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WinGD WARTSILA RT-flex58T-D Maintenance Manual

Supply unit aft end
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Table of Contents

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Maintenance Manual
"Marine"
Vessel:
Type:
Engine No.:
Document ID: DBAC351676
Winterthur Gas & Diesel Ltd.
Schützenstrasse 1−3
CH-8400 Winterthur
Switzerland
RT-flex58T-D
Version 2
Supply Unit Aft End
24hrs Support:
Wärtsilä Services Switzerland Ltd.
Zürcherstrasse 12
CH 8400 Winterthur
Switzerland
+41 52 262 80 10
technicalsupport.chts@wartsila.com

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Summary of Contents for WinGD WARTSILA RT-flex58T-D

  • Page 1 RT-flex58T-D Maintenance Manual “Marine” Version 2 Supply Unit Aft End Vessel: Type: Engine No.: Document ID: DBAC351676 Winterthur Gas & Diesel Ltd. 24hrs Support: Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd. CH-8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland +41 52 262 80 10 technicalsupport.chts@wartsila.com...
  • Page 2 E 2014-04 Winterthur Gas & Diesel Ltd., Printed in Switzerland – All rights reserved No part of this publication may be reproduced or copied in any form or by any means (electron- ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder.
  • Page 3 RT-flex58T-D Maintenance Manual “Marine” Version 2 Supply Unit Aft End Vessel: Type: Engine No.: Document ID: DBAC351676 Winterthur Gas & Diesel Ltd. 24hrs Support: Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd. CH-8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland +41 52 262 80 10 technicalsupport.chts@wartsila.com...
  • Page 4 E 2014-04 Winterthur Gas & Diesel Ltd., Printed in Switzerland – All rights reserved No part of this publication may be reproduced or copied in any form or by any means (electron- ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder.
  • Page 5 Modification Service Engine Documentation RT-flex58T-D Summary for Maintenance Manual Version 2 Supply Unit Aft End (MM) Page No. Modification Title Subject Page or Date Manual new exch. 2013 Issue 2013 Date of publication 2013-01-30 0380-1/A1 (2) 2013-02 TB RT-143 Maintenance Schedule 2728-1: Monthly check of nut to solenoid added 2728-1/A1 Starting Air Valve Check concerning venting of starting air manifold and...
  • Page 6 2015-08 EAAD085234 Tool List Tool numbers 94871 and 94871A added, new cyl. Cover press GF94215A Date of publication 2016-02-17 2751-2/A1 2018 WinGD Input Exhaust Valve: Pge: 7. Paragraph 3.4 - Procedure changed. Disassemble and Assemble 5552-5/A1 2018-02 Wartsila Input Lubrication of Supply...
  • Page 7 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 9: Table Of Contents

    Group0 RT-flex58T-D Maintenance General Information Group 0 For Particular Attention ..........0000−1/A1 Preface .
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  • Page 11 0000−1/A1 RT-flex58T-D 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 13 0001−1/A1 RT-flex58T-D 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.
  • Page 14 Intentionally blank...
  • Page 15 0002−1/A1 RT-flex58T-D Maintenance Table of Contents Table of Contents General Information Group 0 For Particular Attention ..........0000−1/A1 Preface .
  • Page 16 0002−1/A1 Maintenance RT-flex58T-D Table of Contents Bedplate and Tie Rod Group 1 Bedplate and Thrust Bearing: Checking the Foundation Bolts ....1112−1/A1 Main Bearing −...
  • Page 17 0002−1/A1 RT-flex58T-D Maintenance Table of Contents Crankshaft, Connecting Rod and Piston Group 3 Crankshaft: Measuring Crank Deflection ........3103−1/A1 Vibration Damper −...
  • Page 18 0002−1/A1 Maintenance RT-flex58T-D 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 19 0002−1/A1 RT-flex58T-D Maintenance Table of Contents Crank Angle Sensor Unit, Tools Group 9 Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting ... . . 9223−1/A1 Tools: Explanation ............9403−1/A1 Hydraulic Jacks and Pumps: Arrangement and Application .
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  • Page 21: General

    0008−1/A1 RT-flex58T-D Maintenance General Engine Numbering and Designations Turbocharger Cylinder Number DRIVING END FREE END Main Bearing Number Thrust Bearing Pads Exhaust Waste Gate (Option) Rail Unit FUEL SIDE EXHAUST SIDE Supply Unit Counterclockwise Clockwise Rotation Rotation WCH00995 V2 / 2013 1/ 2 Winterthur Gas &...
  • Page 22 0008−1/A1 Maintenance RT-flex58T-D 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 &...
  • Page 23 0011−1/A1 RT-flex58T-D Maintenance General Guidelines for Maintenance Safety Measures and Warnings Overview General ..........General safety precautions .
  • Page 24 0011−1/A1 Maintenance RT-flex58T-D 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 25 0011−1/A1 RT-flex58T-D 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). At all times when somebody is inside the engine casing another person must stand by in order that he can give the necessary aid if something unexpected happens to the person inside the engine.
  • Page 26 0011−1/A1 Maintenance RT-flex58T-D 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 27 0012−1/A1 RT-flex58T-D 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 28 0012−1/A1 Maintenance RT-flex58T-D 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 8600 6100 11 500...
  • Page 29 0012−1/A1 RT-flex58T-D 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 30 0012−1/A1 Maintenance RT-flex58T-D 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. Prior to loading the RUD-swivel lug adjust it in force direction (Fig.
  • Page 31 0012−1/A1 RT-flex58T-D 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 33: Crankshaft And Thrust Bearing

    0330−1/A1 RT-flex58T-D Maintenance Clearance Table Overview − General ..........1/25 −...
  • Page 34 0330−1/A1 Maintenance RT-flex58T-D Clearance Table Crankshaft and Thrust Bearing 003.319/00 WCH00997 2013 2/ 25 Winterthur Gas & Diesel Ltd.
  • Page 35 0330−1/A1 RT-flex58T-D 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] 1132 Main bearing Bearing shell width Lateral clearance per side 1203 Thrust bearing 1224 −...
  • Page 36 0330−1/A1 Maintenance RT-flex58T-D Clearance Table Crankshaft and Main Bearing 003.318/00 MAIN BEARING MAIN BEARING No. 2 No. 1 AND FOLLOWING 003.318/00 2013 4/ 25 Winterthur Gas & Diesel Ltd.
  • Page 37 0330−1/A1 RT-flex58T-D 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 Crankshaft outer ∅ − 0.08 Main bearing inner ∅ Bearing clearance vertical 0.3−0.7...

  • Page 38: Crosshead Guide

    0330−1/A1 Maintenance RT-flex58T-D Clearance Table Crosshead Guide EXHAUST SIDE 003.317/00 2013 6/ 25 Winterthur Gas & Diesel Ltd.
  • Page 39 0330−1/A1 RT-flex58T-D 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 + 0.25 Guide way (column) transverse − 0.20 Guide shoe transverse − 0.31 Guide shoe clearance 0.20−0.90 Guide rail...

  • Page 40: Cylinder Liner

    0330−1/A1 Maintenance RT-flex58T-D Clearance Table Cylinder Liner WCH01000 2013 / V2 8/ 25 Winterthur Gas & Diesel Ltd.
  • Page 41 0330−1/A1 RT-flex58T-D 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 + 0.60 Water guide jacket Ø + 0.40 Clearance total 0.70−1.10...
  • Page 42 0330−1/A1 Maintenance RT-flex58T-D Clearance Table Piston Rod Gland 006.097/99 012.153/04 2013 10/ 25 Winterthur Gas & Diesel Ltd.

  • Page 43: Piston Rod Gland

    0330−1/A1 RT-flex58T-D 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. 22.20 Ring width radial min.

  • Page 44: Exhaust Valve

    0330−1/A1 Maintenance RT-flex58T-D Clearance Table Exhaust Valve VALVE SPINDLE GUIDE BUSH 003.316/00 003.316/00 2013 12/ 25 Winterthur Gas & Diesel Ltd.
  • Page 45 0330−1/A1 RT-flex58T-D 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 − 0.19 Spindle outer ∅ 55.4 − 0.23 2751 Guide bush + 0.03 Bore inner ∅...

  • Page 46: Top And Bottom End Bearings To Connecting Rod

    0330−1/A1 Maintenance RT-flex58T-D Clearance Table Top and Bottom End Bearings to Connecting Rod 003.315/00 003.315/00 2013 14/ 25 Winterthur Gas & Diesel Ltd.
  • Page 47 0330−1/A1 RT-flex58T-D 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 Crosshead pin outer ∅ −...
  • Page 48 0330−1/A1 Maintenance RT-flex58T-D Clearance Table Piston Cooling and Crosshead Lubricating Link 003.314/00 003.314/00 2013 16/ 25 Winterthur Gas & Diesel Ltd.

  • Page 49: Piston Cooling And Crosshead Lubricating Link

    0330−1/A1 RT-flex58T-D Maintenance Clearance Table Piston Cooling and Crosshead Lubricating Link Description Measuring Nominal Maximum clearance, direction dimension dimension (method of (normal, new) (due to wear) measuring) [mm] [mm] 3603 Piston cooling and crosshead lu- bricating link outer ∅ Bearing clearance radial 0.03−0.09 0.20...

  • Page 50: Piston And Piston Rings

    0330−1/A1 Maintenance RT-flex58T-D Clearance Table Piston and Piston Rings EXECUTION WITH THREE PISTON RINGS EXECUTION WITH FOUR PISTON RINGS 2013-08 18/ 25 Winterthur Gas & Diesel Ltd.
  • Page 51 0330−1/A1 RT-flex58T-D 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 Crown outer ∅ 574.7 − 0.2 Crown outer ∅ 577.8 −...

  • Page 52: Driving Wheels For Supply Unit

    0330−1/A1 Maintenance RT-flex58T-D Clearance Table Driving Wheels for Supply Unit WCH01002 WCH01003 2013 / V2 20/ 25 Winterthur Gas & Diesel Ltd.
  • Page 53 0330−1/A1 RT-flex58T-D 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 Shaft outer ∅ Bearing clearance vertical 0.08−0.15 0.25 Axial clearance total 0.6−1.1 Tooth backlash...

  • Page 54: Supply Unit

    0330−1/A1 Maintenance RT-flex58T-D Clearance Table Supply Unit WCH00992 1 3 2 2013 / V2 22/ 25 Winterthur Gas & Diesel Ltd.
  • Page 55 0330−1/A1 RT-flex58T-D 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 Pinion outer ∅ − 0.019 + 0.10 Bearing (fitted) inner ∅ + 0.058 Bearing clearance radial 0.058−0.119...
  • Page 56 0330−1/A1 Maintenance RT-flex58T-D Clearance Table Fuel Pump PLUNGER & CYLINDER 012.098/04 013.032/05 2013 24/ 25 Winterthur Gas & Diesel Ltd.
  • Page 57 0330−1/A1 RT-flex58T-D 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 0.027...
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  • Page 59 0352−1/A1 RT-flex58T-D Maintenance Tightening Values of Important Screwed Connections WCH00985 Remark: The screwed connections must be tightened in accordance with the val- ues not in brackets. The values in brackets [...] are to be used for comparison only. When using other hydraulic jacks, the required pressure in bar must be calculated in relation to the effective jack piston surface! Conversion factor: 1 Nm = 0.102 mkp, 1 bar = kp/cm The relevant lubricant has to be applied to threads and seating surfaces, if no...
  • Page 60 0352−1/A1 Maintenance RT-flex58T-D Tightening Values of Important Screwed Connections WCH00985 2013 / V2 2/ 7 Winterthur Gas & Diesel Ltd.
  • Page 61 0352−1/A1 RT-flex58T-D Maintenance Tightening Values of Important Screwed Connections Starting Air Valve Injection Valve WCH00985 WCH00985 Exhaust Valve WCH00985 V2 / 2013 3/ 7 Winterthur Gas & Diesel Ltd.

  • Page 62: Fuel Pump

    0352−1/A1 Maintenance RT-flex58T-D Tightening Values of Important Screwed Connections Servo Oil Rail WCH00989 Fuel Pump Supply Unit I - I WCH00992 WCH00985 2013 / V2 4/ 7 Winterthur Gas & Diesel Ltd.
  • Page 63 0352−1/A1 RT-flex58T-D Maintenance Tightening Values of Important Screwed Connections Fuel Rail Driving End Fuel Rail Free End WCH00988 Injection Control Unit WCH00987 V2 / 2013 5/ 7 Winterthur Gas & Diesel Ltd.
  • Page 64 0352−1/A1 Maintenance RT-flex58T-D Tightening Values of Important Screwed Connections High Pressure Servo Oil Pipe High Pressure Fuel Pipe WCH00991 WCH00990 2013 / V2 6/ 7 Winterthur Gas & Diesel Ltd.
  • Page 65 0352−1/A1 RT-flex58T-D Maintenance Tightening Values of Important Screwed Connections Crank Angle Sensor Unit WCH00985 Rail Unit Transport WCH00985 V2 / 2013 7/ 7 Winterthur Gas & Diesel Ltd.
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  • Page 67 0352−2/A1 RT-flex58T-D 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 68 0352−2/A1 Maintenance RT-flex58T-D Tightening Values of Standard Screwed Connections Elastic bolts Elastic bolts must be tightened according to the values in the following diagram. Before fitting a elastic bolt clean its thread and corresponding tap hole. The sealing faces must be degreased (e.g. using white spirit) and subsequently primed.
  • Page 69 0360−1/A1 RT-flex58T-D 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 free end 1200 1720 Oil baffle, upper part driving end Oil baffle, lower part...
  • Page 70 0360−1/A1 Maintenance RT-flex58T-D Individual Components per Piece in kg Group Component Execution 3306 Connecting rod 1340 3309 Lower bearing half for bottom end complete bearing with bearing shell and elastic stud 3310 Lower bearing shell half for bottom end bearing Upper bearing shell half for bottom end bearing 3312...
  • Page 71 0360−1/A1 RT-flex58T-D Maintenance Individual Components per Piece in kg Group Component Execution 5564 Injection control unit complete 5612 Exhaust valve control unit complete 6506 Exhaust gas turbocharger A165 2000 A170 3000 A175 4900 A180 7000 MET53MA/MB 3550/2000 MET60MA/MB 4260/4500 MET66MA/MB 6250/6500 TPL73−B 2600...
  • Page 72 Intentionally blank...
  • Page 73 0380−1/A1 RT-flex58T-D 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 − Check concentration of inhibitor (as per supplier’s instructions) 1112−1 Bedplate −...
  • Page 74 0380−1/A1 Maintenance RT-flex58T-D Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals 2303−1 Piston rod gland − Clean rings, establish wear at every piston removal 2708−1 Cylinder cover − Check combustion space for damage at every piston removal 2722−1 Injection valve −...
  • Page 75 0380−1/A1 RT-flex58T-D 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 76 0380−1/A1 Maintenance RT-flex58T-D 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 77 0380−1/A1 RT-flex58T-D 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 78 0380−1/A1 Maintenance RT-flex58T-D 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 79 0380−1/A1 RT-flex58T-D Maintenance Inspection and Overhaul Intervals (Guidelines) Group Component Work to be carried out Intervals 8733−1 HP pipe to − Regrind sealing faces as required injection valve (on cylinder cover) Non-return valve − Random check 18 000 Op.h 8744 Supply unit fuel −...
  • Page 80 0380−1/A1 Maintenance RT-flex58T-D Inspection and Overhaul Intervals (Guidelines) The indicated maintenance intervals must be taken as guidance and may vary depending on the installation. The proper intervals are subject to the points men- tioned below. Experience will show whether these intervals can be extended or must be shortened.
  • Page 81 0803−1/A1 RT-flex58T-D Maintenance Engine Cross Section and Longitudinal Section Cross Section: 8460−1 8733−1 2728−1 5562−1 6545−1 6420−1 8447−1 1903−1 6606−1 6606−2 6708−1 4325−1 3326−1 3326−2 5556−1 5801−1 3301−1 1112−1 WCH00993 V2 / 2013 1/ 2 Winterthur Gas & Diesel Ltd.
  • Page 82 0803−1/A1 Maintenance RT-flex58T-D Engine Cross Section and Longitudinal Section Longitudinal Section: 2751−1 2751−4 2708−1 2708−3 2722−1 3403−1 3403−4 2124−1 2124−3 3425−1 2138−1 2303−1 3303−1 3303−4 8752−1 4103−1 4103−3 3140−1 1132−1 9223−1 1132−2 1203−1 3103−1 1224−1 3130−1 3130−2 WCH00994 2013 / V2 2/ 2 Winterthur Gas &...
  • Page 83 Group1 RT-flex58T-D Maintenance Bedplate and Tie Rod Group 1 Bedplate and Thrust Bearing: Checking the Foundation Bolts ....1112−1/A1 Main Bearing − Loosening and Tensioning of Elastic Studs .
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  • Page 85: Bedplate And Thrust Bearing Checking The Foundation Bolts

