by 1½ turns (gap ’SA’ in Fig. ’B’).
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’B’.
⇒ Operate the hydraulic unit till a pressure of approx. 1030 bar is reached.
’BN’.
⇒ Turn back nuts 10 with round bar 94560 till they are almost touching the pis-
tons of the pre-tensioning jacks.
B
x
3 4 5 94558 10 9 94557
1 94934d 9
BN 94560
014.916/07
94932a
94935a
94942
94935 94934a

2.2 Removal of camshaft wheel

⇒ Fit eye bolt ’RC’ in camshaft wheel 8 and connect it with the crane and lifting
tackle ’HZ’ as shown in Fig. ’C’.
⇒ Remove nuts 10.
⇒ Turn withdrawing screws 11 (M16) into the flange of camshaft 1 in order to
loosen and separate the camshaft wheel.
⇒ Carry away the whole unit (consisting of camshaft wheel 8, shaft 6 and gear
wheel 7) by means of the crane.
HZ I-I
11
I RC
9 10 8 6 7
014.917/07
11
I
10
RC ⇒ Hold camshaft wheel 8 with two nuts 10 provi-

sionally on the shaft 6.
8
⇒ Place the unit on wooden underlays ’HU’.
⇒ Remove nuts 10.
11
⇒ Turn withdrawing screws 11 into the flange of
6 shaft 6 in order to loosen and separate the cam-
shaft wheel.
7
⇒ Lift and move the camshaft wheel away.
HU
015.070/07

3. Fitting the camshaft wheel
⇒ Lower camshaft wheel 8 over the flange of shaft 6.

⇒ Clean and oil the threads of waisted bolts 9.
⇒ Equally press camshaft wheel into the flange of shaft 6 by means of spacers
12 and nuts 10.
⇒ Hang the unit consisting of camshaft wheel 8, shaft 6 with gear wheel 7 on the
crane as shown in Fig. ’E’.
⇒ Remove the spacers and nuts.
⇒ Fit the unit onto the camshaft and tighten it with nuts 10.
Remark: Should a waisted bolt 9 be fitted, oil its thread and then tighten it with a
torque of 140 Nm.
10
12
RC
HU
014.918/07

3.1 Tensioning the waisted bolts

⇒ Clean the areas around nuts 10.
⇒ Connect the pre-tensioning jacks to hydraulic unit 94942 as shown in Fig. ’F’.
⇒ Operate the hydraulic unit till a pressure of 1000 bar is reached.
’BN’.
⇒ Keep pressure constant and tighten nuts 10 with round bar 94560 till firmly
seated.
F
x
3 4 5 94558 10 9 94557 8 6 7
1 94934d 9
BN 94560
014.916/07
94932a
94935a
94942
94935 94934a

Supply Unit
Lubrication of Supply Unit During Maintenance Works

Lubricating device 94844 1 Ball valve 5 Hose clamp
Filling device A 94844a 2 Blind flange 6 Warning plate
Filling device B 94844b 2a Flange 7 Flange
Filling device C 94844c 3 Oil pipe
Flexible hose 94844d 4a Lubrication bore
Cross union 94844e 4b Lubrication bore
Holder 94844f 4c Lubrication bore
1. General
Lubricating device 94844 has been provided to prevent bearing bushes of the ser-
vo oil pump drive from being damaged (dry running) due to turning the engine dur-
ing overhaul works.
For this additional lubrication of the supply unit, system oil (bearing oil) is used (see
Operating Manual 0750−1).
Remark: Clean surroundings of the flanges which are opened up and take care
that no dirt or any kind of debris are entering to the supply unit.
2. Application of lubricating device
⇒ Make sure that the ball valve 1 is closed.

⇒ If it is not already done, exchange blind flange 2 for new flange 2a (flange with
G1/2” thread).
⇒ Remove oil pipes 3 from the lubrication bores 4a/4b/4c.
⇒ Check that the filling device 94844a is installed correct (no contact with flange
7) into the lubrication bore 4a. Between the upper flange of the filling device
94844a and the surface of the supply unit should be a gap of 4mm to ensure
that the filling device does not touch the bottom of the lubrication bore. Check
that the filling devices 94844b / 94844c are installed correct into the lubrica-
tion bores 4b/4c. Between the upper flange of the filling device 94844b should
be a gap of 2mm to ensure that the filling device does not touch the bottom of
the lubrication bore. The flange 94844c on the surface ot the supply unit has
no clearance.
⇒ After install filling devices 94844a / 94844b / 94844c into the lubrication bores
4a/4b/4c tighten the four screws by hand (50 Nm).
⇒ Install the lubrication device 94844 with the cross union 94844e, the flexible
hoses 94844d and connect the hoses to the straight unions of the cross union
94844e and the filling devices 94844a / 94844b / 94844c, tighten the hose
clamps 5.
⇒ During lubrication time, remove inspection covers to check if the lubrication oil
is going through all bores and reaches the bearings.
Remark: Before operating the turning gear, carefully read and follow the remarks
mentioned on the warning plate 6.
Attention! Before taking the engine into operation, rebuild the supply unit in re-
verse sequence.

Lubrication of Supply Unit During Maintenance Works
A
94844f
6
94844
94844d
2
2a
94844e
94844c
7 94844a 94844b
5 94844b 5
94844a
94844c 5
4a 4c
4b
94844a 5 94844b 5
4mm 2mm

Fuel Pump

1 2-part clamping ring 94550 1 Interm. fuel accumulator 29 Intermediate flange
1 Fitting & dismantling device 94551 2 Fuel pipe 30 Regulating (toothed) rack
1 Lifting tool 94552 3 Screw 31 Circlip
1 Spacer 94555 4 Pump cover 32 Ring
1 Fitting & dismantling device 94592 5 Upper housing 33 Head screw
consisting of: 6 Lower housing 34 Valve block
1 Oil trough 94592a 7 Guide piston 35 Valve body (NRV)
2 Limiters 94592b 8 Roller 36 Compression spring
4 Screws 94592c 9 Guide pin 37 Retaining screw
4 Screws 94592d 10 Roller pin 38, 38a Fluted seal rings
2 Screws 94592e 11 Circlip 39 Intermediate disc
1 Assembly tool 94581 12 Pressure disc 40 Circlip
2 Guide screws 94581a 13 Bush 41 Bush
2 Steel wires 94581b 14 Rod seal ring 42 Spindle
1 Assembling device 94593 15 Thrust piece 43 Rod seal ring
consisting of: 16 Circlip 44, 44a Seals
1 Tool half 94593a 17 Retaining ring 45 Oil inlet pipe
1 Tool half 94593b 18 Connection pin (M22x1.5) 46 Oil drain pipe
2 Flat bars 94593c 19 Adapter piece 47 Screw plug
1 Metal sheet 94593d 20 Allen screw 48 Orifice
4 Screws 94593e 21 Lower spring carrier 49 Cover
1 Mandrel 94597 22 Pump plunger 50 Locating pin
1 Mandrel 94597a 23 Pump cylinder 51−57 O-rings
1 Impact wrench 94598 24 Compression spring 58 Screw
2 Extensions 94598a 25 Guide pin DP Depository
1 Socket spanner insert 94598b 26 Regulating sleeve DS Pressure piece
Lifting tackles H1... 27 Upper spring carrier GS Handle screw
28 Screw RC Eye bolt
Overview
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/20
2. Removal of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/20
3. Dismantling of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/20
4. Assembling of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/20
5. Fitting of a fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19/20
6. Oil flow check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20/20
7. Preserving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20/20
1. Preparation
⇒ Stop the engine and switch off the fuel supply pump and lubricating oil pump.
⇒ Close the shut-off valves to fuel inlet and outlet pipes (see 8019−1 in the Oper-
ating Manual).
⇒ Remove casings as far as necessary and the fuel inlet and outlet pipes.
⇒ Remove the fuel pressure piping (see 8752−1).
⇒ Switch of power supply to the actuators and disconnect the connecting ele-
ment between regulating rack 30 and the regulating linkage (see 5801−1).
⇒ Remove oil inlet pipe 45 and oil drain pipe 46 from upper housing 5.
⇒ Turn the engine till roller 8 rests on the cam base circle (Fig. ’O’).

Fuel Pump: Dismantling and Assembling
A
B
58
94552
1
2
58 4
30
3
017.706/08
012.387/04
2. Removal of a fuel pump
⇒ Fit lifting tool 94552 onto pump cover 4.

⇒ Remove all screws 3.
⇒ Using a jacking screw M16, lift fuel pump till locating pin is no longer meshing.
2.1 Fitting assembly tool
⇒ Insert guide screws 94581a into the corresponding bores of assembly tool
94581 and secure them by means of steel wires 94581b.
⇒ Align assembly tool to the height of the tapholes in the fuel pump housing pro-
vided for guide screws 94581a.
⇒ Extract steel wires 94581b.
⇒ Drive guide screws into the tapholes till the stop.
I
C D
94552
I 94581a
94581
94581b
94581a
013.905/06

H2 a 2.2 Removal from supply unit

b c d e
⇒ Connect lifting tackle H1 with lifting lug ’a’ and
H1 lifting tool 94552.
⇒ Connect lifting tackle H2 with lifting lug ’b’ and
assembly tool 94581.
D For the removal of the fuel pumps of BANK B,
the tools are used as drawn with interrupted
94552
lines, however only lifting lugs ’d’ and ’e’ are
94581 BANK B necessary.
012.389/04
⇒ Carefully pull the fuel pump out of the supply

unit housing by means of lifting tackles H1 and
H2.
⇒ Remove lifting tackle H1 from lifting tool
94552 and then lift the fuel pump as high as
possible with lifting tackle H2.
F G
H2 H2
H1
94552

H2 c ⇒ Connect lifting tackle H1 with the short lever

of assembly tool 94581.
⇒ Connect lifting tackle H3 with lifting lug ’c’ and
H1
the long lever of the assembly tool.
H3
94581
012.390/04
⇒ Move the fuel pump towards lifting tackle H3

as far as possible by means of lifting tackles
H1, H2 and H3.
⇒ Disconnect lifting tackle H2 from the long le-
ver and connect it with the short lever of the
assembly tool.
I J
H2 H2
H1
H3

H2 ⇒ Move the fuel pump by means of lifting

tackles H1, H2 and H3, i.e. till it hangs as
shown in Fig. ’K’ with the short lever of as-
H1 sembly tool 94581 now in vertical position.
H3
⇒ Remove lifting tackles H1 and H3.
94581
012.391/04
⇒ Connect lifting tackle H4 with lifting lug ’e’ and

the long lever of the assembly tool.
⇒ Move the fuel pump over the supply unit by
means of lifting tackles H2 and H4 as shown in
Fig. ’M’.
L M
b e
H4
H2 H4 H2

3. Dismantling of a fuel pump
Attention! During dismantling and assembling the fuel pumps, the activity area
has to be clean and as dust-free as possible (grinding dust etc.), and performing
electric welding must absolutely be omitted near or on the engine.
⇒ Fasten fitting and dismantling device 94592 to the upper platform using
screws 94592e , and place oil trough 94592a underneath on the bottom plate.
⇒ Carefully lift and remove the fuel pump (395 kg) from the fuel pump unit, and
cover the latter immediately.
⇒ Fit fuel pump into fitting and dismantling device 94592 using screws 94592c.
For safety reasons always provide limiters 94592b on both sides of the
device and consider unbalanced conditions during removal procedures!
45 94592c
DP (94592c)
46
94592b
94592
DP (94592e)
94592a
94592e
017.706/08
N1 N2

O I-I
I
33
4
STAMP AREA FOR:
− VERSION
− MANUFACTURER
− DATA
− SERIAL NO.
STAMP AREA FOR:

− VERSION
52
23 − MANUFACTURER
− DATA
22 − SERIAL NO.
− PLUNGER ∅ 37, 38
25
27 26
3 24
16 54 44, 55
15 5
19
53
44a, 56
47, 38a
14, 56
51
17 18 48
41
21
7 6
9
12
8
10
11
13
019.325/10

3.1 Removal of guide pin

94551 Risk of accident! Guide pin 9 must only be re-
moved with fitting & dismantling device 94551!
7
8 ⇒ Turn the fuel pump till roller 8 points upwards.
⇒ Mount fitting & dismantling device, and press
9 guide piston 7 inwards by turning the spindle
of the device till guide pin 9 allows to be with-
GS drawn by means of handle screw ’GS’ (M10).
013.909/06
Q R
RC 3.2 Removal of guide piston
⇒ Screw eye bolt ’RC’ (M16) into the hexagon of
tool 94551.
42
⇒ Turn back spindle 42.
94551 ⇒ Loosen equally Allen screws 20 and remove
them.
⇒ Carefully lift now lower housing 6 together
with guide piston 7, lower spring carrier 21
and pump plunger 22 by means of eye bolt
7 ’RC’.
6
⇒ Remove compression spring 24.
21 20
24
22
014.873/06a

⇒ Push pump plunger 22 out from lower spring carrier

21.
Store pump plunger in a manner not to damage it.
⇒ Remove circlip 16 and push retaining ring 17 down-
wards.
⇒ Unscrew connection pins 18 with O-rings 54 by
means of an Allen wrench AF10, and remove lower
spring carrier.
18 54
17
16
21
22
T
13
RC ⇒ Screw two eye bolts ’RC’ (M10) into guide piston 7,
50 12 and withdraw the latter from the housing.
11
10 3.3 Removal of roller
8 ⇒ Remove circlip 11.
7 ⇒ Press out roller pin 10, and remove roller 8 together

with its shrunken bush 13 and pressure discs 12.
Remark: If necessary, the roller and roller pin must be re-
placed as a unit only.
15

U
30
3.4 Removal of regulating rack
⇒ Unscrew all screws 28 and remove cover 49.
⇒ Remove circlip 31 and ring 32.
I I ⇒ Remove intermediate flange 29, and push out regu-
lating rack 30.
I-I
29 28 30 49
019/236/10 32 31
57 43
V
33
3.5 Removal of pump cylinder
4 ⇒ Turn fuel pump till pump cover 4 points upwards.

39 ⇒ Unscrew head screws 33 crosswise in equal steps.
36 40 ⇒ Remove pump cover 4, valve block 34, valve body
52 35 and compression spring 36 (valve block and
35
valve body are marked together).
34
For removing intermediate disc 39 loosen circlip 40.
23
37, 38 ⇒ Remove retaining screw 37 and pump cylinder 23.
Remark: Pump cylinder and pump plunger form a single
5 unit and must not be interchanged.
Therefore, they are not delivered separately.
⇒ Withdraw adapter pieces 19 from upper housing 5

(Fig. ’O’).

3.6 Removal of non-return valve

⇒ By means of 2-part clamping ring 94550 and the four screws M10x60 valve
block 34 can be withdrawn from pump cover 4.
⇒ Remove circlip 40 with a snap ring tong.
Remark: The non-return valve must be replaced as a unit only, i.e. valve block 34,
valve body 35, compression spring 36 and intermediate piece 39.
M10x60
W
94550
3 0.3 mm
STROKE
34
94550
52
36, 35
40
39
4
019.235/10

4. Assembling of a fuel pump
4.1 Preparation
⇒ Clean all parts and check their condition.
Damaged parts must be replaced.
⇒ Replace all O-rings, piston and rod seal rings.
⇒ Check the lubricating oil bores in the housings and in pump cylinder 23 for free
passage using compressed air.
4.2 Fitting the pump cylinder

23
⇒ Place upper housing 5 in vertical position on fitting
37, 38 and dismantling device 94592.
⇒ Carefully fit pump cylinder 23, aligning the groove in
5 the pump cylinder precisely with the bore provided
in the upper housing for retaining screw 37.
⇒ Screw in and tighten the retaining screw together
with its fluted seal ring 38.
Remark: There must be a clearance between retaining
screw 37 and the groove base!
⇒ Oil and insert adapter pieces 19 with their O-rings

53 into upper housing 5 (Fig. ’O’).
4.3 Fitting the non-return valve and pump cover

Remark: Thoroughly check the sealing surfaces for cleanness when fitting the
valve block and the pump cover (Fig. ’V’).
⇒ Fit valve block 34 with the mounted and oiled O-rings 52 in upper housing 5 by
means of a nylon hammer. Then insert the oiled valve body 35 verifying its free
movement and place compression spring 36.
⇒ Fit intermediate disc 39 with circlip 40 into the pump cover.
⇒ Fit pump cover 4 paying attention not to damage the compression spring.
Check that the compression spring fits properly into the hole in the intermediate
CHECK disc by using a flashlight (see arrow in Fig. ’V’).
⇒ Apply Never-Seez NSBT-8 to the threads and head seating surfaces of the
head screws 33 (M27), and tighten them crosswise in three steps with 100,
300 and finally to a torque of 480 Nm. Recheck all head screws 33, i.e. by ap-
plying the corresponding torque again!

Y RC 4.4 Assembling the guide piston

10 ⇒ Clean and oil all bores and parts.
8
⇒ Press thrust piece 15 into guide piston 7.
7
⇒ Fit roller 8 with its shrunken bush 13, pressure disc
12 and roller pin 10 in guide piston 7.
Pay attention to the position of locating pin 50 and
secure roller pin by means of circlip 11 (Fig. ’T’).
44a 4.5 Checking axial clearance of pump piston
21 ⇒ Suspend guide piston on eye bolt ’RC’ (M10).
15 ⇒ Fit pump plunger 22 in lower spring carrier 21 with

x
inserted seals 44 and 44a (for their fitting see para-

44
graph 4.10).
22 ⇒ Push lower spring carrier together with pump plung-
er over guide piston 7. Press lower spring carrier by
hand against thrust piece 15, checking whether
there results a clearance of x = 0.12−0.24 mm.
⇒ Remove lower spring carrier and pump plunger.
4.6 Fitting the regulating rack

⇒ Turn fuel pump in device 94592 till the pump cover points downwards.
⇒ Fit regulating rack 30 according to Fig. ’U’.
Check regulating rack for easy movement.
CHECK
⇒ Place rod seal ring 43 and O-ring 57 in both intermediate flanges 29.
⇒ Push the intermediate flanges onto regulating rack and screw them up with
upper housing.
⇒ Fit rings 32 and circlips 31.
Z 4.7 Fitting the regulating sleeve

51 ⇒ Bring regulating rack 30 to the position shown in Fig.
’Z’, and place spacer 94555.
⇒ Fit guide pin 25.
26 5
⇒ Fit regulating sleeve 26 in the upper housing, the
27
25 toothed rim turned to the bottom and the groove of
12 mm width being flush with guide pin 25.
⇒ Fit upper spring carrier 27.
Remove spacer 94555 and check that the regulating
CHECK
30 94555 rack moves freely over the entire regulating travel.
Remark: The regulating sleeve can only be fitted in
one position: guide pin in upper housing and groove
in regulating bush which is 12 mm wide must corre-
spond. Only in this position, the correct assembly of
the regulating sleeve is possible. Before fitting the
regulating sleeve, the toothed rack has to be posi-
012.413/06a tioned with the spacer.

A1 4.8 Checking axial clearance of regulating sleeve

Press upper spring carrier 27 against upper housing
CHECK
5, checking whether regulating sleeve 26 can be
moved axially (clearance x = 0.5−0.7 mm).
26 I
27
I
30 25
x
26 5
013.919/06a
4.9 Fitting the spring carrier

⇒ Insert O-ring 51 and fit compression spring 36.
⇒ Place tool halves 94593a, 94593b and flat bars 94593c.
⇒ Tighten screws 94593e till the tool halves rest on upper housing 5.
B1 C1
I-I
94593a 94593a
94593e
94593e 24
51
5 5
I I
94593b
013.920/06 013.921/06

D1
21
Remark: Figures ’D1’, ’E1’, ’H1’ and ’I1’ are drawn
17 with former lower spring carrier and connection pin.
16 The assembling procedure is the same, however,
with the exception of the connection pins, which are
screwed into the lower spring carrier.
22 ⇒ Oil pump plunger 22, sliding carefully into pump cyl-
inder 23 and rest it on tool halves.
⇒ Guide retaining ring 17 and circlip 16 over lower
spring carrier 21 and push them onto the pump
plunger.
013.922/06
E1
94593d
17
16
⇒ Install metal sheet 94593d on the tool halves and

place circlip 16 and retaining ring 17.
013.923/06

4.10 Fitting rod seal ring 14 and seals 44, 44a

⇒ Insert O-rings 55 and 56 into the corresponding grooves of lower spring carri-
er 21 and lower housing 6.
⇒ Deform rod seal ring 14 and seals 44 and 44a “kidney-shaped”, insert them
into the grooves concerned and pay attention to their fitting positions as
shown below.
⇒ Press the seal into the groove in direction of the arrows.
⇒ Press mandrel 94597 (∅ 70 mm) by means of a handle screw M16 through
lower spring carrier 21 and bush 41, calibrating the seal after fitting.
Same procedure is to be applied analogously, but with mandrel 94597a (∅ 40
mm) by means of a handle screw M10 in the upper groove of the lower spring
carrier.
F1
21
55
09.276/10
15 44
I
6 21
56 56
14 7 7 44a
016.860/08
G1 I
94597
21, 6
55, 56
44, 44a
6
41
017.738/08 016.860/08

H1
4.11 Final assembly
⇒ Oil guide piston 7 and fit it into lower housing 6.
⇒ Install fitting & dismantling device 94551 on the low-
42 er housing.
94551 ⇒ Turn back spindle 42.

