WÄRTSILÄ RT-flex50-D Maintenance Manual
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WÄRTSILÄ RT-flex50-D Maintenance Manual

WÄRTSILÄ RT-flex50-D Maintenance Manual

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Table Of Contents
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Table of Contents

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"Marine"
Vessel:
Type:
Engine No.:
Document ID: DBAC251330
Wärtsilä Switzerland Ltd
PO Box 414
CH-8401 Winterthur
Switzerland
E 2012-07 Wärtsilä Switzerland Ltd, Printed in Switzerland
RT-flex50-D
Tel.
+41 52 262 49 22
Fax
+41 52 212 49 17
http://www.wartsila.com

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Summary of Contents for WÄRTSILÄ RT-flex50-D

  • Page 1 RT-flex50-D Maintenance Manual “Marine” Vessel: Type: Engine No.: Document ID: DBAC251330 Wärtsilä Switzerland Ltd Tel. +41 52 262 49 22 PO Box 414 +41 52 212 49 17 CH-8401 Winterthur http://www.wartsila.com Switzerland E 2012-07 Wärtsilä Switzerland Ltd, Printed in Switzerland...
  • Page 2 This page is intentionally left blank...
  • Page 3 General Information Bedplate and Tie Rod Cylinder Liner and Cylinder Cover Crankshaft, Connecting Rod and Piston Driving Wheels and Shut-off Valve for Starting Air Supply Unit, Injection and Exhaust Valve Control Scavenge Air Receiver and Auxiliary Blower Cylinder Lubrication Piping Crank Angle Sensor Unit, Tools...
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  • Page 5: Table Of Contents

    RT-flex50-D Group0 Maintenance General Information Group 0 For Particular Attention ..........
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  • Page 7 RT-flex50-D 0000−1/A1 Maintenance 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...
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  • Page 9 RT-flex50-D 0001−1/A1 Maintenance 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.
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  • Page 11 RT-flex50-D 0002−1/A1 Maintenance Table of Contents Table of Contents General Information Group 0 For Particular Attention ..........
  • Page 12 RT-flex50-D 0002−1/A1 Maintenance 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 Waisted Studs .
  • Page 13 RT-flex50-D 0002−1/A1 Maintenance Table of Contents Crankshaft, Connecting Rod and Piston Group 3 Crankshaft: Measuring Crank Deflection ........
  • Page 14 RT-flex50-D 0002−1/A1 Maintenance 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 −...
  • Page 15 RT-flex50-D 0002−1/A1 Maintenance Table of Contents Crank Angle Sensor Unit, Tools Group 9 Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting ... . . 9223−1/A1 Tools: Explanation ............
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  • Page 17 RT-flex50-D 0008−1/A1 Maintenance General Engine Numbering and Designations General Arrangement with One Turbocharger: Turbocharger Auxiliary Auxiliary Blower 1 Blower 2 Cylinder Numbering DRIVING END FREE END Main Bearing Numbering Thrust Bearing Pads Rail Unit FUEL SIDE EXHAUST SIDE Supply Unit...
  • Page 18 RT-flex50-D 0008−1/A1 Maintenance Engine Numbering and Designations General Arrangement with Two Turbochargers: Turbocharger 2 Turbocharger 1 Auxiliary Auxiliary Blower 1 Blower 2 Cylinder Numbering DRIVING END FREE END Main Bearing Numbering Thrust Bearing Pads Rail Unit FUEL SIDE EXHAUST SIDE...
  • Page 19 RT-flex50-D 0008−1/A1 Maintenance Engine Numbering and Designations flex Parts: Fuel Pump 1 Fuel Pump 2 Fuel Pump 3 Fuel Pump Actuator 1 Fuel Pump Actuator 2 Fuel Pump Actuator 3 Servo Oil Pump 2 FUEL SIDE Supply Unit Servo Oil Pump 1 DRAWN FOR 7 &...
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  • Page 21 RT-flex50-D 0011−1/A1 Maintenance General Guidelines for Maintenance Safety Measures and Warnings Overview General ..........
  • Page 22 RT-flex50-D 0011−1/A1 Maintenance Safety Measures and Warnings 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.
  • Page 23 RT-flex50-D 0011−1/A1 Maintenance Safety Measures and Warnings Special safety measures Prior to turning the crankshaft with the turning gear, make sure that no person is inside the engine and no loose parts, tools or devices can get jammed. Also bear in mind that the coupled propeller turns too (danger in surroundings).
  • Page 24 RT-flex50-D 0011−1/A1 Maintenance Safety Measures and Warnings ⇒ 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.
  • Page 25 RT-flex50-D 0012−1/A1 Maintenance General Guidelines for Lifting Tools Wire Rope Slings, Span-sets, Eye Bolts, etc. 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).
  • Page 26 RT-flex50-D 0012−1/A1 Maintenance General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc. Lifting capacity (for information purposes only): Lifting capacity [kg] Eye bolts & eye nuts, single-strand double-strand (45°) thread size 1200 1800 1290 3200 2300 4600 3300 6300 4500...
  • Page 27 RT-flex50-D 0012−1/A1 Maintenance General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc. 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).
  • Page 28 RT-flex50-D 0012−1/A1 Maintenance General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc. 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.
  • Page 29 RT-flex50-D 0012−1/A1 Maintenance General Guidelines: Wire Rope Slings, Span-sets, Eye Bolts, etc. Attaching and disconnecting The following must be observed: Distribution of load: − one strand carries the total of load weight − two strands carry each one half of the load weight −...
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  • Page 31: General

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Overview − General ..........

  • Page 32: Crankshaft And Thrust Bearing

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing 013.025/05 2010 2/ 25 Wärtsilä Switzerland Ltd...
  • Page 33 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Crankshaft and Thrust Bearing Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 1203 Thrust bearing 1224 − 0.5 Thrust bearing pad thickness − 0.6 Thrust bearing clearance axial (total) 0.8−1.3...

  • Page 34: Crankshaft And Main Bearing

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing 018.600/09 MAIN BEARING MAIN BEARING No. 2 No. 1 AND FOLLOWING 018.663/09 2010 / 50−D 4/ 25 Wärtsilä Switzerland Ltd...
  • Page 35 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Crankshaft and Main Bearing Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 1132 Main bearing No. 1 outer ∅ Crankshaft − 0.07 inner ∅ Main bearing...

  • Page 36: Crosshead Guide

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Crosshead Guide 013.027/05 FUEL SIDE 2010 6/ 25 Wärtsilä Switzerland Ltd...
  • Page 37 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Crosshead Guide Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3326 Crosshead guide Guide way (column) transverse − 0.20 Guide shoe transverse − 0.30 Guide shoe clearance 0.20−0.90...

  • Page 38: Cylinder Liner

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Cylinder Liner 016.555/08 2010 8/ 25 Wärtsilä Switzerland Ltd...
  • Page 39 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Cylinder Liner Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 2124 Water guide jacket on cylinder cover + 0.3 Water guide jacket Ø + 0.1...

  • Page 40: Piston Rod Gland

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Piston Rod Gland 013.225/05 2010 10/ 25 Wärtsilä Switzerland Ltd...
  • Page 41 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Piston Rod Gland Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 2303 Piston rod gland Ring width radial min. 25 Ring width radial min. 20.20...

  • Page 42: Exhaust Valve

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Exhaust Valve VALVE SPINDLE GUIDE BUSH 012.999/05 2010 12/ 25 Wärtsilä Switzerland Ltd...
  • Page 43 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Exhaust Valve Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 2751 Valve spindle outer ∅ − 0.14 Spindle 54.40 − 0.17 2751 Guide bush inner ∅...

  • Page 44: Top And Bottom End Bearings To Connecting Rod

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod 013.028/05 2010 14/ 25 Wärtsilä Switzerland Ltd...
  • Page 45 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Top and Bottom End Bearings to Connecting Rod Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3303 Top end bearing 3326 outer ∅ Crosshead pin −...

  • Page 46: Piston Cooling And Crosshead Lubrication

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubrication 013.029/05 2011-12 16/ 25 Wärtsilä Switzerland Ltd...
  • Page 47 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Piston Cooling and Crosshead Lubrication Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3603 Piston cooling and crosshead lubrication inner ∅ + 0.15 Sleeve + 0.12 −...

  • Page 48: Piston And Piston Rings

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Piston and Piston Rings l [mm] l min l min N 504 [mm] CYLINDER LINER BORE 2010 / 50−D 18/ 25 Wärtsilä Switzerland Ltd...
  • Page 49 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Piston and Piston Rings Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3403 Piston crown outer ∅ Crown − 0.2 outer ∅ Crown 497.7 − 0.2...

  • Page 50: Driving Wheels For Supply Unit

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit WCH00139 013.030/05 2010 20/ 25 Wärtsilä Switzerland Ltd...
  • Page 51 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Driving Wheels for Supply Unit Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 4103 Intermediate wheel outer ∅ Shaft Bearing clearance vertical 0.082−0.147 0.25 Axial clearance total 0.6−1.1...

  • Page 52: Supply Unit

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Supply Unit 013.031/05 1 3 2 7 2010 22/ 25 Wärtsilä Switzerland Ltd...
  • Page 53 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Supply Unit Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 5552 Supply unit outer ∅ Pinion − 0.019 inner ∅ + 0.10 Bearing (fitted) + 0.085...