    1112−1/A1 RT-flex58T-D Maintenance Bedplate and Thrust Bearing Checking the Foundation Bolts Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Bedplate 11 Control pin 1 Pre-tensioning jack 94145 2 Foundation bolt 12 Vent screw 1 HP oil pump 94931 3 Foundation bolt 13 Cylinder 1 Hydr.
  • Page 86 1112−1/A1 Maintenance RT-flex58T-D Checking the Foundation Bolts Checking of 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 the foundation bolt to be checked. Screw it completely down with vent screw 12 open until there is only little or no clear- ance at ’x’.
  • Page 87 1112−1/A1 RT-flex58T-D Maintenance Checking the Foundation Bolts Loosening of the foundation bolts ⇒ First screw down pre-tensioning jack 94145 as for checking the pre-tension, then turn back by ½ turn (gap ’SA’). ⇒ Connect the pre-tensioning jack with HP oil pump 94931. Fit plug piece 94934E on one side of Hydr.
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  • Page 89: Main Bearing

    1132−1/A1 RT-flex58T-D Maintenance Main Bearing Loosening and Tensioning of Elastic Studs Tools: Key to Illustrations: 2 Double pre-tensioning jacks 94114 1 Elastic stud 1 Assembly tool 94114A 2 Main bearing cover 1 Feeler gauge 94122 3 Nut 1 Special feeler gauge 94123 4 Nut 1 Hydr.
  • Page 90 1132−1/A1 Maintenance RT-flex58T-D Main Bearing: Loosening and Tensioning of Elastic Studs Tensioning the elastic studs After fitting the main bearing cover as described in 1132−2, elastic studs 1 are to be tensioned as follows: ⇒ Place both double pre-tensioning jacks 94114 onto elastic studs 1 for the main bearing (Fig.
  • Page 91 1132−1/A1 RT-flex58T-D Maintenance Main Bearing: Loosening and Tensioning of Elastic Studs I - I 011.310/03 94935 94942 94932 94934 94114 98.7663 2013 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 93: Removal And Fitting Of A Main Bearing

    1132−2/A1 RT-flex58T-D Maintenance Main Bearing Removal and Fitting of a Main Bearing Tools: Key to Illustrations: 4 Manual ratchets WLL ≥ 94016 (H1…H4) 1 Crankshaft 800 kg 1 Eye bolt 94045−M16 (RC) 2 Main bearing cover* 1 Lifting device 94111 3 Lower main bearing shell** 1 Guide 94115...
  • Page 94 1132−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Main Bearing II - II I - I 004.212/99 004.212/99 004.212/99 Placing of device 94111 Attention! Device 94111 must only be fastened onto the bearing cover with elastic studs 4 loosened and their nuts removed! Device 94111 must always be used for removal and fitting of the bearing covers;...
  • Page 95 1132−2/A1 RT-flex58T-D Maintenance Removal and Fitting of a Main Bearing Removal of main bearing cover Removal of bearing cover No. 1 ⇒ Turn crank of Cyl. No.1 to exhaust side approx. 85_ after T.D.C.. ⇒ Remove upper part of oil baffle and upper casing at the driving end. ⇒...
  • Page 96 1132−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Main Bearing Removal of bearing cover No. 2 and following ⇒ Turn corresponding crank to exhaust side ap- prox. 85_ after T.D.C. ⇒ Install working platform 94142 (see 3301−1). ⇒ Remove nuts for elastic studs (see 1132−1). ⇒...
  • Page 97 1132−2/A1 RT-flex58T-D Maintenance Removal and Fitting of a Main Bearing ⇒ Remove manual ratchet ’H1’. ⇒ Install eyelet 94120 to lifting device 94111. ⇒ Lift bearing cover 2 out of crankcase by means of manual ratchet ’H2’ with rope 94120G and manual ratchet ’H4’. ⇒...
  • Page 98 1132−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Main Bearing Turning out and removal of lower main bearing shell Attention! Never remove two neighbouring bearing shells at the same time! The removing procedure for a lower bearing shell 3 (Fig. ’A’) is the same for all main bearings with the exception of main bearing No.
  • Page 99 1132−2/A1 RT-flex58T-D 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 3 at about 50 mm below the bearing division. ⇒...
  • Page 100 1132−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Main Bearing Turning out main bearing shell No. 1 Crankshaft lifted up by approx. 0.2 mm (see paragraphs 5.1 and 5.2). Remark: Turning-out device 94118 must only be fitted to bearing shell No. 1 instead of turning-out device 94118A, which is provided for all other bearing shells.
  • Page 101 1132−2/A1 RT-flex58T-D Maintenance Removal and Fitting of a Main Bearing Removal of main bearing shell No. 1 ⇒ Fasten lifting tool 94116 to lower bearing shell 3. ⇒ Connect rope 94120B to manual ratchet ’H1’ and lift bearing shell 3. ⇒...
  • Page 102 1132−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Main Bearing Turning out the main bearing shells No. 2 and following Crankshaft lifted up by approx. 0.2 mm (see paragraphs 4.1 and 4.2). ⇒ Install roller support 94117 on the column. ⇒...
  • Page 103 1132−2/A1 RT-flex58T-D Maintenance Removal and Fitting of a Main Bearing Removal of main bearing shells No. 2 and following ⇒ Fasten lifting tool 94116 to lower bearing shell 3. ⇒ Attach rope 94120F to lifting tool 94116 and guide it over roller support 94117 to manual ratchet ’H1’.
  • Page 104 1132−2/A1 Maintenance RT-flex58T-D 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. Attention! Do not scrape the bearing shell in the loaded area.
  • Page 105 1132−2/A1 RT-flex58T-D Maintenance Removal and Fitting of a Main Bearing Turning in the main bearing shell All bearing shells are marked on their faces with DRIVING END. Therefore , they must be fitted correspondingly. Used bearing shells must be fitted into the bearing girders in their original positions.
  • Page 106 1132−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Main Bearing ⇒ While holding the lower bearing shell in position by means of turning-out de- vice 94118 (94118A), lifting tool 94116 can be removed. ⇒ Due to the dead weight, the lower bearing shell slides now slowly into main bearing girder 6 by about 90_ whereby the turning-out device must be fol- lowed up correspondingly.

  • Page 107: Thrust Bearing

    1203−1/A1 RT-flex58T-D Maintenance Thrust Bearing Checking the Axial Clearance Tools: Key to Illustrations: 1 Inside micrometer 94101 1 Coupling flange 7 Thrust bearing pads 1 Feeler gauge 94238 2 Oil baffle, upper part for ASTERN 1 Dial gauge with magnetic base 3 Oil baffle, lower part 7a Thrust bearing pads 4, 4a Holder...
  • Page 108 1203−1/A1 Maintenance RT-flex58T-D Thrust Bearing: Checking the Axial Clearance THRUST 003.311/00 0.8−1.3 mm CHECK HOLE FOR FREE PASSAGE EVERY 6000−8000 OP. HOURS WCH01018 2013 / V2 2/ 2 Winterthur Gas & Diesel Ltd.

  • Page 109: Removal And Fitting The Thrust Bearing Pads

    1224−1/A1 RT-flex58T-D Maintenance Thrust Bearing Removal and Fitting the Thrust Bearing Pads Tools: Key to Illustrations: 1 Turning-out device 94155 1 Thrust bearing flange 5 Screws with locking for engines with 2, 2a Thrust bearing pads plates 1-part gear wheel 3 Gear wheel 6 Bearing cover 1 Turning-out device...
  • Page 110 1224−1/A1 Maintenance RT-flex58T-D Removal and Fitting the Thrust Bearing Pads 2/2a 003.309/00 I - I 94155 2/2a 94155A 003.309/00 94155 94155A 003.309/00 2013 2/ 4 Winterthur Gas & Diesel Ltd.
  • Page 111 1224−1/A1 RT-flex58T-D Maintenance Removal and Fitting the Thrust Bearing Pads ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH FIXED PITCH PROPELLER CLOCKWISE ASTERN AHEAD ROTATING ENGINE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END PADS ON ENGINE SIDE COUNTER-CLOCKWISE ASTERN AHEAD...
  • Page 112 1224−1/A1 Maintenance RT-flex58T-D Removal and Fitting the Thrust Bearing Pads ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH CONTROLLABLE PITCH PROPELLER CLOCKWISE ASTERN AHEAD ROTATING ENGINE VIEW FROM DRIVING END VIEW FROM DRIVING END PADS AT DRIVING END PADS ON ENGINE SIDE COUNTER-CLOCKWISE ASTERN AHEAD...
  • Page 113 1715−1/A1 RT-flex58T-D Maintenance Engine Stays with Friction Shims Checking the Pre-tension Tools: Key to Illustrations: 1 Rod 94005D 1 Engine stays 1 Feeler gauge 94122 2 Friction shims 1 Pre-tensioning jack 94145 3 Screw 1 HP oil pump 94931 4 Nut 1 Hydr.

  • Page 114: Engine Stays With Friction Shims: Checking The Pre-Tension

    1715−1/A1 Maintenance RT-flex58T-D Engine Stays with Friction Shims: Checking the Pre-tension Checking the pre-tension ⇒ Clean the thread of the screw and the seating surface. Subsequently apply MOLYKOTE to the thread. ⇒ Place pre-tensioning jack 94145 on the screw to be checked, and screw it completely down with vent screw 8 open until there is only little or no clearance at ’x’...

  • Page 115: 1903−1/A2

    1903−1/A2 RT-flex58T-D Maintenance Tie Rod Checking the Pre-tension and Tensioning the Tie Rods with M80x6 Thread Diameter Tools: Key to Illustrations: 1 Rod 94005F 1 Cylinder block 12 Bearing girder 1 Feeler gauge 94122 2 Intermediate ring 13 Lower backing ring 2 Pre-tensioning jacks GF 94180 3 Upper tie rod nut...
  • Page 116 1903−1/A2 Maintenance RT-flex58T-D Checking the Pre-tension and Tensioning the Tie Rods with M80x6 Thread Diameter PRE-TENSIONING JACK GF 94180 PRE-TENSIONING JACK GF 94180 PLACED FOR TENSIONING PLACED FOR LOOSENING 94935A 94934A 94934A 94935A 94005F WCH00668 012.947/05 94935 94942 Using a feeler gauge inserted through slot ’KO’, check whether tie rod nut 3 rests CHECK on intermediate ring 2 without any clearance.
  • Page 117 1903−1/A2 RT-flex58T-D Maintenance Checking the Pre-tension and Tensioning the Tie Rods with M80x6 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’). If the tie rods have been newly tensioned, then the elastic studs of the main bearings also have to be checked for correct pretensioning (see 1132−1).
  • Page 118 1903−1/A2 Maintenance RT-flex58T-D Checking the Pre-tension and Tensioning the Tie Rods with M80x6 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 119 1903−1/A2 RT-flex58T-D Maintenance Checking the Pre-tension and Tensioning the Tie Rods with M80x6 Thread Diameter I - I WCH00667 FLUSH V2 / 2013 5/ 5 Winterthur Gas & Diesel Ltd.
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  • Page 121 Group2 RT-flex58T-D Maintenance Cylinder Liner and Cylinder Cover Group 2 Cylinder Liner − Measuring Bore Wear ..........2124−1/A1 −...
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  • Page 123: Cylinder Liner

    2124−1/A1 RT-flex58T-D Maintenance Cylinder Liner Measuring Bore Wear Tools: Key to Illustrations: 1 Inside micrometer 94101 1 Cylinder liner 1 Measuring gauge 94225 2 Antipolishing ring ST Setting screw SETTING SCREW ’ST’ DRAWN FOR COM- PRESSION SHIM THICKNESS = 0 mm. ⇒...
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  • Page 125: Removal And Fitting

    2124−2/A1 RT-flex58T-D Maintenance Cylinder Liner Removal and Fitting Tools: Key to Illustrations: 2 RUD-eye bolts 94040−M16 1 Cylinder block 11 Insulation bandage 1 Device GF 94201 2 Cylinder liner 12 Plate 3 Water guide jacket 13 Tension spring consisting of: 1 Lifting tool GF 94202 (lower part)
  • Page 126 2124−2/A1 Maintenance RT-flex58T-D Cylinder Liner Removal and Fitting Removal and fitting of cylinder liner ⇒ Loosen the screws 8 and remove them together with pipe connection 7 and the transition tubes 6 from the water guide jackets 3 and 5. Remark: Transition tubes are pressed into connection pieces (press fit).
  • Page 127 2124−2/A1 RT-flex58T-D Maintenance Cylinder Liner Removal and Fitting Removal A cylinder liner can be removed by crane and lifting gear. ⇒ Lift the cylinder liner on shackle GF 94202M provided in the center of the device (Fig. ’B’). Fitting ⇒ Place the device GF 94201 diagonally onto the cylinder liner 2 in accordance with paragraph 2.1.
  • Page 128 2124−2/A1 Maintenance RT-flex58T-D Cylinder Liner Removal and Fitting Removal and fitting of antipolishing ring Removal ⇒ Fit four suspension straps 94208. ⇒ Turn the piston to T.D.C. whereby antipolishing ring 4 is pushed out of its seat- ing and then it can be removed. Fitting ⇒...
  • Page 129 2124−2/A1 RT-flex58T-D Maintenance Cylinder Liner Removal and Fitting Removal and fitting of water guide jacket Removal ⇒ Lift cylinder liner according to paragraph 2. ⇒ Fasten the RUD-eye bolts 94040−M16 to the water guide jacket 3 as shown below. ⇒ Remove holder 14. ⇒...
  • Page 130 2124−2/A1 Maintenance RT-flex58T-D Cylinder Liner: Removal and Fitting Removal and fitting of insulation bandage Removal ⇒ Lift the cylinder liner in accordance with paragraph 2. ⇒ Remove the water guide jacket referring to paragraph 4. ⇒ Loosen all tension springs 13 with assembly tool 94345E. ⇒...
  • Page 131 2124−2/A1 RT-flex58T-D Maintenance Cylinder Liner Removal and Fitting Laying down and raising cylinder liner ⇒ Place the device GF 94202 according to paragraph 2.1. ⇒ Change position of shackle GF 94202M as shown below. ⇒ Connect the chain GF 94202L (WLL 4000 kg) to the crane. Lay down the cylin- der liner following the sequence drawn below and secure it against rolling away by means of wooden underlays and wedges.
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  • Page 133: 2124−3/A1

    2124−3/A1 RT-flex58T-D Maintenance Cylinder Liner Removing 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 4 Spacer roller 12 Top piston ring 5 Pipe (column)
  • Page 134 2124−3/A1 Maintenance RT-flex58T-D Cylinder Liner: Re-dressing Lubricating Grooves and Scavenge Ports SHARP EDGES REMOVED II-II WCH01000 018.944/09 2013-02 / V2 2/ 3 Winterthur Gas & Diesel Ltd.
  • Page 135 2124−3/A1 RT-flex58T-D Maintenance Cylinder Liner: Removing Wear Ridge 94299 T.D.C. 2−3 mm 1 mm 009.642/02 009.641/02 2013 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 137: 2138−1/A2

    2138−1/A2 RT-flex58T-D 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 15 Pin (tool) 1 HP oil pump 94931...
  • Page 138 2138−1/A2 Maintenance RT-flex58T-D Lubricating Quill with Pulse Jet Lubrication Removal and fitting of lubricating quill ⇒ Loosen screws 9, nuts of screw-in union 10 and angle union 11 (Fig. ’A’). Dis- connect lubricating oil pipe 12 and protect it against any damages and enter- ing of dirt.
  • Page 139 2138−1/A2 RT-flex58T-D 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 140 2138−1/A2 Maintenance RT-flex58T-D 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 screw-in union 10.