⇒ Lower down carefully lower housing together with
guide piston into lower spring carrier 21 and insert/fit
connection pins 18 with O-rings 54 (crosswise
tighten connection pins (M22x1.5_V4) in four steps
with a final torque of 80 Nm).
7 ⇒ Push up retaining ring 17 and fit circlip 16.
6 ⇒ Turn pump plunger 22 till both drivers fit into the re-
cesses of tool halves 94593a and 94593b.
⇒ Loosen equally screws 94593e and remove the tool
halves.
Remark: When loosening screws 94593e, make sure
17 18 that the pump plunger is not pushed up too!
21
94593a
16 54
22
94593e

I1
⇒ Lower down carefully lower housing 6 together with

guide piston 7, ensuring that the drivers of pump
plunger 22 fit into the slot (guide) of regulating
sleeve 26.
Should this not be possible, the regulating sleeve
94551 must be properly turned by means of regulating rack
30.
⇒ Fit the lower housing to the upper housing with the
two Allen screws 20 (Fig. ’R’).
⇒ Preload compression spring 24 with fitting & dis-
mantling device 94551 till guide pin 9 can be in-
7 serted into the lower housing and guide piston with
6 handle screw ’GS’.
Should this not be possible, the groove in the guide
piston must be aligned turning pressure piece ’DS’
in the required direction.
⇒ Press the pump plunger into T.D.C. using fitting &
21 dismantling device 94551 as shown in Fig. ’K1’, and
check regulating rack 30 for easy movement.
⇒ Release fitting & dismantling device and remove it.
51
22
26
J1 K1
30
DS
GS
013.928/06 013.929/06

5. Fitting of a fuel pump
⇒ Turn the engine till the cam belonging to the fuel pump concerned is on the
base circle (Fig. ’Q’).
Check whether the seating surfaces as well as the guide parts of the supply unit
CHECK housing and the fuel pump itself are in a faultless condition.
⇒ Fit remaining O-rings 45.
⇒ Oil the guide parts and fit the fuel pump, taking care of the locating pin and the
regulating shaft (do not use any jointing agent).
⇒ Fit screws 3 with oiled threads and head seating surfaces.
⇒ Tighten screws 3 to an angle of 64° using socket spanner insert 94598b, ex-
tensions 94598a and pneum. impact wrench 94598.
Check the setting of the regulating linkage (see 5801−1).
CHECK
⇒ Fit all pipings. Apply Never-Seez NSBT-8 to threads and head seating sur-
faces of screws 58 (Fig. ’A’) and tighten them crosswise in equal steps with a
total value of 70 Nm.
⇒ When putting the fuel pump into operation, watch for possible leakages or ab-
normal temperature rise. Fit the casing when everything is in order.
L1
94598
94598a
94598b
3
013.930/06

6. Oil flow check
The oil flow at all fuel pumps must be checked after a fuel pump or plunger exchan-
ge in order to ensure a proper lubrication via orifice 48 to lower housing 6 and guide
piston 7.
D Engine at standstill and lubricating oil pump switched off.
⇒ Remove oil drain pipe 46 from all fuel pumps.
⇒ Switch on the lubricating pump.
⇒ Turn the turning gear in AHEAD direction.
⇒ Check the oil flow from the oil drain pipe.
If no oil is flowing out of a certain oil drain pipe, the respective fuel pump must
be separately checked:
− Turn the crankshaft until roller 8 of the respective fuel pump is on the cam
peak. If after one minute no oil flow is noticed, it might be an indication that
the oil supply is blocked by foreign particles.
− Cut off the fuel pump according to the Operating Manual 5556−2 and re-
place or remedy the fuel pump at the next opportunity.
M1
48
46
45
7
OIL
FLOW
7. Preserving
If a fuel pump has to be stored over a long period of time, the spaces carrying fuel
oil must be filled with Vaseline oil and plugged with plastic stoppers.
Furthermore, oil the fuel pump and protect it against humidity and soiling by wrap-
ping it suitably.
Always store fuel pumps in upright position!

Fuel Pump
Removal of a Jammed Pump Plunger

1 Jack 94595 1 Upper housing 9 Nut
1 Short tappet 94595b 2 Lower housing 10 Head screw (12xM27)
1 Long tappet 94595c 3 Pump plunger 11 Piston
1 Piston reset tool 94595d 4 Pump cylinder 12 Vent screw
2 Screws 94595e 5 Guide pin 13 Spindle
1 HP oil pump 94931 6 Compression spring 14 Indicator
1 Pressure gauge 94932 7 Allen screw
1 HP hose 94935 8 Screw EV Relief valve
1. Preparatory works
D Dismantle the fuel pump as far as possible (see 5556−1).

⇒ Check whether piston 11 is in the top position. If necessary push it fully back by
means of piston reset tool 94595d.
⇒ Insert short tappet 94595b.
⇒ Fasten jack 94595 onto upper housing 1 with head screws 10.
⇒ Remove first screw 8. Insert first screw 94595e and screw together with nut 9,
however keeping a clearance of 10 − 25 mm.
⇒ Remove second screw 8 from opposite side. Insert second screw 94595e and
screw together with nut 9, however keeping a clearance of 10 − 25 mm.
⇒ Remove both Allen screws 7.
A I-I
10 II II
11 94595
94595b I I
8
5
II - II
6
94595
x = 10 − 25 mm
1
1
2
11
7
2
94595d
9
13 94595e
WCH00075 014.181/06

Fuel Pump: Removal of a Jammed Pump Plunger
2. Jacking-out procedure
⇒ Connect jack 94595 with HP oil pump 94931.

⇒ Shut relief valve ’EV’ and actuate HP oil pump till oil flows bubble-free at vent
screw 12.
⇒ Close the vent screw.
Attention! Take care during the jacking-out procedure that nuts 9 show always a
clearance of 10 − 25 mm, readjust repeatedly if required (Fig. ’A’ section II-II).
⇒ Press carefully till pump plunger 3 is jacked out by the spring force or till indica-
tor 14 shows the stroke end, i.e. the indicator is flush with the housing.
D If the pump plunger can now be taken out, remove jack 94595 and short tap-
pet 94595b. Push the piston fully back by means of piston reset tool 94595d.
D In case the pump plunger is still not loose, proceed as described in the follow-
ing paragraph Jacking-out 2nd stage.
Jacking-out 1 st stage with short tappet 94595b:
12
94595
11
94595d 14
94595b
13 FLUSH
94932
WCH00075
94935 EV 94931

Fuel Pump: Removal of a Jammed Pump Plunger
⇒ Insert long tappet 94595c and fasten jack 94595 again onto upper housing 1
with head screws 10.
⇒ Reconnect jack 94595 with HP oil pump 94931.
⇒ Shut relief valve ’EV’ and actuate HP oil pump till oil flows bubble-free at vent
screw 12.
⇒ Close the vent screw.
⇒ Press carefully till pump plunger 3 is jacked out by the spring force or till indica-
tor 14 shows the stroke end, i.e. the indicator is flush with the housing.
⇒ Remove jack 94595 and long tappet 94595c. Push the piston fully back by
means of piston reset tool 94595d.
Jacking-out 2 nd stage with long tappet 94595c:
12
10
94595
94595c
14
1 FLUSH
94932
WCH00075
94935 EV 94931

Injection Control Unit
Removal and Fitting

1 Lifting plate 94584 1 Hose line 11 Lip seal
2 Withdrawing tools 94589 2 Hose line 12 Position sensor
1 Tightening device 94874 3 Fuel leakage return 13 Countersunk screw
4 Fuel rail 14 Nipple
5 Connection piece 15 Filter holder
6 Injection control unit 16 Connecting nipple
7 Screw 17 Dowel pin
7a Screw 18 O-ring
8 Pre-control valve 19 O-ring
9 Screw 20 Oil filter
10 Intermediate plate 21 Circlip
1. General
When working on an injection control unit in principle the engine has to be stopped
and the fuel booster and bearing oil pumps switched off.
If it is necessary to replace an injection control unit, the engine must operate for a
minimum of 1.5 hours with marine diesel oil (MDO). For more data see Operation
Manual 0270−1.
Attention! There must be no pressure in fuel rail 4.
The corresponding drain (screws) valves must be opened as described in 0510−1
of the Operating Manual. Follow the detailed instructions without fail!
Maintenance on the injection control unit can be done only by the manufacturer as
a matter of principle. However, if troubles have been detected on the injection con-
trol unit during operation, it must be replaced by a revised unit, following the in-
struction below.
Remark: No maintenance work is provided for pre-control valve 8. If necessary it
must be replaced as a whole unit!
2. Removal
A
3 ⇒ Remove fuel pressure pipings ac-
cording to 8733−1 and unscrew con-
5 nection pieces 5 from injection con-
6 7a trol unit 6 as shown in Fig. ’D’ (the
connection pieces are screwed into
the spare injection control unit).
7
⇒ Loosen hose lines 1, 2 and unscrew
14 nipple 14 (the nipple is screwed into
the spare injection control unit).
⇒ Remove screws 7 and 7a.
2
011.730/04 1

Injection Control Unit: Removal and Fitting
⇒ Fasten lifting plate 94584 onto injection control unit 6.

⇒ Remove cable plugs from pre-control valves 8 and position sensor 12.
⇒ Loosen screws 9 and remove them together with pre-control valves (Fig. ’B’).
⇒ Lift up the injection control unit.
Remark: Immediately cover the appearing opening in fuel rail 4 to prevent dirt from
entering in any circumstance!
⇒ Lip seal 11 (Fig. ’C’) can be removed (if necessary) with one of withdrawing
tools 94589.
2.1 Cleaning the filter

⇒ Loosen connecting nipple 16, remove filter holder 15 and clean oil filter 20.
Remark: Maintain the flow direction when refitting or replacing the oil filter. More-
over, the three oil filters must be secured by means of circlip 21.
⇒ Apply oil to the filter holder 15 and tighten it with a torque of 120 Nm.
⇒ Apply Never-Seez NSBT-8 to the threads of connecting nipple and tighten it
with 350 Nm.
3
94584
12 4
9
8
011.954/04

3. Fitting
⇒ Insert lip seal 11.

⇒ Lower injection control unit 6 carefully onto the fuel rail and remove the lifting
plate.
⇒ Apply Never-Seez NSBT-8 to the threads of screws 7 and 7a (Fig. ’A’).
⇒ First tighten screws 7a crosswise with a torque of 110 Nm and subsequently
screws 7.
⇒ Replace O-rings 18, if necessary.
⇒ Apply Never-Seez NSBT-8 to screws 9 and fasten pre-control valves 8 to in-
jection control unit 6 with them.
⇒ Tighten screws 9 with a torque of 2.5 Nm.
15 21 16
II 20
FLOW
DIRECTION
11
17
II
13 18
8 10
9
014.279/06

⇒ Apply Never-Seez NSBT-8 to the threads of connection pieces 5.

⇒ Insert new O-rings 19 and fit the connection pieces.
⇒ Fasten tightening device 94874 with its screws to the connecting piece.
⇒ Apply torque wrench on the hexagon of the device and tighten the connecting
piece with a torque of 700 Nm.
⇒ Install hose lines and pipings.
D For fitting the fuel pressure pipings see 8733−1.
D For restarting the injection see instructions 0510−1 in the Operating Manual!
I
I-I
94874
I 5
19
6
014.280/06

Checking the Gas Pre-charge Pressure with Lubrication Pump CLU4
1 Case 94720c 1Hydraulic accumulator 9 Pressure reducing valve

consisting of: 2Protection cap 10 Pressure transmitter
measurement set complete 3Pressure reducing valve 11 Cable socket
for checking / refilling of 4, 4aHose (1m, 4 m) 12 Pressure gauge
hydraulic accumulator 5Control unit with 13 Screw plug
valves A, B and C 14 Stop valve
7 Pressure gauge 0−60 bar 15 Nitrogen bottle
8 Valve block
1. Checking the gas pre-charge pressure
Once filled with gas, the hydraulic accumulator is largely maintenance-free, how-
ever in order to ensure a trouble-free service, maintenance works must be carried
out according to the manufacturer’s detailed operating instructions of the Cylinder
Lubricating System. Checks and maintenance are only to be carried out, when
the engine is at standstill.
The same measurement set 94720c must always be used to refill the accumulator
as provided for checking the gas pre-charge pressure on the lubricating pump’s
hydraulic actuators (see also 7218−1).
Check the filling pressure at least once in the first week after start-up of the accu-
CHECK mulator. If no loss of gas is observed, recheck after three months. If there is still no
change in pressure, an annual check might be sufficient, however, it is recom-
mended to continue carrying out checks every three months.
Attention! Ensure that servo oil supply is shut off before starting accumulator
pressure checking and charging. Also no residual oil pressure in valve block must
be visible on pressure gauge 12 (PI2041L) of pressure reducing valve 8.11−1.
1.1 Preparation
− Stop servo oil supply.
− Close stop valve 14 between rail unit and pressure reducing valve (Fig. ’C’).
− Drain servo oil system by means of screw plug 13.
Screw plug 13 must remain open during entire checking / refilling proce-
dure.
− Remove protection cap 2 from accumulator 1.
1.2 Checking procedure
⇒ Close the three valves A, B and C on control unit 5.
⇒ Connect accumulator 1 to control unit 5 using short hose 4.
⇒ Open valve A and read pressure from gauge 7.
Required gas pressure: min. 20 bar / max. 25 bar.
If gas pre-charge pressure is ok:
⇒ Close valve A and drain remaining pressure in control unit by opening valve B.
⇒ Disconnect short hose from accumulator.
⇒ Refit protection cap.
Remark: During every check a small amount of gas may be lost to the atmo-
sphere. Therefore, make sure a gas bottle is available before a pressure check is
made in order to refill possible loss.
If gas pre-charge pressure is not ok:
⇒ Refill the accumulator.
Wärtsilä Switzerland Ltd 1/ 4 CLU4 / 2012

Pressure Reducing Valve: Checking the Gas Pre-charge Pressure with Lubricating Pump CLU4
2. Refilling the accumulator
Measurement set 94720c must always be used to refill the accumulator.

The hydraulic accumulator may only be filled with super-clean, class 4.0 nitrogen,
99.99 % N2 by volume.
Remark: Check and refill the accumulators of the pressure reducing valves
(8.18−1 & −2) at free end and driving end at the same time on engines with 8 to 12
and 14 cylinders.
2.1 Refilling procedure

⇒ Fit pressure reducing valve 3 to nitrogen bottle 15 and adjust the pressure to
approx. 30 bar.
⇒ Connect pressure reducing valve with long hose 4a to the right side (C), and
accumulator with short hose 4 to the left side (A) of control unit.
⇒ Slowly open valve C and refill accumulator to the required pressure of 25 bar.
⇒ Close valves A and C and drain remaining pressure in control unit by opening
valve B.
⇒ Disconnect hoses 4, 4a and refit all protection caps.
2.2 After checking or refilling procedure

⇒ Reopen stop valve 14 between rail unit and pressure reducing valve valve
(Fig. ’C’).
⇒ Close screw plug 13.
After pressure checking and refilling the accumulator, ensure to run the servo oil
supply and vent air from the system before putting the pulse lubricating system into
operation (see Operating Manual 7218−1).
2012 / CLU4 2/ 4 Wärtsilä Switzerland Ltd

Case with measurement set 94720c for CLU4 and PRV 8.18−1:
A C
Case 94720c B
4, 4a 3 5 1 2 4
Arrangement of equipment:
PI2041L
12
13 7
A C
15
B
8
1 4 5 4a 3 WCH00703

Pressure reducing valve 8.11−1:
14 (4.30−5)
9
PRESSURE REDUCING
UNIT 1, 2
10, 11
FREE
END
SERVO OIL PIPE TO

LUBRICATING PUMPS WCH00853
Details of servo oil rail 4.11 −> pressure reducing valve 8.11−1 −> lubricating pump 8.06:
D E
8.06
RAIL UNIT
4.11
PI2041L
8.11−1
WCH00861
13
DRAWN FROM CONTROL
DIAGRAM 4003−2
WCH00852

Checking the Gas Pre-charge Pressure with Lubrication Pump CLU4−C
1 Case 94720c 1Hydraulic accumulator 9 Pressure reducing valve

consisting of: 2Protection cap 10 Pressure transmitter
measurement set complete 3Pressure reducing valve 11 Cable socket
for checking / refilling of 4, 4aHose (1m, 4 m) 12 Pressure gauge
hydraulic accumulator 5Control unit with 13 Screw plug
valves A, B and C 14 Stop valve
8 Valve block
The same measurement set 94720c must always be used to refill the accumulator
as provided for checking the gas pre-charge pressure on the lubricating pump’s
hydraulic actuators (see also 7218−1).
Check the filling pressure at least once in the first week after startup of the accumu-
CHECK lator. If no loss of gas is observed, recheck after three months. If there is still no
pressure checking and charging. Also no residual oil pressure in valve block must
be visible on pressure gauge 12 (PI2041L) of pressure reducing valve 8.11−1.
1.1 Preparation
− Close stop valve 14 between rail unit and pressure reducing valve (Fig. ’C’).
− Drain servo oil system by means of screw plug 13.
dure.
Wärtsilä Switzerland Ltd 1/ 4 CLU4−C / 2012

Pressure Reducing Valve: Checking the Gas Pre-charge Pressure with Lubrication Pump CLU4−C

Remark: Check and refill the accumulators of the pressure reducing valves
(8.18−1 & −2) at free end and driving end at the same time on engines with 8 to 12
and 14 cylinders.

approx. 40 bar.
⇒ Connect pressure reducing valve with long hose 4a to the right side (C), and
accumulator with short hose 4 to the left side (A) of control unit.
valve B.

⇒ Reopen stop valve 14 between rail unit and pressure reducing valve valve
(Fig. ’C’).
⇒ Close screw plug 13.
2012 / CLU4−C 2/ 4 Wärtsilä Switzerland Ltd

Case with measurement set 94720c for CLU4−C and PRV 8.18−1:
A C
Case 94720c B
4, 4a 3 5 1 2 4
PI2041L
12
13 7
A C
15
B
8
1 4 5 4a 3 WCH00703

Pressure reducing valve 8.11−1:
14 (4.30−5)
9
PRESSURE REDUCING
UNIT 1, 2
10, 11
FREE
END
DRAWN FOR SERVO OIL PIPE TO

RT−flex96C LUBRICATING PUMPS WCH00853
Details of servo oil rail 4.11 −> pressure reducing valve 8.11−1 −> lubricating pump 8.06:
D E
8.06
RAIL UNIT
4.11
PI2041L
8.11−1
13
WCH00861
DRAWN FROM CONTROL
DIAGRAM 4003−2
WCH00852

Exhaust Valve Control Unit
Removal, Fitting, Dismantling and Assembling
1 Valve control block 14 Compression spring
2 Pipe 15 Slide rod
3 Rail valve (pre-control valve) 16 Screw plug
4 Screw 17 Screw
5 Screw 18 Screw plug
6 Servo oil rail 19 Filter
7 Dowel pin 20 Screw plug
8 Connecting block 21 Filter
9 Screw 22 Throttle
10 Cover 23 Plug
11 Piston 24 O-ring
12 Screw 25 O-ring
13 Cover 26 O-ring
1. General
When working on the exhaust valve control unit in principle the engine has to be
stopped.
Attention! Servo oil pipings must be pressureless. Follow the instruction in
0520−1 of the Operating Manual without fail!
The respective work station must be clean; welding and grinding should not be
done nearby!
2. Removal
⇒ For dismantling the exhaust valve control unit, first remove the hydraulic pip-
ing from the exhaust valve control unit (see 8460−1).
⇒ Remove pipes 2.
⇒ Disconnect plugs 23 from rail valve 3.
⇒ Loosen screws 4.
⇒ Carefully lift the complete exhaust valve control unit.
Remark: Immediately cover the appearing opening in servo oil rail 6 to prevent dirt
from entering in any circumstance!
I
A I
2
1 23
6 3
015.138/07

Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling
B 3. Fitting
10 ⇒ Place new O-ring 24 into the groove of servo oil rail 6.
8 ⇒ Lower the complete exhaust valve control unit onto

the servo oil rail.
1 ⇒ Apply oil to screws 4 and tighten them with a torque
of 170 Nm.
⇒ Install piping. For fitting the hydraulic piping to the ex-
I haust valve control unit see 8460−1.
7
I
24
6
015.139/07
4. Dismantling of exhaust valve control unit
⇒ Loosen screws 9 and remove cover 10.

⇒ Withdraw piston 11 using a jacking screw M10.
⇒ Loosen screws 12 and remove cover 13.
⇒ Remove compression spring 14 and slide rod 15.
D In order to remove and clean filters 19 and 21, the relevant screw plugs 18 and
20 must be loosened.
D Throttle 22 is oiled, screwed into filter 21 and tightened with 3 Nm.
D Filter 19 is oiled, screwed into screw plug 18 and tightened with 10 Nm.
C I-I I
25 12
13
14 9
15
25 10
3
5
11
16
015.140/07

Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling
5. Assembling of exhaust valve control unit
⇒ All O-rings must be replaced by new ones.

