Maintenance Manual for Sulzer Diesel Engines Rta76
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Description
.
/
Book No.
V.No.
New Sulzer
Diesel
New Sulzer Diesel AG
Winterthur, Schweiz
Maintenance Manual
for Sulzer - Diesel Engines
RTA76
Installation I Vessel:
Type:
Engine No.:
Mailing address: New Sulzer Diesel AG PO Box CH-8401 Winterthur Switzerland
Telephone Telex Telefax
© 1990 New Sulzer Diesel Ltd. Switzerland - Printed in Switzerland
052 262 49 22 896 06070 sz ch 052 2249 17
000 For particular Attention
This manual is put at the disposal of the recipient solely for use in connection with corresponding DIESEL
ENGINES.
It has always to be treated as confidential.
The intellectual property regarding any and all of the contents of this manual, particularly the copyright, remains with NEW SULZER DIESEL LIMITED, WINTERTHUR, SWITZERLAND. This document and parts thereof must not be reproduced or copied without their written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Before the operator attempts to use the engine or before maintenance work will be undertaken, the respec tive manual is to be read carefully. To ensure the best efficiency, reliability and lifetime of the engine and its components, only original spare
parts should be used.
It is to be ensured as well that all equipment and tools for maintenance are in good condition.
",---,.
The extent of any supplies and services is determined exclusively by the relevant supply contract. The particulars. data. presentations etc.in this manual correspond to the situation existing at the time of going to press and they are based on drawings made by NEW SULZER DIESEL. It must be recognized that such particulars. data. presentations etc. may be subject to later modifications due to further develop ments. experience or any other reason. This manual is primarily intended for use by the engine operating and maintenance personnel. It is as sumed that it will a~ways be at the disposal of such personnel for the operation of the engines and/or for the required maintenance work. This manual has been prepared on the assumption that operation and maintenance of the engines con cerned will always be carried out by personnel having the special knowledge and skill needed to handle in a workman-like manner diesel engines of the corresponding size. the pertaining auxiliary equipment. as well as fuel and other operating media. Therefore. generally applicable rules. which may also concern such items as protection against danger. are specified in this manual in exceptional cases only. It is generally assumed that the operating and mainte nance personnel are familiar with the rules concerned.
This manual has been prepared to the best knowledge and ability of its authors. How ever, neither NEW SULZER DIESEL nor their employees assume any liability under any legal theory whatever including negligence for claims for any damages whatsoever or claims of any other nature such as regarding additional supplies or services or other demands, with regard to this manual and its contents or to any modification thereto or in connection with any use thereof. NEW SULZER DIESEL LIMITED WINTERTHUR SWITZERLAND
New
Sui... Diesel
10.91
Informat
on
The engine can be equipped with "long" or "short" piston rods. With the long version, the rod of the piston is led through the crosshead from above and secured at the bottom with a sui tabl e nut. In the case of short piston rods, connection is effected by means of a strong bolt, which is inserted at the bottom so that it passes through the crosshead and into the piston rod. To rule of the possibility of mistakes, the data relevant to engines equipped with short piston rods are printed on green coloured paper. Customers are requested to remove the pages of the manual that do not apply to their particular engines.
"Long D piston rod
."Short" pi ston rod
!
,
'---" '
Pi ston rod nut
Pi ston rod bolt
SULZER
RT
PRE F ACE
Group:
001
Sheet:
1
Pre f ace The aim of the "M a i n ten a n c e Man u a 1" is to help to ensure
that the maintenance which has to be carried out at specific intervals is done
correct1 y.
It is assumed that the staff charged with such work posses the necessary know
how.
Information covering engine operation as well as the description of the func
tioning of specific systems is contained in a separate book "Description and
Operating Instructions".
The "Maintenance Manual" is divided into the following main chapters: • General Guide Lines for Maintenance • Maintenance Schedule • Tables of Weights, Clearances and Values for Bolted Connections • Work Sheets • Too1s List
The following are a few explanations to the above items:
The "General Guide Lines for Maintenance" contain - in addition to indications
regarding precautionary measures to be taken - recommendations on how to carry
out the work.
In the "Maintenance Schedule" the intervals are specified at which the various
maintenance operations are to be carried out.
The "Tables of Weights. Clearances and Tightening Values for Bolted Connections" deal with weights of individual engine components, normal and maximum permissible clearances as well as the proper tightening of certain important bolted connections. The "standard clearances" mentioned in the Table of Clearances 012/1 &f correspond to those partly resulting from manufacturing tolerances or those adjusted on the ~ engine. The maximum clearances or max./min. dimensions stated are those values which may result from wear after a prolonged period of operation and which are neither to be exceeded nor gone blow. In parts where the clearance can be corrected by a change in the thickness of shims, discs, distance pieces etc. the original standard clearan ce should always be aimed at, and adjusted. Wherever this is not possible, the worn parts must be replaced or reconditioned by building up (chrome plating, welding build-up or metal spray. Should during an overhaul, clearances or dimensions be found close to the permissible limits, it has to be left to the engineer in charge of the engine to decide whether or not the parts have to be replaced. This depends for example on the time of opera tion until the next overhaul and on the wear to be expected from experience made over a certain time span. Detailed instructions are given in the "Work Sheets" on the procedure of maintenance work on certain engine parts. The tools and devices are specified in the "Tools List" which are needed for mainte nance work and which are normally supplied with the engine. All the information contained in the text and the illustrations of this book are
valid at the time of going to press.
Modifications will be incorporated in the next edition.
SULZER
RT
TABLE OF CONTENTS
Group:
002
for Maintenance Manual
Sheet:
1
FOR PARTICULAR ATTENTION
000
PREFACE
001 002 004 008
Table of contents for Maintenance Manual Engine cross- and longitudinal section Numbering of bearings and cylinders as well as definition of engine sides GE~ERAL
GUIDE LINES FOR MAINTENANCE
011
Precautionary measures for maintenance work Recommendations for carrying out the work TABLE OF CLEARANCES -
Crankshaft and thrust bearings Crosshead guides Cylinder liners Piston rod glands Crosshead- and crank pin bearings Crosshead lubrication Working piston and piston rings Piston telescopic pipe glands Gear wheels for camshaft drive and PTO gearbox PTO gearbox Camshaft and reversing servomotor Ancillary gear drives Ancillary and starting air distributor drive Intermediate shaft for ancillary gear drives Roller guides for fuel injection and actuating pumps Drive for cylinder lubricators Overspeed, pick-up and remote tachometer transmitter Balancer drive elements (2nd order 4 to 6 cyl. engines) Balancer drive elements (1st and 2nd order, 4 cyl. engines)
012/1 012/2 (2a RTA58) 012/3 012/4 012/5 012/6 012/7 012/8 012/9 012/9a 012/10 012/11 012/11a 012/11b 012/12 012/13 012/14 012/15 012/15a (RT68, RT76)
lNFORMATION ON THE TIGHTENING OF IMPORTANT SCREWED CONNECTIONS
013
MASSES OF INDIVIDUAL COMPONENTS (per unit in kg)
014
DIMENSIONS AND MATERIAL SPECIFICATIONS OF THE RUBBER RINGS
015
MAINTENANCE SCHEDULE (Table of intervals)
021
WORK SHEETS Checking the lubricating oil by the spot test method Taking of oil sampl es for 1aboratory anal ysi s
042/1 042/2
Bedplate
- Checking the foundation bolts
11 0/1
- Loosening and tightening the bearing thrust bolts - Removal and fitting of a bearing cover and an upper beari ng shell - Removal and fitting of the bearing cover and stopper bridge in the thrust bearing assembly - Removal and fitting of a lower main bearing shell
117/2 117/3
Main bearings
I R
117/4 117/5
1
Q
h
RT
002/1a
Thrust bearing
- Checking the axial clearance - Removal and fitHing of thrust bearing pads
Tie rods
- Checking the pre-tension and tensioning the tie rods
190/1
Cyl inder jacket
- Transporting acyl inder 1iner with fi Hed cylinder jacket - Removal and fitting of the water guide ring
211 /1 211 /2
Cylinder liner
- Measuring bore wear - Removal and fitting - Removal of wear ridge, rectifying 1ubricating grooves and edges of scavenge ports
214/1 214/2 214/4
Lubricating quills
- Function check
215/1
Piston rod gland
- Removal and fitting and measurement of wear
231/1
Cylinder
-
Removal and fitting Hydraulic loosening and tensioning of cylinder head studs Mechanical loosening and tensioning of cylinder head studs Manual rectifying the seal ing face for the fuel injector in the cylinder head
270/1 270/2 270/3
Checking, dismantling, assembling and setting Cleaning and overhauling injector nozzle Lapping of injector body sealing face Checking a circulating valves Cleaning and checking
272/1 272/2 272/3 272/4 273/1
head
Fuel injector valve Starting valve -
I
120/1 120/2
270/4
Relief valve
- Dismantling, assembling and checking
274/1
Exhaust valve
Removing and fitting the exhaust valves in the cylinder head - Dismantling and assembling - EKchanging and grinding the valve seat - Grinding the seat face on the valve spindle
275/1 275/2 275/3 275/4
Crankshaft
- Measuring the crank deflection
310/1