  • Page 141: 2303−1/A1

    2303−1/A1 RT-flex58T-D Maintenance Piston Rod Gland Dismantling and Assembling, Measuring the Wear Tools: Key to Illustrations: 1 Dismantling device 94344 1 Housing (2-part) 11 Cylinder cover stud (recommended special tool) 2 Scraper ring 12 Screw 2 Distance holders 94345 3 Sealing ring 12a Fitted bolt 1 Clamping ring (2-part) 94345B...
  • Page 142 2303−1/A1 Maintenance RT-flex58T-D Piston Rod Gland: Dismantling and Assembling, Measuring the Wear Removing, dismantling and assembling (variant 1) Removing a gland ⇒ Both distance holders 94345 are to be screwed on the foot of piston rod 17 (Fig. ’A’). ⇒ Unscrew the four outer screws 14 to 2-part ring 15 (Fig.
  • Page 143 2303−1/A1 RT-flex58T-D Maintenance Piston Rod Gland: Dismantling and Assembling, Measuring the Wear I - I 012.170/04 2013 3/ 7 Winterthur Gas & Diesel Ltd.
  • Page 144 2303−1/A1 Maintenance RT-flex58T-D Piston Rod Gland: Dismantling and Assembling, Measuring the Wear Assembling a gland ⇒ Place the piston in piston supporting device 94350, its hinged covers 18 must be folded down. ⇒ Attach clamping ring (2-part) 94345B − resting on hinged cover − to piston rod ⇒...
  • Page 145 2303−1/A1 RT-flex58T-D Maintenance Piston Rod Gland: Dismantling and Assembling, Measuring the Wear ⇒ After assembly of the ring supports for grooves ’d’ − ’i’ (Fig. ’D’), place two dis- tance pieces 94345F (19 mm) on the uppermost ring support 5 and fit sealing rings 3, 4 and tension spring 8 for groove ’c’.
  • Page 146 2303−1/A1 Maintenance RT-flex58T-D Piston Rod Gland: Dismantling and Assembling, Measuring the Wear ⇒ Remove all distance pieces 94345F and clamping ring 94345B. Check proper position of all rings with gauge CHECK 94345C resting on hinged cover 18 (Fig. ’E’). ⇒ Smear piston rod and all rings with bearing oil. ⇒...
  • Page 147 2303−1/A1 RT-flex58T-D Maintenance Piston Rod Gland: Dismantling and Assembling, Measuring the Wear 94345B 94345B 94344 ⇒ Clamp 2-part clamping ring 94345B onto the piston rod lying on housing 1 (Fig. ’F’). ⇒ Turn the piston slowly to B.D.C. again and pay 94345B attention that the gland slides out of the gland bore 94344...
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  • Page 149: Cylinder Cover

    2708−1/A1 RT-flex58T-D Maintenance Cylinder Cover Removal and Fitting of Cylinder Cover and Water Guide Jacket Tools: Key to Illustrations: 1 Suspension device GF 94265 1 Cylinder cover 8 Pad 2 Exhaust valve cage 9 Pipe 3 Cylinder liner 10−12 O-rings 4 Joint ring 5 Upper water guide jacket RC Eye bolt...
  • Page 150 2708−1/A1 Maintenance RT-flex58T-D Removal and Fitting of Cylinder Cover and Water Guide Jacket Removal of cylinder cover ⇒ Drain cylinder cooling water (see Operating Manual 8017−1). ⇒ Disconnect all connections to the cylinder cover and to the exhaust valve as well as the expansion piece between exhaust valve and exhaust manifold.
  • Page 151 2708−1/A1 RT-flex58T-D Maintenance Removal and Fitting of Cylinder Cover and Water Guide Jacket Water guide jacket Clean all the sealing faces and O-ring grooves. Fit new O-rings 10 and11 in cylinder cover 1 and oil them slightly. Unscrew Allen screws 7 from the threaded holes ’TH’. Align cylinder cover above upper water guide jacket 5 in such a way that tape holes and through holes in water guide jacket for the Allen screws are in line.
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  • Page 153: Loosening And Tensioning Of Cylinder Cover Elastic Studs

    2708−2/A1 RT-flex58T-D Maintenance Cylinder Cover Loosening and Tensioning of Cylinder Cover Elastic Studs Tools: Key to Illustrations: Hydraulic tensioning device GF 94215 1 Cylinder cover 2 Cylinder cover elastic studs consisting of: Pre-tensioning jacks GF 94215 3 Nut HP hoses GF 94215K Connection block 94934...
  • Page 154 2708−2/A1 Maintenance RT-flex58T-D Loosening and Tensioning of Cylinder Cover Elastic Bolts Where it is found that a nut of the elastic stud can be turned considerably less than the others, it must be assumed that the respective studs has become insufficiently tensioned.

  • Page 155: Machining Of Sealing Face For Injection Valve

    2708−3/A1 RT-flex58T-D Maintenance Cylinder Cover Machining of Sealing Face for Injection Valve Tools: Key to Illustrations: 1 Overhauling device 94270 1 Cylinder cover 6 Centring mandril 2 Milling cutter holder 7 Screw 3 Guide flange 4 Setscrews 5 Profiling cutter DP Depository for screw General The seat sealing face in the cylinder cover must be clean and undamaged as the...
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  • Page 157: 2722−1/A1

    2722−1/A1 RT-flex58T-D Maintenance Injection Valve Checking, Dismantling, Assembling and Adjusting Tools: Key to Illustrations: 1 Protection cap 94271 1 Injection valve 14 Nozzle body 1 OBEL test bench 94272 2 Allen screw 15 Retaining sleeve 1 Connecting piece 94272b 3 Spring plate 16 Snap ring 4 Cup spring packet 17 Dowel pin...
  • Page 158 2722−1/A1 Maintenance RT-flex58T-D 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. From time to time check the pressure gauges of the test bench with a master pres- CHECK sure gauge and adjust them if necessary.
  • Page 159 2722−1/A1 RT-flex58T-D 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: Fuel will spray mainly from the holes in the first level of the nozzle tip at the specified opening pressure.
  • Page 160 2722−1/A1 Maintenance RT-flex58T-D Injection Valve: Checking, Dismantling, Assembling and Adjusting Dismantling an injection valve ⇒ Remove receiver 22. ⇒ Screw down the injection valve on support 20 of test bench 94272, as men- tioned, however without connecting HP hose 21 to the injection valve. ⇒...
  • Page 161 2722−1/A1 RT-flex58T-D Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting I - I II - II 015.743/07 DESIGNATION OF NOZZLE TIP MANUFACTRER x ID‐NO. x EXECUTION x CHARG. NO. 2013-08 5/ 8 Winterthur Gas & Diesel Ltd.
  • Page 162 2722−1/A1 Maintenance RT-flex58T-D Injection Valve: Checking, Dismantling, Assembling and Adjusting Adjusting the opening pressure ⇒ Install the injection valve in the test bench as described in section 2. ⇒ The opening pressure of the injection valve can be set by adjusting spring ten- sioner 7.
  • Page 163 2722−1/A1 RT-flex58T-D Maintenance Injection Valve: Checking, Dismantling, Assembling and Adjusting Arrangement of cup spring packet − Cup spring packet 4 consists of three packs com- posed of five cup springs which are arranged and fitted in spring cage 24 as shown in Fig. ‘D’ . Remark: The spring cage forms a unit and therefore its bush and bottom are diagonally tack welded.
  • Page 164 2722−1/A1 Maintenance RT-flex58T-D Injection Valve: Checking, Dismantling, Assembling and Adjusting Protecting a nozzle tip Remark: To protect the nozzle tip integrated in the injection valve against damage, always fit protection cap 94271 for transport, storage, etc. 94271 Storage and handling of injection valve Store an injection valve in a dry place but not in a place contaminated with exhaust gases or any other corrosive atmosphere.
  • Page 165 2728−1/A1 RT-flex58T-D Maintenance Starting Air Valve Removal, Fitting and Dismantling, Grinding-in and Assembling Tools: Key to Illustrations: 2 Jacking screws 1 Nut 12 Joint ring 2 Cover 13 Control valve 3 Intermediate ring 14 Connecting pipe 4 Casing 15 O-ring 5 O-ring to casing 16 Piston ring 6 Cylinder cover...
  • Page 166 2728−1/A1 Maintenance RT-flex58T-D Starting Air Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling ⇒ Loosen self-locking nut 7 with a socket spanner, and remove it. ⇒ Pull piston 8 and compression spring 11 from the casing. ⇒ Lift casing 4 up over valve spindle 9. Grinding-in Slightly damaged seat faces may be ground in (lapped) manually.
  • Page 167 2728−1/A1 RT-flex58T-D Maintenance Starting Air Valve: Removal, Fitting and Dismantling, Grinding-in and Assembling I - I III - III IV - IV 003.305/00 2013-02 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 169: Relief Valve For Cylinder Cover

    2745−1/A1 RT-flex58T-D Maintenance Relief Valve for Cylinder Cover Checking Blow-off Pressure Tools: Key to Illustrations: 1 OBEL test bench 94272 1 Cylinder cover 9 Allen screw M20x70 1 Valve holder 94272C 2 Relief valve 10 Receiver 1 HP oil pump 94931 3 Indicator valve 2 Hydr.
  • Page 170 2745−1/A1 Maintenance RT-flex58T-D Relief Valve: Checking Blow-off Pressure Checking blow-off pressure For checking relief valve 2 use test bench 94272 and test & calibration fluid (see specification in 2722−1) 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 171: Exhaust Valve

    2751−1/A1 RT-flex58T-D Maintenance Exhaust Valve Removal and Fitting of Exhaust Valve, Replacing of Elastic Studs Tools: Key to Illustrations: 1 Dismantling tool 94008A−M68 1 Elastic stud 6 Expansion piece 2 Pre-tensioning jacks 94252 2 Nut 7 Protection pipe 1 Valve protector 94262 3 Valve cage 1 Wire rope sling...
  • Page 172 2751−1/A1 Maintenance RT-flex58T-D Removal and Fitting of Exhaust Valve, Replacing of Elastic Studs Removal ⇒ Remove all connected pipes. ⇒ Removal of hydraulic pipe see 8460−1. Dismantling the expansion piece ⇒ Expansion piece 6 has to be removed with the aid of lifting lugs 94811 and the wire rope sling GF 94333D.
  • Page 173 2751−1/A1 RT-flex58T-D Maintenance Removal and Fitting of Exhaust Valve, Replacing of Elastic Studs Fitting Before fitting the exhaust valve into the cylinder cover, the sealing surfaces must be checked for cleanliness and possible damage. Make sure that the soft iron gasket of 2 mm thickness lies flat in its recess in the cylinder cover.
  • Page 174 2751−1/A1 Maintenance RT-flex58T-D Removal and Fitting of Exhaust Valve, Replacing of Elastic Studs Replacement of elastic studs When fitting a new elastic stud (in the following text called stud for short) of the cyl- inder cover or exhaust valve cage, the instructions hereafter must be strictly ob- served.
  • Page 175 2751−1/A1 RT-flex58T-D Maintenance Removal and Fitting of Exhaust Valve, Replacing of Elastic 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 Silcoset Silcoset...
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  • Page 177: Dismantling And Assembling

    2751−2/A1 RT-flex58T-D Maintenance Exhaust Valve Dismantling and Assembling Tools: Key to Illustrations: 1 Depth gauge 94124 1 Valve cage 21 Guide bush 1 Pressure element GF 94259 2 Lower housing 22 Rod seal ring 2 Jack screws 94263 3 Nut 23 Valve seat 4 Screw 24 Screw plug...
  • Page 178 2751−2/A1 Maintenance RT-flex58T-D Exhaust Valve: Dismantling and Assembling WCH00736 2013 / V2 2/ 9 Winterthur Gas & Diesel Ltd.
  • Page 179 2751−2/A1 RT-flex58T-D 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 180 2751−2/A1 Maintenance RT-flex58T-D 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 (Fig. ’B’). ⇒ Withdraw guide bush 21 from valve cage 1 by means of jack screws 94263. Check and measure the inner diameter of the guide bush according to Clearance CHECK Table...
  • Page 181 2751−2/A1 RT-flex58T-D 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 182 2751−2/A1 Maintenance RT-flex58T-D 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 183 2751−2/A1 RT-flex58T-D Maintenance Exhaust Valve: Dismantling and Assembling Damper Setting You set the damper 32, Fig. I only after you replace a valve spindle or valve seat, or after one of the seating faces is ground. ⇒ Remove the damper 32. ⇒...
  • Page 184 2751−2/A1 Maintenance RT-flex58T-D 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 185 2751−2/A1 RT-flex58T-D 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 32 (Fig. ’B’) can be removed and the exhaust valve blocked in open posi- tion by means of pressure element GF 94259.
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  • Page 187: Replacing And Grinding The Valve Seat

    2751−3/A1 RT-flex58T-D 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 94279 3 O-ring RC Eye bolt...
  • Page 188 2751−3/A1 Maintenance RT-flex58T-D 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 189 2751−3/A1 RT-flex58T-D 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 190 2751−3/A1 Maintenance RT-flex58T-D 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 191 2751−3/A1 RT-flex58T-D Maintenance Exhaust Valve: Replacing and Grinding the Valve Seat Checking the valve seat After grinding it is necessary to check whether the new or re-ground valve makes CHECK 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 193: Grinding The Seating Surface On The Valve Head

    2751−4/A1 RT-flex58T-D 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. Valves which have had the seating surfaces badly damaged by pitting or corrosion have to be reground by machine.

  • Page 194: 2751−4/A1

    2751−4/A1 Maintenance RT-flex58T-D 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 with marking blue with the valve on the reground valve seat in the valve cage will show only a line contact or a very narrow band (extent of contact) starting from the smaller diameter as shown in Fig.