  • Page 54: Fuel Pump

    RT-flex50-D 0330−1/A1 Maintenance Clearance Table Fuel Pump PLUNGER & CYLINDER 012.098/04 013.032/05 2010 24/ 25 Wärtsilä Switzerland Ltd...
  • Page 55 RT-flex50-D 0330−1/A1 Maintenance Clearance Table Fuel Pump Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 5556 Fuel pump Clearance (plunger / cylinder) A−B radial 0.028−0.030 0.037 Clearance (plunger / cylinder) B−C radial 0.018−0.020...
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  • Page 57 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections Group Description Thread Tightening values Lubricant [bar] [Nm] [_(; mm] 1112−1 1500 MOLYKOTE G Foundation bolt step 900 bar (metal and synthetic chocks) step 1500 bar 1132−1 step 1000 Nm Main bearing, nut for waisted stud...
  • Page 58 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections Group Description Thread Tightening values Lubricant [bar] [Nm] [_(; mm] 2751−1 1500 (155_) Exh. valve cage, nut for waisted stud 2751−2 Exhaust valve, screw for measuring cone − piston Lower − upper housings, nut for...
  • Page 59 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections Group Description Thread Tightening values Lubricant [bar] [Nm] [_(; mm] 4103−3 M24x2 (800) see details in Gear wheel on crankshaft, nut for 4103−3 waisted bolt to flanged connection (secured with LOCTITE No. 262) Elongation 1.20 ±...
  • Page 60 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections Group Description Thread Tightening values Lubricant [bar] [Nm] [_(; mm] 5564−1 Never-Seez Injection control unit − fuel rail, screw NSBT-8 Never-Seez Injection control unit − fuel rail, screw NSBT-8 Never-Seez Screw to pre-control valve NSBT-8 R ¾”...
  • Page 61 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections Group Description Thread Tightening values Lubricant [bar] [Nm] [_(; mm] 8447−1 M10 & 12 Screwed connection to servo oil pipe G¼” Non-return valve 8460−1 M8x90 Screwed connection to hydr. pipe 8733−1 Never-Seez Flange −...
  • Page 62 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections Group Description Thread Tightening values Lubricant [bar] [Nm] [_(; mm] Tools (2124−2) no additional Lifting gear 94202, screw lubricant required (see instructions in 2124−2) Lifting tool 94559 for supply unit RUD-eye bolt...
  • Page 63 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections LIFTING GEAR FOR ENGINE STAY CYLINDER LINER (FRICTION TYPE) 013.633/05 013.634/05 008.570/01 013.636/05 016.589/08a 50−D / 2010 7/ 16 Wärtsilä Switzerland Ltd...
  • Page 64 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 018.723/09 016.590/08a 2010 / 50−D 8/ 16 Wärtsilä Switzerland Ltd...
  • Page 65 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 016.591/08 2010 9/ 16 Wärtsilä Switzerland Ltd...
  • Page 66 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections SUPPLY UNIT 016.592/08 013.645/05 2010 10/ 16 Wärtsilä Switzerland Ltd...
  • Page 67 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections FUEL RAIL 013.647/05 013.646/05 013.648/05 2010 11/ 16 Wärtsilä Switzerland Ltd...
  • Page 68 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 013.649/05 2010 12/ 16 Wärtsilä Switzerland Ltd...
  • Page 69 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections SERVO OIL RAIL WCH00678 I - I 013.651/05 WCH00678 2011-12 13/ 16 Wärtsilä Switzerland Ltd...
  • Page 70 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections I - I 701.013.655 013.655/05 013.656/05 013.654/05 2010 14/ 16 Wärtsilä Switzerland Ltd...
  • Page 71 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections CRANK ANGLE SENSOR UNIT I - I 010.293/02 008.566/01 CONNECTING UNIT TO CRANK ANGLE SENSOR UNIT 008.750/01 008.567/01 2010 15/ 16 Wärtsilä Switzerland Ltd...
  • Page 72 RT-flex50-D 0352−1/A1 Maintenance Tightening Values of Important Screwed Connections 013.659/05 016.593/08 LIFTING TOOL ARRANGEMENT OF BLANK FOR RAIL UNIT FLANGES 94569 / 94569a 016.594/08 013.658/05 2010 16/ 16 Wärtsilä Switzerland Ltd...
  • Page 73 RT-flex50-D 0352−2/A1 Maintenance Tightening Values of Standard Screwed Connections 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.
  • Page 74 RT-flex50-D 0352−2/A1 Maintenance Tightening Values of Standard Screwed Connections Waisted studs Waisted studs must be tightened according to the values in the following diagram. 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.
  • Page 75 RT-flex50-D 0360−1/A1 Maintenance Masses (Weights) Individual Components per Piece in kg Group Component Execution 1115 Main bearing cover 1134 Main bearing shells (upper and lower) 1203 Holder for thrust bearing 1224 Thrust bearing pad 1717 Casing, upper part free end...
  • Page 76 RT-flex50-D 0360−1/A1 Maintenance Individual Components per Piece in kg Group Component Execution 3306 Connecting rod shank Lower bearing half for bottom end complete bearing with studs 3310 Lower bearing shell half for bottom end bearing Upper bearing shell half for bottom end...
  • Page 77 RT-flex50-D 0360−1/A1 Maintenance Individual Components per Piece in kg Group Component Execution 6506 Exhaust gas turbocharger ABB−A175 compl. 4900 ABB−A170 compl. 3000 MET60A complete 4260 6545 Auxiliary blower with electric motor complete 591 ... 885 Electric motor 160 ... 194...
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  • Page 79 RT-flex50-D 0370−1/A1 Maintenance Dimensions O-rings and Round Rubber Rings Inner ∅ Group Place of application Thick- ness [mm] [mm] 1903 Tie rod 5.33 91.44 2106 Cylinder block Cylinder liner 2124 Cylinder liner − water guide jacket Water guide jacket 2130 Connection piece −...
  • Page 80 RT-flex50-D 0370−1/A1 Maintenance Dimensions: O-rings and Round Rubber Rings Inner ∅ Group Place of application Thick- ness [mm] [mm] Supply unit 5552 Spray nozzle − housing 2.62 9.92 Fuel pump 5556 Lower housing − housing of supply unit 6.99 158.12 Upper housing −...
  • Page 81 RT-flex50-D 0370−1/A1 Maintenance Dimensions: O-rings and Round Rubber Rings Inner ∅ Group Place of application Thick- ness [mm] [mm] Scavenge air waste gate 6735 3/2-way valve − solenoid valve 1.78 12.42 8310 Cylinder cooling water piping − outlet orifice 5.33 120.02...
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  • Page 83 RT-flex50-D 0370−2/A1 Maintenance Dimensions Piston and Rod Seal Rings Group Place of application Ring Dimension [mm] type 4325 Shut-off valve for starting air − valve 160 x 155 x 3.8 Shut-off valve for starting air − spindle 30 x 33 x 2.8 5556 Regulating (toothed) rack −...
  • Page 84 RT-flex50-D 0370−2/A1 Maintenance Dimensions: Un-slotted Back-up Rings Tool Place of application of pre-tensioning Part Back-up ring O-ring jack (un-slotted) Dimension [mm] o∅ x i∅ x t i∅ x s 94114 Waisted studs to main bearing piston 74 x 67.8 x 1.4 66.27 x 3.53...
  • Page 85 RT-flex50-D 0370−2/A1 Maintenance Dimensions: Piston Seal Rings Group Place of application Ring Dimension [mm] type 2751 Exhaust valve piston 108 x 92.5 x 6.3 Piston Seal Ring (PSR) Nominal dimension da x di x b) Cylinder Seal ring O-ring Piston...
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  • Page 87 RT-flex50-D 0380−1/A1 Maintenance Maintenance Schedule Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals Lubricating oil − Laboratory analysis 3000 Op. h (operating hours) Cooling water − Determine quality, concentration of inhibitor and weekly pH value (follow instructions of inhibitor manufacturer) 1112−1...
  • Page 88 RT-flex50-D 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals 2138−1 Lubricating quill − Check function and tightness at every piston removal (pulse lubrication) − Check function of non-return valves at every liner removal −...
  • Page 89 RT-flex50-D 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals 3206−1 Turning gear − Inspection interval of turning gear acc. to instructions of turn. gear manufacturer − Re-lubrication of tooth flanks of pinion & flywheel, depending on visual inspections, however every 2000 Op.
  • Page 90 RT-flex50-D 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals 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) −...
  • Page 91 RT-flex50-D 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals 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 −...
  • Page 92 RT-flex50-D 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals 6708−1 Water separator − Check condensate collector through sight glass daily (see Operating Manual 8345−1) − Check condensate collector for free passage 1500−3000 Op. h (see Operating Manual 8345−1)
  • Page 93 RT-flex50-D 0380−1/A1 Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals 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...
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  • Page 95 RT-flex50-D 0803−1/A1 Maintenance Engine Cross Section and Longitudinal Section Cross section: 8460−1 8733−1 2728−1 5562−1 5612−1 5564−1 3603−1 8447−1 6606−1 3326−1 6708−1 3326−2 6420−1 8752−1 5556−1 5801−1 3301−1 3206−1 5552−1 5552−5 4103−1 1112−1 WCH00123 Pulse Jet / 2010 1/ 2...
  • Page 96 RT-flex50-D 0803−1/A1 Maintenance Engine Cross Section and Longitudinal Section Longitudinal section: 2751−1 2751−4 2708−1 2722−1 2708−3 3425−1 2124−1 2124−3 3403−1 3403−4 1903−1 2138−1 4325−1 2303−1 3303−1 3303−5 3146−1 1132−1 1132−2 9223−1 1203−1 1224−1 3130−1 4103−3 3130−2 WCH00126 2010 / Pulse Jet 2/ 2 Wärtsilä...
  • Page 97 RT-flex50-D Group1 Maintenance Bedplate and Tie Rod Group 1 Bedplate and Thrust Bearing: Checking the Foundation Bolts ....1112−1/A1 Main Bearing − Loosening and Tensioning of Waisted Studs .
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  • Page 99 RT-flex50-D 1112−1/A1 Maintenance Bedplate and Thrust Bearing Checking the Foundation Bolts Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Vent screw 11 Nut 1 Pre-tensioning jack 94145 2 Cylinder 12 Conical socket 1 HP oil pump 94931 3 Piston 13 Seating washer 2 Hydr.
  • Page 100 RT-flex50-D 1112−1/A1 Maintenance Checking the Foundation Bolts 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 6 or fitted stud 7 to be checked, and screw it completely down with vent screw 1 open until there is only little or no clearance at ’x’...
  • Page 101 RT-flex50-D 1112−1/A1 Maintenance Checking the Foundation Bolts 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’ in Fig. ’E’). ⇒ Connect the pre-tensioning jack to HP oil pump 94931 according to Fig. ’E’.
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  • Page 103 RT-flex50-D 1132−1/A1 Maintenance Main Bearing Loosening and Tensioning of Waisted Studs Tools: Key to Illustrations: 2 Double pre-tensioning jacks 94114b 1 Main bearing girder 1 Feeler gauge 94122 2 Main bearing cover 1 Special feeler gauge 94123 3 Waisted stud...
  • Page 104 RT-flex50-D 1132−1/A1 Maintenance Main Bearing: Loosening and Tensioning of Waisted Studs 94934g 94114b 94942 94935 94934 94934a 018.675/09 Loosening the waisted studs ⇒ Set-up double pre-tensioning jacks as de- scribed in section 2. ⇒ Start up hydraulic unit 94942. ⇒ Close vent screws 6 on the jacks as soon as oil flows bubble-free.
  • Page 105 RT-flex50-D 1132−1/A1 Maintenance Main Bearing: Loosening and Tensioning of Waisted Studs Tensioning the waisted studs After fitting the main bearing cover (1132−2), waisted studs 3 are to be tensioned as follows: ⇒ Set-up double pre-tensioning jacks 94114b as described in section 2.
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  • Page 107 RT-flex50-D 1132−2/A1 Maintenance Main Bearing Removal and Fitting of a Main Bearing Tools: Key to Illustrations: 1 Thrust device 94110 1 Crankshaft 1 Transportation tool 94116a 2 Bearing girder 1 Lifting lug 94116b 3 Main bearing cover 1 Assembling and dismantling device...
  • Page 108 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing I - I II - II 018.677/09 2010 / 50−D 2/ 17 Wärtsilä Switzerland Ltd...
  • Page 109 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Placing of thrust device 94110 Thrust device 94110 must be used for expanding the upper part of main bearing cover 3, facilitating the removal from its guide in bearing girder 2.
  • Page 110 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Removal of bearing cover No. 1 Remove the external casing at the driving end. Remove the upper part of the oil baffle and protect slinger rings on crankshaft. ⇒ Loosen the nuts for the waisted studs hydraulically and place tool 94110.
  • Page 111 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Removal of bearing covers No. 2 and following Place thrust device 94110 as described in section 2. ⇒ Screw RUD-eye bolt M20 ’RC’ into the guide shoe and tighten it with 115 Nm.
  • Page 112 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing ⇒ Connect manual ratchet H to shackle 94332a and lifting lug 94116b. ⇒ Lift bearing cover until it is completely retracted from the waisted studs. ⇒ By means of manual ratchets H...
  • Page 113 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing ⇒ Detach manual ratchets H and H ⇒ Remove the bearing cover from the crankcase using manual ratchet H spur-geared chain block ’HZ’. ⇒ Place bearing cover 3 on wooden underlay ’HU’ in order not to damage the fitted upper bearing shell 4 and the seating surfaces of the bearing cover.
  • Page 114 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Turning out and removal of lower bearing shells Attention! Never remove two neighbouring lower bearing shells at the same time! For the removal of lower bearing shells No. 1 and 2, the flywheel must in addi- tion be pressed up with jack 16.
  • Page 115 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Lifting the crankshaft ⇒ Measure and note lateral bearing clearances ’y ’ and ’y ’ between crankshaft journal 1 and lower bearing shell 4a at about 50 mm below the bearing divi- sion.
  • Page 116 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Turning out and removal of lower bearing shell No. 1 Crankshaft lifted up by approx. 0.2 mm (see paragraphs 5.1 and 5.2). ⇒ Fasten manual ratchet H to the platform.
  • Page 117 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing ⇒ Remove turning-out device 94118a. ⇒ Fasten transportation tool 94116a to bearing shell 4a and turn it completely out without major effort by means of manual ratchet H Remark: When retracted in upper position, both bearing shell ends are distinctly uplifted from the bearing journal (gap ’x’).