⇒ The threads of all screws, piston 11 and slide rod 15 (Fig. ’C’) must be oiled
prior to their fitting.
⇒ Equally tighten screws 9 and screws 12.
⇒ Fit rail valve 3 with screws 5 and tighten them with a torque of 2.5 Nm.
II-II
D
II III
12
26
9 3
8 17
II III
III-III
19
015.141/07
18
22 21 20

Regulating Linkage
Adjusting
1 Fuel pump 11 Flange
2 Actuator 12 Holder
3 Forked lever 13a−e Connecting rods
4 Torsion spring 14a, b Stop screws
5 Pin 15 Actuator lever
6 Adjusting screw 16 Actuator shaft
7 Limit lever 17 Regulating shaft
8 DU bush 18 Intermediate wheel
9 Regulating (toothed) rack 19 Pointer
10 Stop ring
1. General
After overhauling the linkage or the fuel pumps, as well as after fitting a new fuel
pump or a new actuator, the setting of the linkage must be checked and, if neces-
sary, adjusted.
A
1 Attention! The power to the actuators 2
must be interrupted first, before they are
disconnected from the regulating linkage
2
(see 9362−1 in the Operating Manual).
012.431/04
2. Adjusting of regulating linkage
I-I
B
2.1 Pre-adjusting of forked levers
3 3 ⇒ Adjust clearance ’x’ = 8 mm between
I 8 6 x 7 6 all limit levers 7 and forked levers 3
by means of adjusting screws 6.
I 7 5 7 4 17 011.776/04

Regulating Linkage: Adjusting
2.2 Adjustment of mechanical minimum − maximum limiters on actuator

D The connecting rods (Fig. ’E’) must not be connected with actuator levers 15.
2.2.1 Adjustment of mechanical minimum limiter

⇒ Turn back all stop screws 14a.
⇒ Rotate actuator shaft 16 in counter-clockwise direction till the stop inside the
actuator.
In this position push the actuator lever onto the actuator shaft and place it at
the corresponding stop screw 14a as near as possible.
⇒ Screw in stop screw 14a till it rests on actuator lever. Then turn stop screw by
one further turn.
⇒ Secure stop screws with lock nuts.
15
14a 16 14b
012.439/04
2.2.2 Adjustment of mechanical maximum limiter

⇒ Turn back all stop screws 14b.
⇒ Rotate actuator shaft 16 in clockwise direction till the stop inside the actuator.
In this position push the actuator lever onto the actuator shaft and place it at
the corresponding stop screw 14b as near as possible.
⇒ Screw in stop screw 14b till it rests on actuator lever. Then turn stop screw by
one further turn.
⇒ Secure stop screws with lock nuts.

2.3 Fitting of connecting rods

⇒ Adjust the length of connecting rods 13e (Fig. ’E’) to ’x’ = 151.1 mm and con-
nect them with levers 11.
(there are connecting rods 13e for 11 and 12 cylinder engines only)
⇒ Install connecting rods 13a−d as shown in Fig. ’D’ and ’E’.
D I 13e 19
19
13b
2
13a
13d
13c
19
012.401/04
I 13e 19
E
I-I
13b 13a 15 13d 13c
17
11
13e
13e 18 11
012.402/04

2.4 Adjustment of connecting rods

⇒ Set all actuator levers to the mechanical minimum limiters (Pos. ’0’) as shown
in Fig. ’F’.
⇒ Set pointers 19 to Pos. ’0’ by means of adjusting the length of the correspond-
ing connecting rods 13a−d.
F 13b 13a 13d 13c
012.403/04
2.5 Adjustment of fuel pumps

⇒ Set regulating linkage to Pos. ’5’.
⇒ Fit toothed racks 9 and holders 12 with forked levers 3 (Fig. ’G’).
⇒ Adjust the toothed racks to dimension ’x’ = 48 mm by means of adjusting
screws 6. Always screw in one adjusting screw while unscrewing the other by
the same amount.
D The admissible deviation between the individual fuel pumps is ± 0.1 mm.
D If there are no pointers or incorrectly set ones fitted on the regulating shaft, an
easy alternative adjustment (cross check) can be carried out. I.e. a distance of
approx. 5 mm must result between pump housing and stop ring 10 with actua-
tor shaft at pos. ’0’.
Rotate the actuator shafts while checking whether the fuel regulating linkages are
CHECK freely moveable over the whole regulating range.
Stop rings 10 must not touch the fuel pump housing in any of the end positions. A
possible correction can be carried out by adjusting screws 6.
G I
10
x
9
10
12 6
3
I
19
13e
012.432/04

Scavenge Air Receiver and Auxiliary Blower Group 6

Checking the Air Flaps and Cleaning the Scavenge Air Receiver . . . . . . . . . . . . . . 6420−1/A1
Auxiliary Blower: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545−1/A1
Scavenge Air Cooler: Removal and Fitting of SAC and Cooler Pre-stage . . . . . . . 6606−1/A1
Water Separator: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708−1/A1
Scavenge Air Waste Gate: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . 6735−1/A1

Scavenge Air Receiver
Checking the Air Flaps and Cleaning the Scavenge Air Receiver
1 Scavenge air receiver 9 Plate
2 Auxiliary blower box 10 Distance ring
3 Air flap 11 Guide
4 Door 12, 12a Stop plate
5 Auxiliary blower 13 Shaft
6 Cover 14 Pin
7 Screw 15 Drain
8, 8a Screw with locking plate 16 Relief valve
1. Inspection of air flaps
In the course of periodic cleaning of the scavenge air receiver, air flaps 3 (Fig. ’B’)
CHECK must be checked for damage, movability and fouling.
To check air flaps in scavenge air receiver 1, the two doors 4 arranged at the end
are to be opened and locked with pins 14 on the inner sides (Fig. ’A’ view III).
To check upper air flaps, cover 6 must be opened and locked with one of screws 7
(Fig. ’B’ view IV).
5 2 I III
II
16 III
4 14
I
015.145.07a
II

2. Removal of air flaps
⇒ Loosen screws 8 and remove them together with locking plates, plates 9 and
stop plates 12, 12a.
⇒ Loosen screws 8a and remove them together with guides 11, distance rings
10, shaft 13 and air flap 3. Subsequently the air flaps can be withdrawn from
the shaft.
3. Fitting of air flaps
The fitting procedure is analogously to the removal, but in reverse sequence.

Check that the air flaps are freely moveable in fitted condition.
CHECK
IV
B
II - II
6
7
V
IV
V
VI 12a
3
VI VII
018.273/09
12 9 11 9 3 13 10
8
8a
VII
013.077/05
5.09 2/ 3 Wärtsilä Switzerland Ltd

4. Cleaning the scavenge air receiver
Cleaning and checking of the scavenge air receiver must always be carried out
after a piston overhaul. The inside of the scavenge air receiver has to be cleaned at
regular intervals.
At this opportunity check whether drains 15 are not clogged, so that their function is
CHECK assured during operation (Fig. ’C’).
During a major overhaul relief valve 16 must be checked. The valve is set to an
opening pressure of 4.1 $ 0.2 bar (relative).
Remark: Do not open the relief valve with disc springs! In case of any damages or
malfunctions please contact the manufacturer or Wärtsilä Switzerland Ltd.
C D
RELIEF VALVE WITH

COMPRESSION SPRING
15
50 mm
MAX. STROKE
011.960/04
15
RELIEF VALVE WITH
DISC SPRINGS
178 mm
015.149/07a

Auxiliary Blower
Maintenance

1 Spur-geared chain block 94650 1 Electric motor 7 Screw
(recommended tool) 2 Motor plate 8 Screw
1 Dismantling device 94651 3 Spiral casing 9 Longitudinal beam
consisting of: 4 Impeller 10 Strap
1 Trolley 94651c 5 Support 11 Board crane
2 Centring studs 94652 6 Shim
Overview
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/3
2. Support of electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/3
3. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/3
4. Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/3
5. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/3
1. General
Remark: Auxiliary blowers which are out of service for a longer period should be
started up for a short time twice a month. Where this is not feasible, the impeller
should be turned by hand by several turns. This is necessary to protect the bear-
ings from corrosion damage.
2. Support of electric motor
A support 5 is used for electric motor 1.

Level differences are compensated with fitted shims 6. The shims have to be
marked prior to removal.
3. Removal
⇒ Separate electrical leads from electric motor 1.

⇒ Remove screws 7.
A
2 3
8
5 015.142/07

Auxiliary Blower: Maintenance
⇒ Install trolley 94651c and spur-geared chain block 94650 on longitudinal

beam 9.
⇒ Attach electric motor 1 to spur-geared chain block 94650 with ropes of a lifting
capacity of 2000 kg.
⇒ Of screws 8 (Fig. ’A’), unscrew two screws facing each other, then screw in two
centring studs 94652 instead (Fig. ’B’).
⇒ Unscrew the remaining screws of the motor plate.
⇒ Separate the motor plate 2 from the spiral casing with two jacking screws.
⇒ Extract electric motor with plate and impeller 4 from spiral casing in horizontal
direction.
Attention! When removing take care not to damage the impeller.
I B
94651c
9
94650 94652
94652
I
015.143/07
1 2 4
C
10
11
D By means of a second spur-geared chain

block fastened to strap 10 of the exhaust
manifold, the entire unit can be moved, and
subsequently be removed with board crane
11.

Auxiliary Blower: Maintenance
4. Dismantling
For dismantling works and maintenance of the auxiliary blower please comply with
the instructions of the manufacturer.
Remark: The impeller is statically and dynamically balanced, and therefore must
in no way suffer damage. The impeller must be rebalanced in case of any dam-
aged or replaced parts turning together with the motor shaft.
5. Fitting
⇒ Fit centring stud 94652.

⇒ With the aid of dismantling device 94651 fit electric motor 8 including impeller
4 into spiral casing 3 and firmly tighten screws .
⇒ Remove centring stud and replace it by screws.
⇒ Refit and tighten screws 7.
⇒ Connect electric motor to mains and check direction of rotation.

Scavenge Air Cooler
Removal and Fitting of Scavenge Air Cooler and Cooler Pre-stage

1 Lifting device 94660 1 Butterfly valve 13 Scavenge air cooler
2 Lifting plates 94660a 2 Cooling water inlet pipe 14 Bracket
2 Lifting devices 94663a 3 Cooling water outlet pipe 15 Lifting strap
2 Lifting devices 94663b 4 Drain pipe 16 Door
1 Support 94663d 5 Vent pipe 17 Connecting bend
1 Bracket 94663h 6, 6a Screw 18 Cooler pre-stage
1 Wire rope sling* 94666 7, 7a Cover
* (hereafter called rope) 8, 8a Screw AF Seating surface
9, 9a Connection chamber DF Sealing surface
10 Receiver HU Wooden underlay
11 Screw HZ Lifting tackle
12, 12a Spur-geared chain block RC Eye bolt
1. Preliminary works
Risk of accident! Immediately close the openings off after removing bottom
plates!
Remark: Remove the cooler pre-stage separately before the scavenge air cooler,
if necessary.
Pay attention to General Guidelines for Lifting Tools 0012−1.
⇒ Stop the cooling water pump. Close butterfly valves 1 of both (scavenge air)
coolers 13 and drain the coolers.
⇒ Remove drain and vent pipes 4, 5 of both coolers.
⇒ Remove cooling water inlet and outlet pipes 2, 3 of both coolers above butter-
fly valves 1.
⇒ Remove middle bracket 14 (Fig. ’A’) and reinstall it before one of the two cool-
ers (Fig. ’B’). Install a second bracket 14, which is a part of the engine, before
the opposite cooler.
I I-I
14 5
13 3
2
4
16
014.861/06

Removal and Fitting of Scavenge Air Cooler
2. Removal of scavenge air cooler
⇒ Connect cover 7 (362 kg) to a lifting tackle. Loosen screws 6 and remove the
cover.
⇒ Fasten lifting device 94663a to connection chamber 9.
⇒ Fit eye bolt ’RC’ on the opposite connection chamber.
⇒ Connect lifting tackle ’HZ’ to eye bolt ’RC’ and lifting device 94663a.
14 III II
7
I
014.862/06
RC HZ 94663a
II I
6
8
7
9
III
RC

⇒ Pull out the cooler so far till it can be connected to spur-geared chain block 12
(lifting capacity 5000 kg) and rope 94666.
Risk of accident! Take care not to pull out the cooler to much, therefore it must be
secured against falling to the platform by means of a wooden underlay ’HU’ as
shown in Fig. ’C’.
C
I I-I
12
94666
94663a
HU
014.863/06
D
12a
⇒ Pull out the cooler by max. 2000 mm.

⇒ Fasten lifting device 94660 to the
cooler and connect it to spur-geared
2000 mm chain block 12a.
⇒ Remove wooden underlay ’HU’.
014.863/06
94660 HU

⇒ Remove the cooler completely and place it on the platform.

⇒ Remove rope 94666 and lifting tackle ’HZ’.
12
94666
HZ
94663a
014.864/06
⇒ Connect spur-geared chain block 12 to middle eye of lifting device 94663a.

⇒ Lift the cooler a bit and move it so far as possible in the dismantling tool.
⇒ Place the cooler on the platform and remove lifting device 94660.
12
94660
014.864/06

⇒ Fasten a lifting device 94663a to the other end of the cooler.

⇒ Connect spur-geared chain block 12a to middle eye of lifting device 94663a.
G
12a
94663a
15
014.865/06
⇒ Lift the cooler.

⇒ Turn the cooler by 90_. For this purpose, however depending on the rotating
direction, the corresponding outer lifting straps 15 must be removed from both
lifting devices.
⇒ Place the cooler on the platform and disconnect the spur-geared chain block
from the middle eye.
014.865/06

⇒ Refit lifting straps 15 into both lifting devices and tighten them with a torque of
500 Nm.
⇒ Connect the spur-geared chain blocks to upper lifting straps 15.
⇒ Lift the cooler.
⇒ Remove the bottom plate from the platform.
⇒ Lower the cooler (Fig. ’K’).
15
014.866/06

3. Fitting of scavenge air cooler
⇒ Clean sealing surfaces ’DF’ of the cooler and the corresponding ones on the
receiver.
⇒ Remove the old jointing compound and clean longitudinal seating surfaces
’AF’ on both sides of the cooler and the corresponding ones on the receiver.
⇒ Carry cooler to mounting position analogously to removal but in reverse se-
quence and place it on the correct mounting height (Fig. ’K’ to ’G’).
⇒ Fasten bracket 94663h to support 94663d.
⇒ Fasten support 94663d to the platform and bracket 94663h to receiver 11.
⇒ Fasten lifting device 94660 to the cooler.
⇒ Connect lifting tackle ’HZ’ to support 94663d and the lifting device.
⇒ Apply a high-temperature and non-hardening silicone jointing compound
(e.g. COLTOGUN) to longitudinal seating surfaces ’AF’ on both sides of the
cooler.
⇒ Pull the cooler so far as possible into receiver 11 and then remove lifting de-
vice 94660.
⇒ Apply a high-temperature and non-hardening jointing compound to sealing
surfaces ’DF’.
⇒ Pull the cooler fully into the receiver and fasten it.
⇒ Remove lifting devices and refit all screws which were used to fasten the tools
for removal and fitting procedures, into the corresponding tool.
Remark: The fitting procedure of the cooler is same on the opposite side, however,
support 94663d is used without bracket 94663h.
HZ
94663d
014.867/06
94663d 11 94663h
DF AF 94660 94663a
⇒ Install cover 7 with its seal (Fig. ’B’).

⇒ Install all pipings and platform parts.
⇒ Reinstall brackets 14 (Fig. ’A’), respectively dismantle them, in order to
achieve the condition as before beginning of the removal works.
CHECK Vent cooler element and finally carry out a leak test.

Removal and Fitting of Cooler Pre-stage
4. Removal of cooler pre-stage
Pay attention to section 1 ’Preliminary works’.
5 18
17
4
13
10
017.794/08
⇒ Remove all connecting bends 17.

⇒ Connect cover 7a (392 kg) to a lifting tackle. Loosen screws 6a and remove
the cover.
⇒ Loosen screws 8a in the area of cooler pre-stage 18.
⇒ Separate cooler pre-stage from receiver 10 using appropriate jacking screws.
8a
9a I
7a
I 9
6a
7a
011.872/04

⇒ Fasten lifting device 94663b to connection chamber 9a.

⇒ Fit eye bolt ’RC’ on the opposite connection chamber.
⇒ Connect lifting tackle ’HZ’ (lifting capacity 3000 kg) to eye bolt ’RC’ and lifting
device 94663b.
⇒ Pull out cooler pre-stage so far till it can be connected to spur-geared chain
block 12 (lifting capacity 5000 kg) and rope 94666.
⇒ Continue pulling out cooler pre-stage by max. 2000 mm, and fasten lifting
plates 94660a of device 94660 to cooler pre-stage and connect it to spur-
geared chain block 12a.
⇒ Remove cooler pre-stage completely and place it protected by means of a
wooden underlay on the platform.
12 12a
HZ
RC HZ I 94660
94660a
94663g
017.795/08
94663h
94666
9a
94663b
HZ

5. Fitting of cooler pre-stage
⇒ Clean sealing surfaces ’DF’ of the cooler pre-stage and receiver.

⇒ Carry cooler pre-stage 18 to mounting position analogously to removal but in
reverse sequence, and place it on the correct mounting height.
⇒ Fasten bracket 94663h to support 94663g.
⇒ Fasten support 94663g to the platform and bracket 94663h to receiver 11.
⇒ Fasten lifting plates 94660a of device 94660 to the cooler pre-stage.
⇒ Connect lifting tackle ’HZ’ to support 94663g and the lifting device.
⇒ Pull the cooler pre-stage so far as possible into receiver 11 and then remove
lifting device 94660 with lifting plates 94660a.
⇒ Apply a high-temperature and non-hardening jointing compound to sealing
surfaces ’DF’.
⇒ Pull the cooler pre-stage fully into the receiver and fasten it.
⇒ Remove lifting devices and refit all screws which were used to fasten the tools
for removal and fitting procedures, into the corresponding tool.
Remark: The fitting procedure of the cooler pre-stage is same on the opposite
side, however, support 94663g is used without bracket 94663h.
⇒ Install cover 7a with its seal, all connecting bends 17, pipings and platform
parts.
⇒ Reinstall brackets 14 (Fig. ’A’), respectively dismantle them, in order to
achieve the condition as before beginning of the removal works.
CHECK Vent cooler element and finally carry out a leak test.

Water Separator
Removal and Fitting of Water Separator

1 Carriage 94667 1 Door 11 Plate
2 Stops 94667a 2 Pin 12 Water separator
1 Pulley device 94668 3 Cover 13 Support
1 Support 94669 4 Cover 14 Drain pipe
1 Lifting device 94672 5 Receiver 15 Round rubber ring
1 Wire rope sling* 94673 6 Platform support 16 Round rubber ring
* (hereafter called rope) 7 Grid
8 Screw
9 Intermediate ring HZ Lifting tackle
10 Screw RC Eye bolt
1. Preparation
⇒ Loosen doors 1, open up and lock it on the inside with pin 2.

⇒ Attach lifting tackle ’HZ’ (carrying capacity 1000 kg) to the lug on the platform
support (Fig. ’A’ and ’F’).
⇒ Remove platform support 6 and the corresponding bottom plates which hin-
der the removal of the water separator.
Attention! To prevent having a fall, immediately close the openings off after re-
moving the bottom plates!
A HZ
I
1
6
2
1 1
014.807/06

⇒ Remove drain pipes from covers 3.

⇒ Undo cover 3 (35 kg) and tilt it downwards.
⇒ Undo and remove cover 4 (77 kg).
⇒ Undo and remove grids 7.
B
II - II
I
II
I
3
I-I
014.827/06

⇒ Loosen screws 8 and remove them

together with intermediate ring 9.
C
15
8
9
5
12
I
014.822/06
14 3 14
2. Removal
⇒ Put carriage 94667 on support 13

and fasten it to water separator 15.
⇒ Fasten support 94669 to receiver 5.
014.823/06
94667
13
5
94669

⇒ Fit a stop 94667a each into bores ’b’ on both supports 13.
Risk of accident! Both stops must be provided without fail to prevent the water
separator 12 from being pulled out over support 94669!
Remark: When removing the opposite water separator, stops 94667a must be
fitted into bores ’a’, and support 94669 has to be fastened directly below the water
separator to be removed.
⇒ Fit eye bolt ’RC’ on the opposite side.
⇒ Connect lifting tackle ’HZ’ to eye bolt ’RC’ and carriage 94667 (Fig. ’E’).
⇒ Pull out the water separator till the stops.
a 13 94667 94667a HZ RC
014.824/06
94669 12

F
HZ
⇒ Fasten lifting device 94672 onto wa-

ter separator 12.
⇒ Connect lifting tackle ’HZ’ to the lift-
ing device and lift the water separa-
tor slightly.
94672 94667
⇒ Remove carriage 94667 and support
94669.
12 014.835/06
94669
⇒ Lower water separator 12.