  • Page 195: Crankshaft, Connecting Rod And Piston

    Group3 RT-flex58T-D Maintenance Crankshaft, Connecting Rod and Piston Group 3 Crankshaft: Measuring Crank Deflection ........3103−1/A1 Vibration Damper −...
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  • Page 197: Crankshaft Measuring Crank Deflection

    3103−1/A1 RT-flex58T-D Maintenance Crankshaft Measuring Crank Deflection Tool: Key to Illustrations: 1 Crankshaft checking equipment 94305 1 Flywheel (dial gauge) 2 Pinion General Regular crankweb deflection measurements according to the intervals defined by the class rules are sufficient. Detailed alignment measurements might become ne- cessary only in case of abnormalities, like −...
  • Page 198 3103−1/A1 Maintenance RT-flex58T-D 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 199 3103−1/A1 RT-flex58T-D 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 cause has to be found and the necessary remedial measures taken (defective main bearing, engine stay altered due to hull deformation, loose holding-down bolts, defective propeller shaft bearings or checking equipment 94305, etc.).
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  • Page 201: Vibration Damper

    3130−1/A1 RT-flex58T-D Maintenance Vibration Damper Taking a Silicone Fluid Sample Key to Illustrations: 1 Casing trough 7 Crankshaft 2 Casing cover 8 Cap nut 3 Screw plug 4 O-ring 5 Sealing ring KS Secured by centre punch mark 6 Coupling bolt PB Sample container General Viscous vibration dampers manufactured by Hasse &...
  • Page 202 3130−1/A1 Maintenance RT-flex58T-D 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 203 3130−1/A1 RT-flex58T-D Maintenance Taking a Silicone Fluid Sample SAMPLE CONTAINERS Metaldyne and STE 3/8”BSF (M16) HASSE & WREDE M10x1 M10x1 5/16”BSF (M10) 007.964/97 If a sample is not obtained by the method described, proceed as follows: Leave sample container in position. ⇒...
  • Page 204 3130−1/A1 Maintenance RT-flex58T-D 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 Fax: +49 30 70 09 0835 Remark: Samples taken on dampers manufactured by STE Schwingungstechnik have to be sent to Hasse &...

  • Page 205: Inspection (Geislinger Vibration Damper)

    3130−2/A1 RT-flex58T-D Maintenance Vibration Damper Inspection (GEISLINGER Vibration Damper) Key to Illustrations: 1 Damper casing 6 Coupling bolt 2 Vent nozzles 7 Torsiograph drive 3 Sealing rings 8 Vibration damper 4 Oil supply piping 9 Sealing ring 5 Crankshaft General Depending on the design execution of an engine, a vibration damper of GEIS- LINGER make may be mounted at the free end of the crankshaft.
  • Page 206 3130−2/A1 Maintenance RT-flex58T-D Inspection (GEISLINGER Vibration Damper) FREE END OIL SUPPLY 002.493/96 DRAWN FOR STEEL SPRING DAMPER 000.940/93 2013 2/ 2 Winterthur Gas & Diesel Ltd.

  • Page 207: Axial Damper Dismantling And Assembling

    3140−1/A1 RT-flex58T-D Maintenance Axial Damper Dismantling and Assembling Tools: Key to Illustrations: 1 Manual ratchet (WLL 2500 kg) 94016E 1 Upper part of cylinder 12 Orifice 2 RUD-eye bolts M16 94040-M16 2 Lower part of cylinder 13 Oil inlet pipe 1 Support 94320 3 Bolt M20x150...
  • Page 208 3140−1/A1 Maintenance RT-flex58T-D Axial Damper: Dismantling and Assembling ⇒ Loosen screws 19 and remove housing 10. ⇒ Pull out both taper pins 11 locating the upper and lower part of cylinder 1 and 2. ⇒ Remove all screws 5 and 3 (Fig. ’B’). ⇒...
  • Page 209 3140−1/A1 RT-flex58T-D Maintenance Axial Damper: Dismantling and Assembling ⇒ Fasten support 94320 to the face of the free end of the engine. ⇒ Screw two RUD-eye bolts 94040−M16 into the upper part of cylinder 1, then join these by means of wire rope sling GF 94333D to manual ratchet 94016E. ⇒...
  • Page 210 3140−1/A1 Maintenance RT-flex58T-D 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 6 and 7 due to contamination must be replaced. See also 3146−1 ’Monitoring system’...

  • Page 211: Turning Gear Checking The Toothing

    3206−1/A1 RT-flex58T-D 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 212 3206−1/A1 Maintenance RT-flex58T-D 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 213: Crankcase: Utilization Of Working Platform

    3301−1/A1 RT-flex58T-D Maintenance Crankcase Utilization of Working Platform Tools: Key to Illustrations: 2 Working platforms, 94142 1 Engine longitudinal beam consisting of 2 grids each 2 Crank web 2 Working supports 94143 3 Step 4 Strap To avoid accidents, the grids of working platform 94142 and working supports 94143 should be used for inspections or work in the crankcase.
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  • Page 215: Connecting Rod

    3303−1/A1 RT-flex58T-D Maintenance Connecting Rod Loosening and Tensioning the Connecting Rod Studs Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Connecting rod 2 Pre-tensioning jacks 94314 2 Bottom end bearing 2 Pre-tensioning jacks 94315 3 Top end bearing 1 Hydr. distributor 94934A 4 Stud of bottom end bearing 1 HP hose...

  • Page 216: Loosening And Tensioning The Connecting Rod Studs

    3303−1/A1 Maintenance RT-flex58T-D Loosening and Tensioning the Connecting Rod Studs Loosening and tensioning the connecting rod studs Bottom end bearing Tighten the nuts with a round bar and equally distribute clearance ’y’ between the bearing halves (bearing protrusion) as shown in Fig. A. Tensioning of the studs of bottom end bearing 4 must be carried out in two steps without exception, i.e.

  • Page 217: Inspection, Removal And Fitting Of Bottom End Bearing

    3303−2/A1 RT-flex58T-D Maintenance Connecting Rod Inspection, Removal and Fitting of Bottom End Bearing Tools: Key to Illustrations: 2 Handle screws 94009-M8 1 Connecting rod stud 3 Manual ratchets 94016, A, D (H1...H3) 2 Nut ≥ 3 Crank (WLL 800 kg) 2 RUD-eye bolts 94040-M30 (RC) 4 Bearing cover...
  • Page 218 3303−2/A1 Maintenance RT-flex58T-D Inspection, Removal and Fitting of Bottom End Bearing Inspection of bearing shell Lower bearing cover 4 (see paragraph 1.1). ⇒ Turn the crankshaft to T.D.C. ⇒ Insert four retaining pins 94323 into the bore of guide ways 6. ⇒...
  • Page 219 3303−2/A1 RT-flex58T-D Maintenance Inspection, Removal and Fitting of Bottom End Bearing Removal of bearing cover Remark: Only with a lifting tool having at least 3.5 m hoisting capacity, instead of manual ratchet ’H1’, the bearing cover can be removed directly from the crankcase bottom (Fig.
  • Page 220 3303−2/A1 Maintenance RT-flex58T-D Inspection, Removal and Fitting of Bottom End Bearing Fitting Fitting of the bearing shells and bearing cover is carried out analogous to removal but in reverse sequence. The running surfaces have to be lavishly smeared with clean bearing oil. Tensioning of connecting rod studs must be carried out according to 3303−1.

  • Page 221: Inspection, Removal And Fitting Of Top End Bearing

    3303−3/A1 RT-flex58T-D Maintenance Connecting Rod Inspection, Removal and Fitting of Top End Bearing Tools: Key to Illustrations: 2 Handle screws 94009−M8 1 Elastic stud 12 Guide segment 2 Manual ratchets (WLL ≥ 94016, D (H1) 2 Nut 13 Threaded hole M30 800 kg) 2 Manual ratchets (WLL 2500 kg) 94016E (H2)
  • Page 222 3303−3/A1 Maintenance RT-flex58T-D Inspection, Removal and Fitting of Top End Bearing ⇒ Turn crankshaft to B.D.C.. ⇒ Fit a RUD-eye bolt ’RC2’ on each side of the connecting rod head (threaded hole 13) and tighten it with 190 Nm. ⇒ Fasten manual ratchets ’H1’ with shackles 94572C to the column and connect them with RUD-eye bolts ’RC2’.
  • Page 223 3303−3/A1 RT-flex58T-D Maintenance Inspection, Removal and Fitting of Top End Bearing Removal of bearing shell ⇒ Swing the connecting rod with manual ratchets ’H1’ to fuel side, ensuring that it will not tilt back to exhaust side. ⇒ Remove manual ratchet ’H1’ on fuel side and swing connecting rod to the position as shown in the figure below.
  • Page 224 3303−3/A1 Maintenance RT-flex58T-D Inspection, Removal and Fitting of Top End Bearing Fitting Fitting of the bearing shell and bearing cover (see 3303−5) is carried out analo- gously but in reverse sequence to the removal. The running surfaces have to be lavishly smeared with clean bearing oil. Tensioning of the elastic studs must be carried out according to 3303−1.
  • Page 225 3303−3/A1 RT-flex58T-D Maintenance Inspection, Removal and Fitting of Top End Bearing Fitting the bearing shell The surface of the crosshead pin must be in perfect condition. The contact surfaces of the shell rear side and the bearing bore must be free from any damage.
  • Page 226 3303−3/A1 Maintenance RT-flex58T-D Inspection, Removal and Fitting of Top End Bearing Post lubrication of connecting rod bearing In order to further reduce the risk of dry running on newly fitted bearing shells, con- necting flange 94336 can be fitted after removing the oil pressure pipe ’DL’ to the crosshead bearing as shown in figure below.

  • Page 227: Removal And Fitting

    3303−4/A1 RT-flex58T-D Maintenance Connecting Rod Removal and Fitting Tools: Key to Illustrations: 2 Manual ratchets (WLL 1600 kg) 94016A (H2) 1 Crankpin 2 Manual ratchets (WLL 2500 kg) 94016E (H1) 2 Connecting rod 1 Spur-geared chain block 94017A (H3) 3 Bottom end bearing (WLL 3000 kg) 4 Piston rod 6 RUD-eye bolts (RC1)
  • Page 228 3303−4/A1 Maintenance RT-flex58T-D Removal and Fitting VIEW I −> Piston suspended to cylinder block: 94040−M20 (RC1) GF 94333B GF 94333A 94040-M20 (RC1) WCH01031 VIEW II −> Stop plate mounted and top end bearing cover locked against tilting: 94040−M30 (RC2) GF 94335 94040−M20 (RC1) WCH00390 VIEW III −>...
  • Page 229 3303−4/A1 RT-flex58T-D Maintenance Removal and Fitting Removal Loosen and remove the nuts of the top end bearing according to 3303−1. ⇒ Connect manual ratchets ’H1’ to RUD-eye bolts ’RC1’ in cylinder block 10 and guide shoe middle part 8. ⇒ Tighten RUD-eye bolts ’RC2’ to connecting rod 2 with 330 Nm. ⇒...
  • Page 230 3303−4/A1 Maintenance RT-flex58T-D Removal and Fitting Working platforms 94142 must be removed before tilting the connecting rod and turning the crankshaft. ⇒ Tilt the connecting rod about 20_ towards fuel side by pulling manual ratchet ’H2’ and slackening manual ratchet ’H2a’. ⇒...
  • Page 231 3303−4/A1 RT-flex58T-D Maintenance Removal and Fitting ⇒ Turn the crankshaft anticlockwise until the crankpin is 90_ before T.D.C. ⇒ While constantly turning crankshaft anticlockwise until the crankpin is approx. 45_ before T.D.C. tighten manual ratchet ’H2’ until the connecting rod is pro- truding from the engine.
  • Page 232 3303−4/A1 Maintenance RT-flex58T-D Connecting Rod: Removal and Fitting ⇒ Partially dismount holder 94334 (fastening shaft and threaded rod M24x451) and mount connecting element 94334A to the remaining holder part as shown below. ⇒ Attach manual ratchet ’H2a’ with round sling 94049A to the shackle of the con- necting element.
  • Page 233 3303−4/A1 RT-flex58T-D Maintenance Connecting Rod: Removal and Fitting Fitting Fitting the connecting rod is carried out analogously to the removal, but in reverse sequence, whereby attention must be paid to the instructions 3303−1 to 3303−3. For the assembly bearings and bearing pins must be in perfect condition. They must be smeared lavishly with fresh bearing oil.
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  • Page 235: Removal Of Bearing Cover To Top End Bearing

    3303−5/A1 RT-flex58T-D Maintenance Connecting Rod Removal of Bearing Cover to Top End Bearing Tools: Key to Illustrations: 1 Manual ratchet (WLL 800 kg) 94016 (H3) 1 Piston rod 1 Manual ratchet (WLL 2500 kg) 94016E (H1) 2 Cylinder block 2 Manual ratchets (WLL 250 kg) 94016G (H2) 3 Elastic stud 2 Eye bolts...
  • Page 236 3303−5/A1 Maintenance RT-flex58T-D Removal of Bearing Cover to Top End Bearing ⇒ Fasten wire rope sling GF 94333D with shackles 94572I to the column and connect it with manual ratchet ’H1’. ⇒ Screw eye bolts ’RC’ into bearing cover 5. ⇒...
  • Page 237 3303−5/A1 RT-flex58T-D Maintenance Removal of Bearing Cover to Top End Bearing ⇒ Fasten manual ratchet ’H2’ with round sling 94049A to the column. ⇒ Remove bearing cover 5 from the crankcase using manual ratchets ’H2’ and ’H3’. Fitting Fitting of the bearing cover is carried out analogously to the removal but in reverse sequence.
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  • Page 239: Checking The Clearances And Fitting The Guide Shoes

    3326−1/A1 RT-flex58T-D Maintenance Crosshead Checking the Clearances and Fitting the Guide Shoes Tools: Key to Illustrations: 1 Feeler gauge 94238 1 Crosshead pin 6 Guide rail 2 Guide shoe 7 Middle part 3 Guide shoe 8 Screw 4 Guide way in engine column 9 Screw 5 Top end bearing 10 Retaining cover...
  • Page 240 3326−1/A1 Maintenance RT-flex58T-D Checking the Clearances and Fitting the Guide Shoes Checking the clearances Clearance Clearances between guide shoes and guide ways: The corresponding crankpin must stand in such a position that guide shoes 2 lie on guide ways 4 on fuel or exhaust side.
  • Page 241 3326−1/A1 RT-flex58T-D Maintenance Checking the Clearances and Fitting the Guide Shoes Fitting the guide shoes The lubricating oil bores in guide shoes 2 and 3 are different in design. Therefore, guide shoe 2 must not be replaced with guide shoe 3 and vice versa nor ex- changed! Guide rails 6 are screwed on fuel side only! Attention must be paid when mounting a guide shoe onto middle part 7 so that...
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  • Page 243: Removal And Fitting Of A Crosshead Pin

    3326−2/A1 RT-flex58T-D Maintenance Crosshead Removal and Fitting of a Crosshead Pin Tools: Key to Illustrations: 1 Manual ratchet (WLL 800 kg) 94016 (H1) 1 Crank 2 Manual ratchets (WLL 1000 kg) 94016D (H2, H3) 2 Connecting rod 1 Manual ratchet (WLL 2500 kg) 94016E (H4) 3 Piston rod 1 Manual ratchet (WLL 250 kg)
  • Page 244 3326−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Crosshead Pin Two RUD-eye bolts ’RC1’ tightened to cylinder block with 115 Nm (Fig. ’E’). RUD-eye bolts ’RC2’ tightened to either side of connecting rod 2 with 330 Nm. Wire rope sling GF 94333D attached by means of shackles 94572I to the middle lifting lugs in the column.
  • Page 245 3326−2/A1 RT-flex58T-D Maintenance Removal and Fitting of a Crosshead Pin Removal of crosshaed pin ⇒ Secure the connecting rod with manual ratchets ’H2’ and ’H3’ attached to RUD-eye bolts ’RC2’ (Fig. ’B’). ⇒ Lift off crosshead pin 4 using manual ratchet ’H4’. ⇒...
  • Page 246 3326−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Crosshead Pin ⇒ Secure guide shoe middle parts 6, 6a with manual ratchets ’H2’ and ’H3’ con- nected to RUD-eye bolts RC1. ⇒ Remove end covers 9, 9a. ⇒ Retract guide shoe middle parts form crosshead pin 4 and lift them beyond the crosshead pin.
  • Page 247 3326−2/A1 RT-flex58T-D Maintenance Removal and Fitting of a Crosshead Pin ⇒ Mount deviation pipe GF 94117A on the column. ⇒ Turn crosshead pin by 90_ and remove it from column using manual ratchets ’H4’ and spur-geared chain block ’H6’. ⇒ Lower guide shoe middle parts 6, 6a and remove it from column using manual ratchets ’H1’, ’H2’...
  • Page 248 3326−2/A1 Maintenance RT-flex58T-D Removal and Fitting of a Crosshead Pin Fitting Fitting procedure is analogous to the removal, but in reverse sequence. Fit only crosshead pins which have a perfect, undamaged running surface. For fitting the guide shoes see 3326−1. Before fitting the crosshead pin clean all guide and bearing surfaces carefully and smear them lavishly with bearing oil.