  • Page 118 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Turning out lower bearing shell No. 2 and following Turn crank to exhaust side approx. 90_ after T.D.C. Place working platform. Crankshaft lifted up by approx. 0.2 mm (see paragraphs 5.1 and 5.2).
  • Page 119 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing ⇒ Remove assembling and dismantling device 94117, rope 94120a, device 94119b and turning-out device 94118a. ⇒ Fasten transportation tool 94116a to bearing shell 4a and turn it completely out without major effort by means of manual ratchet H Remark: When retracted in upper position, both bearing shell ends are distinctly uplifted from the bearing journal (see detail with gap ’x’...
  • Page 120 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Inspecting main bearing shells ⇒ Clean the bearing shells with a soft cloth. ⇒ Check the bearing shells for damages such as breakouts or cracks. ⇒ Slight scratches and running marks can be removed by scotch brite.
  • Page 121 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Fitting of bearing shells and bearing covers Bearing covers and bearing shells are marked on their faces with DRIVING END. Therefore, they must be refitted correspondingly. Moreover, every bearing shell should be refitted into the bearing girder in its original position.
  • Page 122 RT-flex50-D 1132−2/A1 Maintenance Measure the bearing clearance again and compare the two measurements. If the CHECK clearance is within the limits (including allowable wear, see 0330−1) the bearing can be reused. The crank deflection should be measured when new bearing shells have been fitted.
  • Page 123 RT-flex50-D 1132−2/A1 Maintenance Removal and Fitting of a Main Bearing Turning in lower bearing shell No. 1: 94116a 94118a 94119b 018.611/09 018.612/09 Turning in lower bearing shell No. 2 and following: 94332 94332a 94117 94119b 018.614/09 018.613/09 2010 / 50−D 17/ 17 Wärtsilä...
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  • Page 125 RT-flex50-D 1203−1/A1 Maintenance Thrust Bearing Checking the Axial Clearance Tools: Key to Illustrations: 1 Inside micrometer 94101 1 Coupling flange 6a Thrust bearing pads 1 Feeler gauge 94238 2 Oil baffle, upper part for AHEAD 3 Oil baffle, lower part...
  • Page 126 RT-flex50-D 1203−1/A1 Maintenance Thrust Bearing: Checking the Axial Clearance Measuring method 2 ⇒ Displace the crankshaft axially until it rests on the engine side thrust bearing pads 6a (AHEAD) and then fix it in this position (Fig. ’A’). ⇒ Measure the distance between the coupling flange and upper part 2 of the oil baffle with inside micrometer 94101 at the position indicated (see Fig.
  • Page 127 RT-flex50-D 1224−1/A1 Maintenance Thrust Bearing Removal and Fitting the Thrust Bearing Pads Tools: Key to Illustrations: 1 Turning-out device 94155 1 Casing 7 Support (with 1-part gear wheel) 2 Oil baffle, upper part 8 Housing 1 Turning-out device 94155a 3 Screw...
  • Page 128 RT-flex50-D 1224−1/A1 Maintenance Removal and Fitting the Thrust Bearing Pads ⇒ Screw RUD-eye bolt ’RC’ into thrust bearing pads 5 or 5a to be removed. ⇒ Fasten lifting tackles ’HZ’ to the straps of supports 7 and connect them with ropes ’a’...
  • Page 129 RT-flex50-D 1224−1/A1 Maintenance Removal and Fitting the Thrust Bearing Pads Fitting 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 replaced in their original position. Note the numbering of the individual pads! Also refer to the follow- ing pages for the arrangement of thrust bearing pads on engines with fixed pitch propellers (F.P.P.) and controllable pitch propellers (C.P.P.) respectively.
  • Page 130 RT-flex50-D 1224−1/A1 Maintenance Removal and Fitting the Thrust Bearing Pads ARRANGEMENT OF THRUST BEARING PADS FOR 5 & 6 CYLINDER ENGINES WITH FIXED PITCH PROPELLER CLOCKWISE ASTERN AHEAD ROTATING ENGINE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END...
  • Page 131 RT-flex50-D 1224−1/A1 Maintenance Removal and Fitting the Thrust Bearing Pads ARRANGEMENT OF THRUST BEARING PADS FOR 5 & 6 CYLINDER ENGINES WITH CONTROLLABLE PITCH PROPELLER CLOCKWISE ASTERN AHEAD ROTATING ENGINE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END...
  • Page 132 RT-flex50-D 1224−1/A1 Maintenance Removal and Fitting the Thrust Bearing Pads ARRANGEMENT OF THRUST BEARING PADS FOR 7 & 8 CYLINDER ENGINES WITH FIXED PITCH PROPELLER CLOCKWISE ASTERN AHEAD ROTATING ENGINE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END...
  • Page 133 RT-flex50-D 1715−1/A1 Maintenance Engine Stays with Friction Shims Checking the Pre-tension Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Engine stays 1 Pre-tensioning jack 94145 2 Friction shims 1 HP oil pump 94931 3 Screw 2 Hydr. distributors 94934a...
  • Page 134 RT-flex50-D 1715−1/A1 Maintenance Engine Stays with Friction Shims: Checking the Pre-tension Checking the pre-tension ⇒ Clean the threads of the screws and the seating surfaces. Subsequently apply MOLYKOTE G paste to the threads. ⇒ Place pre-tensioning jack 94145 on the screw to be checked, and screw it completely down with vent screw 6 open until there is only little or no clearance at ’x’...
  • Page 135 RT-flex50-D 1903−1/A2 Maintenance Tie Rod Checking the Pre-tension and Tensioning the Tie Rods with M72x6 Thread Diameter Tools: Key to Illustrations: 1 Rod 94005b 1 Cylinder block 12 Bearing girder 2 Pre-tensioning jacks 94180a 2 Intermediate ring 13 Lower backing ring...
  • Page 136 RT-flex50-D 1903−1/A2 Maintenance Checking the Pre-tension and Tensioning the Tie Rods with M72x6 Thread Diameter PRE-TENSIONING JACK 94180a PRE-TENSIONING JACK 94180a PLACED FOR LOOSENING PLACED FOR TENSIONING 94934g 94935 94934a 94934 94005b WCH00668 012.947/05 94942 94935 Using a feeler gauge inserted through slot ’KO’, check whether tie rod nut 3 rests CHECK on intermediate ring 2 without any clearance.
  • Page 137 RT-flex50-D 1903−1/A2 Maintenance Checking the Pre-tension and Tensioning the Tie Rods with M72x6 Thread Diameter Loosening and tensioning the tie rods Should tie rods have to be removed or fitted, the following points have to be ob- served: ⇒ Remove clamp screws 10 (Fig. ’D’).
  • Page 138 RT-flex50-D 1903−1/A2 Maintenance Checking the Pre-tension and Tensioning the Tie Rods with M72x6 Thread Diameter Tensioning in one procedure: ⇒ Connect pre-tensioning jacks with hydraulic unit 94942. ⇒ Actuate the hydraulic unit until bubble-free oil flows out through the vent screws.
  • Page 139 RT-flex50-D 1903−1/A2 Maintenance Checking the Pre-tension and Tensioning the Tie Rods with M72x6 Thread Diameter I - I WCH00668 FLUSH 2011 5/ 5 Wärtsilä Switzerland Ltd...
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  • Page 141 RT-flex50-D Group2 Maintenance Cylinder Liner and Cylinder Cover Group 2 Cylinder Liner − Measuring Bore Wear ..........
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  • Page 143 RT-flex50-D 2124−1/A1 Maintenance Cylinder Liner Measuring Bore Wear Tools: Key to Illustrations: 1 Inside micrometer 94101 1 Cylinder liner 1 Tool cylinder liner measuring 94102 2 Antipolishing ring 1 Measuring gauge 94225 ST Setting screw SETTING SCREW ’ST’ DRAWN FOR COM- PRESSION SHIM THICKNESS = 0 mm.
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  • Page 145 RT-flex50-D 2124−2/A1 Maintenance Cylinder Liner Removal and Fitting of Cylinder Liner or Water Guide Jacket Tools: Key to Illustrations: 1 Lifting gear 94202 1 Cylinder block 13 Screw 2 Distance plates 94202b 2 Cylinder liner 14 Centring pin 4 Distance plates...
  • Page 146 RT-flex50-D 2124−2/A1 Maintenance Removal and Fitting of Cylinder Liner or Water Guide Jacket Adjusting lifting gear to crane hook Distance ’x’ must be adjusted so that an axial clearance of 2−5 mm results be- tween the relevant crane hook and distance plates 94202b.
  • Page 147 RT-flex50-D 2124−2/A1 Maintenance Removal and Fitting of Cylinder Liner or Water Guide Jacket Removal and fitting of cylinder liner with water guide jacket ⇒ Loosen screws 5. ⇒ Loosen screws 10 and remove them together with angle plates 11 and con- nection pieces 9 from water guide jacket 3 (view II-II).
  • Page 148 RT-flex50-D 2124−2/A1 Maintenance Removal and Fitting of Cylinder Liner or Water Guide Jacket Placing lifting gear Lifting gear 94202 must be adapted according to paragraph 1.1. ⇒ Place lifting gear diagonally onto cylinder liner 2. ⇒ Apply oil to the threads of screws 94202h.
  • Page 149 RT-flex50-D 2124−2/A1 Maintenance Removal and Fitting of Cylinder Liner or Water Guide Jacket Fitting Lifting gear 94202 must be placed according to paragraph 2.1. ⇒ Clean seating surfaces ’AF’ (Fig. ’C’) on cylinder liner and cylinder block. ⇒ Fasten holders 7 and 7a with screws 6 to cylinder liner as shown in Fig. ’B’.
  • Page 150 RT-flex50-D 2124−2/A1 Maintenance Removal and Fitting of Cylinder Liner or Water Guide Jacket Removal and fitting of water guide jacket Removal Risk of accident! Due to tilting risk, only remove water guide jacket 3 from cylinder liner 2, if the latter is located in the cylinder block! Pay attention to instructions in section 1.
  • Page 151 RT-flex50-D 2124−2/A1 Maintenance Removal and Fitting of Cylinder Liner or Water Guide Jacket Fitting Holders 16 and 16a must be fitted to the cylinder liner as shown in Fig. ’F’. Lifting gear 94202 must be placed according to paragraph 2.1.
  • Page 152 RT-flex50-D 2124−2/A1 Maintenance Removal and Fitting of Cylinder Liner or Water Guide Jacket Removal and fitting of cylinder liner without water guide jacket Removal Water guide jacket must be removed (see paragraph 4.1). 5.1.1 Placing lifting gear ⇒ Place lifting gear 94202 in engine longitudinal direction onto cylinder liner 2.
  • Page 153 RT-flex50-D 2124−2/A1 Maintenance Removal and Fitting of Cylinder Liner or Water Guide Jacket aying down and raising cylinder liner ⇒ Place lifting gear 94202 according to paragraph 5.1.1. ⇒ Connect rope ’a’ (lifting capacity 3000 kg) with crane and lifting ring 17. Lay down the cylinder liner and secure it against rolling away as shown in the fig- ures below.
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  • Page 155 RT-flex50-D 2124−3/A1 Maintenance Cylinder Liner Removing the Wear Ridge, Re-dressing Lubricating Grooves and Scavenge Ports Tools: Key to Illustrations: 1 Wear ridge grinding device 94299 1 Roller support 9 Thread nozzle 2 Holder 10 Carbide milling cutter 3 Holder 11 Cylinder liner...
  • Page 156 RT-flex50-D 2124−3/A1 Maintenance Cylinder Liner: Re-dressing Lubricating Grooves and Scavenge Ports SHARP EDGES REMOVED II-II WCH00106 015.739/07 2010 / Pulse Jet 2/ 3 Wärtsilä Switzerland Ltd...
  • Page 157 RT-flex50-D 2124−3/A1 Maintenance Cylinder Liner: Removing the Wear Ridge 94299 T.D.C. 2 - 3mm 009.642/02 013.047/05 2010 3/ 3 Wärtsilä Switzerland Ltd...
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  • Page 159 RT-flex50-D 2138−1/A1 Maintenance Lubricating Quill Removal and Fitting with Pulse Feed Lubrication Tool: Key to Illustrations: 1 Tool box 94720c 1 Cylinder liner 14 Cu gasket with fittings for charging 2 Lubricating pump 15 4/2-way solenoid valve accumulator 3 Accumulator...
  • Page 160 RT-flex50-D 2138−1/A1 Maintenance Lubricating Quill with Pulse Feed Lubrication Removal and fitting of lubricating quill ⇒ Loosen lower union nut of adjustable angle union 12 and pipe bracket(s) 21 (Fig. ’A’). Separate lubricating oil pipe 13 and protect it against any damages and entering of dirt.
  • Page 161 RT-flex50-D 2138−1/A1 Maintenance Lubricating Quill with Pulse Feed Lubrication Non-return valve Remark: Always replace screwed union 6 with completely fitted non-return valve ⇒ Oil and tighten screwed union with a torque of 30 Nm. WCH00661 Checking a non-return valve For judging the proper functioning of the non-return valve an opening pressure test (opening pressure = 5 bar) must be carried out.
  • Page 162 RT-flex50-D 2138−1/A1 Maintenance Lubricating Quill with Pulse Feed Lubrication Venting of the cylinder lubricating system A function control must be carried out after every assembly of the lubricating quills, tightening lubricating oil pipes 13 and pipe brackets 21. The lubricating oil pipes must be vented at angle union 12 and the lower union nut.
  • Page 163 RT-flex50-D 2138−1/A2 Maintenance Lubricating Quill Removal and Fitting with Pulse Jet Lubrication Tool: Key to Illustrations: 1 Tool box 94720c 1 Cylinder liner 13 4/2-way solenoid valve with fittings for charging 2 Lubricating pump 14 Sink plunger accumulator 3 Accumulator...
  • Page 164 RT-flex50-D 2138−1/A2 Maintenance Lubricating Quill with Pulse Jet Lubrication Removal and fitting of lubricating quill ⇒ Loosen Allen screws 9, nuts of screw-in union 10 and angle union 11 (Fig. ’A’). Disconnect lubricating oil pipe 12 and protect it against any damages and en- tering of dirt.
  • Page 165 RT-flex50-D 2138−1/A2 Maintenance Lubricating Quill with Pulse Jet Lubrication Checking a non-return valve For judging the proper functioning of the non-return valve an opening pressure test (opening pressure = 5 bar) 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.
  • Page 166 RT-flex50-D 2138−1/A2 Maintenance Lubricating Quill with Pulse Jet Lubrication Venting of the cylinder lubricating system A function control must be carried out after every assembly of the lubricating quills, tightening lubricating oil pipes 12 and pipe brackets 19. The lubricating oil pipes must be vented at angle union 11 and the lower union nut.
  • Page 167 RT-flex50-D 2303−1/A1 Maintenance Piston Rod Gland Dismantling and Assembling, Measuring the Wear Tools: Key to Illustrations: 2 Distance holders 94345 1 Housing (2-part) 11 Locking plate 1 Clamp ring (2-part) 94345b 2 Scraper ring 12 Cylinder cover stud 1 Gauge...
  • Page 168 RT-flex50-D 2303−1/A1 Maintenance Piston Rod Gland: Dismantling and Assembling, Measuring the Wear Removing, dismantling and assembling Removing a gland ⇒ For removing the gland, both distance holders 94345 are to be screwed on the foot of piston rod 18. ⇒ Unscrew the four inner screws 10 to 94345 support 16 (Fig.
  • Page 169 RT-flex50-D 2303−1/A1 Maintenance Piston Rod Gland: Dismantling and Assembling, Measuring the Wear I - I II - II 013.215/05 2010 3/ 6 Wärtsilä Switzerland Ltd...
  • Page 170 RT-flex50-D 2303−1/A1 Maintenance Piston Rod Gland: Dismantling and Assembling, Measuring the Wear 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 ⇒...