⇒ Loosen screws 10 (Fig. ’I’) and re-
move them together with plate 11
and then round rubber ring 16 (Fig.
’C’)
014.835/06

3. Fitting
Prior to fitting the water separator, check drain pipes 14 (Fig. ’C’) for free passage.
CHECK
⇒ Move the water separator to the mounting place as shown in Fig. ’E’ to ’G’ for
the removal but in reverse sequence and bring it to the mounting height.
⇒ Fasten pulley device 94668 to the receiver.
⇒ Lead rope 94673 over the pulley device and connect it to lifting tackle ’HZ’ and
carriage 94667.
⇒ Pull water separator 12 completely into the receiver by means of lifting tackle
’HZ’.
H
I-I
I
94668 94673 HZ
94668
014.836/06
12
I

⇒ Insert screws 8 together with intermediate rings 9 into water separator 15,
however by approx. two turns only.
⇒ Oil and press round rubber ring 15 between receiver and water separator in
such a way till it rests on screws 8.
⇒ Oil and press round rubber ring 16 between receiver and water separator.
⇒ Fasten plate 11 with screws 10.
⇒ Tighten screws 8 and install grids 7 (Fig. ’B’).
⇒ Fit cover 4 (Fig. ’B’).
⇒ Tilt up and tighten cover 3 and install drain pipes 14.
⇒ Close and tighten up doors 1 (Fig. ’A’).
I
I II
15
8
9
II
I 12
16
I-I 5
11
10
15
III - III
III III
014.837/06
16
3

Scavenge Air Waste Gate
1 Housing 7 Lock nut
2 Cover 8 Screw
3 Piston 9 Guide ring
4 Pressure reducing valve 10 Piston seal ring
5 Adjusting screw 11 Compression spring
(stroke limitation) 12 Solenoid valve
6 Seal (1 mm thickness) 13 Silencer
1. Dismantling, function check
A function check must be carried out half-yearly on the running engine (see also
Operating Manual 6735−1). If a malfunction in the waste gate valve occurs it must
be overhauled according to the following instructions at the first opportunity:
Attention! Adjusting screw 5 must not be readjusted!
⇒ Loosen screw 8 for cover 2. Specially long screws are fitted for releasing the
spring 11.
⇒ Dismantle piston 3. Clean piston and housing 1.
⇒ Check piston seal ring 10, guide rings 9 and replace them if necessary.
⇒ After reassembling smear piston lightly with oil and check its easy movement
in the housing.
2. Assembling
Assembling is carried out analogously to dismantling but in reverse sequence.

Attention! Should seal 6 need to be replaced, attention must be paid to ensure
that a seal of the same thickness (1 mm) is refitted.
Before assembling smear all moving parts lightly with clean oil.
Remark: The retaining pressure is adjusted with pressure reducing valve 4.
A B
4 3 9 10 11
6
12
2
13
1
WCH00828 014.132/06

Cylinder Lubrication Group 7

Lubrication Pump CLU4: Checking the Gas Pre-charge Pressure . . . . . . . . . . . . . 7218−1/A1
Lubrication Pump CLU4−C: Checking the Gas Pre-charge Pressure . . . . . . . . . . . 7218−1/A2
Wärtsilä Switzerland Ltd 1/ 5 Pulse / RT−flex84T−D / MM / 2010

Lubricating Pump CLU4
Checking / Refilling the Gas Pre-charge Pressure
1 Case 94720c 1 Hydraulic accumulator 9 Lubricating oil inlet

consisting of: 2 Protection cap 10 Servo oil outlet
measurement set complete 3 Pressure reducing valve 11 Measuring connection M16
for checking / refilling of 4 Hose (1 m) 12 Screw plug
hydraulic accumulator 5 Hose (4m) 13 Vent plug (Zyl. Lubr. oil)
6 Control unit with valves A,B,C 14 Nitrogen bottle
7 Pressure gauge 0...60 bar 15 Vent plug (servo oil)
8 Lubricating pump (CLU4)
1. Checking / refilling the gas pre-charge pressure
the engine is at standstill. Furthermore see also Operating Manual 7218−1.
Check the pre-charge pressure directly after the installation of a new accumulator,
CHECK then at least once in the first week after start-up. Afterwards, check the pre-charge
pressure every three months.
pressure checking and charging. Also no residual oil pressure in the servo oil sup-
ply line must be visible on pressure gauge PI2041L of pressure reducing valve
8.11−1.
1.1 Preparation before checking / refilling

Before starting any maintenance work, ensure that the servo oil supply unit is
switched off and the servo oil pressure is completely released.
In any case, when the accumulator has been removed the lubricating pump has to
be vented, see paragraph 2.2 ’Venting the lubricating pump’.
− Close the stop valve 4.30−5 on servo oil rail 4.11 (Fig. ’D’).
− Drain the servo oil system at screw plug 12 of pressure reducing valve 8.11−1
(Fig. ’E’).
Remark: Screw plug 12 must remain open during the entire checking / refilling
procedure.
1.2 Tools for pre-charge pressure checking / filling

For checking / filling the pre-charge pressure of the accumulator always use
the measurement set case 94720c!
Wärtsilä Switzerland Ltd 1/ 5 CLU4 / 2011-07

Lubricating Pump CLU4: Checking / Refilling the Gas Pre-charge Pressure
1.3 Checking the pre-charge pressure on a new-type accumulator

For the below work procedure, the accumulator does not have to be disconnected
from the lubricating pump.
Remark: During every check a small amount of gas may be lost to atmosphere.
Therefore, in order to make up possible losses make sure a nitrogen bottle is avail-
able before a pre-charge pressure check is made.
Procedure for checking / refilling the gas pre-charge pressure:

⇒ Close the three valves A, B and C on control unit 6 (Fig. ’A’).
⇒ Connect accumulator 1 to valve A using hose 4.
⇒ Open valve A and read the pressure on gauge 7.
Required pre-charge pressure: min. 20 bar / max 25 bar.
⇒ If pre-charge pressure is within the given limit, close valve A and vent remain-
ing pressure in the control unit by opening valve B. Disconnect hose 4 from the
accumulator and refit protection cap 2.
If it is required to refill the accumulator, please continue to next point.
Remark: The accumulator may only be filled with super-clean, Class 4.0 nitrogen,
99.99% N2 by volume.
⇒ Connect pressure reducing valve 3 to nitrogen bottle 14 (Fig. ’B’).
⇒ Connect pressure reducing valve to control unit 6 at valve C using hose 5 and
adjust the outlet pressure to approx. 30 bar.
⇒ Close the three valves A, B and C on the control unit.
⇒ Close valves A and C and vent the remaining pressure in the control unit by
opening valve B.
⇒ Disconnect hoses 4 and 5, remove the tools and refit all protection caps.
2011-07 / CLU4 2/ 5 Wärtsilä Switzerland Ltd

2. Final assembly
2.1 After checking / refilling procedure

⇒ Reopen stop valve 4.30−5 on servo oil rail 4.11 (Fig. ’D’).
⇒ Close screw plug 12 of pressure reducing valve 8.11 (Fig. ’E’).
After checking the pressure and refilling the accumulator, ensure to run the servo
oil supply system and vent air from the system before putting the pulse lubricating
system into operation.
2.2 Venting the lubricating pump

The lubricating pump has to be vented after refitting the accumulator.
The lubricating pump contains two vent plugs (Fig. ’C’):
− Vent plug 13 for the cylinder lubricating oil.
− Vent plug 15 for the servo oil.
Required equipment:
− Oil collection tray.
− Cloth to wipe up escaping oil.
Venting the cylinder lubricating oil:

⇒ Place an oil collection tray beneath the lubricating pump.
⇒ Loosen vent plug 13 for the cylinder lubricating oil. For this, turn the plug
counter-clockwise a maximum of three turns.
⇒ Wait until bubble-free oil escapes at the vent plug.
⇒ Tighten the vent plug again.
Venting the servo oil:

Attention! The servo oil system is under high pressure. Oil may spurt out when the
screws are loosened. Do not loosen the vent plug more than three turns. Wear
safety goggles!
Proceed as follows to vent the servo oil section of the lubricating pump:
⇒ Place an oil collection tray beneath the lubricating pump.
⇒ Operate the lubricating system via manual lubrication or intermediate lubrica-
tion operation (for additional details see also the Operating Manual 7218−1).
⇒ This is only possible after the servo oil priming pressure has been achieved by
starting the servo oil pumps.
⇒ Loosen vent plug 15 for the servo oil. For this, turn the plug counter-clockwise
a maximum of three turns.
⇒ Wait until bubble-free oil escapes at the vent plug.
⇒ Tighten the vent plug again.

Case with measurement set 94720c:
A C
Case 94720c B
4, 5 3 6 1 2 4
B 3 7
A C 1
14
5 6 4
2011-07 / CLU4 4/ 5 Wärtsilä Switzerland Ltd

Lubricating pump (CLU4):
TO LUBRICATING
QUILLS
C
13 15
8
9
10
SERVO
OIL 1
11
015.438/07
Details of servo oil rail 4.11 −> pressure reducing valve 8.11−1:
D E
8.06
RAIL UNIT
4.11 PI2041L
8.11−1
12
WCH00861
DRAWN FROM CONTROL
DIAGRAM 4003−2
WCH00852

Lubricating Pump CLU4−C
Checking the Gas Pre-charge Pressure
1 Case (for CLU4−C) 94720c 1 Hydraulic accumulator 8 Lubricating pump (CLU4−C)

consisting of: 2 Protection cap 9 4/2-way solenoid valve
measurement set complete 3 Pressure reducing valve 10 Shut-off valve servo oil
for checking / refilling of 4, 4a Hose (1m, 4 m) 11 Venting valve servo oil
hydraulic accumulator 5 Control unit with 12 Venting valve lube oil
valves A, B and C 13 Screw plug
the engine is at standstill. Furthermore see also Operating Manual 7218−1.
Check the filling pressure at least once in the first week after startup of the accumu-
CHECK lator. If no loss of gas is observed, recheck after three months. If there is still no
pressure checking and charging. Also no residual oil pressure in the servo oil sup-
ply line must be visible on pressure gauge PI2041L of pressure reducing valve
8.11−1.
1.1 Preparation
− Close stop valve 4.30−5 on servo oil rail 4.11 (Fig. ’D’).
− Drain servo oil system on screw plug 13 of pressure reducing valve 8.11−1
(Fig. ’E’).
dure.




Lubricating Pump CLU4−C: Checking the Gas Pre-charge Pressure


approx. 40 bar.
⇒ Connect pressure reducing valve with long hose 4a to the right side, and accu-
mulator with short hose 4 to the left side of control unit.
valve B.

⇒ Reopen stop valve 4.30−5 on servo oil rail 4.11.
⇒ Close screw plug 13 on pressure reducing valve 8.11−1.
2010 / CLU4−C 2/ 4 Wärtsilä Switzerland Ltd

Case with measurement set 94720c for CLU4−C:
A C
Case 94720c B
4, 4a 3 5 1 2 4
B 4 14
10 7
5
A C
4a

Lubricating pump (CLU4−C):
C
TO LUBRICATING
QUILLS
11
SERVO 10
OIL
12
8
2
018.211/09
Details of servo oil rail 4.11 −> pressure reducing valve 8.11−1:
D E
8.06
RAIL UNIT
4.11
PI2041L
8.11−1
13
WCH00861
DRAWN FROM CONTROL
DIAGRAM 4003−2
WCH00852
2012-07 CLU4−C 4/ 4 Wärtsilä Switzerland Ltd

Piping Group 8
Exhaust Waste Gate (Low-Load Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8135−1/A1
Servo Oil Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . 8447−1/A1

Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding . . . . 8460−1/A1
Intermediate Fuel Accumulator: Checking and Setting of Relief Valve . . . . . . . . . . 8750−1/A1
Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling . . . . 8750−2/A1

Removing, Fitting and Regrinding of Sealing Faces . . . . . . . . . . . . . . . . . . . . . . . . . 8733−1/A1
Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8752−1/A1

Exhaust Waste Gate (Low-Load Tuning)
1. General
The Low-Load Tuning concept is based on the combination of a specifically de-

signed turbocharging system setup and appropriately adjusted engine parame-
ters related to fuel injection and exhaust valve control. This allows enhancing the
performance of engines while operating at low part loads, in particular in the range
up to 70% load, by realizing considerably reduced fuel consumption as well as low-
er thermal load and thus improved engine reliability.
2. Maintenance
D Butterfly valve 1 does not require special maintenenace. For a general in-
spection however, the instructions of the valve manufacturer must be fol-
lowed.
D Keep the articulations of the cardan rods clean, but smeared with a heat-
resistant lubricant, e.g. Never-Seez NSBT-8.
D To carry out a function check see 8135−1 in the Operating Manual and Mainte-
nance Schedule 0380−1.
I
7
I
10 4
1
6
8
10
WCH00129
WCH00125
2 3
9 5
1 Butterfly valve 6 Exhaust manifold
2 Control actuator (one or two) 7 Exhaust by-pass line
3 Feedback sensor ZS5372C 8 Exhaust gas turbocharger
4 Orifice 9 Control air supply
5 Control air pipe 10 Cardan rod

Servo Oil Piping
Removing, Fitting and Regrinding

1 Tool box with 1 Servo oil pump 11 Claw
grinding machine 94835 2 Collector block 12 Thrust ring
3 Intermediate piece 13 Screw
4, 4a Servo oil piping 14 Screw with disc
5, 5a Servo oil piping 15 Relief valve
6 Stop valve 16 Screw plug
7 Stop valve 17 O-ring
8, 8a Drain screw 18 O-ring
9 Valve block
10 Flange DF Sealing face
1. Removal
1.1 Removal of servo oil pipings

A ⇒ Remove the casing where necessary.
7 7
⇒ Close stop valves 6 and 7 for corresponding
9 servo oil pipings 4, 4a and 5, 5a.
8a ⇒ Open drain screw 14.
Remark: The spindles of the closed stop valves
must be tightened with 200 Nm.
⇒ Hold corresponding servo oil piping (51−75
10 kg) by means of a lifting tackle.
13 ⇒ Open drain screw 8, vent and drain servo oil

piping by means of relevant screw plugs 18
(Fig. ’B’).
5 ⇒ Push flanges 10 back till they are no more en-
4 gaged, so that the servo oil piping can be re-
moved.
3
D Pay attention not to damage sealing faces
’DF’ when removing servo oil pipings.
4a
5a D All connections must be closed off immediate-
ly and the sealing faces must be protected af-
ter removing the servo oil pipings.
I
I
2 8 6 4a, 5a
15
1
014.785/06 014.305/06

Servo Oil Piping: Removing, Fitting and Regrinding
2. Fitting
x = 10 mm
2.1 Checking the claw position

17
⇒ Before fitting the servo oil piping check
11 16 whether its claws 11 are screwed on properly
as shown in Fig. ’B’, i.e. the servo oil piping
10 must protrude by ’x’ = 10 mm compared to the
claw.
12
D Measure ’x’ can be adjusted by turning the
claw using an open-end wrench.
4, 4a Remark: On newer engines claw 11 and thrust
18 5, 5a ring 12 are provided in one piece.
014.449/06
C
2.2 Replacing an intermediate piece
In order to install the servo oil pipings without ten-
sion, adjusted and accordingly marked intermedi-
ate pieces 3 are provided.
As hardened seating surfaces are applied in the
intermediate piece, regrinding is not possible.
− If replacement is required an intermediate
piece with the same distance ’x’ must be
3 fitted.
x
14 − If replacement of servo oil pipings are re-

quired, first distance ’x’ must be redeter-
mined.
⇒ Fit and align servo oil pipings. Equally fasten
them with corresponding flanges 10 and
screws 13.
⇒ Measure distance ’x’.
014.786/06
D There are intermediate pieces available in
steps of 2 mm for distances ’x’ from 89 to 101

Servo Oil Piping: Removing, Fitting and Regrinding
2.3 Fitting the servo oil pipings

Fitting is carried out analogously to the removal but in reverse sequence, whereby
the following points require special attention:
D Intermediate pieces 3 must be fitted in the same place as before and fastened
with screws 14 and their washers, however after fixing the servo oil pipings.
D Oil threads of screws 13 and tighten them crosswise with a torque of 170 Nm.
D Close drain screws and screw plugs.
D After refitting the servo oil pipings open stop valves 6 and 7, and tighten their
spindles with 200 Nm.
After starting up servo oil system, a leakage check can be carried out by opening
CHECK screw plugs 16 (Fig. ’B’) in flanges 10 (see also 8016−1 in the Operating Manual).
3. Regrinding the sealing faces ’DF’
D
DF
D Tool 94835 must be used according to the
manufacturer’s detailed instructions for re-
grinding sealing face ’DF’.
⇒ Unscrew corresponding claw 11 (Fig. ’B’).
⇒ To prevent grinding compound from entering
the servo oil piping, plug its openings with a
4, 4a piece of cloth.
5, 5a ⇒ After grinding thoroughly clean the servo oil
014.936/06 piping.

Hydraulic Piping for Exhaust Valve Drive

1 Tool box with 1 Exhaust valve control unit 11 Gasket
grinding machine 94835 2 Servo oil rail 12 Clamping flange
3 Cover 13 Clamping flange
4 Pre-control valve 14 Waisted screw
5 Hydraulic piping 15 Joint disc
6 Metallic hose 16 Screw
7, 7a Housing 17 O-ring
8, 8a Screw
9 Holder DF Sealing face
10 Screw KC Check bore
1. Removal
When working on a hydraulic piping 5 the engine has to be stopped, and it is essen-
tial that instructions 0520−1 ’Exchange of defective exhaust valve control unit or
hydraulic piping’ in the Operating Manual be strictly followed.
Before beginning dismantling works recheck whether the servo and control oil sys-
CHECK tem is pressureless and drained.
A
I I
14
12 13
9
10
7a 8a
11
x 015.860/07
II
8
7
3
4
II
1 2
014.788/06

Hydraulic Piping: Removing, Fitting and Regrinding
⇒ Connect the hydraulic piping to the crane. Loosen screws 8, 8a by several

turns and then carefully use the rope reciprocating the hydraulic piping so that
it can be drained via check bore ’KC’.
⇒ Remove holder 9 (Fig. ’A’).
⇒ Loosen screws 8 and undo screws 8a.
⇒ Turn housing 7a back by 2−3 turns, draw hydraulic piping 5 axially back and
move it to the side.
⇒ Undo screws 8 and remove the hydraulic piping by means of the crane.
D Pay attention not to damage sealing faces ’DF’ when removing the hydraulic
piping.
D All openings must be closed off immediately after removing the connections.
B II
I
5
17 16 8a 6
7
x
014.789/06
17
6 5 KC
3 15
15 7a
x
1
014.283/06
2. Fitting
Check before assembly whether the inside of the hydraulic piping, sealing faces
CHECK ’DF’ of the piping ends, the seating surfaces of joint disc 15 are clean and undam-
aged, and whether O-rings 17 (gaskets 11 if necessary) are in good condition.
D Fitting together should be carried out axially, i.e. the objects to be connected
must not be moved closer together laterally, in order to avoid any damaging
of sealing faces ’DF’.
D Housing 7 or 7a (Fig. ’B’) should be screwed on hydraulic piping 5 in such a
manner that after tightening screw 8 or 8a clearance ’x’ is about 3 mm.
D Fasten holder 9 in longitudinal direction without stresses, i.e. providing the
corresponding shims.
Remark: If the hydraulic piping has been separated, the following must be addi-
tionally observed:
− Clean hydraulic piping and clamping flanges 12, 13 and fix them in such a
manner that clearance ’x’ is about 8 mm equally distributed after tightening
waisted screws 14.
− Oil the threads and apply a torque of 70 Nm to the waisted screws and retigh-
ten these after 1000 operating hours.

Hydraulic Piping: Removing, Fitting and Regrinding
3. Regrinding the sealing faces ’DF’
C
DF
D Tool 94835 must be used according to the
manufacturer’s detailed instructions for re-
grinding sealing face ’DF’.
⇒ Screw off housing 7, 7a concerned (Fig. ’B’).
⇒ To prevent grinding compound from entering
the hydraulic piping, plug its openings with a
5 piece of cloth.
⇒ After grinding thoroughly clean the hydraulic
014.936/06 piping.

Removing, Fitting and Regrinding of Sealing Faces

1 Regrinding device 94870 1 Cylinder cover 10 Connection piece
consisting of: 2 Injection valve 11 Drain screw
1 Screw-on sleeve 94870a 3 Injection control unit 12 Pipe bracket
1 Grinding tool 94870b 4 Fuel rail 13−15 O-ring
1 Lock nut 94870c 5 Fuel pressure pipe
1 Template 94870d 6 Claw
7 Thrust ring DF Sealing face
1 Torque wrench 8 Flange EC Emry cloth
9 Head screw HD Hand drill
1. Removal
When working on a fuel pressure pipe 5 the engine has to be stopped, and it is
essential that instructions 0510−1 in the Operating Manual be strictly followed.
⇒ Remove all pipe brackets 12.
⇒ Remove head screws 9 from flange 8 on injection valve 2 and injection control
unit 3 (Fig. ’A’ and ’C’).
D Pay attention not to damage sealing faces ’DF’ when removing fuel pressure
pipes 5.
D All connections must be closed off immediately and sealing faces ’DF’ must be
protected after removing fuel pressure pipes.
I-I
12 13
I 5
9
8
2 7
I
1
6
14
DF
4
014.803/06

Fuel Pressure Piping: Removing, Fitting and Regrinding of Sealing Faces
2. Fitting
Fitting procedure is analogous to the removal but in re-

B
X = 11mm
verse sequence.
Before fitting fuel pressure pipe 5 check whether its
CHECK
claws 6 are screwed on properly, i.e. the fuel pressure
pipe must protrude by ’x’ = 11 mm compared to the claw
as shown in Fig. ’B’.
Measurement ’x’ can be adjusted by turning the claw us-
6 ing an open end spanner.
7 ⇒ Fit fuel pressure pipe.