Torsional vibration damper (on crank shaft and camshaft)
- Taking a silicon fluid sample
313/2
Axial damper
-,Dismantling and assembling
314/1
Turning gear
- Oil change and checking worm gear wheels
320/1
Cftnneeting rod and Cllnnlllcting rod bearings
Checking running clearances - Loosening and tensioning connecting rod bolts Separating the crank pin bearing body from the connecting rod shank Inspecting the crank pin bearings - Inspecting and if necessary replacing crosshead bearing shell s - Removing and fitting a connecting rod
330/1 330/2
P
330/3 330/4 330/5 330/6
~
r---/'
VVC./~U
Crosshead
Working piston
Piston rings
- Checking the clearances
332 i 1
_ Removing and fitting a crosshead with working piston removed
337/3
- Removing a working piston - Fi tting a working pi ston _ Loosening and tightening the piston rod nut (resp. bolt) wi th a sped al spanner - Checking the piston top surface - Dismantling and assembling _ Pressure testing cooling space (leak tightness test) Exchanging pi ston cool ing tel escopic pipes
340/1 340/2
Checking piston ring wear
)
34212
Piston cooling
- Checking the stand pipes Maintenance of glands for the telescopic pipes
360/1 362/1
Camshaft drive gear
- Checking of running clearances, backlashes and condition of teeth _ Removing and fitting the intermediate gear wheel - Replacing the split gear wheel on the crankshaft
410/1 410/2 410/3
Cam sha ft
- Removing and fitting a camshaft section Dismantling and assembling of hydraulically fitted components - Removing the fuel injection and the actuator cam - Pressing on the fuel injection cam - Pressing on the actuator cam - Adjusting the fuel- and the actuator cam - Removing and Fitting the flange coupling - Removi ng and Fitting the camshaft coupling - Removing and fitting the gear wheel on the camshaft
420/2 421/0 421/1 42l/lb 42l/lc 42l/ld 42l/le 42l/lf 42l1lg 421/1 h 421/4
Starting control air - Removing and fitting the pilot valves
di stri butor
'--"
34J/3 340/4 340/5 340/6 342/1
430/1
Starting air shut off valve
- Cleaning and function checking
432/1
Running direction safeguard
- Inspecting and function checking
453/1
Shut-down servomo tor
- Oismantling and assembling
455/1
WOODWARD governor Safety cut-out device
Installing, removing and maintenance - Mai ntenance, fundi on check
510/1 530/1
RT
aD2/lc - Adjusting and checking the timing - Lapping the sealing faces of the covers of the suction, delivery and spill valves - Checking and setting the relief valve - Checking and setting the static pressure regulating val ve - Tighten of nipple for plunger bush
551/1 551/2
Maintenance of valve groups and cleaning the scavenge air receiver - Maintenance of water separator elements
640/1 640/2
Auxil i ary blower
- Mai ntenance
654/1
Scavenge air cooler
Cleaning (airsideJ with engine at stand still - Cleaning (water side) with engine at stand still - Removing and fitting the cooler stack
650/1 660/2 660/3
Cylinder lubricators
- Cleaning
721/1
Driving shaft to the flow control valve of the cylinder lubrication
- Dismantling and assembling
722/1
p. l.O.-Gearbox
- Checki ng the too th profi 1e and tooth backl ash, re aligning the gearbox housing, checking the running performance - Removing and fitting gearbox components as well as the intermediate gear wheel. - Gei slinger coup1 ing, external check for oil 1eaks and constant venting
740/1
Fuel injection
pu~ps
Scavenge air receiver
551/3 551/4
~
551/5
'-..../
Efficiency-Booster
- Removing and fitting the hydraulic coupling as well as the flexible packet coupling. Checking the oil level of the hydro coupling and the alignment of the power turbine. - Funcion checking and maintenance of the shut-off flap and the corner valve
Balancer
740/3 750/i
750/2
- Fitting, Removing, Tensioning the Roller Chain 710/1 - Fitting, Removing the Flexible Coupling and a Camshaft 770/1e and 1f (2nd order section resp. lf and 1g(l st+2nd order)
Exhaust pi pe Hydraulic ~i~e to valve drive
740/2
Adjusting the Belleville washer spring packs on the exhaust pipe mounts .~hau.t
811 /1
- Overhauling the pipe seal faces
846-1
TOOLS
- Explanation
940
Hydr. Jacks and pumps
- Arrangement and application
940/0 & Oa
Hydr. pre-tensioning jack s
- Storage, care and spares stock - General application instructions
940/0b &Dc 940/Dd-Oh(Oi, RT84)
Tools list
- Standard tool s - Recommended tools - Tools obtainable on loan
940/1;41 940/48;51 960/60
12.89
CJ04/1
RTA 76
RTA 76 846/1
811/1
660/1+3
36211--_-+t+-~~~..,j:~ 551 /1+5--_.. .,..":;~
1,20/2~t"--~1L",...;:::j~ , 1,21/1 +I, ~~--..JL~:t;;I
231/1 'C
3g)/I----~~LII-_~~~~
110/1
10.86
001,/2
27~/1
RTA76
211/2------~-iYtr-Ttr~1t1111:tI+==t==\:+t; 3'0/~2~'~5.8
211/1-------:=;tl11~
721/1 J30/2 330/5
1H~.~770/1
3'0/3
7'0/1--_~+:...-..
~10/2i:~-~.~";1;f~.~~;Frn ~,
""-
, 'It il
t ,
t
1 332/1+2
'
~,:~
+t: . . --::.~~W
~~I,
"0/3
330/1f'
330/6
117/3
117/~
117/5
120/1
190/1
120/2
310/1
330/2 330/3 9 -1O'Z 198.411
5.87
RT
Gruppe Group
Numerierung von Lagern und Zylindern sowie Bezeichnung der Motorseiten
SULZER
Numberings of bearings and cyl inders and nomination of engine sides
Blatt Sheet
Antriebseite
1
Freies Ende
Driving end
Free end Zylinder Numerierung
Drucklager
Thrust bearing
~008
~~~~Numbering of cylinders
®
(j)
Schubstangen Numerierung
Numbering of connection rods
r-+-t--...
Kurbelwellen lager Numerierung
Numbering of main bearings
3 - 107156. 218
Rechtsmotor
Linksmotor
Left-hand engine
Right-hand engine
Brenns.toff pumpenseite
Fuel pump. side
Exhaust side
Exhaust side linksdreh(~l1d
counter-clockwise rechtsdrehend
clockwise Ansicht von Antriebseite
View from driving end
L.B.
2.8~
Table of Contents
Maintenance Instructions
Clearance Tables
Tightening Values for Bolt Connection.s
Weights
Maintenance Schedule
WorkSheets
ToolUsts
SULZER
RT
GENERAL GUIDE LINES FOR MAINTENANCE
Group:
011
Sheet:
1
The maintenance work to be carried out on the engine at specific intervals is described in the "Main tenance Schedule ll of this book and is to be understood as a ~ Experience will show whether the intervals may be extended or have to be shortened as mode and condi ti ons of operati on, qual i ty of fuel and 1ubri ca ti ng oil used, as well as many other factors i nfl uence the condition of the engine to a great degree. Precautionary Measures for Maintenance Work Prior to carrying out any maintenance work on the engine (especially on the running gear), the
following precautions have to be taken:
• Close the automatic shut-off valve for starting air as well as the shut-off valves on the starting air receivers • '-/
• Close all the shut-off valves in the control air pressure-reducing unit and the drain cocks in the two air receivers arranged above it • • Open the drain valves placed in the pipes before and after the automatic starting air shut-off
valve and leave in this position until maintenance work is co~pleted•
• Open all indicator cocks on the cylinder heads and leave in this position until maintenance work is comp1eted • • Engage turning gear (gear pinion must be in engaged position) and lock the lever • • Where the engine has been stopped due to overheated running gear or bearings, wait at 1east 10 mi nutes before opening the crankcase doors • • The crankcase doors must always be locked with all the closing dogs whenever the engine is running even if this is only for a short time in order to make temperature checks leg. after changing bear ings during an overhaul, etc.) • • In the case of a fire in the engine having been extinguished by means of C02, the spaces effected
must be well ventilated before work can be carried out within them. Recommendations for carrying out the work - Prior to turning the crankshaft with the turning gear, make sure that nobody is inside the engine and that no loose parts,tools or devices can get jammed. Also ensure that the coupled propeller turns too (danger in surroundings). - When carrying out maintenance work, use the tools and devices intended for the work in question which, as a rule, are supplied with the engine (see "Tools List ll at the end of this book). - Tools and devices should be ready prior to use and be in perfect condition. - Hydraulic tools are to be checked from time to time for tightness and faultless functioning (see also sheet 940/0a). - All work must be carried out with the necessary care, observing utmost cleanliness. - During maintenance, openings of pipes, open oil bores, etc. must be temperarily closed to avoid the entry of any dirt. - All parts overhauled during the course of maintenance have to be checked for perfect functioning prior to starting the engine. Pipes which were removed have to be checked for tightness after re fitting.
Ollila
RT
Clearances of moving parts ~us! be cl,ecked periodically. Should the maxi~u'll perrr-issit,ll " J;'Jes (see clearance tabl es) have beer reache~ or have even beer, exceeded, these parts n us ~ :12 re~,l a ced by either new or renovated snes, except where the clearance car be readjusted by re~ova1 of sh i ms. - Parts taken from the spares stock are to be replaced. When ordering new parts only the code numbers of the code book must be used and engine number, type of engine and name of installation must be mentioned. - When tightening studs, nuts or bolts, the utmost care must be taken not to damage their threads and that they can be screwed in by hand until metal-to-metal contact is obtained. The specified lubricants are to be used. - Where tightening values are stated, these must be strictly adhered to (see table "tightening values for bolted connections 013). - Locking devices of bolts, nuts, etc. must be fitted correctly and secured properly. _ Used rubber rings must always be replaced by new ones when an overhaul of any engine component ta kes place; they lust conform in dimension and quality to the specifications in the list group 015. The fitting of piston seal rings and rod seal rings requires the greatest of care to prevent slid ing rings being damaged, overexpanded or distorted. RECOMMENDATION: Before fitting the sliding ring of a piston seal ring heat it first in boiling water.