  • Page 171 RT-flex50-D 2303−1/A1 Maintenance Piston Rod Gland: Dismantling and Assembling, Measuring the Wear ⇒ After assembly of the ring supports for grooves ’c’ − ’g’, place two distance pieces 94345f (11 mm) on the uppermost ring support 5 and fit sealing rings 3, 4 and tension spring 8 for groove ’b’.
  • Page 172 RT-flex50-D 2303−1/A1 Maintenance Piston Rod Gland: Dismantling and Assembling, Measuring the Wear ⇒ Remove all distance pieces 94345f and clamp ring 94345b. Check the proper position of all rings with gauge 94345c resting on hinged cover CHECK ⇒ Smear piston rod as well as all rings with bearing oil.
  • Page 173 RT-flex50-D 2708−1/A1 Maintenance Cylinder Cover Removal and Fitting of Cylinder Cover and Water Guide Jacket Tools: Key to Illustrations: 1 Suspension device 94265 1 Cylinder cover 8 Joint ring 2 Spec. eye nuts 94265a 2 Water guide jacket 9 Antipolishing ring...
  • Page 174 RT-flex50-D 2708−1/A1 Maintenance Removal and Fitting of Cylinder Cover and Water Guide Jacket Place new O-rings 11 into the grooves of transition tubes 7 and smear them as well as the sealing faces of the water guide jacket 2 with oil.
  • Page 175 RT-flex50-D 2708−1/A1 Maintenance Removal and Fitting of Cylinder Cover and Water Guide Jacket Removal of water guide jacket ⇒ Place the cylinder cover with screwed-down water guide jacket over wooden underlays ’HU’ as shown in Fig. ’D’. Risk of accident! Never put your hand between the water guide jacket and the...
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  • Page 177 RT-flex50-D 2708−2/A1 Maintenance Cylinder Cover Loosening and Tensioning of Cylinder Cover Waisted Studs Tools: Key to Illustrations: 1 Hydr. tensioning device 94215 1 Cylinder cover stud 2 Nut consisting of: 8 Pre-tensioning jacks 94215a 3 Vent screw 2 Connection pieces with HP hoses...
  • Page 178 RT-flex50-D 2708−2/A1 Maintenance Loosening and Tensioning of Cylinder Cover Waisted Studs ⇒ Connect both connection pieces 94215b by their HP hoses to hydraulic jacks 94215a. ⇒ Connect hydraulic unit 94942 to connection pieces 94215b. 94215b 94215b 94215a 94934 94935 012.962/05...
  • Page 179 RT-flex50-D 2708−2/A1 Maintenance Loosening and Tensioning of Cylinder Cover Waisted Studs Tensioning Using a feeler gauge, check whether nuts 2 rest CHECK without clearance. ⇒ Mark position of nuts to seating surface with a felt tipped pen. ⇒ Screw pre-tensioning jacks 94252 onto cylin- der cover studs 1 as mentioned in section 2, however, do not turn back them.
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  • Page 181 RT-flex50-D 2708−3/A1 Maintenance Cylinder Cover Machining of Sealing Face for Injection Valve Tools: Key to Illustrations: 1 Overhauling device 94270 1 Cylinder cover 5 Profiling cutter 2 Milling cutter holder 6 Centring mandril 3 Guide flange 7 Screw 4 Setscrews...
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  • Page 183 RT-flex50-D 2722−1/A1 Maintenance Injection Valve Checking, Dismantling, Assembling and Adjusting Tools: Key to Illustrations: 1 Protection cap 94271 1 Injection valve 15 Snap ring 1 OBEL test bench 94272 2 Allen screw 16 Dowel pin 1 Connecting piece 94272b 3 Spring guide...
  • Page 184 RT-flex50-D 2722−1/A1 Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting Checking an injection valve Before commissioning the instructions and directions of the test bench manufac- turer must be observed. Remark: The work station must be clean; welding and grinding should not be done...
  • Page 185 RT-flex50-D 2722−1/A1 Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting Judging an injection valve For correct functioning and for a reuse of an injection valve observe the following points: Spray pattern: The injection valve works properly if fuel sprays from all spray holes of the nozzle tip at the specified opening pressure;...
  • Page 186 RT-flex50-D 2722−1/A1 Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting Dismantling an injection valve ⇒ Screw down the injection valve on support 19 of test bench 94272, as men- tioned, however without connecting HP hose 20 to the injection valve.
  • Page 187 RT-flex50-D 2722−1/A1 Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting II - II I - I 013.489/05 013.490/05 013.491/05 2010 5/ 8 Wärtsilä Switzerland Ltd...
  • Page 188 RT-flex50-D 2722−1/A1 Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting Adjusting the opening pressure ⇒ Dismantle injection valve (section 4). ⇒ Replace shim rings 8 by adjusting disc 94280 of 10.2 mm thickness. ⇒ Assemble injection valve (section 5). ⇒ Check injection valve (section 2) and note the opening pressure as ’p ’.
  • Page 189 RT-flex50-D 2722−1/A1 Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting Replacing a nozzle tip If nozzle tip 7 should be dismantled only, it is sufficient to remove retaining sleeve 14. Removal ⇒ Using two screw drivers inserted between both re-...
  • Page 190 RT-flex50-D 2722−1/A1 Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting Assembling a spring cage − Cup springs 4 are fitted in spring cage 23. − The spring packet consists of three packs com- posed of three cup springs which are arranged as shown in Fig.
  • Page 191 RT-flex50-D 2728−1/A1 Maintenance Starting Valve Removal, Fitting and Dismantling, Grinding-in and Assembling Key to Illustrations: 1 Cylinder cover 12 Head screw M6x55 2 Housing 13 Control valve (solenoid valve) 3 Cover 14 Plug 4 Piston 15 Joint ring 5 Piston ring...
  • Page 192 RT-flex50-D 2728−1/A1 Maintenance Starting Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling Grinding-in Slightly damaged seat faces may be ground in (lapped) manually. Badly worn seat faces must first be machined and then ground in (lapped) manually. Remark: The valve spindle has an angle of 91_, however, the valve seat angle amounts to 90_.
  • Page 193 RT-flex50-D 2728−1/A1 Maintenance Starting Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling I - I 018.384/09 GL 2 2010 3/ 3 Wärtsilä Switzerland Ltd...
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  • Page 195 RT-flex50-D 2745−1/A1 Maintenance Relief Valve for Cylinder Cover Checking Blow-off Pressure Tools: Key to Illustrations: 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.
  • Page 196 RT-flex50-D 2745−1/A1 Maintenance Relief Valve: Checking Blow-off Pressure 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.
  • Page 197 RT-flex50-D 2751−1/A1 Maintenance Exhaust Valve Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs Tools: Key to Illustrations: 1 Dismantling tool 94008a−M56 1 Waisted stud 11 Distribution box 2 Pre-tensioning jacks 94252 2 Nut 12 Plug 1 Valve protector...
  • Page 198 RT-flex50-D 2751−1/A1 Maintenance Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs Loosening of waisted studs Remark: It is essential that instructions 9403−4 referring to the application of hy- draulic pre-tensioning jacks to screwed fastenings be strictly followed. ⇒ Clean threads of waisted studs 1 as well as the area around nuts 2 (Fig. ‘B‘).
  • Page 199 RT-flex50-D 2751−1/A1 Maintenance Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs Transport of exhaust valve ⇒ Use suspension device 94265 (Fig. ’D’) or RUD-eye bolt ’RC’ (Fig. ’E’) to pull the complete exhaust valve out of the cylinder cover and for transport.
  • Page 200 RT-flex50-D 2751−1/A1 Maintenance Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs Fitting ⇒ Clean all the joint faces on the exhaust valve and in the cylinder cover and check them for damages. ⇒ Clean the soft iron ring of 2 mm thickness, replace it if necessary, then put it in the cylinder cover.
  • Page 201 RT-flex50-D 2751−1/A1 Maintenance Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs Fitting of expansion piece ⇒ Clean the joint faces on expansion piece 8 and the corresponding ones on valve cage and exhaust pipe. ⇒ Apply a thin layer of a heat-resisting lubricant to joint faces and connecting screws.
  • Page 202 RT-flex50-D 2751−1/A1 Maintenance Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs Replacement of waisted studs When fitting a new waisted stud (in the following text called stud for short) of the cylinder cover or exhaust valve cage, the instructions hereafter must be strictly ob- served.
  • Page 203 RT-flex50-D 2751−1/A1 Maintenance Removal and Fitting of Exhaust Valve, Replacing of Waisted Studs 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...
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  • Page 205 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve Dismantling and Assembling Tools: Key to Illustrations: 1 Depth gauge 94126 1 Valve cage 21 Guide bush 1 Pressure element 94259a 2 Lower housing 22 Rod seal ring 1 Torque wrench 3 Nut 23 Valve seat...
  • Page 206 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve: Dismantling and Assembling WCH00406 2011-12 2/ 9 Wärtsilä Switzerland Ltd...
  • Page 207 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve: Dismantling and Assembling Dismantling of exhaust valve 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.
  • Page 208 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve: Dismantling and Assembling Removal of guide bush ⇒ Loosen head screws 20 and remove them together with distance ring 19 and rod seal ring 22. ⇒ Withdraw guide bush 21 from valve cage 1 by means of two jacking screws or threaded rods M10.
  • Page 209 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve: Dismantling and Assembling 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 17 (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.
  • Page 210 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve: Dismantling and Assembling Assembling of valve drive ⇒ Bring valve cage to vertical position and fit disc springs 18 as shown in Fig. ’C’. ⇒ Fit piston 16, valve cotters 15 and circlip 14. ⇒ Fit lower housing 2.
  • Page 211 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve: Dismantling and Assembling Setting of damper Setting of damper 33 is necessary only after a valve spindle or valve seat has been replaced, and after one of the valve seating faces has been ground. Setting is to be carried out, after assembling of the exhaust valve as shown in Fig.
  • Page 212 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve: Dismantling and Assembling Checking filter ⇒ Remove screw plug 24 (detail in Fig. ’B’). Loosen filter 25 together with its orifice and check them for fouling. Checking non-return valve ⇒ Loosen and remove adapter 26.
  • Page 213 RT-flex50-D 2751−2/A1 Maintenance Exhaust Valve: Dismantling and Assembling Blocking of exhaust valve The engine operation must be interrupted temporarily for blocking an exhaust valve. In case of an emergency, i.e. with water leakages into the combustion chamber damper 33 can be removed and the exhaust valve blocked in open position by means of pressure element 94259a.
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  • Page 215 RT-flex50-D 2751−3/A1 Maintenance Exhaust Valve Replacing and Grinding the Valve Seat Tools: Key to Illustrations: 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...
  • Page 216 RT-flex50-D 2751−3/A1 Maintenance Exhaust Valve: Replacing and Grinding the Valve Seat 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.
  • Page 217 RT-flex50-D 2751−3/A1 Maintenance Exhaust Valve: Replacing and Grinding the Valve Seat 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: −...
  • Page 218 RT-flex50-D 2751−3/A1 Maintenance Exhaust Valve: Replacing and Grinding the Valve Seat Remark: Regarding the operation of the grinding machine refer to the operating instructions of the respective manufacturer. The grinding must produce an even and smooth surface. + 2’ Valve seat angle = 30_ The grinding allowance on the valve seat is maximum 3 mm.
  • Page 219 RT-flex50-D 2751−3/A1 Maintenance Exhaust Valve: Replacing and Grinding the Valve Seat Checking the valve seat After grinding it is necessary to check whether the new or CHECK re-ground 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 valve guide bush.
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  • Page 221 RT-flex50-D 2751−4/A1 Maintenance Exhaust Valve Grinding the Seating Surface on the Valve Head Tools: 1 Feeler gauge 94122 1 Valve grinding device 94291 1 Gauge 94292 General Grinding in a valve together with its valve seat with grinding paste is not permitted.
  • Page 222 RT-flex50-D 2751−4/A1 Maintenance 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. Where the precise angle required has been obtained during grinding, a check...
  • Page 223 RT-flex50-D Group3 Maintenance Crankshaft, Connecting Rod and Piston Group 3 Crankshaft: Measuring Crank Deflection ........
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  • Page 225 RT-flex50-D 3103−1/A1 Maintenance Crankshaft Measuring Crank Deflection Tool: Key to Illustrations: 1 Crankshaft checking equipment 94305 1 Flywheel (dial gauge) 2 Pinion General The crank deflections (crankshaft alignment) must be measured in order to ascer- tain whether the crankshaft axis has changed.
  • Page 226 RT-flex50-D 3103−1/A1 Maintenance Measuring Crank Deflection 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.
  • Page 227 RT-flex50-D 3103−1/A1 Maintenance Measuring Crank Deflection Judging the measuring 94305 nB.D.C nT.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...
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  • Page 229 RT-flex50-D 3130−1/A1 Maintenance Vibration Damper Taking a Silicone Fluid Sample Key to Illustrations: 1 Casing trough 6 Coupling bolt 2 Casing cover 7 Cap nut 3 Screw plug 4 O-ring KS Secured by centre punch mark 5 Sealing ring PB Sample container General Viscous vibration dampers manufactured by Hasse &...
  • Page 230 RT-flex50-D 3130−1/A1 Maintenance Taking a Silicone Fluid Sample 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.
  • Page 231 RT-flex50-D 3130−1/A1 Maintenance Taking a Silicone Fluid Sample SAMPLE CONTAINERS Metaldyne and STE ” BSF (M16) Hasse & Wrede M10x1 M10x1 ” BSF (M10) 007.964/97 If a sample is not obtained by the method described, proceed as follows: Leave sample container in position.
  • Page 232 RT-flex50-D 3130−1/A1 Maintenance Taking a Silicone Fluid Sample 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...
  • Page 233 RT-flex50-D 3130−2/A1 Maintenance Vibration Damper Inspection (GEISLINGER Vibration Damper) Key to Illustrations: 1 Damper casing 6 Coupling bolt 2 Vent nozzle 7 Coupling disc 3 Sealing ring (crank angle sensor unit) 4 Oil supply piping 8 Vibration damper 5 Crankshaft...