⇒ Apply Never-Seez NSBT-8 to threads of screws 9
8
and tighten them crosswise with a torque of 40 Nm.
D (Connection piece 10 is smeared with Never-Seez
NSBT-8 and tightened with a torque of 700 Nm).
II - II
5
10
2
1 15
3
13
9
12
5 8
7
11
6
14
014.804/06
10
II II DF

3. Regrinding of sealing faces ’DF’
3.1 With regrinding device 94870

In order to achieve a clean and smooth sealing face the following regrinding pro-
cess is recommended. For deep notches > 0.1 mm choose emery cloth of medium
to coarse grade. Once the deep notches have been ground off, use a fine or ultra
fine emery cloth.
⇒ Place template 94870d on the back of emery cloth

’EC’ .
⇒ Trace inner contour using a pointed pencil or a ball
94870d
pen.
⇒ Cut out precisely the traced contour.
EC
016.738/08
E
⇒ Shape the cut cloth in a manner to obtain a cone with
the grained face being turned inward.
94870b ⇒ Place the emery cloth in the cone of the grinding tool
94870b and fix it by means of its countersunk screw.
GRAINED FACE
TIGHTENED
CONDITION
016.738/08

F
⇒ Remove claw 6 (Fig. ’B’).
1. 2.
⇒ Fix fuel pressure pipe 5, e.g. in a vice.
⇒ Screw on counter nut 94870c until it reaches the
thread end of the fuel pressure pipe.
016.739/08
⇒ Turn screw-on sleeve 94870a up to the counter nut.
5 94870c 94870a ⇒ Lock the screw-on sleeve with the counter nut.
⇒ Clamp grinding tool 94870b in hand drill ’HD’.

⇒ Slide grinding tool into the screw-on sleeve
until it slightly touches the fuel pressure pipe.
016.739/08
⇒ Let the grinding tool rotate with a max. speed
94870b HD of 1500 rpm and grind for 3 to 5 seconds.
H ⇒ Withdraw the grinding tool from the screw-on sleeve

and blow out both parts with pressurized air.
⇒ Verify the surface quality of sealing face ’DF’ and if
necessary repeat the regrinding process using a
DF
fresh emery cloth ’EC’.
Remark: In case of big notches the tube has to be short-
ened in order to restitute a clearance of ’x’ = min. 0.5 mm
between the countersunk screw and the end face.
016.739/08
x ⇒ Remove counter nut and screw-on sleeve.

⇒ After grinding thoroughly clean the fuel pressure
pipe.

Intermediate Fuel Accumulator
Checking and Setting of Relief Valve

1 OBEL test bench 94272 1 Valve housing 11 Fuel overpressure
1 Valve holder 94272a 2 Valve needle safety valve 3.52
1 HP oil pump 94931 3 Ball 12 Receiver
2 Hydr. distributors 94934a 4 Spring carrier 13 Back-up ring
1 HP hose 94935 5 Disc spring (11 pieces) 14 O-ring
6 Stop ring
7 Distance ring
8 Seating washer AB Drain bore
9 Snap ring EV Relief valve
10 Screw plug MK Marking ∅3 mm
A
Y X
10
OPENING PRESSURE
STAMPED IN
3
4
015.499/07
1 2
AB
6 7 14 13 MK 5 8 9
1. General
Before dismantling a relief valve for overhaul (grinding in of the valve needle), dis-
CHECK tance ’X’ must be measured and recorded as ’X’. For this purpose, distance ring 7
must be pressed against stop ring 6 by screw plug 10.
⇒ After grinding valve needle 2 into the seat of valve housing 1, thoroughly clean
all parts, lightly oil valve needle 2 and apply MOLYKOTE paste G to parts 3, 4,
5 and 8.
D During assembly, care must be taken that disc springs 5 are correctly fitted.
⇒ Not yet fit distance ring 7.
⇒ Tighten screw plug till distance ’X’ is approx. the same as before dismantling.
⇒ For testing and setting the relief valve use test bench 94272.
Remark: To identify the new fuel overpressure safety valve (relief valve) 11 two
bores ∅ 3 mm ’MK’ have been provided as a marking.

Intermediate Fuel Accumulator: Checking and Setting of Relief Valve
2. Setting the opening pressure
⇒ Fit relief valve 11 (without joint) into the valve holder and tighten it.
⇒ Connect valve holder 94272a to HP oil pump 94931.
⇒ Increase the pressure by means of HP oil pump and observe at what value the
fuel relief valve opens. Correct opening pressure = 1250 bar.
⇒ Set required pressure by adjusting screw plug 10. Measure distance ’X’ and
note it as ’X1’ (Fig. ’A’).
⇒ Reduce height ’Y’ of distance ring 7 by the difference between distances ’X1’
and ’X’.
⇒ Reassemble relief valve with the distance ring and tighten screw plug until it is
fully down on the distance ring.
Recheck the opening pressure on the completely assembled fuel relief valve.
CHECK
94934a
94935
94272a
11
12
013.484/05 94272
94931 EV 94934a
013.486/05
3. Fitting the relief valve
⇒ Apply Never-Seez NSBT-8 to the thread of valve housing 1.

⇒ Screw the relief valve into the intermediate fuel accumulator and tighten it with
a torque of 300 Nm.

Fuel Pressure Control Valve
Removal, Fitting, Dismantling and Assembling
1 Fuel pressure control valve 15 Intermediate fuel accumulator
2 Piston 16 Flange
3 Valve tip 17 Screw M16x200
4 Valve seat 18 Locating pin
5 Oil pressure regulating valve 19 Intermediate ring
6 Compression spring 20 Connection piece
7 Compression spring 21 Solenoid valve
8 Knurled screw 22 Allen screw M6x55
9 Adjusting disc 23...25 O-rings
10 Housing
11 Cover
12 Cover BA Fuel outlet
13 Filter BE Fuel inlet
14 Union OE Oil inlet pipe
1. General
To avoid any risk of failures related to the fuel pressure control valve (PCV),
Wärtsilä recommends only performing the below mentioned maintenance. PCV
maintenance onboard is limited to:
− Replacement of the complete PCV
− Replacement of the 3/2-way solenoid valve
− Replacement or cleaning of the control oil inlet filter
Remark: In case the PCV was replaced on a previous occasion, Wärtsilä offers a
new or remanufactured PCV which will be equipped and set according to the latest
technical specification with the correct pressure adjustment.
For detailed maintenance intervals of the PCV refer to the Maintenance Schedule
0380−1.
The engine has to be stopped when working on a PCV and the instructions 0515−1
in the Operating Manual must be strictly followed.
1 21
WCH00845

Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling
2. Removal of fuel pressure control valve
⇒ Remove all pipings from fuel pressure control valve 1.

⇒ Connect the PCV (45 kg) to the crane by means of a manual ratchet.
⇒ Loosen screws 17 and move the PCV in arrow direction, taking care that inter-
mediate ring 19 and connection piece 20 do not fall down.
3. Fitting the fuel pressure control valve
⇒ Bring the PCV in fitting position at the fuel rail by means of a manual ratchet.
⇒ Apply Never-Seez NSBT-8 to the screw threads 17.
⇒ Place new O-rings 23 and 24 into the grooves of intermediate ring 19.
⇒ Fit the intermediate ring over locating pin 18 and insert connection piece 20.
⇒ Fasten the PCV to flange 16 with screws 17 and tighten them crosswise with a
torque of 190 Nm.
18 19 20
1 16
17
15
WCH00845
1 23
I
24 16

Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling
4. Cleaning the filter
⇒ Remove oil inlet pipe ’OE’ and union 14.

⇒ Loosen filter 13 and clean it. If necessary replace it.
⇒ Oil the filter, screw it into cover 12 and apply a torque of 10 Nm.
14 12 13
8
9
2
7 OE
6
11
3 25 21 22
5 10
4
BE WCH00763
OIL BA
FUEL OIL
5. Storage on board
The spare parts must be carefully protected against corrosion.

D The PCV has to be free from any dirt, oil and grease.
D Apply coating liquids (e.g. Tectil 506, ISOTEC 337 or similar) on the surfaces
to be preserved.
D All blind holes and tapped holes must be plugged.
Especially consignments transported overseas must be well protected against ad-
verse climatic conditions (intense cold, rain, high humidity, etc.) and kept in a
closed box.


1 Regrinding device 94870 1 Intermediate fuel accumulator 12 Screw with disc
consisting of: 2 Stop valve 13 Intermediate piece
1 Screw-on sleeve 94870e 3 Stop valve 14 Union joint
1 Grinding tool 94870f 4, 4a Fuel pressure piping 15 Heating pipe
1 Lock nut 94870g 5, 5a Fuel pressure piping 16 Fuel pressure pipe
1 Template 94870h 6 Valve block 17 Screw
7 Drain screw 18, 19 O-ring
1 Torque wrench 8 Flange
9 Claw DF Sealing face
10 Thrust ring EC Emery cloth
11 Screw HD Hand drill
1. Removal
14
15
1.1 Preparation to removal

5 Risk of injury! Always use gloves when
4 working on hot components and wear safety
goggles!
13 D If a fuel pressure piping 4, 5 must be
removed, first dismantle the corre-
4a sponding fuel pressure piping 4a, 5a.
5a ⇒ Close steam supply to heating pipes
on plant side.
⇒ Undo union joints 14 of corresponding
heating pipes 15.
⇒ Remove the casing and pipe brackets
where necessary.
⇒ Close stop valves 2 and 3 for corre-
17 3 sponding fuel pressure pipings.
16
Remark: The spindles of the closed stop
valves must be tightened with 100 Nm.
014.825/06

Fuel Pressure Piping: Removing, Fitting and Regrinding
1.2 Removal of fuel pressure piping

⇒ Loosen screws 11 and push flanges 8 slightly back, so that the fuel pressure
pipings can be drained by means of corresponding drain screws 7.
⇒ Undo corresponding screws 11 and push flanges 8 back till they are no more
engaged. Pull the lower fuel pressure piping 4a, 5a away and remove it from
intermediate fuel accumulator 1.
⇒ Undo screws 12 and remove them together with intermediate piece 13, so that
now the upper fuel pressure piping 4, 5 can be removed.
D Pay attention not to damage sealing faces ’DF’ when removing fuel pressure
pipings.
D All connections must be closed off immediately and the sealing faces must be
protected after removing the fuel pressure pipings.
6
B
8
11
14
I 15
14
15
I
12
13
14
014.825/06

2. Fitting
X = 16.5mm
2.1 Checking the claw position

18
9 ⇒ Before fitting the fuel pressure piping check
whether its claws 9 are screwed on properly
7
as shown in Fig. ’C’, i.e. the fuel pressure pip-
10 ing must protrude by ’x’ = 16.5 mm compared
8 to the claw.
D Measure ’x’ can be adjusted by turning the
claw using an open-end wrench.
19
4, 4a
5, 5a
014.493/06
2.2 Replacing an intermediate piece

D
In order to install the fuel pressure pipings without
tension, adjusted and accordingly marked inter-
mediate pieces 13 are provided.
As hardened seating surfaces are applied in the
intermediate piece, regrinding is not possible.
− If replacement is required an intermediate
piece with the same distance ’x’ must be
13 fitted.
x
− If replacement of fuel pressure pipings are re-

quired, first distance ’x’ must be redeter-
mined.
⇒ Fit and align fuel pressure pipings. Equally
fasten them with corresponding flanges 8
and screws 11.
014.826/06 ⇒ Measure distance ’x’.

D There are intermediate pieces available in
steps of 2 mm for distances ’x’ from 11 to 23
mm.

2.3 Fitting of fuel pressure piping

Fitting is carried out analogously to the removal but in reverse sequence, whereby
the following points require special attention:
D Intermediate pieces 13 must be fitted in the same place as before and fas-
tened with screws 12 and their washers, however after fixing the fuel pressure
pipings.
D Apply Never-Seez NSBT-8 to threads of screws 11 and tighten them cross-
wise with a torque of 60 Nm.
D Close all drain screws.
D After refitting the fuel pressure pipings open stop valves 2 and 3 and tighten
their spindles with 100 Nm.
A leakage check can be carried out by opening drain screws 7 (Fig. ’C’) in flanges 8
CHECK (see also 8019−1 in the Operating Manual).
2.4 Fitting of fuel pressure pipe

A defective fuel pressure pipe must always be replaced completely.
Before fitting fuel pressure pipe, check whether their claws are screwed on proper-
CHECK ly, i.e. fuel pressure pipe 16 must protrude by ’x’ = 13.4 mm compared to the claw.
D Apply Never-Seez NSBT-8 to threads of screws 17 and tighten them cross-
wise with a torque of 70 Nm.
16
WCH00084

3. Regrinding of sealing faces ’DF’
3.1 With regrinding device 94870

In order to achieve a clean and smooth sealing face the following regrinding pro-
cess is recommended. For deep notches > 0.1 mm choose emery cloth of medium
to coarse grade. Once the deep notches have been ground off, use a fine or ultra
fine emery cloth.
⇒ Place template 94870h on the back of emery cloth

’EC’ .
⇒ Trace inner contour using a pointed pencil or a ball
94870h
pen.
⇒ Cut out precisely the traced contour.
EC
016.738/08
G
⇒ Shape the cut cloth in a manner to obtain a cone with
the grained face being turned inward.
94870f ⇒ Place the emery cloth in the cone of the grinding tool
94870f and fix it by means of its countersunk screw.
GRAINED FACE
TIGHTENED
CONDITION
016.738/08

H ⇒ Remove claw 9 (Fig. ’C’).

⇒ Fix fuel pressure piping 4, 4a, 5, 5a, e.g. in a vice.
1. 2.
⇒ Screw on counter nut 94870g until it reaches the
thread end of the fuel pressure piping.
016.739/08 ⇒ Turn screw-on sleeve 94870e up to the counter nut.

⇒ Lock the screw-on sleeve with the counter nut.
4,4a,5,5a 94870g 94870e
⇒ Clamp grinding tool 94870f in hand drill ’HD’.

⇒ Slide grinding tool into the screw-on sleeve
until it slightly touches the fuel pressure
016.739/08 piping.
94870f HD ⇒ Let the grinding tool rotate with a max. speed
of 1500 rpm and grind for 3 to 5 seconds.
J ⇒ Withdraw the grinding tool from the screw-on sleeve

and blow out both parts with pressurized air.
⇒ Verify the surface quality of sealing face ’DF’ and if
necessary repeat the regrinding process using a
DF
fresh emery cloth ’EC’.
Remark: In case of big notches the tube has to be short-
ened in order to restitute a clearance of ’x’ = min. 0.5 mm
between the countersunk screw and the end face.
016.739/08
x ⇒ Remove counter nut and screw-on sleeve.

⇒ After grinding thoroughly clean the fuel pressure
piping.

Crank Angle Sensor Unit, Tools Group 9

Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting . . . . . . . . . . . . . 9223−1/A1
Tools: Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−1/A1
Hydraulic Jacks and Pumps: Arrangement and Application . . . . . . . . . . . . . . . . . . . 9403−2/A1

− Storing, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−3/A1
− General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−4/A1
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−5/A1

− Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 01 − 41
− Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 42 − 46
− Special Tools Obtainable on Loan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 47 − 49

Crank Angle Sensor Unit
Dismantling, Assembling and Adjusting

1 Feeler gauge 94122 1 Protection hood 37 Disc
1 Hook spanner 94924 2 Covering cap 38 Key
1 Hook spanner 94925 3 Screw 39 Packing ring
4 Nut 40 Locating pin
5 Shaft 41 Inspection cover
6 Crank angle sensor (CAS) 42 Compression spring
7 Holder 43 Lever
8 Screw 44 Screw with locking plate
9 Toothed belt 45 Throttle
10 Protection plate 46 Housing
11 Screw with locking plate 47 Screw
12 Angle holder 48 Screw
13 Outer shaft encoder 48a Locking plate
13a Inner shaft encoder 49 Connecting unit
14 Bearing housing 50 Locating pin
15(a) Screw 51 Coupling disc
16 Washer 52 Spring tensioner
17 Locking plate 53 Screw with locking plate
18 Gear wheel 54 Adjusting screw
19 Gear wheel 55 Clamp screw w. tab washer
20 Waisted screw 56 Distance piece
21 Screw with locking plate 57 Screw with locking plate
22 Packing ring 58 Locating pin
23 Adjusting disc 59 Spring balance
24 Locking plate 60 O-ring
25 Shaft nut
26 Locking plate
27 Shaft nut GL Tap hole
28 Circlip KD Cable clamp
29 Retaining ring KK Terminal box
30 Sealing ring MB Magnetic base with dial gauge
31 Distance ring MK Mark
32(a) Ball bearing OE Oil inlet
33 Distance ring SU Collar
34 Distance sleeve SH Protective sleeve
35 Disc spring SK Sensor cable
36 Circlip SR Protective pipe
Overview
1. Removal of shaft encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/22
2. Shaft encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/22
3. Fitting the shaft encoder and the toothed belt . . . . . . . . . . . 3/22
4. Removal of crank angle sensor drive . . . . . . . . . . . . . . . . . . . 8/22
5. Dismantling the crank angle sensor drive . . . . . . . . . . . . . . . 9/22
6. Assembling the crank angle sensor drive . . . . . . . . . . . . . . 11/22
7. Fitting the crank angle sensor drive . . . . . . . . . . . . . . . . . . . 14/22
8. Removal and fitting of compression spring . . . . . . . . . . . . 15/22
9. Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18/22
10. Replacement of toothed belt or CAS drive . . . . . . . . . . . . . 22/22

Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting
1. Removal of shaft encoder
FREE END 1.1 Preparation

A
⇒ Pull out plug of sensor cable ’SK’ at terminal
box ’KK’ (Fig. ’A’).
KK ⇒ Unscrew protection hood 1 and remove it to-
SK gether with covering cap 2.
⇒ Unscrew cable clamps ’KD’ as well as protec-
SR
tive sleeve ’SH’ and withdraw sensor cable
OE
from protective pipes ’SR’.
2 1.2 Outer shaft encoder

1
⇒ Loosen screws 3 and remove them together
with protection plates 10.
⇒ Loosen screws 11 and remove them together
with angle holder 12.
⇒ Loosen screws 15, 15a and remove outer
shaft encoder 13 together with toothed belt 9.
008.724/00
II - II
B I
I-I 9 11 12 10 1
CLEARANCE
1 14 11
II
2 13 13a SH
5 4
I
008.725/00 008.758/00
II
15a 15 3 KD SK

1.3 Inner shaft encoder

Removing the inner shaft encoder 13a is only possible after the toothed belt of the
outer shaft encoder 13 has been removed according to paragraph 1.2.
Removal of the inner shaft encoder 13a is carried out analogously to the outer one.
13 13a
I
C I
008.726/00 008.727/00
SK
2. Shaft encoder
Shaft encoders are only supplied complete. The crank angle sensor 6 is fastened
to the holder 7 and set by the manufacturer.
Attention! Never loosen screw 8!
8 7
D 6 19
008.728/00 008.728/00
3. Fitting the shaft encoder
3.1 Inner shaft encoder

⇒ Turn crankshaft to T.D.C. of Cyl. No.1.
⇒ Mount shaft encoder 13a (Fig. ’D’ and ’F’) on the guide plate of bearing hous-
ing 14 with screws 15, washers 16 and locking plates 17. Do not tighten
screws 15. Apply MOLYKOTE paste G to the threads and head seatings.
Slide shaft encoder along the guide plate to check that the shaft encoder is moving
CHECK freely.
⇒ Push shaft encoder inwards.

3.2 Fitting the toothed belt

Only the new belt version (black colour) must be installed.
⇒ Connect gear wheels 19 and 18 with toothed belt 9, paying attention to their
marks ’MK’ which must coincide according to Fig. ’G’ (zero position).
⇒ Push shaft encoder outwards till the toothed belt is lightly tensioned and
meshing properly with the gear wheels. Lightly tighten screws 15. Recheck
marks ’MK’.
⇒ Fit screws 15a, washers 16 and locking plates 17. Apply MOLYKOTE paste G
to the threads and head seatings.
⇒ Align toothed belt exactly in running direction.
⇒ Attach spring balance 59 to the shaft encoder and slightly preload it according
to Fig. ’F’.
⇒ Loosen all screws 15 and 15a, paying attention that the shaft encoder can still
move freely.
⇒ Tension toothed belt with 30 N indicated on spring balance, and fixate shaft
encoder with screws 15 and 15a.
Remark: Pull the spring balance exactly in tensioning direction, keeping the fric-
tion between the holder guide and screw surfaces as small as possible.
15 9 15a 13a
F
I
MK 59
SK I
58
17
16
008.729/00 15a 008.730/00

⇒ In order to align toothed belt 9 on its running track, turn the crankshaft one to
two revolutions with the turning gear.
⇒ Recheck belt tension according to Fig. ’G’ and ’H’ as well as marks ’MK’. Re-
peat tensioning procedure if belt slackened after crankshaft has been turned
or if marks ’MK’ are not matching.
⇒ Adjust and bend the long lugs of locking plates 17 according to Fig. ’G’.
⇒ Tighten all screws 15 and 15a with a torque of 16 Nm and lock them.
Attention! Always use new locking plates, bending them once only!
TOOTHED BELT TOOTHED BELT

G TENSIONED
H LOOSE
9 18 15 15a 17
I
19
T.D.C. 1 T.D.C. 1
008.731/00 I 008.732/00
MK
16
17
008.731/00
15a
MK
I
3.3 Outer shaft encoder
Fitting the outer shaft encoder 13 is carried out analo-
gously to the inner one.
Attention! When fitting shaft encoders, toothed belts
or crank angle sensor drive (section 7) always pay
attention to the following points:
D Crankshaft at T.D.C. of Cyl. No.1.
58 D Bore for locating pin 58 of the crank angle sensor

drive pointing downwards as shown in Fig. ’I’.
D Mark ’MK’ (T.D.C. 1) of gear wheel 18 pointing up-
SK wards as shown in Fig. ’G’ and all other marks
008.733/01 aligned according to Fig. ’I’.