-.J
Table of Contents
Maintenance Instructions
Clearance Tables
Tightening Values for Bolt Connectior]s
Weights
Maintenance Schedule
WorkSheets
ToolUsts
SULZER
Spiele
RT76
Gearances
Kurbetwellen - und Drucklager
Gruppe: Group :
Crankshaft- and Thrust Bearings
Blatt Sheet
012 1
Kurbellllellenlager CRANKSHAFT BEARING
u
d
0
/
Differenz aj - a2 = max. 0,1 mm bei gespannten Bruckbolzen Difference al - a2 = max. 0,1 mm with thrust bolts tensioned v. 4 - 107. 197.046
d
Drucklager THRUST BEARING
o
o
2'-101.198 :812
f
f
'1 Nennmass
Spiel neu
Nominal dimension
Clearance nelll
maximum durch Abnutzung due to lIIear
Spiel neu
Nominal dimension
Clearance nelll
maximum durch Abnutzung due.to lIIear
o
b = 790 B = 790 +0,58 +0,48
Nennmass
f = 100_ 0 03
0,68 c = 0,48
0,8
2,5
e = 20 ~
d = 375
dl + d2 = 15
g = 225 1983
C"p,'ele
SULZER
RT76
J.
KreuzkopffiJhrung
GruPp~:012
CROSSHEAD GUIDANCE
Group : Blatt
1--====----+---------------1 rJ LLearanCes
Sh~~t
2
Brennstoffpumpenseite FUEL PUMP SIDE
.....
o
.
2- 107. 198.414
* Wenn die Gleitschuhe auf der Brennstoffpumpenseite anliegen, muss die Ko'ibenstangenachse zur Zylinderachse
um das halbe Spiel 'bl' gegen die Brennstoffpumpenseite verschoben sein, * WHEN THE GUIDE SHOES LIE AGAINST THE FUEL PUMP SIDE, THE PISTON ROD AXIS MUST BE DISPLACED BY HALF THE
CLEARANCE 'bl' TO THE FUEL PUMP SIDE RELAT IVE TO THE CYLINDER AXIS.
** Das Spiel 'bl' gilt nur fur kalten Motor ohne angezogene Zuganker und Druckbolzen.
Durch das Anziehen von Zuganker und Druckbo1zen vergrossert sich das Spiel im Bereich des U.T.P. Diese Spielveranderungen bleiben fur das Betriebsverhalten des Motors ohne Bedeutung. ** THE CLEARANCE 'b l ' IS ONLY VALID FOR COLD ENGINE ON WHICH THE TIE RODS AND JACK BOLTS ARE NOT TIGHTENED.
TIGHTENING OF THE TIE RODS AND JACK BOLTS INCREASES THE CLEARANCE MAINLY IN THE REGION OF B.D.C. THE FLUCTUAT ION OF TH IS CLEARANCE DOES NOT AFFECT THE DPERAT ION OF THE ENG INE.
Nennmass
Spiel neu
Nominal dimension Clearance new
maximum durch Abnutzung due to wear
-0,2
Spi e1 neu
Nominal dimension
Clearance new 0,5 **
B = 924
a = 370
A = 370
Nennmass
0,09
°03
0,15
b] =
cl
=
c2 =
°,
2
0,15 .. 0,25 15 .. 25
° °
maximum durch Abnutzung due to wear 0,6
0,4
°4
b =924_ 0,25
5.84
S .,
SULZER
~
J----_===p=l=e=e_---I-_zy_It_"nd_e_re_in_s_a_tz
RT76
rJ
LLearanCes
Gruppe: Group :
B/att
Cylinder Liner
012
3
Sheet
A
-
I I
'/ I
1- 107. 197. 095
NennnTlss
Spiel neu
Nominal dimension
Clearance nelll 1, 1 al + a2 = 0,7
A = 1094,5
B = 1100,5
C = 760
maximum durch AbniHzung due to wear
Nennmass
Spiel neu
Nominal dimension
Clearance new f 0,6 f l + 2 = 0,2
F = 1020
b b 1, 1 1+ 2=07 ,
max.¢ = 765,3
G = 945
1,3 gl + g2 = 0,9
H = 935
h 0,8 hI + 2 = 0.5
maximum durch Abniltzung due..:to wear
E = 1030 5.84
Spiele
SULZER
RT76
012
Kolbenstangen - StopfbiJchse
Clearances
4
Piston Rod Gland Box
c
~TEFLON ~
c: .S:! ~
0_
::lo
c:
~.s:! c: ~ :::d~ ~
:§c: .....!:!l 111111 ::lCII
-.:(Q
T . Beim Kontrollieren des Spieles il muss der Abstreifring dem Fuhrungsring ~ aufliegen. WHEN CHECKING THE CLEARANCE AT il THE SCRAPER RING ON GUIDE RING (I).
CI) auf
CD MUST LIE
Beim Kontrollieren der Spiele II, III 1 und kl-mUssen das Schloss und der Abstreifring CI) auf dem Fuhrungsring (l) aufliegen. WHEN CHECKING CLEARANCES II, ml AND kl CLAMP SCRAPER RING CI) MUST LIE ON GUIDE RING (l). Nennmass
Spiel neu
Nominal dimension Clearance new
b = 20 c = 20
c
kd
---TEFLON
~ 4-107.198.444 Nennmass
Spiel neu
Nominal dimension
Clearance new
°
maximum durch Abnuhung due to wear
Dicke = 39 thickness Dicke = 15 thickness Dicke = 18 thickness
11
ml = Dor 0,23
0,5
gl = 0,056 or 0,160
0,4
e = 30
el = 0,4 or 0,7
O,a
f = 35
fl = 0,4 or 0,7
0,8
G = 280
CD
CI) AND
maximum durch Abnutzung due to wear min. min. min. min. min. min.
a = 45
....
280,3
il =
~
kl = 0,05 =
0,08 y
0,26
° 0,1 ~
0,5 0,8 0,5
110/,
SULZER
RT76
Q 5 Grupp~: 012 g Sp,'e/e J-_-====-_---+_IiJ_e_r_e_u_n_d_u_n_t,_c_h_u_bs_t_a_ng_e_n_la_ _e_r~ Group :
rl
LlearanCes
Upper and Lower Connecting Rod Bearings
B/att Sheet
5
Obere Hal He
UPPER HALF
d
Lagerschale BEARING SHELL
'- =I====!r----+------I
4-107,
Nennmass
Spiel neu
Nominal dimension Clearance new a = 65°_ °0,08
a1 + a2 = 0,32TO,50 b = 0,34 .. 0,56 cl + c2 = 0,60TO,80
.~
d = 284
maximum durch Abnutzung due to wear
1~,693
Nennmass
Spiel neu
Nominal dimension
Clearance new
E = 790+0,58 +0,48
f
= 0,48 T 0,66
maximum durch Abnutzung due to wear 0,7
0,6 = 13 ± 13
d1 + d2 = 0,30TO,70
'-..-/
e = 790
g = 335
gl + g2 = 15 ± 0,5 5,84
SULZER
RT76
6
) / c,
Nennmass
Spiel neu
Nominal dimension
Clearance new 0,09 al = 0 03
a = 60
maximum durch Abnutzung due to wear 0,2
c
Nennmass
Spiel neu
Nominal dimension Clearance new 1,2 c = 65 c1 + c2 = 6
maximum durch Abnutzung due to wear
°
~~-~~~+---+---r---I--l "-- ./ b = 95
bl
+
b2 = 4
1983
Spiele
Arbeitskolben und Kolbenringe
Clearances
Working Piston and Piston Rings
SULZER
RT76
/
(jruppe: Group: Blatt Sheet
011" L-
7
a b
c
m
J
m
J
c
40
f
40
~11111·.llill--_--..,..--n
I
m
K
Fuer die Wiederverwendung von gebrauchten Kolbenringen ist die Ringbreite an den Stellen A, B und C massgebend. Gebrauchte Kolbenringe koennen weiterverwendet werden, wenn bis zur naechsten Revision die minimaIe Ringbreite nicht unterschritten wird (siehe Blatt 34212b) The ring width at the positions A,B and C is the decisive criterion for refitting of used piston rings.
Used piston rings my by refitted, if they will keep within their min. ring width till the next revision
(see groupe 342, sheet 2b).
I [mm]
24
-rT'TTT1T'I=
23
-IHlffiI33:
Kolbenring breite 'I' Piston ring
width 'I'
21
221111111 20 19....LLJ..L.U.U...
761
760
762
763
Zylindereinsatz-Durchmesser 'a' I
764
765
766 [mm]
Cylinder liner bore 'a'
Spiel normal. neu maximum durch Nennmass Spiel normal, neu maxmum durch Normal clearance. Abniltzung Normal clearance, Abniltzung new max due to wear Nominal dimension Nominal dimension new max. due to wear Nennmass
765,32
a = 760
.r--. "--""
g = 2BO
b = 755
5,0 .;. 5,45
H= 25
c = 757
3,0 .;. 3,45
d = 75B,7
1,3 .;. 1,7
J = 14 + 0,33 + 0 29 14 + 0, 1B K= + 0 14
f = 759,1
0,9 .;. 1,2
dmin . 75B,2
1 = 24 0 m = 13,92-0 025
j
1
= 0,435
7 k = 0,285 1
0,65 0,55 siehe Diagramm see dia ram
SULZER
RT76
Spiele
Kolbenkiihlrohr - Stopfbiichsen
Clearances
Piston Cooling Pipe Glands
Grupp~:
Group
012
8'.-
Blaff Sheet
~ 1
.C?T~~
.oi
t,
r;;
~
~
0.'
1'\
el, "-.")
•
Ir I
i
~
I
a
A I
I I
I
I
H
I
J
2-107."1.061 ..
a1
0
~
~-=;; I: ~~ ~· I~
~
r::,m:::u;:::::::.d
I'\~~
1'\ 1'\
"',,'\ Ff
U~
PJ ~.