  • Page 234 RT-flex50-D 3130−2/A1 Maintenance Inspection (GEISLINGER Vibration Damper) FREE END OIL SUPPLY 013.052/05 DRAWN FOR STEEL 000.940/93 SPRING DAMPER 2010 2/ 2 Wärtsilä Switzerland Ltd...
  • Page 235 RT-flex50-D 3146−1/A1 Maintenance Axial Damper Dismantling and Assembling Key to Illustrations: 1 Casing upper part 13 2-part gasket 2 Piping 14 Pressure reducing nozzle 3 Axial damper monitoring 15 Orifice 4 Cylinder upper part 16 Gasket 5 Cylinder lower part...
  • Page 236 RT-flex50-D 3146−1/A1 Maintenance Axial Damper: Dismantling and Assembling ⇒ Remove all screws 6. ⇒ Remove all screws 7 to cylinder upper part 4. On engines provided with vibra- tion damper loosen the screws and pull them out as far as possible.
  • Page 237 RT-flex50-D 3146−1/A1 Maintenance Axial Damper: Dismantling and Assembling Remark: Pay attention to General Guidelines for Lifting Tools 0012−1. ⇒ Screw RUD-eye bolts ’RC’ into cylinder upper part 4. ⇒ Connect ropes ’a’ and ’b’ with lifting tackles ’HZ’ and RUD-eye bolts ’RC’ as shown in figure below.
  • Page 238 RT-flex50-D 3146−1/A1 Maintenance Axial Damper: Dismantling and Assembling ⇒ Carefully lift cylinder upper part 4 using ropes ’a’ and ’b’. Attention! When lifting make sure that the cylinder upper part slides out of 2-part gaskets 11 and 13 without jamming, as otherwise the gaskets risk being dam- aged.
  • Page 239 RT-flex50-D 3146−1/A1 Maintenance Axial Damper: Dismantling and Assembling Assembling Remark: The 2-part gaskets normally have no signs of wear, therefore no dimen- sion due to wear is indicated. However, worn or damaged 2-part gaskets 11 and 13 due to contamination must be replaced.
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  • Page 241 RT-flex50-D 3206−1/A1 Maintenance Turning Gear Checking the Toothing Key to Illustration: 1 Turning gear 2 Pinion 3 Toothing of flywheel 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.
  • Page 242 RT-flex50-D 3206−1/A1 Maintenance Turning Gear: Checking the Toothing Checking the toothing 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.
  • Page 243 RT-flex50-D 3301−1/A1 Maintenance Crankcase Utilization of Working Platform Tools: Key to Illustrations: 1 Working platform 94142 1 Engine longitudinal beam 2 Nuts 94142a 2 Crank web 1 Working support 94143 3 Step 4 Strap To avoid accidents, the working platform and support should always be used for inspections or works in the crankcase.
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  • Page 245 RT-flex50-D 3301−2/A1 Maintenance Upper Platform Arrangement of Lifting Tools Tools: Key to Illustrations: 1 Spur-geared chain block 1 Double I-girder (upper platform) 2 Spur-geared chain blocks 2 Reinforcing rib 1 Lifting tool 94335(a) 3 Name plate 2 Bushes 94335b 4 Crane rail...
  • Page 246 RT-flex50-D 3301−2/A1 Maintenance Upper Platform: Arrangement of Lifting Tools CONTINUOUS CRANE RAIL (VARIANT B) 018.385/09 2010 2/ 2 Wärtsilä Switzerland Ltd...
  • Page 247 RT-flex50-D 3303−1/A1 Maintenance Connecting Rod Loosening and Tensioning the Connecting Rod Studs Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Stud of top end bearing 9 Cylinder 2 Pre-tensioning jacks 94314 2 Nut 2 Distance bushes 94314a 3 Top end bearing...
  • Page 248 RT-flex50-D 3303−1/A1 Maintenance Loosening and Tensioning the Connecting Rod Studs Loosening the stud of bottom end bearing ⇒ Clean the threads of studs 4 as well as the 94314 area around nuts 5. ⇒ Place distance bushes 94314a onto the 94314a studs.
  • Page 249 RT-flex50-D 3303−1/A1 Maintenance Loosening and Tensioning the Connecting Rod Studs Tensioning the stud of bottom end bearing ⇒ Clean the threads of studs 4 as well as the area around nuts 5. ⇒ Apply oil to the stud threads and screw on the nuts.
  • Page 250 RT-flex50-D 3303−1/A1 Maintenance Loosening and Tensioning the Connecting Rod Studs Loosening the stud of top end bearing Remark: For loosening the studs always follow the sequence shown in Fig. ’D’ i.e. a+ a and b+ b. ⇒ Clean the threads of studs 1 as well as the area around nuts 2.
  • Page 251 RT-flex50-D 3303−1/A1 Maintenance Loosening and Tensioning the Connecting Rod Studs Tensioning the stud of top end bearing Remark: For tensioning the studs always follow the sequence shown in Fig. ’D’ i.e. a + a and b + b for each step.
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  • Page 253 RT-flex50-D 3303−2/A1 Maintenance Connecting Rod Inspection, Removal and Fitting of Bottom End Bearing Tools: Key to Illustrations: 1 Working platform 94142 1 Connecting rod stud 9 Cylindrical pin 4 Retaining pins 94323 2 Nut 10 Upper bearing shell 3 Crank...
  • Page 254 RT-flex50-D 3303−2/A1 Maintenance Inspection, Removal and Fitting of Bottom End Bearing Removal of bearing cover ⇒ Connect rope ’b’ with lifting tackle ’HZ’. ⇒ Pull up bearing cover 4 towards fuel side with ropes ’a’ and ’b’. ⇒ Detach rope ’a’.
  • Page 255 RT-flex50-D 3303−2/A1 Maintenance Inspection, Removal and Fitting of Bottom End Bearing Inspection of upper bearing shell ⇒ Turn the crankshaft to T.D.C. ⇒ Insert the four retaining pins 94323 into the bores of guide ways 6. 94323 ⇒ Carefully turn crankshaft towards fuel side till the guide shoes come to rest on the retaining pins.
  • Page 256 RT-flex50-D 3303−2/A1 Maintenance Inspection, Removal and Fitting of Bottom End Bearing Fitting the bearing shells Fitting of the bearing shells (and bearing cover) is carried out analogously to the removal but in reverse sequence, whereby attention must be paid to the following: The surface of the crankpin must be in perfect condition.
  • Page 257 RT-flex50-D 3303−3/A1 Maintenance Connecting Rod Inspection, Removal and Fitting of Top End Bearing Tools: Key to Illustrations: 1 Working platform 94142 1 Crankshaft 10 Allen screw 4 Retaining pins 94323 2 Connecting rod 11 Bearing shell 1 Lifting plate 94324...
  • Page 258 RT-flex50-D 3303−3/A1 Maintenance Inspection, Removal and Fitting of Top End Bearing Lifting the crosshead with piston in situ ⇒ Loosen and remove all four nuts 4 of the connecting rod studs to top end bea- ring as instructed in 3303−1.
  • Page 259 RT-flex50-D 3303−3/A1 Maintenance Inspection, Removal and Fitting of Top End Bearing ⇒ Lift crosshead pin 3 beyond the lower bores in guide ways 9 provided for re- taining pins 94323. ⇒ Insert four retaining pins into the guide ways. ⇒ Carefully relieve lifting tackles ’HZ’ till the guide shoes come to rest on the re- taining pins.
  • Page 260 RT-flex50-D 3303−3/A1 Maintenance Inspection, Removal and Fitting of Top End Bearing Lifting the crosshead with removed piston ⇒ Loosen and remove all four nuts 4 of the connecting rod studs to top end bea- ring as instructed in 3303−1. ⇒ Fasten stop plate 94370h to bearing cover 5 and guide shoe 6.
  • Page 261 RT-flex50-D 3303−3/A1 Maintenance Inspection, Removal and Fitting of Top End Bearing Removal of bearing shell ⇒ Swing the connecting rod with lifting tackles H and H (Fig. ’A’) to fuel side, ensuring that it will not tilt back to exhaust side.
  • Page 262 RT-flex50-D 3303−3/A1 Maintenance Inspection, Removal and Fitting of Top End Bearing Fitting the bearing shell Fitting of the bearing shells is carried out analogously to the removal but in reverse sequence, whereby attention must be paid to the following: The surface of the crosshead pin must be in perfect condition.
  • Page 263 RT-flex50-D 3303−4/A1 Maintenance Connecting Rod Removal and Fitting Tools: Key to Illustrations: 4 Retaining pins 94323 1 Inside pipe 10 Guide way 1 Lifting plate 94324 2 Connecting rod 11 Cylinder block 1 Holder 94331 3 Crosshead pin 12 Screw...
  • Page 264 RT-flex50-D 3303−4/A1 Maintenance Connecting Rod: Removal and Fitting Lifting the crosshead with removed piston ⇒ Loosen and remove all four nuts 7 of the connecting rod studs to top end bea- ring as instructed in 3303−1. ⇒ Fasten stop plate 94370h to bearing cover 8 and guide shoe 9.
  • Page 265 RT-flex50-D 3303−4/A1 Maintenance Connecting Rod: Removal and Fitting Lifting the crosshead with piston in situ ⇒ Loosen and remove all four nuts 7 of the connecting rod studs to top end bea- ring as instructed in 3303−1. ⇒ Fasten stop plate 94370h to bearing cover 8 and guide shoe 9.
  • Page 266 RT-flex50-D 3303−4/A1 Maintenance Connecting Rod: Removal and Fitting ⇒ Lift crosshead pin 3 beyond the lower bores in guide ways 10 provided for re- taining pins 94323. ⇒ Insert four retaining pins into the guide ways. ⇒ Carefully relieve lifting tackles ’HZ’ till the guide shoes come to rest on the re- taining pins.
  • Page 267 RT-flex50-D 3303−4/A1 Maintenance Connecting Rod: Removal and Fitting Swiveling and removal of connecting rod ⇒ Swing the connecting rod with lifting tackles and H (Fig. ’A’) to fuel side, ensuring that it will not tilt back to exhaust side. ⇒ Remove lifting tackle H and swing connect- ing rod to the position as shown in Fig.
  • Page 268 RT-flex50-D 3303−4/A1 Maintenance Connecting Rod: Removal and Fitting ⇒ Turn crank 35_ after T.D.C. ⇒ Connect rope ’a’ with lifting tackle H RUD-eye bolt R . Tauten rope. ⇒ Connect rope ’c’ (lifting capacity 1500 kg) with lifting tackles H and to RDU-eye bolt R Tauten rope.
  • Page 269 RT-flex50-D 3303−4/A1 Maintenance Connecting Rod: Removal and Fitting Fitting Fitting of the connecting rod is carried out analogously to the removal but in re- verse sequence, whereby attention must be paid to the instructions 3303−1 3303−3. Remark: Take care that the marking FUEL SIDE on the connecting rod head points to the fuel side! For the assembly bearings and bearing pins must be in perfect condition.
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  • Page 271 RT-flex50-D 3303−5/A1 Maintenance Connecting Rod Removal of Bearing Cover to Top End Bearing Tools: Key to Illustrations: 2 Lifting rings 94332 1 Piston 6 Crosshead pin 2 Bearing cover 7 Spur-geared chain block 3 Stud of top end bearing 4 Screw...
  • Page 272 RT-flex50-D 3303−5/A1 Maintenance Removal of Bearing Cover to Top End Bearing ⇒ Connect rope ’c’ with lifting tackle ’HZ’ and RUD-eye bolts ’RC’. ⇒ Lower bearing cover 2 towards fuel side. ⇒ Connect rope ’d’ with spur-geared chain block 7 and RUD-eye bolts ’RC’ and subsequently remove the bearing cover from the crankcase.
  • Page 273 RT-flex50-D 3326−1/A1 Maintenance Crosshead Checking the Clearances and Fitting the Guide Shoes Tools: Key to Illustrations: 1 Feeler gauge 94238 1 Crosshead pin 5 Top end bearing 2 Guide shoe 6 Guide rail 3 Holding plate 7 Shim 4 Guide way in engine column...
  • Page 274 RT-flex50-D 3326−1/A1 Maintenance Checking the Clearances and Fitting the Guide Shoes Checking the clearances Clearance Clearance between guide shoe and guide way: The corresponding crankpin must stand in such a position that guide shoes 2 lie on guide ways 4 on fuel or exhaust side.
  • Page 275 RT-flex50-D 3326−1/A1 Maintenance Checking the Clearances and Fitting the Guide Shoes Fitting the guide shoes The two guide shoes of a crosshead are the same. However, shims 7 to guide rails 6 can show different thicknesses, and therefore the guide shoes have to be refitted at the same place after a removal.
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  • Page 277 RT-flex50-D 3326−2/A1 Maintenance Crosshead Removal and Fitting of a Crosshead Pin Tools: Key to Illustrations: 1 Working platform 94142 1 Piston 8 Nut 1 Lifting plate 94324 2 Crosshead pin 9 Spur-geared chain block 2 Lifting rings 94332 3 Column lug...
  • Page 278 RT-flex50-D 3326−2/A1 Maintenance Removal and Fitting of a Crosshead Pin Removal of crosshead pin 94666 ⇒ Fit wire rope sling 94666 onto column lug 3. ⇒ Fasten lifting plate 94324 with their shackles to crosshead pin 2 with nuts 8 (Fig. ’E’) of the screwed connection for the piston rod foot.
  • Page 279 RT-flex50-D 3326−2/A1 Maintenance Removal and Fitting of a Crosshead Pin ⇒ Provide wooden underlay ’HU’ in the lower corner of the column as shown in Fig. ’C’. ⇒ Direct the connecting rod towards exhaust side with lifting tackles H and H (Fig.
  • Page 280 RT-flex50-D 3326−2/A1 Maintenance Removal and Fitting of a Crosshead Pin ⇒ Fasten lifting rings 94332 to cylinder block 7 with screws 6 and tighten these with 200 Nm. ⇒ Screw RUD-eye bolts ’RC’ into guide shoes 5. ⇒ Connect lifting tackles H...
  • Page 281 RT-flex50-D 3326−2/A1 Maintenance Removal and Fitting of a Crosshead Pin ⇒ Clear crosshead pin 2 from guide shoe ’free end’ 5 towards driving end and lift off the loose guide shoe (Fig. ’F’). ⇒ Clear crosshead pin 2 from guide shoe ’driving end’ 5 towards free end and lift off the loose guide shoe (Fig.
  • Page 282 RT-flex50-D 3326−2/A1 Maintenance Removal and Fitting of a Crosshead Pin ⇒ Rotate the crosshead pin 90_ around its axis, connect it to spur-geared chain block 9 and then remove it from the engine. Removal of guide shoes ⇒ Connect lifting tackle ’HZ’ to RUD-eye bolt ’RC’...
  • Page 283 RT-flex50-D 3326−2/A1 Maintenance Removal and Fitting of a Crosshead Pin ⇒ Remove guide shoes 5 from the engine by means of lifting tackle ’HZ’ and spur-geared chain block 9. 013.249/05 Fitting Fitting procedure is analogous to the removal, but in reverse sequence.
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  • Page 285 RT-flex50-D 3403−1/A1 Maintenance Piston Removal and Fitting Tools: Key to Illustrations: 1 Piston ring tensioning device 94338 1 Piston rod 15 Waisted stud 2 Pre-tensioning jacks 94340 2 Crosshead pin 16 Piston skirt 1 Suspension device 94341 3 Waisted stud...
  • Page 286 RT-flex50-D 3403−1/A1 Maintenance Piston: Removal and Fitting ⇒ Start up HP oil pump 94931 with closed relief valve ’EV’ and at the same time open vent screws 5 of the pre-tensioning jacks till oil flows out bubble-free. Close vent screws.
  • Page 287 RT-flex50-D 3403−1/A1 Maintenance Piston: Removal and Fitting Tensioning the waisted studs of piston foot fastening ⇒ Clean the threads of waisted studs 3 PRE-TENSIONING JACK PLACED FOR TENSIONING LOOSENING and the area around nuts 4. ⇒ Apply oil to the threads of the waisted studs and screw on the nuts.
  • Page 288 RT-flex50-D 3403−1/A1 Maintenance Piston: Removal and Fitting Removal of piston Adjusting suspension device to crane hook Distance ’x’ must be adjusted so that an axial clearance of 2−5 mm results be- tween the relevant crane hook and distance plates 94341a.