  • Page 249: Removal And Fitting

    3403−1/A1 RT-flex58T-D Maintenance Piston Removal and Fitting Tools: Key to Illustrations: 1 Feeler gauge 94122 1 Piston crown 13 Securing screw 1 Piston ring tensioning device 94338 (94338A) 2 Piston skirt 14 Platform support 1 Suspension device 94341 3 Piston rod 15 Support 1 Insertion funnel GF 94342...
  • Page 250 3403−1/A1 Maintenance RT-flex58T-D Piston: Removal and Fitting Loosening and tensioning the elastic studs of piston rod foot fastening Please refer to General Application Instructions 9403−4 for hydraulic pre-tension- ing jacks. Tensioning of elastic studs 6 must be carried out in two steps without excep- tion, i.e.
  • Page 251 3403−1/A1 RT-flex58T-D Maintenance Piston: Removal and Fitting Removal of piston 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). Fit locking devices GF 94343 in order to prevent the cylinder liner from being lifted when the piston is pulled out (for the relevant details see also Fig.
  • Page 252 3403−1/A1 Maintenance RT-flex58T-D Piston: Removal and Fitting ⇒ Fasten piston supporting device 94350 to platform supports 14 at the upper platform. ⇒ Pull piston by crane out of cylinder liner. ⇒ Loosen screwed connection 17 and push supports 15 of piston supporting de- vice 94350 completely outwards and turn up hinged covers 18.
  • Page 253 3403−1/A1 RT-flex58T-D Maintenance Piston: Removal and Fitting When the piston has to be dismantled, it must be secured against turning when loosening elastic screws 11, whereby the procedure is as follows: ⇒ Lower the piston until access is obtained to securing screws 13. ⇒...
  • Page 254 3403−1/A1 Maintenance RT-flex58T-D 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 255 3403−1/A1 RT-flex58T-D 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 17 (Fig. ’E’) and push both supports 15 outwards. Then lift the piston including piston rod gland 8 so far that the two hinged covers 18 can be GF 94343 turned up.
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  • Page 257: Changing The Compression Shims

    3403−2/A1 RT-flex58T-D Maintenance Piston Changing the Compression Shims Tools: Key to Illustrations: 2 RUD-eye bolts 94040−M20 1 Cylinder block 5 Allen screw 1 Working platform 94142 2 Piston rod 6 Compression shim 2 Lifting bosses GF 94333A 3 Piston rod foot 7 Elastic stud 2 Suspension chains GF 94333B...
  • Page 258 3403−2/A1 Maintenance RT-flex58T-D Piston: Changing the Compression Shims ⇒ Turn crank upwards to exhaust side until suspension chains GF 94333B can be put into lifting bosses GF 94333A. The crank may be turned max. 30_ towards T.D.C. GF 94333B ⇒ Carefully turn crank downwards until elastic GF 94333A studs 7 are cleared from piston rod foot 3.

  • Page 259: Dismantling And Assembling

    3403−3/A1 RT-flex58T-D Maintenance Piston Dismantling and Assembling Tools: Key to Illustrations: 1 Suspension device 94341 1 Piston crown 8 Centering pin 1 Piston supporting device 94350 2 Spraying plate with oil pipe 9 Screw 2 Jacking screws 94363 2a Spraying nozzle 10 Locating pin 2 Jacking screws 94364...
  • Page 260 3403−3/A1 Maintenance RT-flex58T-D Piston: Dismantling and Assembling Assembling of a piston For assembling the piston the following points must be observed: Damaged spraying nozzles 2a may under no circumstances be reused. New ones must be fitted with liquid securing agent LOCTITE No. 0648. Whenever possible always use new O-rings, they must conform in dimen- sions and quality to our specifications.
  • Page 261 3403−3/A1 RT-flex58T-D Maintenance Piston: Dismantling and Assembling I - I II - II 003.708/95 IV - IV 003.708/95 003.708/95 V - V 003.708/95 003.708/95 2013 3/ 4 Winterthur Gas & Diesel Ltd.
  • Page 262 3403−3/A1 Maintenance RT-flex58T-D Piston: Dismantling and Assembling 94341 SEPARATING THE PISTON CROWN 94363 003.513/00 94350 SEPARATING THE PISTON SKIRT 94364 003.513/00 003.513/00 2013 4/ 4 Winterthur Gas & Diesel Ltd.

  • Page 263: Checking Piston Top Surface

    3403−4/A1 RT-flex58T-D Maintenance Piston Checking Piston Top Surface Tools: 1 Feeler gauge 94122 1 Template 94366 1 Template 94366A Every time a piston is pulled out, the piston top surface contour must be checked CHECK with template 94366 and with feeler gauge 94122. The template is placed on the topmost piston ring and rotated around the piston axis (see Fig.
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  • Page 265: Piston Rings

    3425−1/A1 RT-flex58T-D Maintenance Piston Rings Checking Wear of Piston Rings and Ring Grooves with Four Piston Rings Tools: Key to Illustration: 1 Inside micrometer 94101 1 Piston ring 1 Feeler gauge 94122 2 Cylinder liner 1 Piston ring tensioning device 94338 3 Piston head 4 Claw...
  • Page 266 3425−1/A1 Maintenance RT-flex58T-D Checking Wear of Piston Rings and Ring Grooves with Four Piston Rings Measure coating thickness with piston in situ (through scavenge ports) Before each measurement the layer measurement tool 94356 must be calibrated. Use the delivered calibration foils and the bare top flank of a spare top piston ring as base material for proper setting.
  • Page 267 3425−1/A1 RT-flex58T-D Maintenance Checking Wear of Piston Rings and Ring Grooves with Four Piston Rings Lifetime calculation Calculate the wear rate and the remaining lifetime of a piston ring. Use the formula below to calculate the wear rate: WR = (D1−D2) x 1000 T2−T1 WR = Wear rate [mm/1000 h] T2 = Actual running hours [h]...
  • Page 268 3425−1/A1 Maintenance RT-flex58T-D Checking Wear of Piston Rings and Ring Grooves with Four Piston Rings Measuring piston ring grooves Check all dimensions and record them (see Clearance Table 0330−1 ’Piston and CHECK piston rings’). These records are important for later evaluation of the running gear. They should encompass all dimensions, the date of overhaul and operating hours of the various components and of the engine itself.
  • Page 269 3425−1/A1 RT-flex58T-D Maintenance Checking Wear of Piston Rings and Ring Grooves with Four Piston Rings Measurement with piston removed from cylinder liner The measurement of the piston ring clearance has to be carried out on at least four positions around the complete circumference of the piston head. ⇒...
  • Page 270 3425−1/A1 Maintenance RT-flex58T-D Checking Wear of Piston Rings and Ring Grooves with Four Piston Rings Removing piston rings For removing piston rings 1, always use the corresponding tensioning device with its specially designed claws 4 preventing the coating from being chipped off at the ring ends.
  • Page 271 3425−1/A1 RT-flex58T-D Maintenance Checking Wear of Piston Rings and Ring Grooves with Four Piston Rings 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. Always fit piston ring with the marking TOP upwards (when the piston is assembled the piston rings must be turned such that the ring gaps are staggered by 180_).
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  • Page 273 3425−1/A2 RT-flex58T-D Maintenance Piston Rings Checking Wear of Piston Rings and Ring Grooves with Three Piston Rings Tools: Key to Illustration: 1 Inside micrometer 94101 1 Piston ring 1 Feeler gauge 94122 2 Cylinder liner 1 Piston ring tensioning device 94338 3 Piston head 2 Claws for gastight piston ring...
  • Page 274 3425−1/A2 Maintenance RT-flex58T-D Checking Wear of Piston Rings and Ring Grooves with Three Piston Rings Measure coating thickness with piston in situ (through scavenge ports) Before each measurement the layer measurement tool 94356 must be calibrated. Use the delivered calibration foils and the bare top flank of a spare top piston ring as base material for proper setting.
  • Page 275 3425−1/A2 RT-flex58T-D Maintenance Checking Wear of Piston Rings and Ring Grooves with Three Piston Rings Lifetime calculation Calculate the wear rate and the remaining lifetime of a piston ring. Use the formula below to calculate the wear rate: WR = (D1−D2) x 1000 T2−T1 WR = Wear rate [mm/1000 h] T2 = Actual running hours [h]...
  • Page 276 3425−1/A2 Maintenance RT-flex58T-D Checking Wear of Piston Rings and Ring Grooves with Three Piston Rings Measuring piston ring grooves Check all dimensions and record them (see Clearance Table 0330−1 ’Piston and CHECK piston rings’). These records are important for later evaluation of the running gear. They should encompass all dimensions, the date of overhaul and operating hours of the various components and of the engine itself.
  • Page 277 3425−1/A2 RT-flex58T-D Maintenance Checking Wear of Piston Rings and Ring Grooves with Three Piston Rings Measurement with piston removed from cylinder liner The measurement of the piston ring clearance has to be carried out on at least four positions around the complete circumference of the piston head. ⇒...
  • Page 278 3425−1/A2 Maintenance RT-flex58T-D Checking Wear of Piston Rings and Ring Grooves with Three Piston Rings Removing piston rings For removing piston rings 1, always use the corresponding tensioning device with its specially designed claws 4 preventing the coating from being chipped off at the ring ends: Claws 94338A must be fitted onto piston ring tensioning device for the 1 gastight...
  • Page 279 3425−1/A2 RT-flex58T-D Maintenance Checking Wear of Piston Rings and Ring Grooves with Three Piston Rings 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. Always fit piston ring with the marking TOP upwards (when the piston is assembled the piston rings must be turned such that the ring gaps are staggered by 180_).
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  • Page 281: Driving Wheels And Shut-Off Valve For Starting Air

    Group4 RT-flex58T-D 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 Crankshaft ....... 4103−3/A1 Shut-off Valve for Starting Air: Cleaning and Function Check .
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  • Page 283 4103−1/A1 RT-flex58T-D 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 General Gear wheels of new engines have to be checked visually during the running-in pe- riod after about 1−2 operating hours.
  • Page 284 4103−1/A1 Maintenance RT-flex58T-D 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. Always use lead wires of the same diameter and quality.

  • Page 285: Replacing The Gear Wheel On Crankshaft

    4103−3/A1 RT-flex58T-D Maintenance Driving Wheels Replacing the Gear Wheel on the Crankshaft Tools: Key to Illustrations: 1 Ring slugging wrench 94002−46 1 Gear wheel 6 Flange screw 1 Feeler gauge 94122 2 Crankshaft flange 7 Distance sleeve 1 Fork wrench 94412E 3 Elastic studs 8 Self-locking nut...
  • Page 286 4103−3/A1 Maintenance RT-flex58T-D 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 287 4103−3/A1 RT-flex58T-D 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. All surfaces must be in faultless condition.
  • Page 288 4103−3/A1 Maintenance RT-flex58T-D 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 elastic studs 3, on the 001.167/97 top (Fig.
  • Page 289 4103−3/A1 RT-flex58T-D Maintenance Replacing the Gear Wheel on the Crankshaft The elastic studs are correctly pretensioned if an extension of nL 1.10± 0.05 mm CHECK 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 291: Shut-Off Valve For Starting Air Cleaning And Function Check

    4325−1/A1 RT-flex58T-D Maintenance Shut-off Valve for Starting Air Cleaning and Function Check Key to Illustrations: 1 Valve seat 16 Handwheel 2 Cover 17 Locking lever 3 Spring 18 Common start valve 4 Valve 19 Stopper 5 Spindle 6 Spindle guide 7 Valve seat BB Balance bore 8 Valve guide...
  • Page 292 4325−1/A1 Maintenance RT-flex58T-D 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 12. ⇒ Check balance bores ’BB’ for free passage. ⇒...
  • Page 293 4325−1/A1 RT-flex58T-D 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. Screw plug 15 of the shut-off valve has to be removed.
  • Page 294 4325−1/A1 Maintenance RT-flex58T-D Shut-off Valve for Starting Air: Cleaning and Function Check By turning the spindle carefully to position OPENED, the contact with spindle guide CHECK 6 can be felt. The clearance ’S ’ can thus be determined externally and it shall be min.