-1
ii~t~~~~~ ~~@~~t
CD
!t- Ir·. I
••
Ur.
-41
~j~l~f:~ ~:~~~;~;~~ Ki1~W~ ~~{~~~It~
I
CD
tr-e
:fWl ~@~~~1 ~~~~lf?:;~ ~;~jl@
:~~~~1~~~~~!~nJ:
~.~
"-/
I
~~~~il· ~~;~%~~~~~~
02
L..
:~M l~l~~t
ii,~: f~~~~:
l~ 0
CD
0
CD
CD
,
I
I
, '-..-/
'-1Ul. 198."7
Spiel neu
Nominal dimension Clearance new 0,114 a = 50 al + a2 = 0,050
maximum durch Abnutzung due to wear
=
0,08
°
0,23 cl = 0 05 0,40
dl + d2 = 0,05
Nennmass
Spiel neu
Nominal dimension
Clearance new 0,08 f] 0 0,25 gj = 0 02
maximum durch Abnutzung due to wear
~
max. ~ max. diam.
A= 50
- 0,3
., ~ ~~~l!~j f.~~~~~f ~.
Lc::
d2
d
d1
~~
Ir
I
Bei mKontrol1ieren der Spiele fl, gl und cl muss das Schloss auf dem Fuhrungsring aufliegen und der Abstre ifri ng WHEN CHECK ING THE CLEARANCES fl, gl AND cl THE CLAMP RING AND SCRAPER RING MUST LIE ON THE GUIDE RING (1).
- 0,05
D d2
d
r-l-
l~
, f.I
0·
d = 39
~
D d1
0
bl
•
~r
Beim Kontro11ieren des Spie1es b] muss der Abstreifring auf dem Fuhrungsri ng aufl iegen. WHEN CHECK ING THE CLEARANCE AT b1 THE SCRAPER RING MUST LIE ON GU IDE RING
Nennmass
bI,
::;::::::.;;.
A
CD
k
.......
0,5
=
5J
min. min. min. mi n.
h = 9,5 i = 7,5 0,15 ml = 0,05
Mass = 7,5 dimension Mass = 6 dimension 0,5
0 = 39
I 1.85
SULZER
Rader zum Steuerwellenantrieb und P T.O. - Getriebe
Spiele
RT76
Clearances
Wheels for CamshGft Drive and Drive for PT.D.-Gear Box
GruPp~:012
Group :
Blatt Sh~et
9
''"-../
1 - 107 197 322
Nennmass
Spiel neu
Nominal dimension Clearance new
maximum durch Abnutzung due to wear
Nennmass
Spiel neu
Nominal dimension
Clearance new
maximum durch Abnutzung* due to wear
A = 270 a = 270
0,234 al = 0 142
b = 290
bl
+
b2 =
0,35
°1,1,6
1,5
c = 340
C]
d = 290
1,1 d1 + d2 = 0,6
max.*
°
C = 340 0,348 0,252
Zahnflankenspiele/Backlash of teeth max.* norma 1 norma1 0,32 0,78 54 0,43 0,78 2 0,65 0,43 0,75 3 0,66
0.45 1,8
6.87
SULZER
L-
RT76
~-=S==p=ie=l=e_---+_p_._T._O_,-_G_et_n_·eb_e
Nennmass
Spiel neu
Nominal dimension
Clearance new
=
340
b = 250 c
=
190
d
=
220
0,348 al = a,252 b _ 0,343 1 - 0,285
0,31
C] = a,252 d _ 0,321 1 - 0,258
e = 1,1
0,6
maximum durch Abnuhung due to wear 0.45 0,63 0,56 0,58 1,8
~~~~~e:: 012
Blatt 9 -, ---l...:S~h~ee::..t...:...- __a--l'---""
..L::G::e::Q::r:::Q::n::c:::e::s=---J_p_T._O_'-_D_r_iv_e
b
a
--l
bl
c
Nennmass
Spiel neu
Nominal dimension
Clearance new
~1
maximum durch Abnutzung* due to wear
1,51 2,0 1,0 0,91 1,5 9 = a,50 Zahnflankenspiele/Backlash of teeth normal max. * max.* normal 0,43 0,32 0,58 0,75 0,66 0.47 0,32 0,66 0,51 f
CD CD
=
CD
"
6.87
SULZER
RT76
Grupp~:
Steuerwelle und Umsteuerservo mo tor
Spiele
Group :
Blatt
Camshaft and Reversing Servomotor
Clearances
10
Sh~et
c ~ :1
012
d
, i
I'
o
4 - 107 199.345
Nennmass
Spiel neu
Nominal dimension
Clearance new 0,232 aj 0,150
a
=
300
maximum/minimum durch Abnutzung due to wear
0,35
A = 300+ 0,200 +0,150
Nennmass
Spi e1 neu
Nominal dimension
Clearance new 0,3 c
=
0,1
d1 + d 2 bl + b2
=
°0,45 , 14
O,16 =
0,10
maximum durch Abnutzung due to wear
0,4 0,3
0,6
5.84
SULZER
Spiele
RT76
Gearances
Getriebe fur Hilfsantriebe
11
Gearing for Auxiliary Drives
(:;\~
Siehe auch Bl'att 012/13
~~ See also sheet 012/13
~
0----1 ""'-",\1
.~~.~~';;;:t:~
Siehe auch Blatt 012/11b See also sheet 012/llb Siehe auch Blatt 012/14 See also sheet 012/14
2- 101.197.010
Nennmass
Sp ieI neu
Nominal dimension
Clearance new
maximum durch Abnutzung* due to wear normal 0,12 0,26 0,14 0,26
CD CD
0,10 0,21
Zahnf1ankenspiele/Backlash of teeth max.* normal max.* 10 0,47 00'2 0 0,34
CD
,
0,40 0,38 1983
SULZER
RT76
Spiele Clearances
Getriebe filr Hi/fsantriebe und Anlass - Steuerluftverteiler
Gruppe: Group
Gearing for Auxiliary Drives and Starting Control Air Distributor
Blatt Sheet
012 110
Anlass - Steuerluftverteiler
e
STARTING CONTROL AIR DISTRIBUTOR
0-1
o
,
cp
I
3 - 107. 19'1058
Nennmass
Spiel neu
Nominal dimension
Clearance new 0,090 a1 0,030 0,175 b] 0,] 1O 0,175 cl 0,1] 0,175 d1 0,110 0,136 m1 0,060
a ; 80 b ; 50 c ; 45 d ; 50 m; 60
°
e ; 1 f ; 1
maximum durch Abnutzung due to wear
Nennmass
Spiel neu
Nomina] dimension
Clearance new 1,0
0,15
9 ;
maximum durch Abnutzung* due to wear
°,5
h ; 1,0 0,5 . 0,20 1 ; , 15 k ; 0,22 0,14
0,3
°
0,3 0,3
0,3 0,3
0,2 norma]
Zahnf1ankenspie1e/Back1ash of teeth max.* normal 0,10 20
°
0,30
max.*
SULZER
RT76
Spiele
Zwischenwelle fur Hilfsantriebe
Clearances
Grupp~:012
Group :
Blatt
Intermediate Shaft for Auxiliary Drives
Sh~~t
11b
J Si ehe auch B1 att 012/11 1 ~ See also sheet 012/11
-==::::1
2 -107. 197.306
Nennmass Nominal dimension a
=
100
Spiel neu Clearance new 0,106 a1 0,036 b 0,8 0,3
maximum durch AbnUtzung due to wear 0,2 0,9
norma1 0,12 0,26
CD
Zahnflankenspie1e Backlash of teeth max.* max.* normal 0,12 0,50 0,47 0,28
CD
1983
SULZER
Spiele
RT76
Gearances
Rollenfilhrungen zu Brennstoff und Hubgeber - Pumpen
Gruppe: Group :
Roller Guides to and Actuator
Blatt Sheet
Fuel Pump
012 12
:: ~:~:~:~: ~: ~: ~: ~: ~:'
mfff) -:.:-:.:-:.:-:.:-: - - C "tJt---tt-+-
ol,)
e b
b1
b2
E
4 - 107. 197. 325
B
Nennmass
Spiel neu
Nominal dimension = 64 -0,030 a -0,060
Clearance new 0,030 al = ,090 0,250 bl + b2 = ,352
b =265 -0,250 -0,300 B -265 +0,052
°
°
- °
'---'
c
=108 -0,036 -0,058
cl
0,066 0,110
maximum durch AbniJtzung due to wear 0,35 0,5
0,16
Nennmass
Spiel neu
Nominal dimension
Clearance new 0,036 dl 080
d
=
90 -0,036 -0,058 o = 90 +0,022 e
= 120 -0,36 -0 54
°
°
0,51 81 + e2 = 79
°
maximum durch AbniJtzung due to wear 0,12
1,5
E = 120 +0,25 +0 15
C =108 +0,052 +0,030 5.84
SULZER
Spiele
RT76
Gearances
Zahnradpumpe zum Antrieb der Zylinderschmierpumpen
Gruppe: Group:
Gear Pump for Cyl. Lub. Pump Drive
Blatt Sheet
1
01.'') L
13
3 -107.134.605
Siehe auch Blatt 012/11 See also sheet 012/11
Nennmass
Spiel neu
Nominal dimension
Clearance new
a = 38
al
b
0,050 0,009
min. 0,055 max. 130
°
maximum durch AbnUtzung due to wear 0,15
Nennmass
Spiel neu
Nominal dimension
Clearance new
CD CD
min. max. min. max.