  • Page 289 RT-flex50-D 3403−1/A1 Maintenance Piston: Removal and Fitting Removal Remark: Loosen and remove all screws for the screwing piston rod gland / cylin- der block (see 2303−1). Remove the antipolishing ring from the collar of the cylinder liner (see 2124−2). ⇒ Screw fasten both distance holders 94345 to the piston foot (Fig. ’D’).
  • Page 290 RT-flex50-D 3403−1/A1 Maintenance Piston: Removal and Fitting ⇒ Fasten piston supporting device 94350 to platform supports 9 designed for this on the cylinder cover platform (Fig. ’F’ and ’G’). ⇒ Pull the piston by crane out of the cylinder liner.
  • Page 291 RT-flex50-D 3403−1/A1 Maintenance Piston: Removal and Fitting Fitting the piston Prior to fitting the piston, the following works must be carried out: ⇒ Remove piston rings with tensioning device 94338 (see 3425−1) and clean piston exterior thoroughly (do not use any tools that might damage the sur- face!).
  • Page 292 RT-flex50-D 3403−1/A1 Maintenance Piston: Removal and Fitting Fitting ⇒ Turn crank of the cylinder concerned to T.D.C. ⇒ Slightly lift piston by crane. Loosen screwed con- nections 14 (Fig. ’F’) and push both supports 10 outwards. Then lift the piston including piston rod gland 12 so far that the two hinged covers 11 can be turned up.
  • Page 293 RT-flex50-D 3403−2/A1 Maintenance Piston Changing the Compression Shims Tools: Key to Illustrations: 1 Working platform 94142 1 Piston rod gland support 6 Compression shim 2 Lifting bosses 94333a 2 Piston rod 7 Waisted stud 2 Suspension chains 94333b 3 Piston rod foot...
  • Page 294 RT-flex50-D 3403−2/A1 Maintenance Piston: Changing the Compression Shims ⇒ Turn crank upwards to exhaust side until suspension chains 94333b can be put into lifting bosses 94333a as shown in Fig. ’B’. The crank may be turned max. 30_ towards T.D.C.
  • Page 295 RT-flex50-D 3403−3/A1 Maintenance Piston Dismantling and Assembling Tools: Key to Illustrations: 1 Suspension device 94341 1 Piston crown 14 Piston 2 Pre-tensioning jacks 94346 2 Spraying plate with oil pipe 15 Cylinder 1 Piston supporting device 94350 2a Spraying nozzle...
  • Page 296 RT-flex50-D 3403−3/A1 Maintenance Piston: Dismantling and Assembling Loosening waisted studs of piston crown ⇒ Clean the threads of waisted studs 5 and the area around nuts 13. ⇒ Place pre-tensioning jacks 94346 crosswise on the waisted studs (a/a) and completely screw them on with opened vent screws 16 till there is no or little clearance at ’x’...
  • Page 297 RT-flex50-D 3403−3/A1 Maintenance Piston: Removal and Fitting Tensioning waisted studs of piston crown PRE-TENSIONING JACK PLACED FOR TENSIONING LOOSENING ⇒ Clean the threads of waisted studs 5 and the area around nuts 13. ⇒ Apply oil to the threads of waisted studs and screw on the nuts.
  • Page 298 RT-flex50-D 3403−3/A1 Maintenance Piston: Dismantling and Assembling Dismantling of a piston ⇒ Fit two jacking screws M27x2 into the two opposite tapholes ’GB’ in the piston rod head and drive them in till they press against the centring screws (Fig. ’D’).
  • Page 299 RT-flex50-D 3403−3/A1 Maintenance Piston: Dismantling and Assembling 94341 94350 018.393/09 SEPARATING OF SEPARATING OF PISTON CROWN PISTON SKIRT 94364 AF10 SECURED WITH 016.529/08 CENTRE PUNCH 018.224/09 50−D / 2010 5/ 6 Wärtsilä Switzerland Ltd...
  • Page 300 RT-flex50-D 3403−3/A1 Maintenance Piston: Dismantling and Assembling I - I III - III IV - IV AF 14 V - V VI - VI 018.394/09 II - II FUEL SIDE VII - VII 2010 / 50−D 6/ 6 Wärtsilä Switzerland Ltd...
  • Page 301 RT-flex50-D 3403−4/A1 Maintenance Piston Checking Piston Top Surface Tools: 1 Feeler gauge 94122 1 Template 94366a 1 Template 94366b Every time a piston is pulled the piston top surface contour must be checked with CHECK the checking template 94366b. The template is placed on the topmost piston ring and rotated around the piston axis (see Fig.
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  • Page 303 RT-flex50-D 3425−1/A1 Maintenance Piston Rings Checking Piston Ring Wear Tools: Key to Illustration: 1 Inside micrometer 94101 1 Piston ring 1 Feeler gauge 94122 2 Claw 1 Piston ring tensioning device 94338 2 Claws for gastight piston ring 94338a 1 Equipment case with instruments 94356 for measuring chrome layers 1 Micrometer (0−30 mm)
  • Page 304 RT-flex50-D 3425−1/A1 Maintenance Piston: Checking Piston Ring Wear Evaluation of piston ring running surface Chrome-Ceramic (CC) coated piston ring The chrome-ceramic coating is a lifetime coating. However, the actual wear de- pends on piston running conditions. Wear of CC-coating can be monitored by means of chrome thickness measurement tool 94356 (see Recommended Spe- cial Tools 9403−5).
  • Page 305 RT-flex50-D 3425−1/A1 Maintenance Piston: Checking Piston Ring Wear 3.2.3 Reuse of piston ring Pull one piston after approx. 2000 operating hours, to establish the wear rate of the cylinder liner and the piston rings. With the aid of the diagram in Clearance Table 0330−1...
  • Page 306 RT-flex50-D 3425−1/A1 Maintenance Piston: Checking Piston Ring Wear Fitting piston rings When reusing piston rings, only rings in perfect condition may be fitted, how- ever in the same position and groove as removed. ⇒ The edges of the ring gap must be rounded off with a radius of 0.5 mm (with exception of CC coated piston ring).
  • Page 307 RT-flex50-D 3603−1/A1 Maintenance Piston Cooling and Crosshead Lubrication Removal and Fitting of Inside Pipe Tools: Key to Illustrations: 1 Lifting tool 94337 1 Oil inlet pipe 8 Connection piece 1 Centring piece 94337a 2 Screw with locking plate 9 Guide shoe...
  • Page 308 RT-flex50-D 3603−1/A1 Maintenance Piston Cooling and Crosshead Lubrication: Removal and Fitting of Inside Pipe ⇒ Loosen screws 2. ⇒ Loosen screws 3. ⇒ Lower ring holder 4 together with sleeve 5 (Fig. ’D’). ⇒ Turn crank to B.D.C. ⇒ Remove inside pipe 6 together with sleeve 5 and ring holder 4 downwards.
  • Page 309 RT-flex50-D 3603−1/A1 Maintenance Piston Cooling and Crosshead Lubrication: Removal and Fitting of Inside Pipe Fitting ⇒ Turn the corresponding crank to B.D.C. ⇒ Push ring holder 4 and sleeve 5 over inside pipe 6. ⇒ Fasten lifting tool 94337 to inside pipe and connect it to lifting tackle ’HZ’ as shown in Fig.
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  • Page 311 RT-flex50-D Group4 Maintenance 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 − Replacing the Gear Wheel on the Crankshaft ......
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  • Page 313 RT-flex50-D 4103−1/A1 Maintenance Driving Wheels Checking the Running and Backlash Clearances and Condition of Teeth Tools: Key to Illustrations: 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...
  • Page 314 RT-flex50-D 4103−1/A1 Maintenance Checking the Running and Backlash Clearances and Condition of Teeth 15 mm Measuring tooth backlash with lead wire 15 mm Use a fresh piece of lead wire Pb 99.9 fine of 1.5 mm diameter for each measurement.
  • Page 315 RT-flex50-D 4103−3/A1 Maintenance Driving Wheels Replacing the Gear Wheel on the Crankshaft Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Gear wheel 6 Flange screw 1 Retaining wrench 94412e 2 Crankshaft flange 7 Distance sleeve 3 Waisted stud 8 Self-locking nut...
  • Page 316 RT-flex50-D 4103−3/A1 Maintenance Replacing the Gear Wheel on the Crankshaft 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.
  • Page 317 RT-flex50-D 4103−3/A1 Maintenance Replacing the Gear Wheel on the Crankshaft 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.
  • Page 318 RT-flex50-D 4103−3/A1 Maintenance Replacing the Gear Wheel on the Crankshaft ⇒ Turn the gear wheel half to the bottom (Fig. ‘E’) and place the second gear wheel half, which is also pro- vided with two pre-assembled waisted studs 3, on 001.167/97...
  • Page 319 RT-flex50-D 4103−3/A1 Maintenance Replacing the Gear Wheel on the Crankshaft The waisted studs are correctly pretensioned if an extension of nL 1.20± 0.06 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.
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  • Page 321 RT-flex50-D 4325−1/A1 Maintenance Shut-off Valve for Starting Air Cleaning and Function Check Key to Illustrations: 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...
  • Page 322 RT-flex50-D 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check 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.
  • Page 323 RT-flex50-D 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check Function check After completing the assembly carry out a function check, for which the following precautions have to be taken: Initial position The stop valves of the starting air receivers must still be closed.
  • Page 324 RT-flex50-D 4325−1/A1 Maintenance Shut-off Valve for Starting Air: Cleaning and Function Check By turning the spindle carefully to position OPENED, the contact with spindle guide CHECK 19 can be felt. The clearance ’S ’ can thus be determined externally and it shall be min.
  • Page 325 RT-flex50-D Group5 Maintenance 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 .
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  • Page 327 RT-flex50-D 5552−1/A1 Maintenance Supply Unit Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive Key to Illustrations: 1 Servo oil pump 12 Gear wheel 2 Screw 13 Spray nozzle 3 Screw 14 Cover 4 Pump support 15 Screw...
  • Page 328 RT-flex50-D 5552−1/A1 Maintenance Supply Unit: Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive Removal of pinion ⇒ Loosen screws 3 and remove pump support 4. ⇒ Withdraw shaft 5 together with pinion 6 from housing 7.
  • Page 329 RT-flex50-D 5552−1/A1 Maintenance Supply Unit: Removal and Fitting of Servo Oil Pump and Servo Oil Pump Drive Spray nozzles A spray nozzle 11 is provided for each pinion in order to spray oil between pinion 6 and gear wheel 12.
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  • Page 331 RT-flex50-D 5552−2/A1 Maintenance Supply Unit Removal and Fitting of Camshaft and Bearing Shells Tools: Key to Illustrations: Devices (roller lifting tools) 94430 1 Fuel pump 15 Screw 2 Servo oil pump 16 Screw (depending on number of cylinders) 1 Support...
  • Page 332 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells ⇒ Remove covers 4 and 5. ⇒ Remove servo oil pump 2 and spray nozzle 6 (see 5552−1). 012.980/05 Numbering of bearings Bearing No. 2 is designed as thrust bearing, the other ones as normal bearing.
  • Page 333 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Removal of bearing shells ⇒ Loosen waisted screws 7 to bearings No. 2 4 and remove the bearing covers (Fig. ’C’). ⇒ Place assembly template 94567 on an upper bearing shell (Fig. ’D’).
  • Page 334 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Removal of camshaft Removal of supports ⇒ Loosen screws 13 and remove covers 14 from supports 94566 and 94566a. ⇒ Loosen screws 15 a bit. ⇒ Fasten supports 94566 and 94566a to housing 10 as follows, using: −...
  • Page 335 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells ⇒ Refit covers 14 to the supports with screws 13. ⇒ Remove the remaining bearing covers and bearing shells as described in sec- tion 3. ⇒ Roll out the camshaft (with the gear wheels) onto the supports and secure it at the stop with wooden wedges ’HK’...
  • Page 336 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells 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:...
  • Page 337 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Final assembly Determine radial and axial clearances, see Clearance Table 0330−1 ’Supply Unit’. CHECK ⇒ Apply sealing compound to sealing surfaces of covers 3, 4, 5 and fit the latter.
  • Page 338 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Application of torque amplifier Torque amplifier 20 must be used for tightening the waisted screws 7 to bearing covers 9. The following figures ’N’ to ’X’ are drawn for 7 & 8 Cyl. engines, however, there are also shown all applications for 5 &...
  • Page 339 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Torque amplifier applications The following figures show the torque amplifier application for every single waisted screw 7. Backing rod 23 or 24 is drawn in the required position: −...
  • Page 340 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells BEARING COVER NO. 3 94566c BEARING COVER NO. 4 94566c 013.072/05 2010 10/ 11 Wärtsilä Switzerland Ltd...
  • Page 341 RT-flex50-D 5552−2/A1 Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells BEARING COVER NO. 5 94566c BEARING COVER NO. 6 94566c 013.073/05 2010 11/ 11 Wärtsilä Switzerland Ltd...
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  • Page 343 RT-flex50-D 5552−3/A1 Maintenance Supply Unit Removing and Fitting the Gear Wheel on Camshaft Key to Illustration: 1 Camshaft 4 Gear wheel 2 Gear wheel 5 Head screw 3 Shaft 6 Head screw Removing The camshaft must be removed from the supply unit for removing and fitting the gear wheel 2 (see 5552−2).
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  • Page 345 RT-flex50-D 5552−4/A1 Maintenance Supply Unit Removal and Fitting Tools: Key to Illustrations: 1 Lifting tool 94557 1 Supply unit 9 Housing (for transporting supply unit) 2 Fuel pump 10 Spray nozzle Devices 94430 3 Cover 11 Screw with distance sleeve...
  • Page 346 RT-flex50-D 5552−4/A1 Maintenance Removal and Fitting of Supply Unit ⇒ Screw RUD-eye bolts ’RC’ into housing of supply unit 1 as shown in Fig. ’D’. ⇒ Suspend lifting tool 94557 on lifting tackles ’HZ’ (lifting capacity 2000 kg each) and connect these with RUD-eye bolts ’RC’.
  • Page 347 RT-flex50-D 5552−4/A1 Maintenance Removal and Fitting of Supply Unit Fitting ⇒ Connect supply unit 1 with the engine cran as described for the removal. ⇒ Apply a non-hardening sealing compound to the cleaned sealing surfaces of housing 9. ⇒ Move supply unit 1 carefully to the housing (Fig. ’A’).
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  • Page 349 RT-flex50-D 5552−5/A1 Maintenance Supply Unit Lubrication of Supply Unit During Maintenance Works Key to Illustration: 1 Supply unit 2 Cap 3 Oil pipe 4 Funnel General Manual lubrication has been provided to prevent bearing bushes of the servo oil pump drive from being damaged (dry running) due to turning the engine during overhaul works.