  • Page 295: Supply Unit, Injection And Exhaust Valve Control Group

    Group5 RT-flex58T-D 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 297: 5552−1/A1

    5552−1/A1 RT-flex58T-D 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 5 Shaft 16 Screw 6 Pinion...
  • Page 298 5552−1/A1 Maintenance RT-flex58T-D 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. I - I 012.977/05 Removal of shaft...
  • Page 299 5552−1/A1 RT-flex58T-D 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. Clogged spray nozzles must be dismantled for cleaning.
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  • Page 301: Removal And Fitting Of Camshaft And Bearing Shells

    5552−2/A1 RT-flex58T-D 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 94566 3 Cover 17 Dowel pin...
  • Page 302 5552−2/A1 Maintenance RT-flex58T-D 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 303 5552−2/A1 RT-flex58T-D Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Removal of bearing shells ⇒ Loosen elastic 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 304 5552−2/A1 Maintenance RT-flex58T-D 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 305 5552−2/A1 RT-flex58T-D 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 306 5552−2/A1 Maintenance RT-flex58T-D 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: The camshaft can be installed in every position, however: all parts to be fitted must be clean and undamaged! for the assembly apply oil to bearing shells, thrust bearing ring halves and...
  • Page 307 5552−2/A1 RT-flex58T-D 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 308 5552−2/A1 Maintenance RT-flex58T-D Supply Unit: Removal and Fitting of Camshaft and Bearing Shells Application of torque amplifier Torque amplifier 20 must be used for tightening the elastic screws 7 to bearing cov- ers 9. The following figures ’N’ to ’X’ are drawn for 7 & 8 Cyl. engines, however, there are also shown all applications for 5 &...
  • Page 309 5552−2/A1 RT-flex58T-D 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 elastic screw 7. Backing rod 23 or 24 is drawn in the required position: −...
  • Page 310 5552−2/A1 Maintenance RT-flex58T-D Supply Unit: Removal and Fitting of Camshaft and Bearing Shells BEARING COVER NO. 3 94566C BEARING COVER NO. 4 94566C 013.072/05 2013 / V2 10/ 11 Winterthur Gas & Diesel Ltd.
  • Page 311 5552−2/A1 RT-flex58T-D Maintenance Supply Unit: Removal and Fitting of Camshaft and Bearing Shells BEARING COVER NO. 5 94566C BEARING COVER NO. 6 94566C 013.073/05 V2 / 2013 11/ 11 Winterthur Gas & Diesel Ltd.
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  • Page 313: Removing And Fitting The Gear Wheel On Camshaft

    5552−3/A1 RT-flex58T-D 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 315: Removal And Fitting

    5552−4/A1 RT-flex58T-D Maintenance Supply Unit Removal and Fitting Tools: Key to Illustrations: 2 RUD-eye bolts 94040−M16 1 Supply unit 8 Head screw 1 Lifting tool 94557 2 Fuel pump 9 Housing (for transporting SU_5, 6 Cyl.) 3 Cover 10 Spray nozzle 1 Lifting tool 94557A 4 Dowel pin...
  • Page 316 5552−4/A1 Maintenance RT-flex58T-D Removal and Fitting of Supply Unit ⇒ Screw two RUD-eye bolts 94040−M16 into housing of supply unit 1 as shown in Fig. ’D’. ⇒ Suspend lifting tool 94557 on manual ratchets ’MR’ (WLL 2000 kg each) and connect these with RUD-eye bolts.
  • Page 317 5552−4/A1 RT-flex58T-D Maintenance Removal and Fitting of Supply Unit Fitting ⇒ Connect supply unit 1 with the engine crane 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 319 5552−5/A1 RT-flex58T-D Maintenance Supply Unit Lubrication of Supply Unit During Maintenance Tools 1 Lubricating tool 94844 1 Reduction nipple 1 Adapter 1 Adapter General The engine has a manual lubrication system. This system prevents damage to the bearings and bushes of the supply unit (5, Fig. A) during dry-running of the engine. Clean system oil is used for the lubrication.
  • Page 320 5552−5/A1 Maintenance RT-flex58T-D Supply Unit Lubrication of Supply Unit During Maintenance I - I 94844 II - II WCH03859 2018−02 2/ 2 Winterthur Gas & Diesel Ltd.

  • Page 321: 5556−1/A1

    5556−1/A1 RT-flex58T-D Maintenance Fuel Pump Dismantling and Assembling Tool: Key to Illustrations: 1 Handle screw 94009−M6 1 Actuator 23 Screw 1 2-part clamping ring 94550 2 Connecting element 24 Flange 1 Fitting & dismantling device 94551 3 Screw 25 Regulating (toothed) rack 1 Cover 94552 4 Pump cover...
  • Page 322 5556−1/A1 Maintenance RT-flex58T-D 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 323 5556−1/A1 RT-flex58T-D Maintenance Fuel Pump: Dismantling and Assembling Dismantling of a fuel pump Dismantle and assemble the fuel pumps in a clean room which should be as dust-free as possible (grinding dust, 94551 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 324 5556−1/A1 Maintenance RT-flex58T-D 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 325 5556−1/A1 RT-flex58T-D 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. 013.679/05 Removal of pump cylinder ⇒...
  • Page 326 5556−1/A1 Maintenance RT-flex58T-D Fuel Pump: Dismantling and Assembling Removal of non-return valve ⇒ By means of 2-part clamping ring 94550 and the four screws M10x60 valve block 29 can be withdrawn from pump cover 4. ⇒ Remove circlip 35 with a snap ring tong. Remark: The non-return valve must be replaced as a unit only, i.e.
  • Page 327 5556−1/A1 RT-flex58T-D 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 328 5556−1/A1 Maintenance RT-flex58T-D 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. CHECK ⇒...
  • Page 329 5556−1/A1 RT-flex58T-D 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 until the stop.
  • Page 330 5556−1/A1 Maintenance RT-flex58T-D 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.

  • Page 331: Fuel Pressure Control Valve: Removal, Fitting, Dismantling And Assembling . . . . 5562−1/A1

    5562−1/A1 RT-flex58T-D 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 5 Oil pressure regulating valve 19 Intermediate ring 6 Compression spring...
  • Page 332 5562−1/A1 Maintenance RT-flex58T-D 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 333 5562−1/A1 RT-flex58T-D 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. 12 13 WCH00763 FUEL OIL...
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  • Page 335: Fuel Overpressure Safety Valve: Checking And Setting

    5562−2/A1 RT-flex58T-D 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 3 Ball 12 Receiver 2 Hydr.
  • Page 336 5562−2/A1 Maintenance RT-flex58T-D 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 337: Injection Control Unit: Removal And Fitting

    5564−1/A1 RT-flex58T-D Maintenance Injection Control Unit Removal and Fitting Tools: Key to Illustrations: 1 Lifting plate 94584 1 Piping 10 Position sensor 2 Withdrawing tools 94589 2 Hose line 11 Nipple 3 Hose line 12 Nipple 4 Fuel rail 13 Dowel pin 5 Injection control unit 14 Connecting nipple 6, 6a Screw...
  • Page 338 5564−1/A1 Maintenance RT-flex58T-D Injection Control Unit: Removal and Fitting ⇒ Fasten lifting plate 94584 onto injection control unit 5. ⇒ Remove cable plugs from pre-control valves 7 and position sensor 10. ⇒ Loosen screws 8 and remove them together with pre-control valves. ⇒...
  • Page 339 5564−1/A1 RT-flex58T-D Maintenance Injection Control Unit: Removal and Fitting Fitting ⇒ Insert lip seal 9. ⇒ Lower injection control unit 5 carefully onto the fuel rail and remove the lifting plate. ⇒ Apply Never-Seez NSBT-8 to the threads of screws 6 and 6a (Fig. ’A’). ⇒...
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  • Page 341: 5610−1/A1

    5610−1/A1 RT-flex58T-D Maintenance Pressure Reducing Valve 8.11−1 Checking the Gas Pre-charge Pressure Tool: Key to Illustrations: 1 Case 94720C 1 Hydraulic accumulator 9 Pressure reducing valve 2 Protection cap 10 Pressure transmitter consisting of: measurement set complete 3 Pressure reducing valve 11 Cable socket for checking / refilling of 4, 4a Hose (1m, 4 m)
  • Page 342 5610−1/A1 Maintenance RT-flex58T-D 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 343 5610−1/A1 RT-flex58T-D Maintenance Pressure Reducing Valve: Checking the Gas Pre-charge Pressure Case with measurement set 94720C for CLU4−C and PRV 8.11−1: Case 94720C 4, 4a Arrangement of equipment: PI2041L WCH00703 2013 3/ 4 Winterthur Gas & Diesel Ltd.
  • Page 344 5610−1/A1 Maintenance RT-flex58T-D Pressure Reducing Valve: Checking the Gas Pre-charge Pressure Pressure reducing valve 8.11−1: PRESSURE RE- FREE DUCING UNIT (4.30−5) WCH01022 1, 2 WCH00852 SERVO OIL PIPE TO 10, 11 LUBRICATING PUMPS Details of servo oil rail 4.11 −> pressure reducing valve 8.11−1 −> lubricating pump 8.06: 8.06 4.11 PI2041L...

  • Page 345: Exhaust Valve Control Unit: Removal, Fitting, Dismantling And Assembling

    5612−1/A1 RT-flex58T-D Maintenance Exhaust Valve Control Unit Removal, Fitting, Dismantling and Assembling Key to Illustrations: 1 Valve control block 15 Slide rod 2 Pipe 16 Screw plug 3 Rail valve (pre-control valve) 17 Screw 4 Screw 18 Screw plug 5 Screw 19 Filter 6 Servo oil rail 20 Screw plug...
  • Page 346 5612−1/A1 Maintenance RT-flex58T-D Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling Fitting ⇒ Place new O-ring 25 into the groove of servo oil rail 6. ⇒ Lower the complete exhaust valve control unit onto the servo oil rail. ⇒ Apply oil to screws 4 and tighten them with a torque of 170 Nm.
  • Page 347 5612−1/A1 RT-flex58T-D Maintenance Exhaust Valve Control Unit: Removal, Fitting, Dismantling and Assembling Assembling of exhaust valve control unit ⇒ All O-rings must be replaced by new ones. ⇒ The threads of all screws, piston 11 and slide rod 15 (Fig. ’C’) must be oiled prior to their fitting.
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  • Page 349: Regulating Linkage

    5801−1/A1 RT-flex58T-D 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 4 Actuator shaft 11 Spot-face 5 Lever...
  • Page 350 5801−1/A1 Maintenance RT-flex58T-D 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 351 5801−1/A1 RT-flex58T-D 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 353: 5801−1/A2

    5801−1/A2 RT-flex58T-D Maintenance Regulating Linkage Adjusting with Woodward ProAct II − Digital Actuator Tools: Key to Illustrations: 2 Spacers GF 94555A 1 Fuel pump 8 Toothed rack 2 Actuator 9 Set screw 3 Shaft 10 Self-locking nut 4 Lever 11 Mark 5 Clamping sleeve 6 Screw 7 Connecting element...
  • Page 354 5801−1/A2 Maintenance RT-flex58T-D Regulating Linkage: Adjusting with Woodward ProAct II − Digital Actuator Actuator − Align ⇒ Refer to the manufacturer’s instructions for the configuration and settings of the actuator. ⇒ Make sure that the actuator is electrically disconnected. ⇒ Make sure that the connecting element (1, Fig. B) is disconnected from the lever (4).
  • Page 355 5801−1/A2 RT-flex58T-D Maintenance Regulating Linkage: Adjusting with Woodward ProAct II − Digital Actuator 36 mm 36 mm GF 94555A 016.366/07 WCH03870 WCH03870 WCH03870 2018−02 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 357: Scavenge Air Receiver And Auxiliary Blower Group

    Group6 RT-flex58T-D 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 359: 6420−1/A1

    6420−1/A1 RT-flex58T-D Maintenance Scavenge Air Receiver Checking the Air Flaps and Cleaning the Scavenge Air Receiver Key to Illustrations: 1 Hinged cover 8 Stop plate 2 Scavenge air receiver 9 Relief valve 3 Door 10 Water drainage piping 4 Inspection cover 11 Screw 5 Fixed support (suction space) 12 Distance ring...
  • Page 360 6420−1/A1 Maintenance RT-flex58T-D Checking the Air Flaps and Cleaning the Scavenge Air Receiver 11 12 018.183/09 The air flaps 7 in scavenge air receiver and the fixed support 5 (Fig. ’A’) can be removed after the screws 11 have been unscrewed. WCH01063 Cleaning the scavenge air receiver Scavenge air receiver 2 should be checked for cleanliness at regular intervals (see...
  • Page 361 6420−1/A1 RT-flex58T-D Maintenance Checking the Air Flaps and Cleaning the Scavenge Air Receiver RELIEF VALVE WITH RELIEF VALVE WITH COMPRESSION SPRING DISC SPRINGS WCH00969 WCH00970 2013 3/ 3 Winterthur Gas & Diesel Ltd.
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  • Page 363: Auxiliary Blower Maintenance

    6545−1/A1 RT-flex58T-D Maintenance Auxiliary Blower Maintenance Tools: Key to Illustrations: 1 Spur-geared chain block 94650 1 Electric motor 6 Fixed support (WLL 1000 kg) 2 Motor plate 7 Screw 1 Dismantling device 94651 3 Spiral casing 8, 8a Screw 4 Impeller 9 Longitudinal I-beam consisting of: 1 Trolley...
  • Page 364 6545−1/A1 Maintenance RT-flex58T-D Auxiliary Blower: Maintenance Removal Remark: Pay attention to General Guidelines for Lifting Tools 0012−1. ⇒ Install trolley 94651C and spur-geared chain block 94650 (WLL 1000 kg) on the longitudinal I-beam 9. ⇒ Attach electric motor 1 to spur-geared chain block with corresponding ropes. ⇒...
  • Page 365 6545−1/A1 RT-flex58T-D Maintenance Auxiliary Blower: Maintenance Dismantling For dismantling works and maintenance of the auxiliary blower, please comply with the instructions of the manufacturer. The impeller is statically and dynamically balanced, and therefore must in no way suffer damage. The impeller must be rebalanced in case of any damaged or re- placed parts turning together with the motor shaft.
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  • Page 367: Scavenge Air Cooler

    6606−1/A1 RT-flex58T-D Maintenance Scavenge Air Cooler Cleaning (Water Side) on Engine at Standstill Tools: Key to Illustrations: Tube brushes 1 Cover 6 Cooling fins 2 Return chamber 7 Tube plate 3 Connection chamber 8 Scavenge air receiver 4 Air duct before cooler 9 Hinged cover 5 Cooling tubes 10 Drain...
  • Page 368 6606−1/A1 Maintenance RT-flex58T-D Scavenge Air Cooler: Cleaning (Water Side) on Engine at Standstill Cleaning methods The cooling tubes can be cleaned by mechanical, by hydraulic or by chemical means. Mechanical cleaning in fitted condition ⇒ First unscrew and remove the cover 1 (Fig. ’A’). ⇒...
  • Page 369 6606−1/A1 RT-flex58T-D Maintenance Scavenge Air Cooler: Cleaning (Water Side) on Engine at Standstill Locating and sealing of leaking cooler tubes in service Due to corrosion or mechanical damage tube leakages may occur. This causes cooling water to enter the air duct before cooler 4 and the scavenge air receiver 8. If it is not possible to wait with the localization or sealing of leaky cooling tubes, this can be carried out during operation.
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  • Page 371: Removal And Fitting Of Tube Stack

    6606−2/A1 RT-flex58T-D Maintenance Scavenge Air Cooler Removal and Fitting of Tube Stack Tools: Key to Illustrations: 1 Manual ratchet 94016 (H1) 1 Cover 13, 13a Screw 1 Device complete 94661 2 Return chamber 14 Packing strip consisting of: 3 Connection chamber 15 Double spring clip 1 Roller plate 94662(A)
  • Page 372 6606−2/A1 Maintenance RT-flex58T-D Scavenge Air Cooler: Removal and Fitting of Tube Stack Removal ⇒ Loosen screws 13 in cover 1. ⇒ Remove screws 13a from tube stack 12. 010.938/03 010.939/03 1 14 2013 2/ 6 Winterthur Gas & Diesel Ltd.
  • Page 373 6606−2/A1 RT-flex58T-D Maintenance Scavenge Air Cooler: Removal and Fitting of Tube Stack ⇒ Mount pin 94665 and roller 94665A on the corresponding support as shown in Fig. ’C’. Lock pin with its double spring clip 15. ⇒ Fasten manual ratchet ’H1’ to the upper support 16 and connect it to cover 1 via roller 94665A.
  • Page 374 6606−2/A1 Maintenance RT-flex58T-D Scavenge Air Cooler: Removal and Fitting of Tube Stack ⇒ Fasten pulley support 94664 to the platform support which is near connection chamber 3 (designated also as fixed side). Attach pull rope ’ZS’ of pulling tackle on roller plate and pull the tube stack out until arrester stop (see Fig. ’C’).
  • Page 375 6606−2/A1 RT-flex58T-D Maintenance Scavenge Air Cooler: Removal and Fitting of Tube Stack Fitting ⇒ Mount pulley support 94664 on the platform support nearest to the fixed side (Fig. ’E’). ⇒ With the help of the engine room crane, lower tube stack to the fitting height and fasten roller plate 94662(A) and assembling device 94663A(B).
  • Page 376 6606−2/A1 Maintenance RT-flex58T-D Scavenge Air Cooler: Removal and Fitting of Tube Stack 010.576/02 94662(A) 94663A(B) Final assembly ⇒ Screw in as much as possible of screws 5. ⇒ Push / pull tube stack 12 towards the air side by means of screws 13, 13a. ⇒...