0,14 0,26 0,06 0,13
max i mu'm durch AbnUtzung due to wear 0,40 0,20
max. 0,20 5.84
Spiele
Antrieb fur Uberdrehzahl, Pick up und Ferndrehzahl-Geber
Gruppe: Group :
Clearances
Overspeed- J Pick up - and Remote Tachometer 7ransmitter - 0 rive
Blatt Sheet
SULZER
RT76
012 14
3 ~ Si ehe auch B1 att 012/11
See also sheet 012/11
-0'\
A~
;+-~ /
~r-7 ,~
- --+-} Ueberdrehzah1-Geber-Antrieb ''i-' 1 Overspeed Transmitter-Drive -_ ...._-----------..
-
-'--
-
\. {+} 2""t-'
--
a.at
~ ~
II
Pick-up-Transmitter~rive
4 -107. 197. 333
-~ "
~
=~
~--"
-
" "'" -"', -"\ """~ -ts1
I
.....b
-.-1
L d
Nominal dimension Clearance new 0,040 a = 22 a = 1 0,094 min. 0,1 b = max. 0,5
----<
r-- t-""
~t\.'\jr~
r / / /v / / /
+-
V//////
~
j ~
.,. ,-.::::
....
e,
~'"
I~ n~ ~
~
~~
L
e.
.~
~/ C
Spiel neu
~f', "'l\r:: "
n I"J ~ 3-107.f97.321
Nennmass
l
A~~~~~'"~ -"~
~ I" ~~~-~-~_l L~~
~--
f'rndr,hzahl-6,b'r
Pi ck-up-Geber-Antri eb
~
~ ~~
-
Remote Tachometer Transmitter-Drive
ri-
--
~-
-
e
Ott
4 -107.197.320
Pick-up-Geber / Pick-up-Transmitter Ueberdrehzah1-Geber / Overspeed Transmitter
maximum durch Abnutzung due to waar
Nennmass
Spiel neu
Nominal dimension
Clearance new
0,15
maximum durch Abnutzung* due to wear
f = 1,5
min. 0,2 g - max. 0,5
max. 1,0
max. 1,
°
c = 1,0 d = 1,0 e = 22
0,040 e = 1 0,094
0,15
Zahnfiankenspie1e/Back1ash of teeth normal normal max. * 0,10 0,12 0,51 = 0,21 = 0,29 0,12 0,51 = 0,29
CD CD
CD
max. * 0,38
5.84
SULZER
RT76
Massenausgleich -Antriebselemente 2.0rdnurg
Spiele Clearances
Balancer drive units Second order
Grupp~:
Group
012
Blatt
15
Sh~eat
gezeichnet fur freies Ende DRAWN FOR FREE END
Elast. Kupplung
FLEXIBLE COUPLING
,
'1
1- 107. 198.403
Nennmass
Spiel neu
Nominal dimension Clearance new a = 210
c = 390 d = 124,7
0,30 al = ,17 b b 0,6 1 + 2 = I ,4 0,58 cl = ,40
°
°
d1 = 0,3
T
0,7
maximum durch Abnutzung due to wear
Nennmass
Spiel neu
Nominal dimension
Clearance new
0,4
e = 390
el
2,0
f = 124,7
0,58 40 fl = 0,3 .. 0,7
0,7
g = 300
gl
°
0,304 0,208
maximum durch Abnutzung due to wear 0,7 1,5 0,4
1,5 1983
Spiele
SULZER
RT76
Massenausgleich -Antriebselemente 1.+2. Ordnung
Clearances
Gruppe: Group
012
Blatt
Balancer drive units 1. and 2. order
150
Sheet
gezeichnet fur freies Ende DRAWN FOR FREE END
Elast. Kupplung
FLEXIBLE COUPLING
Nennmass
Spiel neu
Nominal dimension
Clearance new 0,30 al"017 ,
a " 210
maximum durch AbnDtzung due to wear
Nennmass
Spiel neu
Nominal dimension
Clearance new
maximum durch Abnutzung due to wear
0,4
0,6 bl + b2 " 1,4
2,0
c " 390
cl
0,58 0,40
0,7
9 " 300
gl
=
0,304 0,208
0,4
d " 124,7
dl " 0,3 ;. 0,7
1,5
h = 265
hl
=
0,40 0 25
0,5
~
5.84
Table of Contents -\......-,---------------------------------- Maintenance Instructions
Clearance Tables
lightening Values for Bolt Connections
Weights
Maintenance Schedule
WorkSheets
ToolUsts
SULZER
Group:
Indications for the tightening
013
,---,
RT76
'-"
of important screwed connections
4
3
2
1
I
c
en
CD f-'
'" .-C 0 ' "" ->-- >-
7
-.
e
'-'
0,-
0
'" 0..
en
en
bar**
013
Sheet:
2
c 0'
c
•
~
en
.~
c
Q,)
~~~
c o
~
0
0'
.~
0'
C
.....
ro
ro
CJl
0' C
c 'r C
Q,)
'" c
C
0 ro
-+-'
or-
..c
..c
c
'"
I-e-~
e- .....
.~
:::l
'
0- ' 0' '- 0 Or- 01---
0' '
0
0
''-' .~
c' 0
en C
0
'+
0....- ••
'f""""
-+-'-+-'
'-'
ro '"
'"
'"
0.. . '-' .-....s::: -0 en
en
4
fie rod for fuel pump housing
M55
50
551
Nut to pl unger guide
M145x4
2 teeth
M30
El asti c stud fo r hydraul i c actuator cyl i nder
, C
Nm*
55"1
551
7
5
5
~
e
Group:
90
0
90
0
4 4
551/5
551/1
551
Elastic stud for fuel pum p block
M45
551
Valve cover for fuel pump block
M12
60
551/1
551
Pressure nipple for sucti on and spi 11 valves
M39x2
300
551/1
740
Fixing of gearbox to engine
M30
325
740
-.
Fixing of generator support (top)
740 Fixing of generator support (bottom) 740 Beari ng .bo 1ts 740
Flange bolts
740 Fixing of gearwheel to coupling 740 770
El asti c bolts for fixing of bearing Bearing cover on coupling shaft, elastic stud
0
-4
G71 0
60
0
114U 1990
85
0
M 36
M24
570
30
0 0
M42 PTO
15
M64x4 " 600 M3U
M30
n140
45
M42
B180
100 0 40
M36
0
.4: -4
-4
4 4:
4
77 0/1
770 Clamping cover on balancer mass, elastic stud Fixing bolts for balancer, housing with col umn, 770 el asti c studs
M48
600
770/1
M48
600
770/1
770 Screwed connecti on of fl ex. and camshaft coupl ing
M30
540
770
Screwed connecti on .of fl ex • and camshaft coupl ing
M36
900
811
Sl iding foot for exhaust pipe
M30
Top edge of the disc spring 811 /1 1Avel with rAd mark 1M'
811
Tie rod for exhaust pipe
M64
30
0
4
Remark: * The tightening values apply only when Molikote Paste 'G' is used as lubricant on the thread. ** The pressure indicated apply only for the use of the original, jacks supplied with the engine. ~~~~;?,!h1~~J~~~~+~~e u~~d the required pressures must be calculated in proportion of the ef r
'nn· 1 Nm ~
n In?
mkn
1
h~~ ~
1
n'J
'-'n/nm'J
4.86
Table of Contents '------------------------------------- Maintenance Instructions
Clearance Tables
Tightening Values for Bolt Connections
Weights
Maintenance Schedule
Work Sheets
Tool Lists
SULZER
RT76
liJ
I
G
HT S
of individual components oer unit in kg
Secti 0 n 117
E
Components Main bearing cover (narrow)
Parti cul ars 4 9
; ;
Group:
014
Sheet:
1
RT58
RT76
8 cyl. 12 cy 1•
454 370
Main bearing cover (wide) Main bearing shell (narrow)
per pair, inc 1• shim
215
Main bearing shell (wide)
per pai r, incl. shim
368
Main beari ng thrust bolt
compl.
156
120
Thrust bearing segment
190
Tie rod
211
571
135
without nuts
1714
Lower ti e rod nut
40
Upper ti e rod nut
33
Cylinder jacket
compl. with accessor.
19587
Cylinder jacket
without accessories
13500
Accessori es for cylinder jacket: Waisted stud bolts (8 off, total
=
464 kg)
with nut
Water guide ring End cylinder jacket Cylinder jacket end piece
213
Water guide jacket
214
Cylinder liner
231
Pi ston rod gl and
58 544
without accessories
16700 3025
163
4923
145 [:
0'
I
SULZER
RT76
W E I G H T S
of individual components per unit in kg
Section 270
Parti cu1ars
Components
Gro up:
014
Sheet:
2
RT58
RT76
Cylinder head
without valves
3340
Cylinder head
compl. with val ves
5210
272
Fuel injector
com pl.
31
273
Starting valve
camp l.
63
274
Relief valve
compl.
7
275
Exhaust valve
com pl.
1680
Exhaust valve spindle
310
312
123
Crankshaft (~emi -buil t) 4 cyl.
incl. thrust beari no shaft
5 cyl.
n
n
97100
6 cyl.
n
n
113200
7 cyl •
n
n
129300
8 cyl.
n
n
145300
9 cyl.
n
n
17 0100
10 cyl.
n
n
186200
12 cy1•
n
n
218400
3400 .. 7000 6400 .. 16500
Flywheel (light) Flywheel
330
81000
Connecting rod (shaft dia 600)
compl.