3.4 Final works

⇒ Fit angle holder 12 using screws 11 with their locking plates. Subsequently
install protection plates 10 in such a way that they contact each other at the
centre without overlapping and touching any moveable parts, using screws 3
with their locking plates.
⇒ Tighten and lock screws 3 and 11.
⇒ After assembling fit carefully the sensor cables ’SK’. Pay attention to the clear-
ance which must exist between sensor cables and housing (Fig. ’B’, section
II).
Fit protection hood 1 together with covering cap 2.
3.5 Toothed belt change

If there should be changed only one toothed belt, proceed as follows:
⇒ Remove protection plate 10 and angle holder 12 (Fig. ’B’).
⇒ Remove screws 15a with locking plates and washers.
⇒ Remove screws 15, replace locking plates and loosely refit the screws.
⇒ Push shaft encoder inwards and replace toothed belt.
D For fitting pay attention to paragraphs 3.1 to 3.4.
3.6 Rechecking of toothed belt tension

In accordance with Maintenance Schedule 0380−1 ’Crank angle sensor unit’ the
toothed belt tension must be visually rechecked as shown in Fig. ’G’ and ’H’, and by
lightly tapping on the toothed belt with a finger.
If necessary or in case of doubt the toothed belt must be retensioned as described
in paragraph 3.2!
Attention! After every loosening of a shaft encoder the toothed belt tension must
be rechecked after about five operating hours!

3.7 Adjustment of crank angle offset in WECS

After the mechanical work on the CAS and CAS drive, the crank angle offsets must
be adjusted.
⇒ Turn the engine with the turning gear until the flywheel marks show T.D.C. of
Cyl. No.1 = 0.0_.
⇒ Marks ’MK’ must be aligned as indicated in Fig. ’J’.
⇒ T.D.C. of the Cyl. No.1 can be cross checked from the crankcase. But safety
measures must be taken accordingly before opening of the crankcase, see
’Warning labels’ located near the crankcase doors on the engine.
⇒ Start the ’flexView’ programme and go to the ADJUST card.
⇒ With the flywheel position as described above, read the crank angle values
displayed in the fields ’Crank angle 1/2’. If they are different from 0.0_ CA,
enter the displayed values as offset in the fields ’CA 1/2 Offs’.
Remark! For negative deviations, e.g. 359.8 <_, use negative values − 0.2 <_.
Crank Angle Crank Angle
CA 1/2 Offs. 0.0 < _ 0.0 < _ CA 1/2 Offs. 0.1 < _ -0.2 < _
Crank angle 1/2 0.1 < _ 359.8 <_ Crank angle 1/2 0.0 < _ 0.0 < _
MK
T.D.C. 1
008.731/00 008.726/00
MK

4. Removal of crank angle sensor drive
⇒ Preparation according to paragraph 1.1.

⇒ Loosen and remove nuts 4.
Attention! When loosening nut 4 hold up shaft 5 by means of an open end span-
ner AF27!
⇒ Remove screws 21 and withdraw the crank angle sensor from the waisted
screw 20 (view II).
Remark: Do not unscrew adjusting disc 23.
K I-I
I
21
22 21
II
5 4 20
23
I
008.735/01
SK
008.734/01
II
008.736/01

5. Dismantling the crank angle sensor drive
Recommendation: To ensure a high availability and quality standard we recom-

mend that a complete crank angle sensor drive according to Fig. ’K’, view II (in-
cluding shaft encoder Fig. ’D’) always be kept in stock. Maintenance works as de-
scribed in sections 5 and 6 may be carried out only by qualified manufacturers as a
matter of principle.
⇒ Remove shaft encoder according to paragraphs 1.2 and 1.3.
⇒ Unbend locking plate 24, loosen and remove shaft nut 25 using hook spanner
94924.
⇒ Withdraw gear wheel 18 from the shaft 5.
Remark: If withdrawing by hand is not possible, the gear wheel must be removed
by means of the two tap holes ’GL’ and suitable tools, however, without striking and
damaging the toothing.
L
18 24 25
GL 5
008.737/01
⇒ Remove circlip 28 using a snap ring tong.

⇒ Unbend locking plate 26, loosen and remove shaft nut 27 using hook spanner
94925.
⇒ Remove shaft 5, however, key 38 remains in situ.
M
26 27 38
28
008.738/01

x
N Parts to be removed in the following sequence:
− Retaining ring 29 (using tap holes ’GL’) to-
14 34 35 60 gether with sealing ring 30 and O-ring 60.
− Distance ring 31.
− Ball bearing 32, distance ring 33, distance
GL
sleeve 34 and disc springs 35.
31 − Circlip 36.
− Disc 37 together with ball bearing 32a.
29
30
008.739/01
36 37 32a 33 32

6. Assembling the crank angle sensor drive
⇒ Clean all parts and check their conditions prior to assembling.

⇒ Replace sealing ring 30, ball bearings 32, 32a and O-ring 60 (Fig. ’N’).
6.1 Determining of thickness ’x’ of distance ring 33 (Fig. ’N’)

⇒ Push ball bearing 32a, distance sleeve 34, ball bearing 32 and distance ring
31 onto the shaft 5 according to Fig. ’O’.
Attention! Big collar ’SU’ on inner ring of the ball bearings must point outwards!
⇒ Screw shaft nut 27 onto shaft 5 and lightly tighten it by means of hook spanner
94925.
⇒ Measure and note down distance ’a’.
O a
SU SU 38
008.740/01
P 32a 34 32 31 27 5
b
14
⇒ Measure and note down distance ’b’ in housing 14.

According to the following formula determine thickness
’x’ for distance ring 33 to be fitted:
x = a − b − 4.2 mm
Tolerance ’x’ amounts to " 0.2 mm.
008.741/01

6.2 Sub-assembly of bearing housing

⇒ Remove the parts which are fitted on shaft 5
as shown in Fig. ’O’.
⇒ Oil ball bearing 32a and insert it into housing
14. Pay attention to the fitting position in para-
graph 6.1!
⇒ Place disc 37 with its smaller seating surface
pointing to the ball bearing and fit circlip 36.
36 37 32a 14
008.742/01
6.3 Completing of the bearing housing

⇒ Oil all parts.
⇒ Fit shaft 5.
⇒ Push distance sleeve 34 onto the shaft.
⇒ Fit disc springs 35 according to view I.
⇒ Fit distance ring 33 with thickness ’x’ determined under paragraph 6.1.
⇒ Oil ball bearing 32 and insert it into housing 14. Pay attention to the fitting
position in paragraph 6.1!
⇒ Fit retaining ring 29 with new sealing ring 30 and O-ring 60 according to view
II.
⇒ Fit distance ring 31. I
34
R
14 34 35 35
33
31 5 14
008.744/01
II
31
30
29
II
I 14
33 32
008.743/01 008.744/01 60

6.4 Tightening the shaft nut

⇒ Apply MOLYKOTE paste G to the thread and seating surface of shaft nut 27.
⇒ Fit locking plate 26 and screw down shaft nut.
⇒ Put torque wrench with socket spanner AF27 on the hexagon of shaft 5 and
tighten the shaft nut with 25 Nm using hook spanner 94925.
⇒ Lock shaft nut with locking plate.
⇒ Fit circlip 28.
S
26 27
5
28
008.738/01
6.5 Fitting gear wheel 18

⇒ Oil bore and push gear wheel 18 onto shaft 5 till the stop.
⇒ Apply MOLYKOTE paste G to the thread and seating surface of shaft nut 25.
⇒ Fit locking plate 24 and screw down shaft nut 25.
⇒ Put torque wrench with socket spanner AF27 on the hexagon of shaft 5 and
tighten the shaft nut with 25 Nm using hook spanner 94924.
T 14
24 25
58 18 5
008.737/01

6.6 Fitting the shaft encoder

For the purpose of improved accessibility the shaft encoders 13 and 13a may be
fitted onto the bearing housing 14 (Fig. ’T’) outside the engine. For that proceed as
described under paragraphs 3.1 and 3.2 with the difference that shaft 5 must be
turned several times by hand in order to adapt it to its running track.
When fitting the toothed belt pay attention to the important points in paragraph 3.3!
7. Fitting the crank angle sensor drive
⇒ Push crank angle sensor drive with packing ring 22 a little onto waisted screw
20 and turn shaft 5 in such a way that locating pin 40 and the corresponding
bore in the shaft are in line.
⇒ Push crank angle sensor drive further till the locating pin fits into the corre-
sponding bore in shaft 5.
⇒ Fasten screws 21 with their locking plates.
Turn crankshaft to an appropriate position.
CHECK Remove inspection cover 41 and check through the opening the fitting positions of:
− Compression springs 42, lever 43 and connection according to view I.
⇒ Apply MOLYKOTE paste G to the thread and seating surface of nut 4.

⇒ Screw nut onto waisted screw 20 and tighten it with a torque of 140 Nm.
U Attention! When tightening nut 4 hold up shaft 5 by

means of an open end spanner!
41
Check adjustments according to paragraph 3.3.
CHECK
7.1 Final works

39 ⇒ Carry out final works according to paragraphs
22 3.4 and 9.1.
40 21
43
I
43 40 5 20
I 5 4 20
42 58 23
008.745/01
44 NO CLEARANCE
008.734/01

8. Removal and fitting of compression spring
47 46
V
8.1 Preparation
⇒ Remove oil inlet ’OE’ (Fig. ’A’).
⇒ Dismantle crank angle sensor drive according to
section 4.
⇒ Remove screws 47 and housing 46.
20
008.746/01
W
49 ⇒ Remove screws 48 and connecting unit 49.
⇒ Remove screws 44 and withdraw waisted screw 20
from the lever 43.
50
I
20
I-I
50
43
44 40
I 43
48a
48
51 48
008.748/01
008.747/01 51 44

8.2 Removing the compression spring

X I ⇒ Loosen screws 53 and remove them together with
spring tensioner 52.
FITTING
⇒ Remove and check compression springs.
POSITION
Remark: When replacing only one compression spring
42, it is recommend to remove also the second spring
tensioner for carrying out further adjustments.
Check spring seating surface for wear.
CHECK
57
42
I 54
55 55
008.749/01 52
008.750/01
53 52 51 54
8.3 Fitting of the lever

⇒ When fitting lever 43 pay attention to its fitting position (Fig. ’X’).
⇒ Replace locking plates to screws 57.
⇒ Apply MOLYKOTE paste G to threads and seating surfaces of screws 57.
⇒ Tighten screws 57 with a torque of 60 Nm and lock them.
8.4 Fitting the compression spring

Y ⇒ Loosen clamp screws 55 of spring tensioner
52 (Fig. ’X’). Replace locking plates. Apply
x
MOLYKOTE paste G to threads and seating

surfaces of screws 55 and refit them.
008.751/01 ⇒ Oil and adjust all adjusting screws 54 to
’x’ = 10 " 0.10 mm (Fig. ’Y’).
52 54
⇒ Insert compression springs 42, fit spring ten-
sioner with screws 53 and new locking plates,
applying MOLYKOTE paste G to threads and
seating surfaces.
⇒ Tighten screws 53 with a torque of 60 Nm and
lock them.

8.5 Adjusting the compression spring

⇒ By means of synchronously adjusting screws 54 (i.e. if one of the adjusting
screws is screwed-in by e.g. ½ turn, the opposite one must be screwed-out by
½ turn) move the relevant compression spring pair 42 until lever 43 shows the
same distance ’x’ between the stops on both sides (centering lever).
For measuring use feeler gauge 94122.
⇒ Tighten all clamp screws 55 with a torque of 35 Nm and lock them.
50 II - II
40 II 42
x
x
008.752/01
II
56 43
55
008.749/01 54
8.6 Fitting the connecting unit (Fig. ’W’)

⇒ Fit waisted screw 20 and screw 44 with new locking plates. Tighten and lock
the latter (Fig. ’U’ view I).
Remark: Screw 44 must not press against waisted screw 20!
⇒ Fit connecting unit 49 and screws 48 together with new locking plates 48a,
applying MOLYKOTE paste G to threads and seating surfaces.
⇒ Tighten screws 48 with a torque of 60 Nm and lock them.
Locating pin 40 and locating pin 50 must point upwards on Cyl. No.1 at T.D.C. ac-
CHECK cording to Fig. ’W’ and ’Z’!

8.7 Final fitting the crank angle sensor unit

⇒ Fit housing 46 with joint and fasten with screws 47 (Fig. ’V’).
⇒ Fitting of the crank angle sensor drive according to section 7.
⇒ Carry out final works according to paragraphs 3.4 and 9.1.
9. Checks
The periodical checks must be carried out according to Maintenance Schedule

0380−1 ’Crank angle sensor unit’.
9.1 Lubricating oil flow in the crank angle sensor drive

⇒ Start main lubricating oil pump and adjust bearing oil pressure.
⇒ Remove inspection cover 41.
With correct oil flow at operating temperature an oil spray results according to Fig.
’B1’. However, the oil outlets should be filled up.
⇒ Refit inspection cover 41.
I-I
A1
41
008.753/01
OIL OUTLET
I
B1
008.725/00
008.754/01
OIL SPRAY

9.2 Checking the throttle

Before reaching the crank angle sensor unit, the oil flows first through throttle 45,
which reduces the oil quantity and also keeps back larger oil particles.
Checking the throttle is carried out as follows:
⇒ Stop main lubricating pump.
⇒ Remove oil inlet ’OE’ from the throttle.
⇒ Unscrew throttle and check its oil spray holes for free passage. Clean if neces-
sary.
⇒ Reinstall all parts.
II C1
II
I OE
008.755/01
II - II
45
OIL INLET
008.724/00
008.756/01

9.3 Checking the shaft eccentricity

The following chekcs and the replacement of CAS parts can only be carried out if
Ckeck the shaft eccentricity in case of CAS exchange.
It is essential to perform the eccentricity check according to the Maintenance
Schedule 0380−1.
9.4 Eccentricity check

⇒ Remove the protection hood 1 of the CAS drive (see Fig.’B’).
⇒ Install the magnetic base with dial gauge ’MB’.
D1
9 MB
18
Remark! The measuring point must be horizontally adjacent of the gear wheel 18.
⇒ Read the deviation on the dial gauge while turning the crankshaft with the
turning gear.
The average shaft eccentricity under normal working and assembly condition
must be less than 0.15 mm.
In case the measured value is out of the stated average eccentricity value, it is rec-
ommended to replace the CAS with a new one (see sections 5 and 7). A CAS drive
is available as a standard spare part.

9.5 Checking the clearance between shaft and internal bearing of the CAS
In case the CAS is over five years in service or has more than 48 000 operating
hours, it is recommended to check the condition of the CAS before a new belt ver-
sion is installed. The CAS condition is checked by measuring the clearance be-
tween the shaft and internal CAS bearing.
Procedure for measuring the clearance:

⇒ Remove the protection hood 1 of the CAS drive (see Fig.’B’).
⇒ Remove the protection plate 10.
⇒ After loosening the screws 15a and 15, remove first the toothed belt of the out-
er CAS and then the toothed belt of the inner CAS.
⇒ After removing the toothed belt, tighten the screws 15a and 15 again.
⇒ Install the magnetic base with dial gauge ’MB’ as shown below.
⇒ Push the gear wheel of the CAS to the left and right direction.
The measurements ’X’ and ’Y’ have to be done in fixed condition of the outer and
inner CAS but without the toothed belts.
⇒ Read the deviation on the dial gauge while pushing the gear wheel of the CAS.
The average CAS clearance under normal working and in assembly condi-
tion must be less than 0.05 mm.
E1
X Y
15a 15 10 MB
9.6 Checking the toothed belt condition

The toothed belt has to be checked every 3000 operating hours for its pre-tension.
In addition a visual inspection of the belt ha to be performed, which means check-
ing for possible cracks and worn-out areas.
Attention! Worn-out toothed belts must be replaced immediately.

10. Replacement of toothed belt or CAS drive
10.1 Replacement of the toothed belt

The new toothed belt version must be used (Fig. ’E’), which can be ordered sepa-
rately as single part according to the Spare Parts Code Book.
Do not use the old toothed belt anymore.
10.2 Reasons for CAS drive replacement

There are two reasons which require a CAS drive overhaul:
− High shaft eccentricity: To verify the eccentricity, see the paragraph 9.3.
− Maintenance schedule: Work to be carried out at 48 000 operating hours.
Before carrying out the replacement of a CAS drive which is available as a stan-
dard spare part, a new CAS drive must be ordered unless a repair kit is available on
board.
The spare parts order number is to be found in the Spare Parts Code Book, Group
9, Chapter 9601−1, within item ’Crank Angle Sensor Unit’ and named ’Shaft en-
coder drive, complete’ or ’Shaft encoder, complete (box)’.
Remark! According to IACS regulations, at least one Shaft Encoder Package box
containing the spring balance is part of the standard spare parts supply per ship.

Tools
Explanation
1. General
The tools required for erection and maintenance of the engine are divided into
three groups as per the following ’Tool List’:
− Standard tools
− Recommended special tools
− Special tools available on loan
When ordering additional tools or replacements, the tool No. as well as the tool
description including engine type must be indicated (see 9403−5).
Detailed instructions on the arrangement and application, storing, servicing and
maintenance of the hydraulic pre-tensioning jacks are given in 9403−2 to 9403−4.
When oil must be added to the hydraulic pumps, the specification regarding oil
quality issued by the pump manufacturers must be followed. Utilize generally an
engine lub. oil having viscosities SAE 30 to SAE 40.
A cylinder lubricating oil also can be used in exceptional cases.
A separate set of tools is issued for certain components from sub-suppliers, which
should also be stored separately from the engine tools.
2. Standard tools
... are tools and devices required for normal maintenance work on the engine. In
this respect take into consideration that, depending on the design execution of the
engine, certain tools and devices which are mentioned in the above sheets are not
required for specific maintenance work, and are therefore not part of the engine
tools supply.
3. Recommended special tools
... are tools and devices, which allow certain maintenance work to be done with
more ease, and in a shorter time, than with the standard tools.
These tools can be ordered separately either with the engine or at a later date.
4. Special tools available on loan
... are such tools and devices which are loaned for transportation and for erection
of the engine. They are to be returned to the engine manufacturer after completion
of engine erection.

Hydraulic Jacks and Pumps
Arrangement and Application
8
13 12 11 10
9
3 14 13 11
4
7 10
1 16 17 13
12 1
11
10
D D
19
6
18 5
20
18
21
A
B B
C C
015.175/07
A = Tensioning / loosening of waisted studs to main bearings, tie rods, valve

cages, top and bottom end bearings to connecting rod; waisted bolts to cam-
shaft and gear wheel bearings, supply unit housing.
B = Tensioning / loosening of jack bolts to main bearings.
C = Tensioning / loosening of waisted studs to cylinder cover.
D= Removing and fitting of main bearing shells, and jacking out of cylinder liners.

Hydraulic Jacks and Pumps: Arrangement and Application
8
13 12 11 10
9
14 13 11
3
4
14 17 16
2
E
7 10
13
12
11
10
23 18 20
19
H 6 H
18 5
18 015.176/07
10
30
31 17
18 G G
014.127/06
E = Tensioning / loosening of foundation bolts and engine stays.

F = Tightening / loosening of gear wheel on the crankshaft
(only to be applied when replacing a gear wheel on the crankshaft).
G = Tensioning / loosening of waisted studs to piston crown.
H = Tensioning / loosening of waisted bolts to intermediate gear wheel.