  • Page 377: Water Separator

    6708−1/A1 RT-flex58T-D Maintenance Water Separator Maintenance of Water Separator 1-part Water Separator Tools: Key to Illustrations: 2 Manual ratchets (WLL 800 kg) 94016 (H1) 1 Receiver 10 Tension washer 2 Air flaps 11 Door 3 Water separator 12 Coupling 4 Cover on WS 13 Water drain 5 Seal 14 Cover...
  • Page 378 6708−1/A1 Maintenance RT-flex58T-D Maintenance of Water Separator 1-part Water Separator Removal ⇒ Fasten manual ratchets ’H1’ to the corresponding lugs in the receiver, connect and tighten them with the water separator. ⇒ Remove screws 15 and put both covers 14 with their air flaps 2 fitted (approx. 47 kg each) on the bottom of receiver 1.

  • Page 379: Maintenance Of Water Separator (1-Part Water Separator)

    6708−1/A1 RT-flex58T-D Maintenance Maintenance of Water Separator 1-part Water Separator Cleaning The water separator should be cleaned with the same media as used for cleaning the scavenge air cooler in operation. Do not use any sharp tools for cleaning. Fitting Before fitting the water separator, its location in the scavenge air receiver must be thoroughly cleaned and the water drains checked for free flow.
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  • Page 381 6708−1/A2 RT-flex58T-D Maintenance Water Separator Maintenance of Water Separator 2-part Water Separator Tools: Key to Illustrations: 2 Manual ratchets (WLL 800 kg) 94016 (H1) 1 Receiver 12 Screw 2 Air flaps 13 Sleeve 3 Water separator 14 Pressure spring 4 Hinged cover 15 Disc 5 Screw 16 Door...
  • Page 382 6708−1/A2 Maintenance RT-flex58T-D Maintenance of Water Separator 2-part Water Separator Removal Remark: If the water separators must be dismantled above the supply unit, the half close to the free end must be removed first! ⇒ Open hinged cover 4 and door 16 (Fig. ’A’). ⇒...

  • Page 383: Maintenance Of Water Separator 2-Part Water Separator

    6708−1/A2 RT-flex58T-D Maintenance Maintenance of Water Separator 2-part Water Separator Cleaning The water separator should be cleaned with the same media as used for cleaning the scavenge air cooler in operation. Do not use any sharp tools for cleaning. Fitting Before fitting the water separator, its location in the scavenge air receiver must be thoroughly cleaned and the water drains checked for free flow.
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  • Page 385: Cylinder Lubrication Group

    Group7 RT-flex58T-D Maintenance Cylinder Lubrication Group 7 Lubrication Pump CLU4−C: Checking the Gas Pre-charge Pressure ... 7218−1/A2 RT−flex58T−D / Pulse / MM / 2013 Winterthur Gas & Diesel Ltd. 1/ 4 Winterthur Gas &...
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  • Page 387: 7218−1/A2

    7218−1/A2 RT-flex58T-D Maintenance Lubricating Pump CLU4−C Checking the Gas Pre-charge Pressure Tool: Key to Illustrations: 1 Case (for CLU4−C) 94720C 1 Hydraulic accumulator 8 Lubricating pump (CLU4−C) 2 Protection cap 9 4/2-way solenoid valve consisting of: measurement set complete 3 Pressure reducing valve 10 Shut-off valve servo oil for checking / refilling of 4, 4a Hose (1m, 4 m)
  • Page 388 7218−1/A2 Maintenance RT-flex58T-D 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 389 7218−1/A2 RT-flex58T-D 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 / 2013 3/ 4 Winterthur Gas & Diesel Ltd.
  • Page 390 7218−1/A2 Maintenance RT-flex58T-D 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 −> lubricating pump 8.06: 8.06 4.11 PI2041L 8.11−1 4.30−5 WCH00205 DRAWN FROM CONTROL DIAGRAM 4003−2 PRESSURE REDUCING WCH00852 UNIT...

  • Page 391: Group 8

    Group8 RT-flex58T-D Maintenance Piping Group 8 Exhaust Waste Gate (Low-Load Tuning) ........8135−1/A1 HP Servo Oil Pipe: Removing, Fitting and Regrinding .
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  • Page 393: Exhaust Waste Gate (Low-Load Tuning)

    8135−1/A1 RT-flex58T-D Maintenance Exhaust Waste Gate (Low-Load Tuning) General The Low-Load Tuning provides the lowest possible Brake Specific Exhaust gas Flow (BSFC) in the operating range of 40 to 70% engine load. With Low-Load Tuning, engines can be operated continuously and reliably at any load in the range of 30 to 100%.
  • Page 394 8135−1/A1 Maintenance RT-flex58T-D Exhaust Waste Gate (Low-Load Tuning) Maintenance Butterfly valve 1 does not require special maintenance. For a general inspec- tion however, the instructions of the valve manufacturer must be followed. To carry out a function check see 8135−1 in the Operating Manual and Mainte- nance Schedule 0380−1.

  • Page 395: Hp Servo Oil Pipe Removing, Fitting And Regrinding

    8447−1/A1 RT-flex58T-D Maintenance HP Servo Oil Pipe Removing, Fitting and Regrinding Tools: Key to Illustrations: 1 Regrinding device 94834 1 Servo oil rail 10 Thrust ring 2 HP servo oil pipe 11 Non-return valve 3 HP servo oil pipe 12 Valve housing 4,4a,4b Screw 13 Connecting block 5,5a Flange...
  • Page 396 8447−1/A1 Maintenance RT-flex58T-D HP Servo Oil Pipe: Removing, Fitting and Regrinding Removal of HP servo oil pipe 3 ⇒ Loosen screws 4. ⇒ Push flanges 5 back until they are no more engaged, so that HP servo oil pipe 3 can be removed. Removal of HP servo oil pipe 2 ⇒...
  • Page 397 8447−1/A1 RT-flex58T-D Maintenance HP Servo Oil Pipe: Removing, Fitting and Regrinding Regrinding the sealing faces ’DF’ ⇒ Loosen claw 9 (Fig. ’D’). 94834 ⇒ To prevent grinding compound from entering the HP servo oil pipe, plug its opening with a piece of cloth. ⇒...
  • Page 398 8447−1/A1 Maintenance RT-flex58T-D HP Servo Oil Pipe: 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 HP servo oil pipes have been tightened! Apply oil to the threads of screws 4, 4a, 4b and tighten them crosswise with a torque of 40 Nm.

  • Page 399: Hydraulic Pipe For Exhaust Valve Drive: Removing, Fitting And Regrinding . . . . . 8460−1/A1

    8460−1/A1 RT-flex58T-D Maintenance Hydraulic Pipe for Exhaust Valve Drive Removing, Fitting and Regrinding Tools: Key to Illustrations: 1 Regrinding device 94834 1 Hydraulic pipe 9 Claw 2 Servo oil rail 10 Thrust ring 3 Screw plug 11 O-ring 4 Pre-control valve 12 O-ring 5 Exhaust valve control unit 13 Stop valve...
  • Page 400 8460−1/A1 Maintenance RT-flex58T-D Hydraulic Pipe: Removing, Fitting and Regrinding ⇒ Loosen screws 6 by several turns. ⇒ Undo screws 7 and push flange 8a back until it is no more engaged. ⇒ Push hydraulic pipe 1 back in axial direction and turn it to the side. ⇒...
  • Page 401 8460−1/A1 RT-flex58T-D Maintenance Hydraulic Pipe: Removing, Fitting and Regrinding Fitting WCH01044 Check prior to assembly if the inside of the hydraulic pipe and sealing faces ’DF’ of CHECK pipe ends are clean and undamaged and if O-rings 12 are in perfect condition. Be sure to fit objects together axially, i.e.
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  • Page 403: 8733−1/A1

    8733−1/A1 RT-flex58T-D Maintenance HP Pipe to Injection Valve Removing, Fitting and Regrinding of Sealing Faces Tools: Key to Illustrations: 1 Regrinding device 94870 1 Cylinder cover 10 Pipe bracket 2 Injection valve 11 O-ring consisting of: 1 Screw-on sleeve 94870A 3 Injection control unit 12 O-ring 1 Grinding tool...
  • Page 404 8733−1/A1 Maintenance RT-flex58T-D HP Pipe to Injection Valve: Removing, Fitting and Regrinding of Sealing Faces 2. Fitting Fitting procedure is analogous to the removal but in reverse sequence. Before fitting HP pipe 4 check whether its claws 5 are screwed on properly, i.e. the CHECK HP pipe must protrude by ’x’= 8 mm compared to the claw.
  • Page 405 8733−1/A1 RT-flex58T-D Maintenance HP Pipe to Injection Valve: 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 406 8733−1/A1 Maintenance RT-flex58T-D HP Pipe to Injection Valve: Removing, Fitting and Regrinding of Sealing Faces ⇒ Remove claw 5 (Fig. ’B’). ⇒ Fix HP pipe 4 e.g. in a vice. ⇒ Screw on counter nut 94870C until it reaches the thread end of the HP pipe.

  • Page 407: 8752−1/A1

    8752−1/A1 RT-flex58T-D Maintenance HP Fuel Pipe Removing, Fitting and Regrinding Tools: Key to Illustrations: 1 Regrinding device 94870 1 Upper HP fuel pipe 13 Screw 2 Lower HP fuel pipe 14, 14a Flange consisting of: 1 Screw-on sleeve 94870E 3 Fuel rail 15, 15a Screw 1 Grinding tool 94870F...
  • Page 408 8752−1/A1 Maintenance RT-flex58T-D HP Fuel Pipe: Removing, Fitting and Regrinding Removal Remark: Always start removing a HP fuel pipe by disengaging its upper end. Pay attention not to damage sealing faces ’DF’. All connections must be closed off immediately and the sealing faces must be protected after removing the HP fuel pipe.
  • Page 409 8752−1/A1 RT-flex58T-D Maintenance HP Fuel Pipe: Removing, Fitting and Regrinding Fitting Fitting procedure is analogous to the removal but in reverse sequence. The fuel pressure pipings must be installed as stress-free as possible achieving a proper sealing function. Before fitting HP fuel pipes 1, 2 check whether their claws 18 are screwed on pro- CHECK perly, i.e.
  • Page 410 8752−1/A1 Maintenance RT-flex58T-D HP Fuel Pipe: Removing, Fitting and Regrinding 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 411 8752−1/A1 RT-flex58T-D Maintenance HP Fuel Pipe: Removing, Fitting and Regrinding ⇒ Remove claw 18 (Fig. ’B’). ⇒ Fix HP fuel pipe 1 and 2, e.g. in a vice. ⇒ Screw on counter nut 94870G until it reaches the thread end of the HP fuel pipe. 016.739/08 ⇒...
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  • Page 413 Group9 RT-flex58T-D Maintenance Crank Angle Sensor Unit, Tools Group 9 Crank Angle Sensor Unit − Dismantling, Assembling and Adjusting (at Free End) ..... 9223−1/A1 −...
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  • Page 415: 9223−1/A1

    9223−1/A1 RT-flex58T-D 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 4 Nut 40 Locating pin 5 Shaft...
  • Page 416 9223−1/A1 Maintenance RT-flex58T-D 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 417 9223−1/A1 RT-flex58T-D 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. Removal of the inner shaft encoder 13a is carried out analogously to the outer one.
  • Page 418 9223−1/A1 Maintenance RT-flex58T-D 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 419 9223−1/A1 RT-flex58T-D 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 420 9223−1/A1 Maintenance RT-flex58T-D 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 421 9223−1/A1 RT-flex58T-D 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 422 9223−1/A1 Maintenance RT-flex58T-D 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 423 9223−1/A1 RT-flex58T-D 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 424 9223−1/A1 Maintenance RT-flex58T-D 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 425 9223−1/A1 RT-flex58T-D 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’). Determining of thickness ’x’...
  • Page 426 9223−1/A1 Maintenance RT-flex58T-D 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 427 9223−1/A1 RT-flex58T-D 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 428 9223−1/A1 Maintenance RT-flex58T-D 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 turned several times by hand in order to adapt it to its running track.
  • Page 429 9223−1/A1 RT-flex58T-D 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. 008.746/01 ⇒...
  • Page 430 9223−1/A1 Maintenance RT-flex58T-D 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 431 9223−1/A1 RT-flex58T-D 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 432 9223−1/A1 Maintenance RT-flex58T-D 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 433 9223−1/A1 RT-flex58T-D 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. Checking the throttle is carried out as follows: ⇒...
  • Page 434 9223−1/A1 Maintenance RT-flex58T-D 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. It is essential to perform the eccentricity check according to the Maintenance Schedule 0380-1.
  • Page 435 9223−1/A1 RT-flex58T-D 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 436 9223−1/A1 Maintenance RT-flex58T-D 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. Do not use the old toothed belt anymore.
  • Page 437 9223−1/A2 RT-flex58T-D Maintenance Crank Angle Sensor Unit Assembly and Replacement of Proximity Sensor (Pickup) at Gear Wheel Key to Illustrations: 1 Proximity sensor 4 Terminal boxes E.96.1 / E96.2 2 Crank angle mark (1 / 2) 5 Plug with cable 3 Gear wheel on crankshaft 6 Bolt with locking plate and nut General...
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  • Page 439 9403−1/A1 RT-flex58T-D 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 441: 9403−2/A1

    9403−2/A1 RT-flex58T-D Maintenance Hydraulic Jacks and Pumps Arrangement and Application 3, 6...9 WCH00964 A = Tensioning / loosening of tie rods, elastic studs to exhaust valve cage, top and bottom end bearings to connecting rod, piston rod foot B = Tensioning / loosening of elastic studs to cylinder cover C = Set-up of pre-tensioning jacks 4 (collecting squeezing oil) D = Tensioning / loosening of foundation bolts and engine stays 2013...
  • Page 442 9403−2/A1 Maintenance RT-flex58T-D Hydraulic Jacks and Pumps: Arrangement and Application WCH00728 WCH00724 E = Tensioning / loosening of elastic studs to main bearing F = Removal and fitting of main bearing shell G = Checking and setting of fuel overpressure safety valve H = Checking of non-return valve in lubricating quill for pulse lubrication I = Removal and fitting of main bearing shell 2013...
  • Page 443 9403−2/A1 RT-flex58T-D Maintenance Hydraulic Jacks and Pumps: Arrangement and Application Tool 1 Double pre-tensioning jacks (main bearing) ... . 94114 2 Pre-tensioning jack (foundation bolts & engine stays) . . . 94145 3 Pre-tensioning jacks (tie rods) .
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  • Page 445: 9403−3/A1