Lower connecting rod bearing (shaft dia. 600)
upper half
6090 750
SULZER
RT76
W E I G
HT s
of individual components oer unit in kg
Group:
014
Sheet:
3
Secti on
Components
330
Lower connecting rod bearing (shaft di a. 600)
lower half
462
Upper connecting rod head
upper half
260
Upper connecting rod head
lower half
430
Parti cul ars
Beari ng shell for upper connecti ng rod bearing head Connecti ng rod bolt fo r lower bearing
with nut
43
Connecting rod bolt for upper bearing
with nut
43 3104
Crosshead pin
without guide shoes
Guide shoe for crosshead 340
RT75
33
Connecti ng rod shaft
337
RT58
Working piston
2190 380
short piston rod long piston rod
compl. with piston rod and telescooic Dioes
3350 3387
Piston crown
948
Piston sk i rt
262
Piston rod
shod desi gn lona desion
with bolt with nut
2125 2147
Piston rod nut (only for short piston rods)
60
Piston rod screw (only for long pi ston rods)
16
342
Pi ston cooling telescopic pipe
15
360
Piston cooling stand pipe
361
Piston cooling box
410
Gearwheel on crankshaft Intermediate wheel for camshaft drive
9
229
compl. compl. with bearing journal s 1 or 2-piece
2456 2290
SULZER
IN E I
RT76
421
s
of individual components per unit
in kg
Secti on 420
G H T
Parti cul ars
Components Camshaft
with cams and shaft couplinQ
4 cy1•
014
Sheet:
4
RT58
RT76 5516
5 cyl •
n
n
7414
6 cy 1•
n
n
8311
7 cy l.
n
n
10211
8 cy1.
n
n
11044
9 cy1•
n
n
12867
10 cyl.
n
n
13698
12 cyl.
n
n
16495
Fuel pump cam
161
Actuating pump cam
210
510
WOODWARD governor (PGA-200J
551
Fuel injection pump body
compl. without plunger and guide bush
651
Exhaust gas turbocharger VTR 564
comp1.
compl.
667
6300
n
n
VTR 714
n
12100
n
n
n
rotor VTR 564
n
487
n
n
n
n
980
n
713
n
1370
n
n
VTR 714
n
n
n
for VTR 714
Air fi Her segments for VTR 564
n
115
n
Silencer with air filter for VTR 564
654
Group:
n
Auxiliary blower
n
6 x 15.
for VTR 714
6 x 20
compl. wi th el eetr. motor
1132 1295
~
SULZER
RT76
WEI G H T S
Group:
of individual components per unit in kg
Sh eet:
Secti on 660
Components Charge air cooler GEA, SERCK 4,5,7,8,9 and 10 cy1.
"
770
Parti cul ars
"
II
GEA, SERCK 5,6,7,9,10 and 12 cyl.
Balancing mass l-st order (Balancer 4-cyl.) Campl.
"
II
2-nd
"
(
II
4.. 6 cyl.) Campl.
Flexible Coupling of Balancer
811
RT58
014 5 RT76 2350 3350
4486 1628 .. 2050 2240
Roller Chain of Balancer
3t 4"
322 470
Exhaust pipe
4 cyl.
5156
5 cyl.
5878
6 cyl.
6595
7 cyl.
7660 .. 9770
8 cyl.
10210
9 cyl.
11308
10 cyl. 12 cyl.
5.8'"
"
a:; DIMENSIONS AND MATERIAL SPECIFICATIONS OF THE RUBBER RINGS Where applied
e
(
(
(
Gro up in Code' Book
Dimensions in mm RT 58 1.0
RT68 Thickness
I,D.
~laterial
RT76 Thickness
I. D.
specifications
RT84 Thick. ness
1.0.
Thi ckness
Relief valves on casing doors (type Horbiger)
170
460
Tie rod (bottom)
191
113,67
6,99
132,72
6,99
151,77
6,99
164,47
6,99
Water guide ring
211
750
9
900
9
900
9
11 00
9
Special
Cylinder liner (collar, water guide jacket)
2'14
800
9
955
9
1010
9
1160
9
seamless
Cylinder liner (guide part in cylinder jacket)
214
680
9
800
9
900
9
990
9
rubber
Piston rod gland (ring carrier)
231
-
-
300
5
340
5
380
5
Piston rod gland (ring carrier)
231
266.29
3.53
-
-
-
-
-
-
A
Piston rod gland (lower housing)
231
304,17
6,99
6,99
A
12
541
354,97
14
6,99
618
393,07
18
6,99
700
417,96
20
A
A
=
c..n
Piston rod gland (upper housing)
.=
;
13
",A3a \
\\
\ \
\
1
26
17
D
19
~
19 --20
21 22 13
gezeichnet fur RT 58 DRAWN FOR RT 58
L.B.
22
23 24
Hier buendig FLUSH
0-107.195.506
5.84
RT
190/1d
@
@
13
130
/
c .~~
~~
.!! ~
.b_ C:Q::
~Cl
f
e
c
0
b
d
,-j
f
f
e
c
0
b
d
3 -107.195.507
L.B.
2.84
SULZER
RT76
CYLINDER JACKET Transport of a Cylinder Liner with Cylinder Jacket
Too 1s:
Key
1 Suspension girder 94202 2 Web supports 94203
1 2 3 4 5
Group:
211
Sheet:
1
to Illustrations:
Cylinder liner Cylinder jacket Cylinder head stud Cylinder head nut Position of the suspension pin for transport ing the end cylinders
5
Remark: For transporting the cylinder jacket alone or with fitted cylinder liner the suspension girder 94202 must be used. The two web supports 94203 are placed o~ the suspension girder to form a combination device as shown in the illustration on the left. They are tightened down with two cylinder head nuts each. This tools arangement ensures the saf positioning of the cylinder liner whi ch is important for a good seal on the landing face 'AFr.
94203 94202
3 1
2
AF 3- 107.198.424
4 94203 94202
3 -107.197.559
SULZER
68 RT 76
CYLINDER JACKET
Group:
Removal and Fitting of the Water Guide Ring
Sheet:
84
Tools:
Key to Illustration
Set of suspension ropes 94265 or Suspension 3 Eye screws M24 1 Tommy bar
1 2 3 4
Cylinder jacket Water guide ring Eye screw Rubber ring
H Jemmy N Recesses AF Landi ng face
3
7
AF
, H 2
3 - 107.197. 336
211 2
211/2a
RT68/76/84
To remove a water guide ring, proceed os follows:
(Cylinder liner is removed).
_ Fit eye screws with suitable washers into the three threaded holes just below the upper edge. - Pay particular attention to the fact, that the eye screws threads are not too long; they might other wise jam the water guide ring, requiring removal, in the cylinder jacket.
- Attach the eye screws by a three rope set to the crane.
- Ease the water guide ring from its seating with a jemmy 'HI attacking in two opposite recesses 'N' at the bottom edge of the water guide ring, do not pull with the crane before the ring has been eased of - When the water guide ring is thus loosened off its seating pull in small steps with the crane, if ne cessary assist the lifting with the jemmy from below. Preparations for Fitting • • Clean the guiding and landing surfaces on the water guide ring and on the cylinder jacket .Place
~
rubber rings of the specified quality into the grooves
.Smear rubber rings and guiding surfaces liberally with tallow. Fitting Insert the water guide ring, hanging on the crane, into the cylinder jacket. Pay particular attention
to the requirement that the ring must only slide in on its own weight through the guide portions, un-c
til it finally rests on its landing at the bottom.
- Check that the water guide ring really rests on its landing and does not protrude above the seating surface 'AF' for the cylinder liner on the top of the cylinder jacket.
5.84
~
SULZER
CYLINDER LINER
RT
Measuring Bore Wear
Group:
214
Sheet:
1
Key to Drawi ng
Tools: 1 Inside micrometer 1 Measuring gauge
1 Cylinder liner 2 Oi 1 groove
94101 94225
94225
94101
1
Whenever a working piston is re moved for overhaul, the cylinder liner bore has also to be measu red. The figures found are to be recorded so that they can serve as comparison with earlier or later measurements. In this way, normal wear can be determi ned and followed. Comparisons with other measure ments can, however, onl y be made if the measurements are always taken at the same place. For this reason, use the measuring gauge 94225 which is part of the tool kit. The measurements have to be taken in both longitudinal and transversal direction to engine axis by putting the inside mi crometer 94101 into the holes especially provided for this purpose in the measuring gauge. The ridge formed during the course of operation at the top of the cylinder bore has to be removed carefully without dama ging the running surface for the piston rings.
,,- 107.197.056
T .R .
')
PIl
SULZER
RT76
CYLINDER LINER
Group:
214
Removal and Fitting
Sheet:
2
~:
1 1 1 2 2 1
Suspensi on gi rder Jacki ng gi rder Jack support Suspension straps Screws to 94206 Hydr. Jack wi th HP Hose High pressure oil purnp
(, ey to Illustrations
942 ': 2 94204 94205 94206 94207 94950 94935 94931
1 2 3 4 5 6 7 8 9
Holding p~2re Holder Centring pin Ro 11 pi n Screw Screw Screw Locki ng p1ate Locking p1ate
Cy 1i nder head 11 11dter gui de ri ng 12 Cylinder jacket 13 Cylinder liner 14 Water guide ring AF Seati ng surface H Hard wood bedding S Screws to 94204 :"
®
5
1-107.197.587
1984
RT
214/2a It is vital that the following preparations are carried out before a cylinder liner is removed:
• Drain the cylinder cooling water from the respective cylinder, i.e. first shut the two valves cylinder cooling water inlet and outlet; The drain valve is situated immediately behind the cooling water inlet valve at the bottom of the cylinder jacket on the fuel pump side, the cooling water outlet valve however on the top above the exhaust valve cage. Open the drain valve in the cylinder cooling water outlet pipe of the respective cylinder. • Remove the pi stan rod gl and (see Group 231, Sheet 1). • Remove both bolts 5 (one each on fuel pump and exhaust sides, see Fig. 1iner onto the cyl inder jacket.
Ie')
which hold the cylinder
• Discommect all cylinder lub. oil pipe connections from the lubricating quills.