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  • Page 351 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump Dismantling and Assembling Tool: Key to Illustrations: 1 Fitting and dismantling 1 Actuator 23 Screw device 94551 2 Connecting element 24 Flange 1 Cover 94552 3 Screw 25 Regulating (toothed) rack 1 Spacer 94555 4 Pump cover...
  • Page 352 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump: Dismantling and Assembling Removal of a fuel pump ⇒ Turn the engine until roller 8 is seated on the cam base circle (Fig. ’A’). ⇒ Remove all screws 3. ⇒ Using a jacking screw M12, lift the fuel pump until the locating pin is no longer meshing.
  • Page 353 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump: Dismantling and Assembling Dismantling of a fuel pump 94551 Dismantle and assemble the fuel pumps in a clean room which should be as dust-free as possible (grinding dust, etc). Removal of guide pin ⇒ With the head of the pump turned towards the bot- tom, fasten the fuel pump onto a work bench.
  • Page 354 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump: Dismantling and Assembling ⇒ Remove Allen screws 16. ⇒ Separate lower housing 6 from upper housing. Remark: If bush 37 has to be replaced, the new one must be secured with LOCTITE No. 648 and tightened with a torque of 200 Nm.
  • Page 355 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump: Dismantling and Assembling 27 24 Removal of regulating rack ⇒ Unscrew all screws 23. ⇒ Remove circlip 26 and stop ring 27. ⇒ Remove flange 24 together wit rod seal ring 38, and push out regulating rack 25.
  • Page 356 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump: Dismantling and Assembling Assembling of a fuel pump Preparation ⇒ Clean all parts and check their condition. Damaged parts must be replaced. ⇒ Check the lubricating oil bores in the housings and in pump cylinder 33 for free passage using compressed air.
  • Page 357 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump: Dismantling and Assembling Fitting the regulating rack ⇒ With the pump cover turned towards the bottom, fasten the upper housing onto a work bench. ⇒ Fit regulating rack 25 according to Fig. ’H’. Check regulating rack 25 for easy movement.
  • Page 358 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump: Dismantling and Assembling Checking the plunger position 94556 ⇒ Bring regulating rack 25 to the position shown in Fig. ’N’ and place spacer 94555. 94555 ⇒ Remove screw plug from the checking bore and in- sert checking gauge 94556 in its place till the stop.
  • Page 359 RT-flex50-D 5556−1/A1 Maintenance Fuel Pump: Dismantling and Assembling Final assembly ⇒ Assemble guide piston 7, provided that parts have been removed (Fig. ’E’). Check the axial clearances according to the Clearance Table 0330−1 ’Fuel Pump’. CHECK ⇒ Lubricate O-ring 41 and push snap ring 14 with grease into the concentric position (Fig.
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  • Page 361 RT-flex50-D 5562−1/A1 Maintenance Fuel Pressure Control Valve Removal, Fitting, Dismantling and Assembling Key to Illustrations: 1 Fuel pressure control valve 15 Fuel rail 2 Piston 16 Intermediate piece 3 Valve tip 17 Screw M16x200 4 Valve seat 18 Locating pin...
  • Page 362 RT-flex50-D 5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling 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.
  • Page 363 RT-flex50-D 5562−1/A1 Maintenance Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling 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.
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  • Page 365 RT-flex50-D 5562−2/A1 Maintenance Fuel Overpressure Safety Valve Checking and Setting Tools: Key to Illustrations: 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...
  • Page 366 RT-flex50-D 5562−2/A1 Maintenance Fuel Overpressure Safety Valve: Checking and Setting Remark: Pay attention to the manufacturer’s detailed instructions and working specifications of the test bench. ⇒ Fit relief valve 11 into the valve holder and tighten it. ⇒ Connect valve holder 94272a to HP oil pump 94931 (or hydraulic unit 94942).
  • Page 367 RT-flex50-D 5564−1/A1 Maintenance Injection Control Unit Removal and Fitting Tools: Key to Illustrations: 1 Lifting plate 94584 1 Servo oil inlet 10 Screw 1 Withdrawing tool 94589 2 Servo oil outlet 11 Lip seal 3 Leakage fuel return 12 Position sensor...
  • Page 368 RT-flex50-D 5564−1/A1 Maintenance Injection Control Unit: Removal and Fitting ⇒ Fasten lifting plate 94584 onto injection control unit 7. ⇒ Remove cable plugs from pre-control valves 9 and position sensor 12. ⇒ Loosen screws 10 and remove them together with pre-control valves.
  • Page 369 RT-flex50-D 5564−1/A1 Maintenance Injection Control Unit: Removal and Fitting Fitting ⇒ Insert lip seal 11. ⇒ Lower injection control unit 7 carefully onto the fuel rail and remove lifting plate 94584. ⇒ Apply Never-Seez NSBT-8 to the threads of screws 8 and 8a (Fig. ’A’).
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  • Page 371 RT-flex50-D 5610−1/A1 Maintenance Pressure Reducing Valve 8.11−1 Checking the Gas Pre-charge Pressure Tool: Key to Illustrations: 1 Case (for CLU4−C) 94720c 1 Hydraulic accumulator 9 Pressure reducing valve 2 Protection cap 10 Pressure transmitter consisting of: measurement set complete 3 Pressure reducing valve...
  • Page 372 RT-flex50-D 5610−1/A1 Maintenance Pressure Reducing Valve: Checking the Gas Pre-charge Pressure 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 % N by volume.
  • Page 373 RT-flex50-D 5610−1/A1 Maintenance Pressure Reducing Valve: Checking the Gas Pre-charge Pressure Case with measurement set 94720c for CLU4−C and PRV 8.18−1: DRAWN FOR CLU4−C Case 94720c 4, 4a Arrangement of equipment: WCH00703 PI2041L 2011 3/ 4 Wärtsilä Switzerland Ltd...
  • Page 374 RT-flex50-D 5610−1/A1 Maintenance Pressure Reducing Valve: Checking the Gas Pre-charge Pressure Pressure reducing valve 8.11−1:: FREE RETURN PIPING 10, 11 1, 2 SERVO OIL PIPE TO LUBRICATING PUMPS WCH00694 Details of servo oil rail 4.11 −> pressure reducing valve 8.11−1 −> lubricating pump 8.06: RAIL UNIT 4.11...
  • Page 375 RT-flex50-D 5612−1/A1 Maintenance Exhaust Valve Control Unit Removal, Fitting, Dismantling and Assembling Key to Illustrations: 1 Servo oil rail 15 Filter holder 2 Drain screw 16 Seal 3 Screw plug 17 Circlip 4 Valve control block 18 Oil filter 5 Allen screw M16x160...
  • Page 376 RT-flex50-D 5612−1/A1 Maintenance Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling Exhaust valve control unit Removal ⇒ Remove the hydraulic piping from exhaust valve control unit (see 8460−1). ⇒ Remove return pipe 22 from screw-in angle on valve control block 4.
  • Page 377 RT-flex50-D 5612−1/A1 Maintenance Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling Dismantling and assembling of exhaust valve control unit ⇒ Loosen Allen screws 11 and remove cover 10. ⇒ Remove compression spring 12 and slide rod 13. ⇒ Loosen pan head screw 9 and withdraw sealing flange 7.
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  • Page 379 RT-flex50-D 5801−1/A1 Maintenance Regulating Linkage Adjusting with Heinzmann StG 10-01 Actuator Tools: Key to Illustrations: 1 Adjusting scale 94575 1 Fuel pump 8 Connecting element 1 Adjusting pin 94575a 2 Actuator 9 Toothed rack 3 Centring flange 10 Set screw...
  • Page 380 RT-flex50-D 5801−1/A1 Maintenance Regulating Linkage: Adjusting with Heinzmann StG 10-01 Actuator Adjusting of regulating linkage ⇒ Place adjusting scale 94575 on ac- tuator 2 as shown in Fig. ’B’. Push the tool against centring flange 3 aligning it parallel with the outer ac- tuator edge simultaneously.
  • Page 381 RT-flex50-D 5801−1/A1 Maintenance Regulating Linkage: Adjusting with Heinzmann StG 10-01 Actuator Fitting of connecting element ⇒ Join connecting element 8 with lever 5 and toothed rack 9 of fuel pump 1 using set screws 10. Remark: The connecting element must be fitted in such a way that its spot-face 11 points to lever 5.
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  • Page 383 RT-flex50-D 5801−1/A2 Maintenance Regulating Linkage Adjusting with Woodward ProAct II − Analog Actuator Tools: Key to Illustrations: 2 Spacers 94555a 1 Fuel pump 8 Connecting element 2 Actuator 9 Toothed rack 3 Output shaft 10 Set screw 4 Damper 11 Self-locking nut...
  • Page 384 RT-flex50-D 5801−1/A2 Maintenance Regulating Linkage: Adjusting with Woodward ProAct II − Analog Actuator 36 mm 36 mm 94555a 016.366/07 WCH00245 012.882/05 5 12 2011 2/ 2 Wärtsilä Switzerland Ltd...
  • Page 385 RT-flex50-D Group6 Maintenance Scavenge Air Receiver and Auxiliary Blower Group 6 Scavenge Air Receiver: Checking the Air Flaps and Cleaning the Scavenge Air Receiver ....6420−1/A1 Auxiliary Blower: Maintenance .
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  • Page 387 RT-flex50-D 6420−1/A1 Maintenance Scavenge Air Receiver Checking the Air Flaps and Cleaning the Scavenge Air Receiver Key to Illustrations: 1 Scavenge air receiver 6 Screw 2 Auxiliary blower 7 Locking plate 3 Cover 8 Holder 4 Cover 9 Relief valve...
  • Page 388 RT-flex50-D 6420−1/A1 Maintenance Checking the Air Flaps and Cleaning the Scavenge Air Receiver 6, 7 WCH00119 018.396/09 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.
  • Page 389 RT-flex50-D 6545−1/A1 Maintenance Auxiliary Blower Maintenance Key to Illustration: 1 Scavenge air receiver 2 Auxiliary blower 3 Scavenge air cooler 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.
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  • Page 391 RT-flex50-D 6606−1/A1 Maintenance Scavenge Air Cooler Removal and Fitting (with Integrated Lifting IL) Tools: Key to Illustrations: 2 RUD-eye bolts (RC) 94040−M30 1 Scavenge air cooler 12 Rail 4 Swivel lugs 94048−M30 2 Receiver 13 Stopper 1 Support 94661−IL 3 Butterfly valve...
  • Page 392 RT-flex50-D 6606−1/A1 Maintenance Removal and Fitting of Scavenge Air Cooler (with Integrated Lifting IL) Removal Remark: Pay attention to General Guidelines for Lifting Tools 0012−1. ⇒ Mount the trolleys with spur-geared chain blocks H and H (WLL 1500 kg each) on rail 12.
  • Page 393 RT-flex50-D 6606−1/A1 Maintenance Removal and Fitting of Scavenge Air Cooler (with Integrated Lifting IL) ⇒ Carefully draw the cooler out from the receiver over a length of approx. ’x’ = 750 mm by means of manual ratchet H keeping the cooler in horizontal posi- tion with spur-geared chain block H ⇒...
  • Page 394 RT-flex50-D 6606−1/A1 Maintenance Removal and Fitting of Scavenge Air Cooler (with Integrated Lifting IL) 94661−IL WCH00115 I - I 94663−IL 94048−M30 94663d 94663a−IL 94663b−IL WCH00113 ⇒ Continue drawing the cooler up to max. ’x ’ = 195 mm before the guide end of supports 94663a−IL and 94663b−IL (view II).
  • Page 395 RT-flex50-D 6606−1/A1 Maintenance Removal and Fitting of Scavenge Air Cooler (with Integrated Lifting IL) ⇒ Somewhat lower the cooler. ⇒ Hook the engine crane into wire rope sling 94666 and lift the cooler slightly. ⇒ Detach trolley with spur-geared chain block H from RUD-eye bolt ’RC’.
  • Page 396 RT-flex50-D 6606−1/A1 Maintenance Removal and Fitting of Scavenge Air Cooler (with Integrated Lifting IL) ⇒ Slowly lower the cooler using spur-geared chain block H until the latter car- ries no more load. The weight of the cooler having been taken over by manual ratchet H ⇒...
  • Page 397 RT-flex50-D 6606−1/A1 Maintenance Removal and Fitting of Scavenge Air Cooler (with Integrated Lifting IL) Fitting ⇒ Clean the sealing surfaces on the cooler, receiver and frame. ⇒ Fasten support 94661−IL to the corresponding platform support. ⇒ Fit supports 94663a−IL and 94663b−IL to the left and right side of receiver frame.
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  • Page 399 RT-flex50-D 6708−1/A1 Maintenance Water Separator Removal and Fitting of Water Separator Tools: Key to Illustrations: 1 Lifting and withdrawing gear 94667 1 Receiver (underslung) 11 Frame 1 Withdrawing gear 94667a 2 Scavenge air cooler 12 Rail 1 Lifting tool 94667b...
  • Page 400 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator I - I II - II AIR FLOW III - III IV - IV 018.359/09 2010 2/ 10 Wärtsilä Switzerland Ltd...
  • Page 401 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator Removal and fitting of 1 x water separator Removal 94667d 94667b 94667f 94667 018.322/09 ⇒ Mount the trolleys with spur-geared chain blocks H and H (WLL 500 kg each) on rail 12.
  • Page 402 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator 94667d 018.323/09 ⇒ Using manual ratchet H (WLL 800 kg) pull out water separator 3 from the re- ceiver by approx. ’x’ = 1030 mm, i.e. slightly more than half of the water sepa- rator.
  • Page 403 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator 018.325/09 ⇒ Completely withdraw the water separator by means of manual ratchet H while continuously following with spur-geared chain blocks H and adjust- ing the height correspondingly. 018.326/09 ⇒ Remove manual ratchet H...
  • Page 404 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator Fitting ⇒ Clean guide bars 6, seating surfaces on water separator 3 and frame 11 as well as the areas of round rubber cords 13 and 14. ⇒ Attach holder 94667f on the opposite side.
  • Page 405 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator Removal and fitting of 2 x water separators Removal 018.328/09 94667c 94667e 94667b 94667 ⇒ Mount the trolleys with spur-geared chain blocks H and H (WLL 500 kg each) on rail 12.
  • Page 406 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator 94667e 018.329/09 ⇒ Using manual ratchet H (WLL 800 kg) pull out water separator 3 from the re- ceiver by approx. ’x’ = 860 mm, i.e. slightly more than half of the water separa- tor.
  • Page 407 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator 018.331/09 ⇒ Completely withdraw the water separator by means of manual ratchet H while continuously following with spur-geared chain blocks H and adjust- ing the height correspondingly. 018.332/09 ⇒ Remove manual ratchet H...
  • Page 408 RT-flex50-D 6708−1/A1 Maintenance Removal and Fitting of Water Separator Fitting ⇒ Clean guide bars 6, seating surfaces on water separator 3 and frame 11 as well as the areas of round rubber cords 13 and 14. ⇒ Attach holder 94667f on the opposite side.
  • Page 409 RT-flex50-D 6735−1/A1 Maintenance Scavenge Air Waste Gate Dismantling and Assembling Key to Illustrations: 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...
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  • Page 411: Cylinder Lubrication