24
27 27
18 20 17 14 14
13 12 1110 18
10
19
18 6
3 7 5 13 11 4
K
28
14
29
J
8
13 12 11 10
9 WCH00417
3
14
L
13
12
11 11
25 22
26
M 014.133/06
15
I = Fitting / removing the 2-part fuel cam
J= Checking / setting the relief valve, and removal of a
jammed fuel pump plunger
K= Checking of non-return valve in lubricating quill for
pulse lubrication
014.138/06
L= Repositioning the driving wheel for servo oil pumps
M= Set-up of pre-tensioning jacks 94215a (i.e. collecting
the sequeezing oil)

Tool
1 Hydraulic jack 1000 kN (100 t) . . . . . . . . . . . . . . . . . . . . . . 94936
2 Hydraulic ram 44.8 kN (4.48 t) . . . . . . . . . . . . . . . . . . . . . . 94412d
3 HP oil pump 2500 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94931
4 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94942
5 Hydraulic distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94934a
6 Pressure gauge 1600 bar . . . . . . . . . . . . . . . . . . . . . . . . . . 94932a
7 Plug piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94934e
8 Pressure gauge 2500 bar . . . . . . . . . . . . . . . . . . . . . . . . . . 94932
9 Hydraulic distributor
10 Adapter
11 Closing valve
12 Coupling socket
13 Adapter
14 High pressure hose max. 2500 bar . . . . . . . . . . . . . . . . . . 94935
15 Oil drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94935c
16 Adapter
17 Closing valve
18 Coupling socket
19 Safety valve
20 High pressure hose max. 1800 bar . . . . . . . . . . . . . . . . . . 94935a
21 Connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94427
22 Connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94426
23 Connecting element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94934d
24 Hydr. jacking tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94424
25 Valve holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94272a
26 Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94595
27 Adapter piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94426a
28 Hydr. distributor (with pressure gauge 0...25 bar) . . . . . . 94934h
29 Connection nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94934i
30 Connection block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94934c
31 High pressure hose max. 1800 bar . . . . . . . . . . . . . . . . . . 94935b

Storing, Servicing and Maintenance
1. General
The hydraulic pre-tensioning jacks forming part of the engine tool kit are to be
stored in their tool boxes when not in use, in a clean place, where they are pro-
tected from damage (after greasing them and closing the connections with dust
plugs). We recommend to always keep in stock a sufficient number of new O-rings,
back-up rings, piston seal rings and rod seal rings of the specified quality and di-
mensions.
When fitting new back-up rings, piston seal rings and rod seal rings proceed with
care, to avoid their damage; do not use any sharp edged utensils for assis-
tance.
Heat unslit back-up and sealing rings which are used as piston seal rings in boiling
water before fitting them.
Tool 94145 Pre-tensioning jacks for foundation bolts and engine stays
Tool 94314 Pre-tensioning jacks for waisted studs to bottom end bearing
Tool 94315 Pre-tensioning jacks for waisted studs to top end bearing and
waisted stud (spindle) 94561d on camshaft
Tool 94556 Pre-tensioning jacks for waisted studs to bearing of intermedi-
ate wheel (supply unit)
1 Piston 8 Back-up ring
Sealing
2 Cylinder 9 O-ring ring
3 Vent screw 10 Allen screw
4 Adapter 11 Pin
5 Connection piece
6 Back-up ring
Sealing ring
7 O-ring
10
3
4
11
6
7
1 9
8
2
003.902/96

Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance
Tool 94215a* Pre-tensioning jacks for waisted studs to cylinder cover

Tool 94215a1**
Tool 94252 Pre-tensioning jacks for waisted studs to exhaust valve
cage
Sealing ring
2 Cylinder (LEFT* and RIGHT**) 9 O-ring
3 Vent screw 10 Nut
4 Adapter 11 Screw
5 Connection piece 12 Disc spring
6 Back-up ring
Sealing ring
7 O-ring
5 10
3
4 11
6
1
7
2
9
8
003.902/96

Tool 94180 Pre-tensioning jacks for tie rod

Sealing ring
2 Cylinder 7 O-ring
3 Vent screw 8 Back-up ring
Sealing ring
4 Adapter 9 O-ring
5 Connection piece 10 Nut
10
3 5
4
1
6
2 7
015.178/07

Tool 94346 Pre-tensioning jacks for waisted studs of piston crown

Sealing ring
2 Cylinder 7 O-ring
Sealing ring
4 Adapter 9 O-ring
5 Connection piece
6
7
1
9
8
012.100/04

Tool 94557 Pre-tensioning jacks for waisted studs to supply unit

housing and camshaft bearings and gear wheel on
camshaft
Sealing
2 Cylinder 7 O-ring ring
Sealing ring
4 Adapter 9 O-ring
5 Connection piece
5
3
4
1
6
2
7
9
8
012.102/04

Tool 94424 Hydr. jacking tool for camshaft

1 Piston supporting plate 8 Allen screw
2 Piston 9 Ball
3 Ring piece 10 Screw
4 Adapter 11 Screw plug
5 Connection piece
6 Piston seal ring
Sealing ring
7 O-ring
7 6
9
8
10
I-I
I I
1
2
11
3
014.578/06
4 5

Tool 94595 Jack for removal of a jammed fuel pump plunger

1 Piston 5 Adapter
2 Cylinder 6 Connection piece
3 Push rod 7 Back-up ring
4 Vent screw 8 O-ring
6 4 8
5
7
1
2
014.579/06

General Application Instructions
1. General
For distinct screwed connections different designs and sizes of waisted bolts or
waisted studs (bolts/studs) are used, which are pretensioned by hydraulic pre-ten-
sioning jacks. The bolts/studs have threads which extend over the nut. The pre-
tensioning jack is mounted on this thread end.
For each thread of the various bolts/studs a suitable pre-tensioning jack is sup-
plied. Since the bolts/studs are pretensioned with the pre-tensioning jacks, the
nuts are threaded-on only manually until seated.
Prior to the mounting of the pre-tensioning jacks, their threads as well as the
threads of the waisted bolts/studs must be carefully cleaned. The threads must be
undamaged and freely working. Concerning utilization of lubricant for screwing on
nuts the instructions in 0352−1 must be followed.
Risk of accident! Always use gloves, a face shield and wear safety goggles when
working with hydraulic tools.
2. Working procedure for loosening
⇒ Thread the pre-tensioning jack by hand onto the extending thread end of the
bolts/studs to be loosened until it is landed on the part and the piston on the
cylinder without any clearance. On pre-tensioning jacks with round nuts these
have to be slightly tightened.
D Then, depending on the design of the pre-tensioning jack, turn it or the round
nut back by about ½ to 4 turns. The clearance thus obtained between pre-ten-
sioning jack and landing face of the part or piston and cylinder is essential,
before starting the pre-tensioning of the bolts/studs. It enables the loosening
of the nut till total relaxation of the bolts/studs in one single working sequence.
⇒ Connect the HP oil pump and pre-tensioning jack with the HP hose.
⇒ Open the vent screw on top of the pre-tensioning jack a little.
⇒ Shut relief valve at the HP oil pump and actuate it. As soon as oil flows out
bubble-free close the vent screw at the pre-tensioning jack.
D When tensioning attention should be paid that the pins of the pre-tensioning
jacks protrude slightly above the upper edges of the pistons (stroke limita-
tion!).
D Pre-tensioning jacks providing red limiting grooves on the pistons, the latter
must not exceed the indicated stroke limitation.
⇒ Raise the pressure approx. 20−30 bar beyond the nominal pressure (see
0352−1). The nut is now slack, loosen it with a round bar, while keeping the
pressure constant.
⇒ Release the pressure at the HP oil pump and remove the pre-tensioning jack.

Hydraulic Pre-tensioning Jacks: General Application Instructions
3. Working procedure for tensioning
⇒ Use a felt pen and mark the positions of the nuts, which already have been
firmly seated against their landings on the part. The marks are later a refer-
ence for judging the correct pre-tensioning.
⇒ Thread on by hand the pre-tensioning jack onto the protruding thread end of
the bolts/studs until it is fully seated without any clearance between the jack
and the part or the piston is seated on the cylinder without any clearance. On a
pre-tensioning jack with round nut tighten it lightly.
⇒ It may be necessary to turn the jack back a little to gain easy access through
the slot in the jack cylinder for manipulating a round bar to tighten the nut.
⇒ Connect HP oil pump and pre-tensioning jack by the HP hose.
⇒ Open the vent screw on top of the pre-tensioning jack a little.
⇒ Shut relief valve at the HP oil pump and actuate it. As soon as oil flows out
bubble-free close the vent screw at the pre-tensioning jack.
D When tensioning attention should be paid that the pins of the pre-tensioning
jacks protrude slightly above the upper edges of the pistons (stroke limita-
tion!).
D Pre-tensioning jacks providing red limiting grooves on the pistons, the latter
must not exceed the indicated stroke limitation.
⇒ Raise the pressure with the HP oil pump, in accordance with the indication on
the tightening of important screwed connections (see 0352−1).
⇒ Maintain the oil pressure constant at the adjusted value and use the round bar
to tighten the nut onto its seating surface until firmly seated.
Check with the feeler gauge whether actually no clearance remains between nut
CHECK and seating.
Check with the referenced markings, whether all the nuts of a screwed connection
have been turned by the same value as mentioned in 0352−1. If big differences are
noted their causes have to be investigated and the tensioning procedure must be
repeated.
⇒ Release the pressure at the HP oil pump and remove the pre-tensioning
jacks.
D For operation and maintenance of the HP oil pump we also refer to the
manufacturer’s documentation.

Tool List
Standard Tools
94000 Combination wrenches

94000−36 2 Pieces . . . . AF36
94000−41 2 Pieces . . . . AF41
94000−46 2 Pieces . . . . AF46
94000−50 2 Pieces . . . . AF50
94000−55 2 Pieces . . . . AF55 000.385/93
94000−60 2 Pieces . . . . AF60
94001 Open end wrenches

94001−65 1 Piece . . . . . AF65
94001−70 1 Piece . . . . . AF70
94001−75 1 Piece . . . . . AF75
94001−80 1 Piece . . . . . AF80 000.384/93
94001−85 1 Piece . . . . . AF85
94001−95 1 Piece . . . . . AF95
94001−110 1 Piece . . . . . AF110
Slugging open end wrenches

94001a−145 1 Piece . . . . . AF145
94001a−160 1 Piece . . . . . AF160
93.7463
94002 Ring slugging wrenches

94002−27 1 Piece . . . . . AF27
94002−30 1 Piece . . . . . AF30
94002−32 1 Piece . . . . . AF32
94002−36 1 Piece . . . . . AF36
94002−41 1 Piece . . . . . AF41
94002−46 1 Piece . . . . . AF46
94002−50 1 Piece . . . . . AF50
94002−55 1 Piece . . . . . AF55
94002−60 1 Piece . . . . . AF60
000.382/93
94002−65 1 Piece . . . . . AF65
94002−70 1 Piece . . . . . AF70
94002−75 1 Piece . . . . . AF75
94002−80 1 Piece . . . . . AF80
94002−85 1 Piece . . . . . AF85
94002−95 1 Piece . . . . . AF95
94002−110 1 Piece . . . . . AF110
94002−145 1 Piece . . . . . AF145
94002−155 1 Piece . . . . . AF155
94003 Allen keys

94003−17 1 Piece . . . . . AF17
94003−19 1 Piece . . . . . AF19
94003−22 1 Piece . . . . . AF22 000.381/93
94003−24 1 Piece . . . . . AF24
94003−27 1 Piece . . . . . AF27

Standard Tools
94004 Angle screwdrivers

94004−10 1 Piece . . . . . b = 10 mm
94004−12 1 Piece . . . . . b = 12 mm
94004−25 1 Piece . . . . . b = 25 mm 000.380/93
b
94005 Rods
for pre-tensioning jacks
94005−8 3 Pieces . . . . Ø 8 mm
94005−10 3 Pieces . . . . Ø 10 mm
94005−14 3 Pieces . . . . Ø1 14 mm
Ø
94005−14.6 3 Pieces . . . . Ø 14.6 mm 000.379/93 Ø1 015.224/07
94005−20 3 Pieces . . . . Ø 20 mm
94006 Socket head keys

94006−11 1 Piece . . . . . AF11
94006−12 1 Piece . . . . . AF12
94006−14 1 Piece . . . . . AF14
94006−17 1 Piece . . . . . AF17
94006−19 1 Piece . . . . . AF19
94006−27 1 Piece . . . . . AF27
94006−32 1 Piece . . . . . AF32
94006−36 1 Piece . . . . . AF36 000.377/93
94006−41 1 Piece . . . . . AF41

94006−50 1 Piece . . . . . AF50
94006−60 1 Piece . . . . . AF60
94007 Tongs
94007−C8 1 Piece . . . . . Type C 8
94007−C19 1 Piece . . . . . Type C 19
000.376/93
94007−C40 1 Piece . . . . . Type C 40
94007−A10 1 Piece . . . . . Type A 10
94007−A19 1 Piece . . . . . Type A 19
94007−A40 1 Piece . . . . . Type A 40
000.375/93 014.381/06
94007−A41 1 Piece . . . . . Type A 41
94008 Withdrawing gears

for taper & cylindrical dowels and pins
94008−M4 1 Piece . . . . . M4
94008−M5 1 Piece . . . . . M5
94008−M6 1 Piece . . . . . M6
94008−M8 1 Piece . . . . . M8
94008−M10 1 Piece . . . . . M10
94008−M12 1 Piece . . . . . M12
94008−M16 1 Piece . . . . . M16
94008−M20 1 Piece . . . . . M20
X
WCH00836
for removal of Cyl. cover waisted stud
94008a−M90 1 Piece . . . . . M90x6
X = 193 mm

Standard Tools
94009 Grip screws

94009−M4 2 Pieces . . . . M4x150
94009−M5 2 Pieces . . . . M5x150
94009−M6 2 Pieces . . . . M6x150
000.372/93
94009−M8 2 Pieces . . . . M8x150
94009−M10 2 Pieces . . . . M10x150
94010 1 Torque spanner 3/8”

(Range of adjustment 2−25 Nm)
94010a Adapter piece 3/8”−½” 010.229/02
94011 1 Torque spanner ½”

010.230/02
94012 1 Torque spanner ¾”

with extension tube and tool box
94012a adapter piece ¾”-½”, 010.231/02
94012b shell type ratchet ¾”-¾”
Torque spanner
94013 1 (Range of adjustment 8−40 Nm)
94013a 1 (Range of adjustment 20−120 Nm)
with open end spanner inserts:
94013−24 AF24
94013−27 AF27
94013−30 AF30
94013b 2 Torque spanners 013.558/05

with open end spanner inserts:
94013−24 AF24
94013−27 AF27
94013−32 AF32
94013−36 AF36
94013−46 AF46
94013−50 AF50
94013−55 AF55
94017b 2 Spur-geared chain blocks

(WLL 5000 kg)
94017a 1 Spur-geared chain block
(WLL 3000 kg)
94017c 2 Spur-geared chain blocks
(WLL 1000 kg)
012.232/04

Standard Tools
94022 1 Adapter piece 3/8”−¼”

94022a 1 Socket wrench insert
010.233/02
AF3
94022b 1 Socket wrench inserts ¾”
94025 1 Tool box with socket wrench set ½”

000.368/93
94026 1 Tool box with hex. head drivers ½”

000.368/93
94032 1 High pressure grease gun

for lubricating grease nipples on
fuel pump regulating linkage
000.370/93
94045 Eye bolts

94045−M10 8 Pieces .... M10
94045−M12 8 Pieces .... M12
94045−M16 8 Pieces .... M16
94045−M20 8 Pieces .... M20
94045−M24 8 Pieces .... M24
94045−M30 8 Pieces .... M30
94045−M36 8 Pieces .... M36
94045−M42 8 Pieces .... M42
93.7472
94045−M48 4 Pieces .... M48
94045−M56 2 Pieces .... M56
Eye screw 93.7468
94045a−M16 6 Pieces . . . . M16x145

Standard Tools
94050 1 Tool for pressure measurement b d c f g

for pneumatic elements
94050a 1 Compressed air pump
94050b 1 Pressure gauge 0−4 bar
94050c 1 Pressure gauge 0−6 bar
94050d 1 Pressure gauge 0−16 bar
94050e 2 HP hoses
94050f 1 Adjusting tool
94050g 1 Measuring connection M12x1
94050h 1 Measuring connection M14x1
002.552/98
h a e

Standard Tools
94101 1 Inside micrometer

with case 000.366/93
(Measuring range 50−1010 mm)
94101a 2 Extensions
Length of 480 mm 000.365/93
94107 1 Assembly template

for positioning locating dowel pins
in main bearing shell 004.768/00
X = 260 mm
X
94116 1 Lifting tool

for removal and fitting of
main bearing shell
X = 290 mm 008.541/01
94117 2 Roller supports

for removal of main bearing
with screws M30x60 and washers ∅68 mm
X = 140 mm
(max. lifting capacity 900 kg)
94118 1 Turning-out device

main bearing shell
X = 330 mm
011.114/03

Standard Tools
94119 1 Lifting yoke

main bearing shell
X = 460 mm
000.768/99
X
Rope (∅ 9 mm)
with shackle(s) for removal and fitting
of main bearing cover and shell
94120b 2 Pieces . . x = 300mm

94120c 1 Piece . . . x = 1200mm
94120d 1 Piece . . . x = 1500mm
94120e 1 Piece . . . x = 1800mm 005.932/00
94120f 1 Piece . . . x = 2000mm

94120g 1 Piece . . . x = 2300mm
94120i 1 Piece . . . x = 2800mm
94120k 1 Piece . . . x = 3000mm
94120l 1 Piece . . . x = 3500mm
94120m 1 Piece . . . x = 4000mm
Rope (∅ 9 mm)
with two shackles for removal and
fitting of main bearing cover and shell
008.551/01
94120q 1 Piece x = 1000mm X

Standard Tools
94122 1 Feeler gauge
000.361/93
94123 1 Special feeler gauge

for main bearing
X = 620 mm
000.395/93
94124 1 Depth gauge

measuring range 250 mm
002.668/98
94126 1 Depth gauge

measuring range 700 mm
000.394/93
94141 1 Support
for lifting crankshaft for Y 017.848/08
removal of main bearing shells
X = 1300 mm
94141a 2 Ground plates

X = ∅ 240 mm
Y = 70 mm
008
94142 2 Working platforms

consisting of three grids each
X = 1030 mm
000.392/93

Standard Tools
94143 3 Working supports

X = 920−1170 mm
X
009.323/01
94145 1 Pre-tensioning jack

for foundation bolts,
including a metal box
X = 170 mm
008.132/96
94155 1 Turning-out device

with screws
for turning out thrust bearing pads
(with 1-part gear wheel)
X = 268 mm
003.973/96
94155a 1 Turning-out device

with screws
for turning out thrust bearing pads
(with 2-part gear wheel)
X = 268 mm
004.036/96

Standard Tools
94180 2 Hydraulic pre-tensioning jacks

for tie rods,
X = 440 mm
015.196/07
94201 1 Device
for fitting and transporting
a cylinder liner
consisting of:
X
94202 1 Lifting gear 012.579/04 94202d
X = 350 mm
94202
94202d 2 Distance plates
with 8 screws M12x50 and nuts 94206
94206 2 Suspension straps

with 2 screws each
X
X = 225 mm
94207
94207 2 Special screws M42
94208 4 Suspension straps

with screws M16x25
for removal and fitting of an
antipolishing ring
X
X= 101 mm 001.865/99

Standard Tools
94209 1 Lifting hook

for removal and fitting of the
antipolishing ring
X = 1000 mm X
012.242/04
94215 1 Hydraulic tensioning device

with connecting elements b
for cylinder cover studs,
consisting of:
a = 4 pre-tensioning jack LEFT
a1 = 4 pre-tensioning jack RIGHT
b = High pressure hoses,
900 mm long
c = Suspension device
d = 2 piston reset devices a
a1
001.431/97
94219 1 Cylinder pressure measuring tool

(indicator),
including a wooden box
X = 165 mm
X
012.243/04

Standard Tools
94224 1 Ladder
for measuring cylinder liner bore
X = 3600 mm
000.420/93
94225 1 Measuring gauge X

for measuring cylinder liner bore
(accessory for it:
inside micrometer tool 94101) 000.419/93
X = 3636 mm
94238 1 Feeler gauge (10-part)

for checking bearing clearances
Leaf length = 600 mm 000.418/93
94252 2 Pre-tensioning jacks

for exhaust valve cage
X = 325 mm
009.339/02
94259 2 Retaining screws

for exhaust valve
X = 80 mm
X
012.246/04

Standard Tools
94261 1 Valve seat fitting and extracting device

X = 745 mm
000.415/93
X
94263 2 Jack screws

to guide bush
for exhaust valve M16x180
000.413/93
94265 1 Suspension device

for cylinder cover and exhaust valve
cage
X = 980 mm
further:
a = 2 Special eye nuts
X = 356 mm
b = 3 Protection caps
X = 100 mm
X
b
X
a a
003.971/96

Standard Tools
94266 1 Cradle
for removal and fitting of water guide
jacket
X = 2306 mm
X
015.198/07
94270 1 Device
for overhauling injection valve seat in
cylinder cover
X= 484 mm
X
001.432/97
94271 Protection cap

for fuel nozzle
(1 piece each nozzle)
X
X= 110 mm
001.092/97

Standard Tools
94272 1 OBEL test bench

for setting and testing of:
− injection valve
− relief valve (cylinder cover)
− relief valve (intermediate fuel accu.)
X = 1458 mm
including:
X
94272a 1 Valve holder
for checking and adjusting relief valve
X = 149 mm
94272b 1 Connecting piece

for adjusting the injection valve 94272c X 013.579/05
X = 124 mm
94272c 1 Valve holder

for checking relief valve to cylinder 94272a 94272b
cover X X
X = 68 mm
94279 1 Gauge
for checking wear on exhaust valve
seat
X = 210 mm
X
002.563/98
94292 1 Gauge
for checking wear on disc of
exhaust valve spindle
X = 262 mm
004.061/96

Standard Tools
94299 1 Grinding device

for removing a built-up wear ridge at
top of cylinder liner running surface
X = approx. 600 mm
000.463/93
94305 1 Crankshaft checking equipment

for measuring crank deflection
(in wooden box)
X = 364 mm
000.412
94314 2 Pre-tensioning jacks X

for tensioning connecting rod studs
to bottom end bearing,
X = 270 mm

for tensioning connecting rod studs to
top end bearing, including a metal box
X = 230 mm
008.129/96

Standard Tools
94323 4 Retaining pins

to prop up crosshead guide shoes
when removing or fitting a connecting
X
rod or a crosshead
X = 125 mm
000.409/93
94324 1 Cover and lifting plate

(incl. shackle) to crosshead
X = 450 mm
(max. lifting capacity 11 600 kg)
X 015.199/07
94331 1 Holder
for removal and fitting of a connecting
rod,
including: 4 Nut pieces
2 Lifting lugs
X = 1446 mm
015.200/07
94331a 1 Connecting element with shackle

X = 70 mm

Standard Tools
94333 1 Lifting device

to piston for removal of
top end bearing cover,
consisting of:
94333a 2 Suspension straps

X = 240 mm
X
94333b 2 Wire ropes with hooks
X
X = 1856 mm
94333c 2 Eye bolts M30
001.314/97
94338 1 Piston ring tensioning device