    9403−3/A1 RT-flex58T-D 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 446 9403−3/A1 Maintenance RT-flex58T-D Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Overview of pre-tensioning jacks Tool 94114 Double pre-tensioning jack for elastic bolts to main bearing 1 Piston 7 Distance sleeve 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Double cylinder 10 Cover 5 Back-up ring...
  • Page 447 9403−3/A1 RT-flex58T-D Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94145 Pre-tensioning jack for foundation bolt and engine stay 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 10 Control pin 5 Back-up ring Sealing ring O-ring...
  • Page 448 9403−3/A1 Maintenance RT-flex58T-D Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool GF 94180 Pre-tensioning jack for tie rod 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 10 Eyelet 5 Back-up ring Sealing ring O-ring GF 94180−KJ Kit with back-up and O-rings...
  • Page 449 9403−3/A1 RT-flex58T-D Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool GF 94215 Pre-tensioning jack for elastic bolt to cylinder cover 1 Piston 7 Adapter piece 2 Back-up ring 8 Closing valve Sealing ring O-ring 9 Eyelet 4 Cylinder 5 Back-up ring Sealing ring O-ring GF 94215−KJ Kit with back-up and O-rings...
  • Page 450 9403−3/A1 Maintenance RT-flex58T-D Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94252 Pre-tensioning jack for elastic bolt to exhaust valve cage 1 Piston 7 Adapter piece 2 Back-up ring 8 Closing valve Sealing ring O-ring 9 Control pin 4 Cylinder 5 Back-up ring Sealing ring O-ring...
  • Page 451 9403−3/A1 RT-flex58T-D Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94314 Pre-tensioning jack for elastic bolt to bottom end bearing 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 10 Control pin 5 Back-up ring Sealing ring...
  • Page 452 9403−3/A1 Maintenance RT-flex58T-D Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94315 Pre-tensioning jack for elastic bolt to top end bearing 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 10 Control pin 5 Back-up ring Sealing ring...
  • Page 453 9403−3/A1 RT-flex58T-D Maintenance Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance Tool 94340 Pre-tensioning jack for elastic bolt to piston rod foot 1 Piston 7 Vent screw 2 Back-up ring 8 Adapter piece Sealing ring O-ring 9 Closing valve 4 Cylinder 10 Control pin 5 Back-up ring Sealing ring...
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  • Page 455: 9403−4/A1

    9403−4/A1 RT-flex58T-D Maintenance Hydraulic Pre-tensioning Jacks General Application Instructions Tools: Key to Illustrations: Hydr. pre-tensioning jacks for 1 Cylinder Main bearing 94114 2 Piston 3 High pressure connection b) Hydr. pre-tensioning jacks for 4 Vent screw Tie rod GF 94180 5 Elastic bolt Cylinder cover GF 94215...
  • Page 456 9403−4/A1 Maintenance RT-flex58T-D Hydraulic Pre-tensioning Jacks: General Application Instructions Overview of hydr. pre-tensioning jacks: Group Jack Tightening Comparison Reset of jack value [bar] [_(, mm] [turns] 1112−1 94145 1000 − step 600) ½ 1132−1 94114 1500 − ¾ 1715−1 94145 −...
  • Page 457 9403−4/A1 RT-flex58T-D Maintenance Hydraulic Pre-tensioning Jacks: General Application Instructions Jack with Limiting Groove Working procedure for loosening 2.1. Loosening procedure −> jack with limiting groove ⇒ Thread the jack with opened vent screw 4 onto the extending thread end of bolt 5 to be loosened until it is landed on the part and piston 2 on cylinder 1 if possible without clearance at ’x’.
  • Page 458 9403−4/A1 Maintenance RT-flex58T-D Hydraulic Pre-tensioning Jacks: General Application Instructions Jack with Control Pin 2.2. Loosening procedure −> jack with control pin ⇒ Thread the jack with opened vent screw 4 onto the extending thread end of bolt 5 to be loosened until it is landed on the part and piston 2 on cylinder 1 if possible without clearance at ’x’.
  • Page 459 9403−4/A1 RT-flex58T-D Maintenance Hydraulic Pre-tensioning Jacks: General Application Instructions Jack with Limiting Groove Working procedure for tensioning Tensioning procedure −> jack with limiting groove ⇒ Firmly tighten nut 6 with round bar ’RS’. Check with a feeler gauge through slot ’KO’ whether actually no clearance remains CHECK between nut and seating.
  • Page 460 9403−4/A1 Maintenance RT-flex58T-D Hydraulic Pre-tensioning Jacks: General Application Instructions Jack with Control Pin Tensioning procedure −> jack with control pin ⇒ Firmly tighten nut 6 with round bar ’RS’. Check with a feeler gauge through slot ’KO’ whether actually no clearance remains CHECK between nut and seating.

  • Page 461: 9403−5/A1

    9403−5/A1 RT-flex58T-D Maintenance Tool List Standard Tools 94000 Combination wrenches 94000−36 2 Pieces ..AF36 94000−41 2 Pieces ..AF41 94000−46 2 Pieces ..AF46 94000−50 2 Pieces ..AF50 2 Pieces .
  • Page 462 9403−5/A1 Maintenance RT-flex58T-D 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 for pre-tensioning jacks 94005D 3 Pieces...
  • Page 463 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94009 Handle screws 94009−M4 2 Piece ..M4x150 94009−M5 2 Piece ..M5x150 94009−M6 2 Piece ..M6x150 93.7474 94009−M8 2 Piece ..M8x150 94009−M10 2 Piece...
  • Page 464 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94017A − Spur-geared chain block platform with crane rail (WLL 3000 kg) 012.232/04 GF 94020 1 Tool box consisting of: GF 94020A 1 Power amplifier 013.554/05 (with transmission factor 1:5) 1 Short backing rod GF 94020B GF 94020C 1 Angle GF 94020D...
  • Page 465 9403−5/A1 RT-flex58T-D Maintenance Standard Tools GF 94027 4 Extensions for intermediate wheel assembly 250 mm 94032 1 High pressure grease gun for lubricating grease nipples on fuel pump regulating linkage 000.370/93 94040 RUD-eye bolts 94040−M16 2 Pieces ..94040−M20 6 Pieces .
  • Page 466 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94050 1 Tool for pressure measurement for pneumatic elements 94050A 1 Compressed air pump 94050B 1 Pressure gauge 0−4 bar 94050C 1 Pressure gauge 0−6 bar 94050D 1 Pressure gauge 0−16 bar 94050E 2 HP hoses 94050F 1 Adjusting tool 94050G...
  • Page 467 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94101 1 Inside micrometer with case 000.366/93 (Measuring range 50−1010 mm) 94101A 1 Extension Length of 480 mm 000.365/93 94111 1 Lifting device for removal and fitting of main bearing cover X = 733.4 mm 002.669/98 94114 Double pre-tensioning jacks...
  • Page 468 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94117 1 Roller support for removal and fitting of main bearing 74 mm 002.788/98 GF 94117A 1 Deviation pipe for removal and fitting of: − main bearing cover, shell − crosshead pin X = 300 mm WCH00265 94118 Turning-out device...
  • Page 469 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94122 1 Feeler gauge 000.361/93 94123 1 Special feeler gauge for main bearing 625 mm 000.395/93 94124 1 Depth gauge measuring range 250 mm 012.237/04 94128 1 Allen wrench for Allen screw to main bearing 680 mm 004.220/99 94129...
  • Page 470 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94141 Support for removal and fitting of main bearing shells 870 mm 017.848/08 94141A Ground plates X = ∅ 100 mm Y = 50 mm 010.399/02 94142−L 94142−R Working platform X = 1532 mm Grid left side 94142−L Grid right side 94142−R...
  • Page 471 9403−5/A1 RT-flex58T-D Maintenance Standard Tools GF 94155 1 Turning-out device with screws for turning out thrust bearing pads (with 1-part gear wheel) 178 mm WCH00986 GF 94180 Pre-tensioning jacks for tie rods, including a metal box X = ∅ 246 mm GF 94180−KJ Kit with back-up and O-rings for pre-tensioning Jack...
  • Page 472 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94208 4 Suspension straps for removal and fitting of antipolishing ring 88 mm 005.928/00 GF 94215 Pre-tensioning jacks for cylinder cover including a metal box 167 mm GF 94215K High pressure hoses Y = 1328 mm WCH00999 GF 94215−KJ Kit with back-up and O-rings...
  • Page 473 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94238 1 Feeler gauge (10-part) for checking bearing clearances 000.418/93 Leaf length = 600 mm 94252 Pre-tensioning jacks for exhaust valve cage including a metal box 225 mm 94252−KJ Kit with back-up and O-rings for pre-tensioning Jack 002.266/00 GF 94259 1 Pressure element...
  • Page 474 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94263 2 Jack screws with nuts to guide bush for exhaust valve M10x120 000.413/93 GF 94265 1 Suspension device for cylinder cover 690 mm 016.769/08 94270 1 Device for overhauling injection valve seat in cylinder cover 344 mm 003.294/00 94271...
  • Page 475 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94272 OBEL test bench for setting and testing of: − injection valve − relief valve (cylinder cover) − relief valve (PCV) X = 1458 mm including: 94272A Valve holder for checking and adjusting relief valve 94272A X = 149 mm Connecting piece...
  • Page 476 9403−5/A1 Maintenance RT-flex58T-D 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 94314...
  • Page 477 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94323 4 Retaining pins to prop up crosshead guide shoes when removing or fitting a connecting rod or a crosshead 85 mm 000.409/93 94324 1 Cover and lifting plate to crosshead 255 mm 000.408/93 94325 2 Holders for removal of a crosshead guide shoe 70 mm...
  • Page 478 9403−5/A1 Maintenance RT-flex58T-D Standard Tools GF 94333D 1 Wire rope sling for removal and fitting of a crosshead pin, Ø and an expansion piece X = 1238 mm (WLL 1500 kg at ( 45...60_) 012.316/04 94334 1 Holder for removal and fitting of connecting rod including: 2 Fastening shafts 2 Threaded rods 1 Lifting lug...
  • Page 479 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94338 1 Piston ring expander X = 549.5 mm Y = 285.5 mm 17.830/08 94340 Pre-tensioning jacks for piston rod screw connection, including a metal box 110 mm 94340−KJ Kit with back-up and O-rings for pre-tensioning Jack 010.400/02 94341 1 Piston suspension device...
  • Page 480 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94345 2 Distance holders for removal and fitting of piston rod gland and piston 554 mm 7056−03/F101181 94345B 1 Clamping ring 55 mm 93.7515 94345C 1 Gauge for fitting scraper rings 366 mm 012.158/04 94345D 1 Cover plate for covering bore of piston rod gland in cylinder jacket (when piston and gland are removed)
  • Page 481 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94345F Distance pieces for fitting rings to upper gland group 2 pieces each 19 mm 305 mm 94345G Distance pieces for fitting rings to upper gland group 005.655 2 pieces each 11 mm 305 mm 94348 1 Tap M20 for cleaning carbon deposits in...
  • Page 482 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94366 1 Template for shape of top of piston crown 634 mm 010.410/02 94366A 1 Template for shape of top of piston crown (for use with piston in situ) 640 mm 010.411/02 GF 94410B 2 Pins 013.698/05 for intermediate wheel assembly 170 mm...
  • Page 483 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94552 1 Cover with Allen screws M12 for removal and fitting of fuel pump 116 mm 701.013.603 013.603/05 94555 Spacer for cutting out of individual fuel pumps 72 mm GF 94555A Spacers for cutting out of individual fuel pumps 016.649/08 36 mm 008.765/01...
  • Page 484 9403−5/A1 Maintenance RT-flex58T-D 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 94566C 1 Limiter for tightening or loosening bearing...
  • Page 485 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94567 1 Assembly template for removal and fitting of bearing shells to supply unit 68 mm 701.013.609 013.609/05 GF 94569 Blank flange to fuel pump with 4 Screws M12x50 and 1 O-ring 42.52x2.62 mm 93 mm GF 94569A Blank flange to valve housing at fuel rail with...
  • Page 486 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94583 1 Pipe for pressure built-up in fuel rail during commissioning 431 mm 015.674/07 94584 1 Lifting plate for removal and fitting of injection control unit, including 4 screws M10x25 88 mm 015.675/07 (max. lifting capacity 180 kg) 94587 8 Conical plugs (4 pieces per Cyl.) for servo and fuel oil returns in rail unit...
  • Page 487 9403−5/A1 RT-flex58T-D Maintenance Standard Tools In case of a turbocharger breakdown 94653 Covers to gas inlet housing and gas connection X = 510 mm (TPL 73−B) X = 600 mm (TPL 77−B) X = 665 mm (MET 66S) X =600 mm (MET 60MA/MB) X =675 mm (ABB A170) X = 810 mm (ABB A175) X = 870 mm (ABB A180)
  • Page 488 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94663B 1 Plate for cooler type: GEA 150/38/24/6 680 mm 004.018/96 94664 1 Pulley support for dismantling and assembling the scavenge air cooler 140 mm 010.696/03 94665 94665 with double spring clip 94665A for removal and fitting of tube stack including: 94665A Roller...
  • Page 489 9403−5/A1 RT-flex58T-D Maintenance Standard Tools 94831 1 Blank flange for blanking off starting air pipe during emergency operation 200 mm 004.017/96 94834 1 Regrinding device to hydraulic pipes for radius of 100 mm 38 mm 015.676/07 94870D 1 Stencil 48 mm 016.740/08 94870H 1 Stencil...
  • Page 490 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94874 1 Special spanner for fitting claws on HP pipe to injection valve 24 mm 000.699/98 94924 Hook spanner for crank angle sensor 205 mm Hook spanner 94925 008.771/00 for crank angle sensor 242 mm 94930 1 SW-download package to WECS−9520 for flexView operator...
  • Page 491 9403−5/A1 RT-flex58T-D Maintenance Standard Tools Hydraulic parts and pump 94931 HP oil pump 94934F working pressure max. 2800 bar 94934F Adapter piece 010.001/02 94932 2 Hydr. distributor with pressure gauge 010.242/02 94934 1 Connection block 005.956/00 94934A Hydr. distributor with pressure gauge 94934K 94934K Relief valve...
  • Page 492 9403−5/A1 Maintenance RT-flex58T-D Standard Tools 94934J 3 Closing valve with Tredo joint 94935 3 HP hoses 2600 bar with closing valves and coupling sockets X = 2130 mm 005.954/00 94935A 2 HP hoses 1500 bar with closing valves and coupling sockets X = 1880 mm 005.954/00...
  • Page 493 9403−5/A1 RT-flex58T-D Maintenance Recommended Special Tools GF 94155A 1 Turning-out device with screws for turning out thrust bearing pads (with 2-part gear wheel) 178 mm WCH00996 94291 Valve grinding device complete 94291A for valve spindle and valve seat 94291A Grinding discs (C-M No.
  • Page 494 9403−5/A1 Maintenance RT-flex58T-D Recommended Special Tools 94336 1 Connecting flange for pre-lubrication of crosshead and bottom end bearing 140 mm 000.462/93 94344 1 Dismantling device for removal of piston rod gland downwards 812 mm 003.988/96 94349 1 Pressure testing device for piston 252 mm 004.134/98...
  • Page 495 9403−5/A1 RT-flex58T-D Maintenance Recommended Special Tools 94412E 1 Fork wrench for 2-part gear wheel on crankshaft, AF55 X = 140 mm WCH00158 94650 1 Spur-geared chain block for removing and fitting electric motor to auxiliary blower (WLL 1000 kg) 000.460/93 94655 1 Cover to air inlet casing with suction pipe...
  • Page 496 9403−5/A1 Maintenance RT-flex58T-D Special Tools Obtainable on Loan 94105 1 Measuring apparatus for leveling bedplate consisting of: 4 Supports 4 Weights with wire 1 Measuring underlay X = 1335 mm 000.459/93 GF 94174 1 Thread protector to upper threads of tie rod with screw M24x55 38 mm WCH00668...
  • Page 497 9403−5/A1 RT-flex58T-D Maintenance Special Tools Obtainable on Loan 94691 Transport tool for 5 or 6 Cyl. rail unit modules (max. lifting capacity 14 000 kg) X = 4164 mm consisting of: 94690A Lifting elements incl. 24 screws M24x80 and nuts 94690A 016.149/07 94692...
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