    RT-flex50-D Group7 Maintenance Cylinder Lubrication Group 7 Lubrication Pump CLU4−C: Checking the Gas Pre-charge Pressure ..7218−1/A2 Pulse / RT−flex50−D / MM / 2010 Wärtsilä Switzerland Ltd 1/ 4 Wärtsilä Switzerland Ltd...
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  • Page 413 RT-flex50-D 7218−1/A2 Maintenance Lubricating Pump CLU4−C Checking the Gas Pre-charge Pressure Tool: Key to Illustrations: 1 Case (for CLU4−C) 94720c 1 Hydraulic accumulator 9 4/2-way solenoid valve 2 Protection cap 10 Shut-off valve servo oil consisting of: measurement set complete...
  • Page 414 RT-flex50-D 7218−1/A2 Maintenance Lubricating Pump CLU4−C: Checking the Gas Pre-charge Pressure 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 % N by volume.
  • Page 415 RT-flex50-D 7218−1/A2 Maintenance Lubricating Pump CLU4−C: Checking the Gas Pre-charge Pressure Case with measurement set 94720c for CLU4−C: Case 94720c 4, 4a Arrangement of equipment: CLU4−C / 2010 3/ 4 Wärtsilä Switzerland Ltd...
  • Page 416 RT-flex50-D 7218−1/A2 Maintenance Lubricating Pump CLU4−C: Checking the Gas Pre-charge Pressure Lubricating pump (CLU4−C): TO LUBRICATING QUILLS SERVO 018.211/09 Details of servo oil rail 4.11 −> pressure reducing valve 8.11−1 −> lubricating pump 8.06: RAIL UNIT 4.11 8.11−1 PI2041L WCH00409 DRAWN FROM CONTROL DIAGRAM 4003−2...
  • Page 417 RT-flex50-D Group8 Maintenance Piping Group 8 ..... . Servo Oil Piping: Removing, Fitting and Regrinding 8447−1/A1 Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding .
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  • Page 419 RT-flex50-D 8447−1/A1 Maintenance Servo Oil Piping Removing, Fitting and Regrinding Tools: Key to Illustrations: 1 Regrinding device 94834 1 Servo oil rail 10 Thrust ring 2 Servo oil piping 11 Non-return valve 3 Servo oil piping 12 Leakage oil pipe...
  • Page 420 RT-flex50-D 8447−1/A1 Maintenance Servo Oil Piping: Removing, Fitting and Regrinding Removal of servo oil piping 3 ⇒ Loosen screws 4. ⇒ Push flanges 5, 5a back till they are no more engaged, so that servo oil piping 3 can be removed.
  • Page 421 RT-flex50-D 8447−1/A1 Maintenance Servo Oil Piping: Removing, Fitting and Regrinding Regrinding the sealing faces ’DF’ ⇒ Loosen claw 9 (Fig. ’E’). 94834 ⇒ To prevent grinding compound from entering the servo oil piping, plug its opening with a piece of cloth.
  • Page 422 RT-flex50-D 8447−1/A1 Maintenance Servo Oil Piping: Removing, Fitting and Regrinding Fitting Fitting is carried out analogously to the removal but in reverse sequence. Remark: Take care that screws 6 of intermediate pieces 7 are tightened after all servo oil pipings have been tightened! Apply oil to the threads of screws 4, a, b and tighten them crosswise with a torque of 40 Nm.
  • Page 423 RT-flex50-D 8460−1/A1 Maintenance Hydraulic Piping for Exhaust Valve Drive Removing, Fitting and Regrinding Tools: Key to Illustrations: 1 Regrinding device 94834 1 Hydraulic piping 8 Drain screw 2 Pre-control valve 9 Screw plug 3 Exhaust valve control unit 10 O-ring...
  • Page 424 RT-flex50-D 8460−1/A1 Maintenance Hydraulic Piping: Removing, Fitting and Regrinding ⇒ Loosen screws 4. ⇒ Push flanges 5 back and remove hydraulic piping 1. Pay attention not to damage sealing faces DF. All connections must be closed off immediately and sealing faces DF must be protected after removing hydraulic pipings.
  • Page 425 RT-flex50-D 8460−1/A1 Maintenance Hydraulic Piping: Removing, Fitting and Regrinding Adjusting the claws Before fitting hydraulic piping 1 check whether its claws 6 are screwed on properly CHECK (Fig. ’D’), i.e. the hydraulic piping must protrude by ’x’ = 5.5 mm compared to the claw.
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  • Page 427 RT-flex50-D 8733−1/A1 Maintenance Fuel Pressure Piping Removing, Fitting and Regrinding of Sealing Faces Tools: Key to Illustrations: 1 Regrinding device 94870 1 Cylinder cover 9 Flange 2 Injection valve 10 Drain screw consisting of: 1 Screw-on sleeve 94870a 3 Fuel pressure pipe...
  • Page 428 RT-flex50-D 8733−1/A1 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding of Sealing Faces Fitting Fitting procedure is analogous to the removal but in re- verse sequence. Before fitting fuel pressure pipe 3 check whether its CHECK claws 5 are screwed on properly, i.e. the fuel pressure pipe must protrude by ’x’...
  • Page 429 RT-flex50-D 8733−1/A1 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding of Sealing Faces Regrinding of sealing faces ’DF’ 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.
  • Page 430 RT-flex50-D 8733−1/A1 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding of Sealing Faces ⇒ Remove claw 5 (Fig. ’B’). ⇒ Fix fuel pressure pipe 3, e.g. in a vice. ⇒ Screw on counter nut 94870c until it reaches the thread end of the fuel pressure pipe.
  • Page 431 RT-flex50-D 8752−1/A1 Maintenance Fuel Pressure Piping Removing, Fitting and Regrinding 5 and 6 Cylinder Engines Tools: Key to Illustrations: 1 Regrinding device 94870 1 Fuel pressure piping 13 Pressure spring 2 Fuel pump 14 Non-return valve consisting of: 1 Screw-on sleeve...
  • Page 432 RT-flex50-D 8752−1/A1 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding 5 and 6 Cylinder Engines Removal Remark: Always start removing a fuel pressure pipe by disengaging its upper end. ⇒ Loosen all screws 4 and remove mounting clamps 5 from holders 17 and 17a.
  • Page 433 RT-flex50-D 8752−1/A1 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding 5 and 6 Cylinder Engines Fitting Fitting procedure is analogous to the removal but in reverse sequence. Before fitting fuel pressure piping 1, check whether their claws 15 are screwed on CHECK properly, i.e.
  • Page 434 RT-flex50-D 8752−1/A1 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding 5 and 6 Cylinder Engines Regrinding of sealing faces ’DF’ 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.
  • Page 435 RT-flex50-D 8752−1/A1 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding 5 and 6 Cylinder Engines ⇒ Remove claw 15 (Fig. ’D’). ⇒ Fix fuel pressure piping 1, e.g. in a vice. ⇒ Screw on counter nut 94870g until it reaches the thread end of the fuel pressure piping.
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  • Page 437 RT-flex50-D 8752−1/A2 Maintenance Fuel Pressure Piping Removing, Fitting and Regrinding 7 and 8 Cylinder Engines Tools: Key to Illustrations: 1 Regrinding device 94870 1 Fuel pressure piping 13 Pressure spring 2 Fuel pump 14 Non-return valve consisting of: 1 Screw-on sleeve...
  • Page 438 RT-flex50-D 8752−1/A2 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding 7 and 8 Cylinder Engines Removal Remark: Always start removing a fuel pressure pipe by disengaging its upper end. ⇒ Loosen all screws 4 and remove mounting clamps 5 from holders 17 and 17a.
  • Page 439 RT-flex50-D 8752−1/A2 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding 7 and 8 Cylinder Engines Fitting Fitting procedure is analogous to the removal but in reverse sequence. Before fitting fuel pressure piping 1, check whether their claws 15 are screwed on CHECK properly, i.e.
  • Page 440 RT-flex50-D 8752−1/A2 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding 7 and 8 Cylinder Engines Regrinding of sealing faces ’DF’ 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.
  • Page 441 RT-flex50-D 8752−1/A2 Maintenance Fuel Pressure Piping: Removing, Fitting and Regrinding 7 and 8 Cylinder Engines ⇒ Remove claw 15 (Fig. ’D’). ⇒ Fix fuel pressure piping 1, e.g. in a vice. ⇒ Screw on counter nut 94870g until it reaches the thread end of the fuel pressure piping.
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  • Page 443 RT-flex50-D Group9 Maintenance Crank Angle Sensor Unit, Tools Group 9 Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting ... . . 9223−1/A1 Tools: Explanation ............
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  • Page 445 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit Dismantling, Assembling and Adjusting Tools: Key to Illustrations: 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...
  • Page 446 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting Removal of shaft encoder FREE END Preparation ⇒ Pull out plug of sensor cable ’SK’ at terminal box ’KK’ (Fig. ’A’). ⇒ Unscrew protection hood 1 and remove it to- gether with covering cap 2.
  • Page 447 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 448 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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’...
  • Page 449 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting ⇒ 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’...
  • Page 450 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 451 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 452 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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! ⇒...
  • Page 453 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 454 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting Parts to be removed in the following sequence: − Retaining ring 29 (using tap holes ’GL’) to- gether with sealing ring 30 and O-ring 60. − Distance ring 31.
  • Page 455 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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’).
  • Page 456 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 457 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 458 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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...
  • Page 459 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting Removal and fitting of compression spring Preparation ⇒ Remove oil inlet ’OE’ (Fig. ’A’). ⇒ Dismantle crank angle sensor drive according to section 4. ⇒ Remove screws 47 and housing 46.
  • Page 460 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting Removing the compression spring ⇒ 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.
  • Page 461 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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...
  • Page 462 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 463 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 464 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting Checking the shaft eccentricity The following chekcs and the replacement of CAS parts can only be carried out if the engine is at standstill. Ckeck the shaft eccentricity in case of CAS exchange.
  • Page 465 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 466 RT-flex50-D 9223−1/A1 Maintenance Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting 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.
  • Page 467 RT-flex50-D 9403−1/A1 Maintenance Tools Explanation 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.
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  • Page 469 RT-flex50-D 9403−2/A1 Maintenance Hydraulic Jacks and Pumps Arrangement and Application WCH00724 016.623/08 A = Tensioning / loosening of tie rods, waisted studs to exhaust valve cages, top and bottom end bearings to connecting rod, piston rod screwing and waisted studs to piston crown...
  • Page 470 RT-flex50-D 9403−2/A1 Maintenance Hydraulic Jacks and Pumps: Arrangement and Application 018.664/09 013.539/05 D= Tensioning / loosening of waisted studs to main bearing E = Removal and fitting of main bearing shells F = Checking and setting of fuel overpressure safety valve G = Set-up of pre-tensioning jacks 94215a (i.e.
  • Page 471 RT-flex50-D 9403−2/A1 Maintenance Hydraulic Jacks and Pumps: Arrangement and Application Tool 1 HP oil pump (2800 bar) ....... .
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  • Page 473 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks Storing, Servicing and Maintenance 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).
  • Page 474 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94145 Pre-tensioning jack for foundation bolt and engine stay 1 Piston 6 Back-up ring Sealing ring O-ring 2 Cylinder 3 Vent screw 8 Back-up ring Sealing ring O-ring 4 Adapter 5 Connection piece 013.471/05...
  • Page 475 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94215a Pre-tensioning jack for waisted stud to cylinder cover 1 Piston 6 Back-up ring Sealing ring O-ring 2 Cylinder 3 Vent screw 8 Back-up ring Sealing ring O-ring 4 Adapter...
  • Page 476 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94180a Pre-tensioning jack for tie rod (M72x6) 1 Piston 6 Back-up ring Sealing ring O-ring 2 Cylinder 3 Vent screw 8 Back-up ring Sealing ring O-ring 4 Adapter 5 Connection piece 10 Eyelet 94180a−KJ Kit with back-up and O-rings...
  • Page 477 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94314 Pre-tensioning jack for waisted stud to bottom end bearing 1 Piston 7 Back-up ring Sealing ring O-ring 2 Cylinder 3 Distance bush 9 Back-up ring Sealing ring O-ring...
  • Page 478 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94252 Pre-tensioning jack for waisted stud to exhaust valve cage 1 Piston 6 Back-up ring Sealing ring O-ring 2 Cylinder 3 Vent screw 8 Back-up ring Sealing ring O-ring...
  • Page 479 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94315 Pre-tensioning jack for waisted stud to top end bearing 1 Piston 6 Back-up ring Sealing ring O-ring 2 Cylinder 3 Vent screw 8 Back-up ring Sealing ring O-ring...
  • Page 480 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94340 Pre-tensioning jack for waisted stud to piston foot fastening 1 Piston 6 Back-up ring Sealing ring O-ring 2 Cylinder 3 Vent screw 8 Back-up ring Sealing ring O-ring...
  • Page 481 RT-flex50-D 9403−3/A1 Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94346 Pre-tensioning jack for waisted stud to piston crown 1 Piston 6 Back-up ring Sealing O-ring 2 Cylinder ring 3 Vent screw 8 Back-up ring Sealing ring 4 Adapter...
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  • Page 483 RT-flex50-D 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks General Application Instructions 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.
  • Page 484 RT-flex50-D 9403−4/A1 Maintenance Hydraulic Pre-tensioning Jacks: General Application Instructions 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.
  • Page 485 RT-flex50-D 9403−5/A1 Maintenance Tool List Standard Tools 94000 Combination wrenches 94000−36 2 Pieces ..94000−41 2 Pieces ..94000−46 2 Pieces ..94000−50 2 Pieces ..94000−55 2 Pieces .
  • Page 486 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94004 Angle screwdrivers 94004−10 1 Piece ..10 mm 94004−12 1 Piece ..12 mm 94004−25 1 Piece ..25 mm 000.380/93 94005...
  • Page 487 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94010 1 Torque spanner ” (Range of adjustment 2−25 Nm) 94010a Adapter piece ”−½” 010.229/02 1 Torque spanner ½” 94011 (Range of adjustment 20−200 Nm) 010.230/02 1 Torque spanner ¾” 94012 (Range of adjustment 140−760 Nm) with extension tube and tool box adapter piece ¾”-½”,...
  • Page 488 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94020 1 Tool box 013.554/05 consisting of: 701.013.554 94020a 1 Power amplifier (with transmission factor 1:5) 94020b 1 Short backing rod 94020c 1 Angle 701.013.55 94021 1 Large backing rod to power amplifier 540 mm 013.555/05...
  • Page 489 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94032 1 High pressure grease gun for lubricating grease nipples on fuel pump regulating linkage 000.370/93 94040 RUD-eye bolts 94040−M8 6 Pieces ..94040−M10 6 Pieces ..94040−M12 6 Pieces .
  • Page 490 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94101 1 Inside micrometer (Measuring range 50−1000 mm) 000.366/93 with case 94110 1 Thrust device for renoval and fitting of main baring cover 594 mm 018.664/09 94114b 2 Double pre-tensioning jacks for waisted studs to main bearing,...
  • Page 491 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94118a 1 Turning-out device with 2 head screws M6x25 for removal and fitting of main bearing shell 018.662/09 215 mm 94119b 1 Device 018.662/09 with 3 shackles for removal and fitting of main bearing shell 190 mm 94120a 1 Rope (∅...
  • Page 492 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94122 1 Feeler gauge 000.361/93 94123 1 Special feeler gauge for main bearing 620 mm 000.395/93 94126 1 Depth gauge measuring range 760 mm 000.394/93 94141 1 Support for removal of main bearing shells 735 mm 013.565/05...
  • Page 493 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94145 1 Pre-tensioning jack for foundation bolts and engine stays, including a metal box 130 mm 013/567/05 94155 1 Turning-out device with screws M20x90 for turning out thrust bearing pads (with 1-part gear wheel) X = 161.4 mm 013.568/05...
  • Page 494 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94201 Device for fitting and transporting a cylinder liner, consisting of: 94202 Lifting gear Lifting ring 786 mm (WLL 2470 kg at pin) (WLL 2240 kg at lifting ring) 94202g 94202h 94202b Distance plates 013.571/05...
  • Page 495 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94215b 94215 Hydraulic tensioning device for cylinder cover studs, consisting of: 94215a Pre-tensioning jacks 151 mm 94215b Connection pieces with HP hoses 94215c Tool box 841 mm 013.574/05 701.013.574 94215a 013.575/05 94219 1 Cylinder pressure measuring tool...
  • Page 496 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94252 2 Pre-tensioning jacks for exhaust valve cage, including a metal box 194 mm 009.952/02 94259a 1 Pressure element for exhaust valve 216 mm 016.765/08 94261 1 Valve seat fitting and extracting 000.415/93 device 490 mm...
  • Page 497 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94265 1 Suspension device for cylinder cover and exhaust valve cage 604 mm including: a = 2 special eye nuts 238 mm (WLL 2100 kg) 013.577/05 003.971/96 94270 1 Device for overhauling injection valve seat in...
  • Page 498 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94272 OBEL test bench for checking and adjusting of: − injection valve − relief valve (cylinder cover) − fuel overpressure control valve 3.52 X = 1458 mm including: 94272a Valve holder for fuel overpressure safety valve...
  • Page 499 RT-flex50-D 9403−5/A1 Maintenance 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) 364 mm 000.412/93...
  • Page 500 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94323 4 Retaining pins to prop up crosshead guide shoes when removing or fitting a connecting rod or a crosshead 75 mm 013.584/05 701.013.584 94324 1 Cover and lifting plate to crosshead including: 2 shackles 6.5 t...
  • Page 501 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94332 2 Lifting rings for removal and fitting of: − main bearing − bearing cover of top end bearing − guide shoe − connecting rod 013.587/05 194 mm (WLL 8000 kg) 94332a 1 Shackle M23...
  • Page 502 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94337 1 Lifting tool for removal and fitting of inside pipe to piston cooling & crosshead lubrication 137 mm 013.589/05 701.013.589 94337a 1 Centring piece for alignment of inside pipe 58 mm 701.013.590 013.590/05 94337b 1 Flange...
  • Page 503 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94340 2 Pre-tensioning jacks for piston rod screw connection, including a metal box 88 mm 013.594/05 94341 Piston suspension device 94341b 417 mm 94341a (WLL 3000 kg) 94341a Distance plates 94341b Distance plates 013.012/05 94342...
  • Page 504 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94345 2 Distance holders for removal and fitting of piston rod gland and piston 495 mm 013.596/05 701.013.596 94345b 1 Clamp ring 52 mm 000.402/93 94345c 1 Gauge for fitting scraper rings 270 mm 701.013.597 013.597/05...
  • Page 505 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94346 2 Pre-tensioning jacks for waisted studs to piston crown, including a metal box 66 mm 016.649/08 94348 1 Tap M16 for cleaning carbon deposits in threaded holes of piston crown 102 mm 013.599/05 94350...
  • Page 506 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94366a 1 Template for shape of top of piston crown (for use with piston in situ) 549 mm 009.973/02 94366b 1 Template for shape of top of piston crown (with 3 piston rings) 557 mm Y = 223.5 mm...
  • Page 507 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94551 1 Fitting and dismantling device for removal and fitting of guide pin to fuel pump 255 mm 008.762/00 94552 1 Cover with Allen screws M12 for removal and fitting of fuel pump 116 mm 701.013.603...
  • Page 508 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94566 1 Support for removal and fitting of camshaft 510 mm 013.605/05 94566a 1 Support for removal and fitting of camshaft 510 mm 013.606/05 94566b 1 Centring device for aligning bearing shells 70 mm 013.607/05...
  • Page 509 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94569 Blank flange to fuel pump with 4 Screws M12x50 and 1 O-ring 42.52x2.62 mm 93 mm 94569a Blank flange to valve housing at fuel rail with 016.650/08 4 Screws M12x80 92 mm 94575 1 Adjusting scale...
  • Page 510 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94587 8 Conical plugs for servo and fuel oil returns in rail unit 20 mm 011.976/04 94589 2 Withdrawing tools for removing lip seal from injection control unit X = 310 mm and 638 mm 012.308/04...
  • Page 511 RT-flex50-D 9403−5/A1 Maintenance Standard Tools Tools for removal and fitting of scavenge air cooler SAC261 & SAC265 types engines with ABB−A165, A170, A175 turbochargers or engines with MET53MB, MET60MB turbochargers (with Integrated Lifting IL) 94661−IL 1 Support including: 6 Screws M12x45...
  • Page 512 RT-flex50-D 9403−5/A1 Maintenance Standard Tools Tools for removal and fitting of water separator engines with 1 scavenge air cooler (underslung SAR design) 94667 1 Lifting and withdrawing gear including: 1 Shackle 4 Screws M12x25 X = 330 mm (WLL 400 kg and 6000 N) 016.829/08...
  • Page 513 RT-flex50-D 9403−5/A1 Maintenance Standard Tools Tools for removal and fitting of water separator engines with 2 scavenge air coolers (underslung SAR design) 94667 1 Lifting and withdrawing gear including: 1 Shackle 4 Screws M12x25 X = 330 mm (WLL 400 kg and 6000 N) 016.829/08...
  • Page 514 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94666 1 Wire rope sling Ø 14 mm with 2 shackles for removal and fitting of a crosshead Ø pin and a scavenge air cooler 800 mm (WLL 2400 kg at ( 0−45_) 012.316/04 94720c 1 Case (for CLU4−C)
  • Page 515 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94870 Regrinding device for sealing surfaces on fuel pressure piping (8733−1) 101 mm consisting of: 94870a Screw-on sleeve (AF 32) 94870b Grinding tool with countersunk screw M4 94870c Lock nut M18x1.5 (AF 27) 016.740/08 94870d...
  • Page 516 RT-flex50-D 9403−5/A1 Maintenance Standard Tools Hydraulic parts and pump 94931 HP oil pump 94934f working pressure max. 2800 bar 94934f Adapter piece 010.001/02 94934 1 Connection block 005.956/00 94934a 2 Hydr. distributors with pressure gauges 010.242/02 94934g 2 Coupling elements 013.620/05...
  • Page 517 RT-flex50-D 9403−5/A1 Maintenance Standard Tools 94935 4 HP hoses 2600 bar with closing valves and coupling sockets X = 2130 mm 005.954/00 94935c 1 Hose for set-up of pre-tensioning jacks Length = 2000 mm 701.013.621 013.621/05 94936 2 Hydraulic jacks 500 kN (50 t) 005.952/00...
  • Page 518 RT-flex50-D 9403−5/A1 Maintenance Recommended Special Tools 94016 Manual ratchets (WLL 800 kg) 94016a Manual ratchets (WLL 1600 kg) 94016b Manual ratchets (WLL 3200 kg) 94016c Manual ratchets 012.233/04 (WLL 6300 kg) 94102 1 Tool cylinder liner measuring complete with extension and case (Measuring range 150−600 mm)
  • Page 519 RT-flex50-D 9403−5/A1 Maintenance Recommended Special Tools 94300 1 Tool cupboard X = 1120 mm 000.500/93 94335a Lifting tool 94335b for removal and fitting of heavy engine 94335c components (platform without crane rail) 94335b Bushes 016.622/08 94335c Screws 964 mm (WLL 1740 kg)
  • Page 520 RT-flex50-D 9403−5/A1 Maintenance Recommended Special Tools 94349 1 Pressure testing device for piston 255 mm 010.005/02 94356 1 Equipment case with instruments for measuring chrome layers 280 mm 014.527/06 94412e 1 Retaining wrench for 2-part gear wheel on crankshaft AF 46 116 mm 013.623/05...
  • Page 521 RT-flex50-D 9403−5/A1 Maintenance Special Tools Obtainable on Loan 94174a 4 Thread protectors to upper tie rod thread including: 4 screws M24x60 43 mm WCH00668 94177a 1 Thread protector to lower tie rod thread including: 1 screw M16x25 85 mm 94599...
  • Page 522 RT-flex50-D 9403−5/A1 Maintenance Special Tools Obtainable on Loan 94922 1 Alignment tool for crank angle sensor 172 mm 008.773/00 2010 38/ 38 Wärtsilä Switzerland Ltd...

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