X = 500 mm
Y = 303.5 mm
17.830/08
94341 1 Piston suspension device

X = 467 mm
000.406/93
1.09 18/ 49 Wärtsilä Switzerland Ltd

Standard Tools
94342a 1 Insertion funnel

for fitting the piston
X = 945 mm
lincluding:
2 Holders
2 Screws M16x35
2 Screws M42x60
X 001.866/99
94342b 1 Insertion funnel (2-part)

for fitting the piston with restricted
height to crane hook
including: 2 Holders
2 Screws M16 x 35
2 Screws M42 x 60
2 Fitted screws M8 x 55
X = 945 mm
012.664/05
X
94345 2 Distance holder

for removal and fitting of piston rod
gland and piston
X = 600 mm
X
001.407/96
94345b 1 Clamp ring

for 94345a
X = 75 mm
X
000.402/93

Standard Tools
94345c 1 Gauge
for fitting scraper rings
X = 386 mm
X
012.158/04
94345d 1 Cover plate X

for covering bore of piston rod gland in
cylinder jacket (when piston and gland
are removed)
X = 762 mm
93.7517
94345e 2 Assembly tools

for tensioning springs to
piston rod gland
X = 160 mm
X
004.284/98
94345f 4 Distance pieces X

for fitting rings to upper gland group,
2 pieces each 11 and 19 mm
X = 405 mm
005.655/99
94346 4 Pre-tensioning jacks X

for waisted studs to piston crown
X = 126 mm
012.276/04

Standard Tools
94347 1 Propping device

consisting of 2 segments for
changing compression shims
X = 540 mm
X
93.7518
94348 1 Tap M24

for cleaning carbon deposits in
threaded holes of piston crown
000.398/93
94350 2 Devices
for supporting piston and removal
of piston rod gland
X = 1210 mm
001.090/97

Standard Tools
94363 2 Jacking screws

for separating piston crown from piston
skirt 7056−03/F101198
X = M20
X
94364 2 Jacking screws

for separating piston skirt from piston
rod
X = M24
7056−03/F101198
94366 1 Template
for shape of top of piston crown
X = 892 mm
001.423/97
94366a 1 Template X
for shape of top of piston crown
(for use with piston in situ)
X = 986 mm 001.422/97
94410 Adjusting devices

for alignment of intermediate wheel
3 pieces for 5−7 cylinder engines
6 pieces for 8−10 cylinder engines 7056−03/F101217
X = 270 mm
X
94410a Adjusting devices
X = 230 mm

Standard Tools
94412 1 Tightening device

(supplied only for engine equipped
with 2-part gear wheel on crankshaft)
consisting of:
94412b
94412a 1 Clamping fork
X
(for 5−7 cylinder engines)
94412a
X = 485 mm
94412b 1 Support
X
(for 5−10 cylinder engines)
X = 640 mm 94412d
94412d 1 Hydraulic ram 44.8 kN 94412e

ENERPAC RC-57 94412g
94412e 1 Forked piece 015.202/07
94412g Impact ring spanners AF 75
94412c 1 Retaining device 94412c

with screw M30x50
X = 1090 mm
X
015.226/07
94412f
94412f 1 Holding wrench AF 75
015.227/07
94424 1 Hydr. jacking tool

for removing & fitting fuel cams with conical bush,
including 6 screws M16x180
X = 540 mm
X 014.409/06
X
94426 1 Connection piece
for repositioning the driving wheel of servo
oil pumps 004.027/96
X = 247 mm

Standard Tools
94426a 1 Adapter piece

for removing and fitting 2-part fuel cam
X = 45 mm
94427 1 Connection piece M22x1.5 G¼”

for removing and fitting
of jack bolts to main bearing
015.204/07
X = 198 mm
94430 4 Devices (roller lifting tools)

for cutting out & in of fuel pump(s)
X
X = 116 mm
012.278/04
94435 1 Lifting plate

for removal and fitting of Dynex servo
oil pump
X = 190 mm
(max. lifting capacity 280 kg) X
94550 1 2-part clamping ring

for removal of non-return valve to fuel
X
pump with 4 screws M10x60

X = 210 mm
019.235/10
94551 1 Fitting & dismantling device

for removal and fitting of guide pin to
fuel pump
X = 304 mm
008.762/00
94552 1 Cover
with head screws M12x70
for removal and fitting of a fuel pump
X = 120 mm
012.280/04

Standard Tools
Lifting tools to supply unit
94553b 1 Lifting support

for removal and fitting of cover and
bearing covers to supply unit,
including:
1 Flange (1)
with 4 screws M16x35 X
1 Distance plate (2)

with 4 screws M16x110
X = 2383 mm
(max. lifting capacity 540 kg) 1
014.386/06
94554 1 Fork lever 94554b

for lifting camshaft 94554d
consisting of:
94554e
94554a Face plate 94554a
94554b Rocker arm
94554c Nut 94554c
94554d Bolt with circlip X
94554e Web with screw
X = 329 mm
012.283/04
94555 Spacers
008.764/01
for cutting out of individual fuel pumps,
depending on number of cylinders:
X = 95 mm

Standard Tools

for waisted bolts to intermediate wheel
bearing of supply unit,
X = 195 mm
00.7014

for gear wheel and waisted bolts to
camshaft bearing,
X = 155 mm
012.284/04
94558 2 Sleeves
X = 166 mm
X
012.285/04
94559 1 Socket wrench

X = 206 mm X
012.286/04

Standard Tools
94560 2 Round bars Ø 6 mm

X = 100 mm
X
012.287/04
94561 1 Device
for removal and fitting of pinion to
supply unit
X = 1376 mm
014.387/06
X
94562 1 Cam adjusting gear

X = 194 mm
consisting of:
X
94562a 1 Angle rail

including: 2 Fitted bolts M16x40
1 Washer
(there are appropriate tools 94562e
94562f
depending on number of cylinders)
94562e 1 Guide tube 94562a
94562f 1 Positioning unit
94563 1 Distance holder

for setting fuel cam No. 1
X = 365 mm X
014.495/06
94563a 1 Distance holder X

for setting fuel cams No. 2
X = 200 mm
014.496/06

Standard Tools
94566 2 Supports
for removal and fitting of camshaft
X = 1097 mm
012.296/04
94566a 2 Tension nuts

012.302/04
to supports 94566
X = 692 mm X
94567 1 Assembly template

for removal and fitting of bearing
shells to supply unit
X = 100 mm X
including: X
012.297/04
94567a 1 Pipe
X = 200 mm
94569 2 Blank flanges

to fuel pump
with screws M12x55 mm
X = 110 mm
94569a 2 Blank flanges

to intermediate fuel accumulator X
with screws M12x50 mm
X
X = 110 mm

Standard Tools
94571 1 Rail
for removal and fitting of intermediate WCH01168
wheel to supply unit,
including: 2 Shackles
(Lifting capacity 1500 kg)
4 Screws M30x130
X = 2565 mm X
94571b
94571a 2 Screws M20x200
94571a
94571b 2 Washers
012.299/04
94571c 1 Carriage
to rail 94571 94571d
X = 280 mm
94571d 8 Screws M16x130

94571c
to carriage 94571c X
012.300/04
94571e 1 Support (Left side)

94571e
94571f 1 Support (Right side)

94571f
WCH01168
94581 1 Assembly tool

for removal and fitting of fuel pump
X = 905 mm
including: 94581a
94581a 2 Guide screws

X
94581b 2 Steel wires
94581b
012.301/04

Standard Tools
94582 1 Support
for removal and fitting of fuel pump X
X = 640 mm
015.206/07
94583 1 Pipe
X
for pressure built-up in fuel rail
during commissioning
X = 632.5 mm
012.303/04
94584 1 Lifting plate

for removal and fitting of injection
control unit,
X = 300 mm X
012.304/04
94585 2 Screw plugs

for fuel rail
X = 220 mm X
011.975/04
94587 8 Nuts with conical plugs

for servo oil return
X = 20 mm X 011.976/04
94589 2 Withdrawing tools

for removing lip seal from injection
control unit X
X = 310 mm & 638 mm
012.308/04

Standard Tools
94592 1 Fitting and dismantling device

94592c
for fuel pump
X = 1029 mm 94592b
Mass approx. 89 kg
consisting of: 94592e
94592a 1 Oil trough X

94592b 1 Limiter
with 4 screws M12x100 and washers 94592d
94592c 2 Screws
94592d 4 Screws (M20x50) 94592a
94592e 2 Screws (M12x90)
016.787/08
94593 1 Assembling device X

for assembling fuel pump
consisting of:
94593d
94593a 1 Tool half
94593c
94593b 1 Tool half
94593a
94593c 2 Flat bars 94593b
X = 270 mm 014.390/06
94593e
94593d 1 Metal sheet
94593e 4 Screws M30x260
94597 1 Mandrel
for fitting seal into lower spring carrier X
and lower housing of fuel pump
X = 70 mm 014.494/06
94597a 1 Mandrel
for fitting seal into lower spring carrier
X = 40 mm
94598 1 Impact wrench X

for loosening and tightening fuel
pump on supply unit
X = 256 mm
94598
94598a 2 Extension 1” X
X = 330 mm
94598b 1 Socket spanner insert 1” 94598b

AF 46 mm 94598a 014.389/0

Standard Tools
94651 1 Dismantling device

for auxiliary blower
consisting of:
009.995/02
94651c 1 Trolley
94652 2 Centring studs

for removal and fitting of electric motor 000.427/93
on auxiliary blower
X
X = 615 mm
In case of a turbocharger breakdown,

engines with 2 turbochargers TPL 80
94653 2 Covers to gas inlet housing

and exhaust manifold
X = 672 mm
94653 1 Cover for air connection

X = 628 mm
In case of a turbocharger breakdown,

engines with 2 turbochargers MET 71S
000.487/93
94653 2 Covers to gas inlet housing
and exhaust manifold
X = 665 mm X
94653 1 Cover for air connection

X = 580 mm

scavenge air cooler,
depending on type of scavenge air cooler
X =1426 − 1776 mm
X
94660a 2 Lifting plates X
SAC with cooler pre-stage only 017.895/08 015.207/07
X = 300 mm

Standard Tools
94663a 2 Lifting devices X

scavenge air cooler,
6 cylinder engines with

turbochargers TPL 77−B or MET 66S
Y
and SACs GEA 150/38/24/6
X = 900 mm
Y = 700 mm 015.208/07
7 cylinder engines with

X = 1140 mm
Y = 700 mm
6, 8, 9 cylinder engines with

TPL 80−B or MET 66S; 71S
X = 1140 mm
Y = 700 mm
5, 6, 8, 9 cylinder engines with

and SACs GEA 240/48/24 (4+20) or
GEA 4−Nsv−S120−34N253
X = 1140 mm
Y = 560 mm
94663b 2 Lifting devices

SAC with cooler pre-stage only
X = 540 mm X
(WLL = 1000 kg)
017.895/08

Standard Tools
94663d 1 Support
for removal and fitting of scavenge air
cooler,
X = 809 mm X
015.209/07
94663g 1 Support
cooler and cooler pre-stage,
(for SAC with cooler pre-stage only)
X = 1217 mm
X
015.210/07
94663h 1 Bracket
X
for fitting of scavenge air cooler,
X = 1107 mm
015.211/07
94666 1 Wire rope sling Ø 24 mm

cooler
X = 743 mm X
Ø
(max. lifting capacity 5000 kg at 0−60_)
015.212/07

Standard Tools
94667 1 Carriage
for removal and fitting X
of water separator,
X = 641 mm
015.213/07
94667a 2 Stops
for removal and fitting of water
separator
X = 87 mm
X
015.214/07
94668 1 Pulley device

separator,
X = 230 mm X
012.322/04
94669 1 Support
X
separator,
X = 440 mm 012.323/04

separator,
X = 1966 mm
(max. lifting capacity 850 kg) X
012.324/04

Standard Tools
94673 1 Wire rope sling Ø 8 mm with shackle

for removal and fitting of water Ø
separator
X = 3410 mm
012.325/04
X
94720c 1 Case
consisting of:
measurement set complete
for checking / refilling of
018.472/09
hydraulic accumulator
94811 2 Lifting lugs

(incl. 2 shackles) for removal and
fitting expansion piece to exhaust
valve cage
X = 445 mm
000.471/93
94831 1 Blank flange

for blanking off starting air pipe
during emergency operation
X = 280 mm
004.017/96

Standard Tools
94835 1 Tool box with grinding machine

for regrinding of sealing surfaces,
including User Manual
X = 450 mm
015.218/07
94870 1 Regrinding device

for sealing surfaces on fuel pressure
piping (8733−1)
X = 106 mm
consisting of:
d
94870a 1 Screw-on sleeve (AF 36) b

a
94870b 1 Grinding tool with
c
countersunk screw M6 X X
94870c 1 Lock nut M20x1.5 (AF 30) 016.740/08
94870d 1 Template
X = 50 mm
94870 1 Regrinding device

for sealing surfaces on fuel pressure
piping (8752−1)
X = 158.5 mm
h
consisting of:
f
e
94870e 1 Screw-on sleeve (AF 55)
94870f 1 Grinding tool with g X
countersunk screw M8 X
94870g 1 Lock nut M33x2 (AF 55)
016.741/08
94870h 1 Template
X = 80 mm
94844 1 Lubricating device

to supply unit
X = 600 mm
Y = 200 mm
X
WCH01042

Standard Tools
94844a 1 Filling device

to lubrication device
X = 482 mm
Y = 225 mm X
WCH01042
94844b 1 Filling device

X = 203 mm X
Y = 165 mm
WCH01042
94844c 1 Filling device

X = 312 mm
Y = 140 mm X
WCH01042
X
94844d 3 Flexible hoses
X = 2000 mm
WCH01042
94844e 1 Cross union

X = 94 mm X
Y = 112 mm
WCH01042 Y

Standard Tools
94844f 1 Holder
WCH01042
94874 1 Tightening device X

for loosening and tightening
connection piece on injection control
unit,
X = 95 mm
014.408/06
94924 1 Hook spanner

for crank angle sensor
X = 205 mm
94925 1 Hook spanner

008.771/00
X = 242 mm
94930 1 SW-download package

to WECS−9520 for flexView
operator
consisting of:
1 USB−memory stick
1 CAN cable (ca. 10 m)
1 UBS to CAN adapter
1 Connection diagram
1 Requirements
018.127/09
ca. 1000 80

Standard Tools
Hydraulic parts and pump
94931 1 HP oil pump 94936

working pressure max. 2500 bar
94935a
94932a
94932 1 Pressure gauge
∅ 100 mm 94934a
working pressure 0−2500 bar
connecting branch G½” 94934e
94932a 1 Pressure gauge

∅ 100 mm 94934d
working pressure 0−1600 bar
connecting branch G½”
012.335/04
94934a 1 Hydr. distributor
94935
94934c 2 Connection blocks
94942
94934d 2 Connecting elements
94934e 1 Plug piece 015.220/07
94935 3 HP hoses
length approx. 1800 mm
94935
94935a 2 HP hoses
001.547/97
94935b 4 HP hoses
94931
working pressure max. 1800 bar 94932
94935c 1 Oil pipe drain

for set-up of pre-tensioning jacks
lenght = 2000 mm
94934c
94936 2 Hydraulic jacks 1000 kN (100t)
94935b 94935c
94942 1 Hydraulic unit

012.336/04

Standard Tools
94934h 1 Hydr. distributor

with pressure gauge 0...25 bar
WCH00724
94934i 1 Connection nipple (G¼”)
WCH00724

Recommended Special Tools
94016 2 Manual rachets

94016a 2 Manual rachets

94016b 2 Manual rachets

94016c 2 Manual rachets

012.233/04
94017b 1 Spur-geared chain block

Lifting capacity 5000 kg
012.232/04
94203a 2 Brackets X
(with reduced height Y)
for removing a cylinder liner Y
X = 550 mm
Y = 145 mm
019.266/10
94262 1 Valve protector

(only to be applied for transporting a
complete exhaust valve)
X = 710 mm
000.414/93

94291 1 Valve grinding device complete

for valve spindle and valve seat
94291a 2 Grinding discs

(C-M No. 11373-04-05)
016.774/08 016.773/08
94300 1 Tool cupboard

X = 1120 mm X
001.412/96
94336 1 Connecting flange

for pre-lubrication of top and bottom
X
end bearings
X = 155 mm
001.411/96
94344 1 Dismantling device

for removal of piston rod gland
downwards
X = 1180 mm
001.082/97

94349 1 Pressure testing device

for piston
X = 340 mm
000.461/93
94356 1 Equipment case

with instruments
for measuring thickness of chrome-
ceramic-layer on piston rings
WCH01216
94357 1 Calliper gauge

for measuring piston ring grooves
94481 1 Metal box

for storage of spare filter cartridges
Remark: Dimensions are

depending on size of parts to
be accommodated inside.
012.235/04

94595 1 Jack
for removal of a jammed fuel pump
plunger (with 12-hole pump cover)
X = 270 mm
014.499/06
94595b 1 Short tappet

to jack 94595(a)
X = 222 mm
X
94595c 1 Long tappet
to jack 94595(a)
X = 344 mm
014.500/06
94595d 1 Piston reset tool

to jack 94595(a)
X = 173 mm (with 12-hole pump cover)
014.501/06
X
94595e 2 Screws M30

with nuts
X
X = 400 mm
014.502/06

94650 1 Spur-geared chain block

for removing and fitting of electric motor on
auxiliary blower
carrying capacity 2000 kg
000.460/93
In case of a turbocharger breakdown

(turbocharger with suction pipe)
94655 1 Cover
for air outlet casing
X = 630 mm (for TPL 80)
X = 580 mm (for MET 71S)
017.970/08

Special Tools Obtainable on Loan
94105 1 Measuring apparatus

for leveling bedplate
X
consisting of:
4 Supports
4 Weights with wire
1 Measuring underlay
X = 1680 mm
000.459/93
94174 4 Thread protectors
M36
to upper threads of tie rods, when
fitting a cylinder jacket
X
X = 160 mm
000.458/93
000.458/93
94177 1 Thread protector

to lower thread of tie rod
X = 170 mm
000.458/93

X
94574 1 Lifting tool complete
for transporting a complete supply unit,
5 & 7 Cyl. engines
X = 1565 mm
consisting of:
012.334/04
94574a 1 Holder
with head screws M20x180
X = 176 mm
94574b 3 Holders X
with head screws M20x130 X
X = 125 mm
94574a 94574b

94691 1 Transport tool

for 7 Cyl. rail unit module
X = 6140 mm
consisting of: X1 94690b
X
94690a 1 Lifting element
X1 = 1750 mm
94690b 1 Lifting element

X1 = 1750 mm
X1
94690c 1 Bracket
X2 = 2640 mm
94690c
incl. 48 screws M24x80 and nuts
94690a
X2
014.411/06
94922 1 Alignment tool

X = 172 mm
008.773/00


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RT-flex84T-D

Document ID: DBAC352008

Wärtsilä Switzerland Ltd 24hrs Support: +41 52 262 80 10

E 2014-07 Wärtsilä Switzerland Ltd, Printed in Switzerland

RT-flex84T-D_WECS-9520_Dynex Summary for Maintenance Manual

RT-flex84T-D_WECS-9520_Dynex Summary for Maintenance Manual

0370-1/A1 Dimensions Material specification deleted x

Date of publication 2010-08-27

Date of publication 2010-11-01

RT-flex84T-D_WECS-9520_Dynex Summary for Maintenance Manual

Date of publication 2011-02-25

Date of publication 2012-04-12

Date of publication 2012-05-24

RT-flex84T-D_WECS-9520_Dynex Summary for Maintenance Manual

RT-flex84T-D_WECS-9520_Dynex Summary for Maintenance Manual

3103-1/A1 Measuring Crank 1. General aspects; 2. Condition of measuring and 4. Crank x

Date of publication 2014-04-02

Date of publication 2014-07-22

1 Bedplate and Tie Rod

2 Cylinder Liner and Cylinder Cover

3 Crankshaft, Connecting Rod and Piston

4 Driving Wheels and Shut-off Valve for Starting Air

5 Supply Unit, Injection and Exhaust Valve Control

6 Scavenge Air Receiver and Auxiliary Blower

9 Crank Angle Sensor Unit, Tools

General Information Group 0

Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

Masses (Weights): Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . 0360−1/A1

Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) . . . . . . . . 0380−1/A1

Wärtsilä Switzerland Ltd 1/ 1 RT−flex84T−D / MM / 2010-08

Wärtsilä Switzerland Ltd

Wärtsilä Switzerland Ltd 1/ 1 2008

The instructions contained in this ”Maintenance Manual” are intended to help to

− General guidelines for maintenance

A few explanations to the above:

Wärtsilä Switzerland Ltd 1/ 1 2008

General Information Group 0

Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330−1/A1

Masses (Weights): Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . 0360−1/A1

Maintenance Schedule: Inspection and Overhaul Intervals (Guidelines) . . . . . . . . 0380−1/A1

Wärtsilä Switzerland Ltd 1/ 5 2013-08

Bedplate and Tie Rod Group 1

Hydraulic Engine Stays: Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 1715−1/A2

Cylinder Liner and Cylinder Cover Group 2

Injection valve: Checking, Dismantling, Assembling and Adjusting . . . . . . . . . . . . . 2722−1/A1

2013-08 2/ 5 Wärtsilä Switzerland Ltd

Crankshaft, Connecting Rod and Piston Group 3

Axial Damper: Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3146−1/A1

Driving Wheels and Shut-off Valve for Starting Air Group 4

Wärtsilä Switzerland Ltd 3/ 5 2013-08

Supply Unit, Injection and Exhaust Valve Control Group 5

Pressure Reducing Valve 8.11−1

Injection Control Unit: Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5564−1/A1

Scavenge Air Receiver and Auxiliary Blower Group 6

Cylinder Lubrication Group 7

Servo Oil Piping: Removing, Fitting and Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . 8447−1/A1

Fuel Pressure Piping

2013-08 4/ 5 Wärtsilä Switzerland Ltd

Crank Angle Sensor Unit, Tools Group 9

Hydraulic Pre-tensioning Jacks

Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403−5/A1

Wärtsilä Switzerland Ltd 5/ 5 2013-08

DRIVING FREE END