I-I
©
10 11
6
4 2 13
8
Brennstoffpumpenseite FUEL PUMP SIDE
3
I
II- II
® 11
5 ---i!dIiI~ 1
7'~E~
9
1-107.195.505
2.84
214/2b Removal ~
(Figures 'AI and 'B')
Procedure:
----------
- With the bearer 94204 suspended from the crane, lower it through the cylinder liner bore and bolts
it to the bottom edge of the cylinder liner with both the bolts'S'. - Bring the crosshead to T.D.C. - Place support 94205 and jack 94950 above each other on the crosshead. - Connect up jack to high-pressure pump 94931 and then jack the cylinder liner out of its guide sec tions.
Lay two planks of wood opposite each other between cylinder jacket and cylinder liner collar in order
to prevent the cylinder liner from sliding back into its guide section. - Lift off and remove jack together with support from crosshead. Remove jacking girder 94204. - Place the suspension beam 94202 on the cylinder liner and connect it to the susptnsion straps 94205 ~ith screws 94207. - Lift out and take away the cylinder liner with the crane. Preparations for fitting: .Thoroughly clean guide sections and sealing surfaces of cylinder liner and jacket and dress any da mage • • 'nsert rubber rings of the quality and dimensions specified into the grooves of the cylinder liner • • Coat all the rubber rings and guide sections of the cylinder liner and jacket with tallow • • Thoroughly clean seating surface 'AF' of cylinder jacket • • Check that water guide ring has been fitted. Fitting
(Figure'E')
- Fit the transporting device to the cylinder liner to be installed in the same way as was used for 'Removal' (See Fig. 'B'). - With the cylinder liner hung on the crane bring it above the cylinder jacket. Before lowering it smear the seating surface 'AF' of both the cylinder jacket and that on the cylinder liner collar with a nonsetting sealing compound. Lower the cylinder liner, thereby ensuring that the centring pin 3 (Fig. 'C') engages in the centring hole in the cylinder jacket (on the fuel pump side). - Place a cylinder head on the cylinder liner and screw it down with four evenly distributed nuts. Tightening these in a crosswise manner will result in the cylinder liner being pressed fully down into the cylinder jacket (Fig. 'E'). - After removing the cylinder head insert the screws 5 and tighten them.
Putting the cylinder liner uprjght (Figure 'F')
There are two diametrically opposite threaded holes at the same level cut in the collar of the cylinder
liner. These servo to accept the two special bolts 94207.
These, together with the slinging wires, make up a suspension device which is used when handling a bare
cylinder liner in the ~orkshop during manufacture or such like.
For reasons of safety, this suspension arrangement should never be used as transport device on board. Always use the device as shown on Fig. 'B' for this purpose •
.!..J •
_.
~..,
,...,
214/2c
RT7G
®
® 94202 94206 94207
!
!
I
~~::="''''''''~,-==--il..+
2-107.197.688
H
Gezeichnet fur RT 58 DRAWN FCiR RT 58
4 -107. 198.851
H
1984
SULZER
RT
Cylinder Liner
Group:
214
Removing the wear Ridge, Re-dressing the lubricating Grooves, as well as the Edges of the scavenge Ports
Sheet:
4
Key to III ustrati ons
Too 1s: 1 Wear ri dge gri ndi ng devi ce Emery cloth Assorted files Fine grain carborundum oil brick
94299
1 2 3 4 5 6
Roller support Holder Holder Spacer ro 11 er Pipe (column) Grinder
7 8 9 10 11
Air hose Hose oiler Thread nozzle Carbide milling cutter Cylinder liner
®
Check drilling
([) Scavenge port
(f)
',,--,
Due to wear om to where heir depth, also happens
Lubricating grooves
by the piston movement in the cylinder liner running surface ridges are formed on top and bot the piston does not reach. Due to the wear the lubricating grooves in the cylinder liner loose furthermore the corner radii of the scavenge port edges become smaller and thereby sharper. It that the edges get damaged.
When a piston is removed the opportunity should be used to measure the bore of the cylinder liner (see 214, sheet 1) and to remedy any changes which occurred. The following points are of particular importance: • Protect the space below the cylinder liner with suitable material from falling particles. • After completing the reconditioning clean the bore of the cylinder liner thoroughly and remove any trace of metal dust (particulartly from the lubricating grooves). • Carefully remove waste particles which may have passed into the scavenge space through the ports. • Actuate the cranks of the cylinder lubricators until oil flows from all the lubri cating points, thereby flushing any metal dust which accumulated there.
Removina the wear Ridae When grinding away the wear ridge take greatest care not to damage the running surface within the area co vered by the piston and piston ring stroke from T.D.C. to B.D.C. We therefore recommend using a wear ridge grinding device (Fig. '0 1 ) for carrying out this work. It is listed in the tools list under "Recommended special tools". Redressi na the 1ubri cat; na arooves If the depth of the lubricating grooves has worn to less than 1.5 mm (new depth 2.5 mm) re-dress them to their original depth and slightly chamfer their edges with an oil stone or similar. Re-dressinq the Edqes on the scavenqe Ports On the next page the edge shapes on new cylinder liners are depicted. In case the condition of the edges requires reconditioning (depending on the degree of wear or aamage) aim at matching these shapes. Take great care not to damage the running surface in the cylinder liner bore. Polish the passages into the run~ ing surface with emery cloth.
L. B.
5.85
RT68 76 e14
214/40
/
I
j
(
985
RT
214 /4b
5\ \
1 \ \
@
I ~
: -~91,299
II
0-107. 215.291.
10
gezeichnet fur RT 58 DRAWN FOR
RT 58
Hartmetall - Fraser Zahnung III HARD METAL CUTTER TOOTHING III
¢8
I
0
~()
DC
SULZER
RT
Lubricating Quills and Accumulators (MULTI LEVEL LUBRICATION) Function Check
Group:
215
Sheet:
1
Key to III ustrati ons: 1 2 3 4 5 6
Accumul ator cyl i nder Spring ~,ccumulator piston Cap nut Diaphragm Accumulator-casing 7 Cap nut 8 Backing screw 9 Copper sealing rings
10 11 12 13 14
Cyl i nder 1i ner Lubricating qui 11 Filling pin Steel ball Non-return valve ho us ing 15 Non-return valve in cylinder liner 16 Spring guide 17 Steel ball 18 Copper joint ring
When pulling a working piston, the cylinder lubrication system should also be checked for correct fun ctioning. (The function check must also be carried out in case of malfunctioning of the cylinder lubri cation) Turn the crank of the respective cylinder lubricating pump until oil emerges from all the lubricating points in the bore of the cylinder liner. On cyl inder liners with two rows of lubricating points (MULTI LEVEL LUBRICATION) the oil delivery for the upper rQW must be set on the cylinder lubricating pump to 30% (Abb. 'A') and for the lower row to 70% (~bb. 'B') of the total quantity delivered. To ensure that thi s proportion is maintai ned see that all 1ubri cati ng .poi nts 0 one row yi el d the same oil flow. Should deliveries differ, re-adjust on the cylinder lubricating pump the setting screw pertaining to the respective lubricating point. Use the occasion to check at random several accumulators. Open them to inspect the diaphragm 5. If oil is found in the inner space of the accumulator piston 3 or in cylinder 1, the diaphragm is leaking and must be replaced by a new one. New diaphragms are supplied in special plastic boxes, ready for fitting. Fit the diapragm with greates care so as not to damage it. In case a non-return valve must be replaced, remove first the backing screw 8 after which the valve can be pulled out together with the filling pin 12 which is joined to it. Non-return valves are only supplied complete with filling pin as replaoement parts. After fitting the new valve tighten the backing screw 8 moderately and lock it with a center punch. When replacing a non-return valve 15 in the cylinder liner (Fig. "B") the thread must be sealed with 'LOCTITE', Replacement of non-return valve 15 is only possible on the removed cylinder liner. After changing the non-return valve a leakage check must be carried out. Remark: Lubricating quills for the II Multi Level Lubrication" have filling pins 12 of different lengths. The fi lli ng pi ns of the 1ubri cati ng quill s 11 for the upper row of 1ubri cati ng poi nts are lon ger than those for the lower lubric~ting points/grooves.
I
~
RT
215/10 1
fA' \CJ
FUr obere Schmiernufen FOR UPPER LUBR/CATION GROOVES
4
8---~
12'--------'
3 -107. 125.039
11
10
®
FOr untere Schmiernuten FOR LOWER WBR/CAT/ON GROOVES
9----.1
9 1112
Ganze 6ewindelange abgedichtet mit Loctite ENT/RE THREADED LEN6TH SEALD W/TH LOCTITE
15
17 16 18
4 -107. 240. 301
L. B.
1988
SULZER
RT
PISTON ROD GLAND
Group:
231
Removal and Fitting as well as Measuring the Wear
Sheet:
1
Too 1s:
Key to 111 ustrati ons
2 Eye screws 2 Jacking screws Hand 1 amp Assorted spanners De'lice far fitting the garter sprirgs of the oil scraper 94231 ri ngs
1 2 3 4 5 6 7 8
Sc rew Locking plate to item Screw Locking p1ate to item 3 Scraper ri ng, 3 parts Sealing ring, 3 parts Guide ring, in 1 piece Piston rod
o
I-I
9 Roll pin, Dowel 10 Garter spri ng 11 Garter spri ng 12 Oil scraper irng, 2 parts 12a Oi 1 scraper ri ng 3-piece 13 Seal ing ring, in 1 pi ece 14 Ring holder in upper casing 15 Ring carrier with 10' ring groove
16 17 18 19 20 21 22 23 24 25 AD
~II
Ring holder in lower casing Upper casing Cylinder jacket O-ring Garter spring O-ri ng Lower casing O-ring Lock piece Spacer ring (bronze) Threaded hole for jacking screw or eye screw respectively
5 6
7
1
22
Geze;chnet fur RT 58 DRAWN FOR RT 58
8
AD
11
3
1
20
1-107. 198.897 ~.
B.
231/1a
RT
During every piston overhaul the piston rod glands must also be removed and checked. Parts which are badly
worn must be replaced (please refer to indications further down on this sheet).
It is very important to have the glands in excellent condition when they are reassembled, as the next dis- '-/ mantling is not possible without removing the piston i.e. not before the next working piston overhaul. The piston rod gland is removed as a complete unit after the piston has been pulled out.
For removal of the gland, loosen and remove the screws 3 and jack the gland out of its centring guide with
the jacking screws inserted in the threaded holes 'AD' and tightened equally.
When the gland is loose, remove the jacking screws and insert two eye screws in their place. Attach the
gland to these eye screws and lift it with the crane through the bore of the cylinder liner.
It is advisable to immerse the whole gland in a container with cleaning solution and to subject it to a
preliminary cleaning before it is dismantled for inspection.
After removing the screws 1 separate the two gland groups and remove the individual parts. The ring hol-
ders are equipped with threaded holes permitting their removal with grip screws.
The ring holders 15 are somewhat smaller in diameter than the ones in the upper casing, they are therefore the first to be refitted in the lower casing. After dismantling check the wear by measuring the following parts: Upper gland group: Scraper ring 5 (in 3 parts) Sealing ring 5 (in 3 parts) Guide ring 7 (in 1 piece) Lower gland group: Oi 1 scraper ri ng 12 (2-piece) according to Fig. 'B' Oil scraper ring 12a (3-pi ece) according to Fi g. 'B l ' in design variant Sealing ring 13 (l-piece) The admissible wear on the wearing parts is indicated in the clearance table group 12 sheet 4. Any parts which are near to the still acceptable limit values or have already exceeded them must be repla ced by new ones. In doubtful cases it is better to decide on replacement, as they can only again be che cked when the next piston overhaul is taken in hand, which can be as long as 10'000 operating hours away. The garter springs 20, 11 or 10 as well as the rubber a-rings 19, 21 or 23 must also be replaced unless they are in perfect condition. When assembling a gland ensure that the individual parts are i~stalled in the same order and position as shown on the figures 'A' and 'B' or design variant 'Bl'(note also the design variant Fig.'e' for the RT5~) Remarks: In one of each oil scraper and sealing ring group a hole is drilled in the ring above into which the roll pin (dowel) of the ring below has to fit (see detail on Fig. 'BI). All the oil scraper rings including the sealing rings must be easily movable when the screws 1 are fully tightened. The screws 1 must be locked with locking plates. Do not at first install the following parts of the upper gland group: scraper ring 5, sealing ring 5, lock piece 24 and the garter springs 20 and 11. Fit these parts only after the working piston has been fitted.
I
Q
RI
231/1b Fitting
Smear the rubber O-rings 19 and 23 and the corresponding centring surfaces liberally with TALLOW (sheeps fat), then insert the cornpleate gland into the cyl inder jacKet. Tighten the screws 3 and lock them wi th the lock i ng pl a tes 4. ~fter fi Hi ng the worki ng pi ston fi t the i terns 5, 5 and 24 and cl amp them wi th the garter spri ngs 20 and 11 to the pi ston rod.
® ----Pos.7
Pos.13
Gezeichnet fur RT58 2 -107.198.894
DRAWN FOR RT58
2.84
RT
231/1c
Kolbenstongenstopfbuchse - Ausfuhrungsvorionte PISTON ROO GLAND-DESIGN VARIANT
Pos. 5
Pos.6
Pos.?
Pos.120
Pos.25
Pos.120
Gezeichnet fur RT 58 DRAWN FOR RT 58
2 - 107 215 238
, ,.,
231/1d
RT 68 75 84
Vorrichtung zur Federmontage der Oe/abstreifringe DEVICE TO SPRING MOUNTING OF OIL SCRAPER RINGS
4 - 107.240.113
101¥'
SULZER
RT76
CYLINDER HEAD
Group:
270
Removal and Fitting
Sheet:
1
'-"
-Too 1s: 94215 Hydr. Jack Suspension device 94265 3 Protective caps 94265(a) Various spanners
5 Fuel injection valve Cylinder head 6 Starting air valve Nut Cylinder head studs 7 Indicator valve Outlet of cylinder 8 Relief valve 9 Water guide ring cooling water 4 Exhaust valve cage 1 2 2a 3
x
K Safety chain R Eye screw S Suspension screw X Threaded holes for jacking screws
8
2 UJ
20
UJ
.... ' - V)
Q)
.... '-
C) V)
V)
'
Q)C Q)
V) 0.. o.:~ .'::'
~
I II)
6
o
V)
,::, ~
O\:t
1;;0..
.0>( lo4,J
C:-.J C:UJ
'0::{
Q),::,
Q5~
3
s
x
1- t07. 198. 438
emoval Drain the cylinder cooling water from the affected cylinder, i.e. first shut the two valves for cylinder cooling water inlet and outlet; the drain valve is located directly behind the cooling water inlet valve at the bottom of the cylinder jacket on the fuel pump side, the cooling water outlet valve however is on the top above the exhaust valve cage. Open the vent valve in the cylinder cooling water outlet pipe of the respective cylinder! Disconnect all the pipes to the cylinder head and to the exhaust valve. Clean all the thread protrusions on the cylinder head studs. Loosen the nuts of the cylinder head studs (in accordance with the instructions on sheet 270/2) and re
move them to a clean safe place.
On each cylinder head stud situated nearest the suspension screws'S', a protective cap 94265(a) must be placed; they are needed to centre the cylinder head and thus protect the stud thread • . Attach suspension device 94265 to crane, hook it onto the 3 suspension screw'S' and, to stabilize the cylinder head (with fitted exhaust valve) pass the safety chain 'K' through the eyelet of the eye-screw IR' and attach it. Lift the cylinder head carefully with the crane (see Fig. IB'). emark: The three screws'S' are fitted with Loctite in the cylinder head and therefore locked; they should therefore be left there also after removing the suspension device.
270/10
RT76
® 94265
K
I.4.J
R
V)
I
9
.~
~
'
~gj II) o~
~~
////
94265 (a)
~,
I
, l
I
.- ~2a j
I
3- 107. 215.283
5.85
270/lb
RT
Fi tting
Note the following points before replacing the cylinder head:
~
- Neither foreign matter nor dirt may be present in the combustion space. - The landing faces of cylinder liner and cylinder head must be clean and undamaged. Place a 2 mm thick soft iron sealing ring on the cy1inder 1iner so that it 1ies flat over its fu11 cir cumference. - The inside of the water guide jacket 9 bolted to the cy1inder head as we11 as the re1evant guide sec tions on the cy1inder liner collar must be clean and smeared with tal1ow. ~
rubber rings of the specified size and qua1ity have to insert in the grooves of the cy1inder 1iner. They too must be smeared with ta11ow.
- The cy1inder head stud bolt threads must be clean and smeared with MOLYKOTE paste. - P1ace a protection cap 94265(a) over each of the three cy1inder head studs situated nearest the suspen sion screws (S). (This instruction app1ies on1y to the engines RT 68, -76 and -84). Once the above conditions have been met, 10ver the cy1inder head carefu11y over the cy1inder head stud bo1ts with the aid of the suspension device 94265. The correct position wi11 be assured by the guide pins
(see Sheet 214/2a).
~
- After removing the suspension device, screw on a11 the nuts by hand onto the cylinder head studs, check
ing that they run freely. If necessary, dress the stud bolt thread until the nuts can be screwed on by hand. - With the aid of the hydro tensioning device 94215, tension the stud bolts according to Sheet 270/2 then connect up all the pipe connections. - Finally, close the drain and vent cocks and reopen the jacket cooling water inlet and outlet cocks.
SULZER
CYLINDER HEAD
RT76
Hydraulic Loosening and Tensioning Of Cylinder Head Studs
: 00 1s:
:'\ey
Simul-l:aneous pretensioning device 94215 ~ i r hydraulic HP oil Pum p 94941
~
L
3 4 5 5 7 8 9
Screw Eye screw Suspension stud Coupl i ng socket Round nut Vent screw Cover Stack of spring washers Screw
Do ub 1e cylinder Pi stan Piston seal ri ng Rod seal ring Cylinder head nut Cyl i nder head wai sted studs 14 Pressure limiting valve 15 Flow through valve 15 Pressure gauge
94941
"',/,/,
;()(;()(>~~~~~~.
,,,,/,/,"', /,/,/\./,/ ,/,/,/,/, /'J''''''''' '/'J'/'/' /,/,/
,/,/,/, /,/,/,/,/
''''1''''/' ,.,/,/,"',/ ,/,/,/,/, /
........ , / , / , /
)()()()()'m~"...,.,...,f","( tl
~
-t-
-
E
-I-.
- -+---+--
I
~
'+
I
Grap:
®
I'
+) Thre ads and nut seating smeared with Molycote paste G.n
Engine Tolerance AF
.. ..
( )
lin. ( ) .ax. Bolt elongation
Cl earance j
AL +
Tightening torque Nm )
(II)
In the measuring range for fig. , [ I (a cc. Fig.' BI) (801 t stu 11Y tightened) C) Cl
RT 62
RT 38
RT 48
RT 58
RT 68
RT 76
RT 84
...(),07 ...() , 11
-0,09 ...() , 13
...(),13 -0,17
...(),15 ...(),19
...(),18 ...(),22
...(),20
...(),24
0,19 0,31
0,28 0,41
,4! 0,5
°
0,47 0,60
0,57 0,69
0,63
0,75
0, 6O:fO ,05
°,85:fO ,05
~,75:fO,05
1800
2800
3400
1,0:fO ,05 1,JS:fO,OS 1,05:fO ,05 5100
6300
8500
Attention! The two bores of the gear wheel '0 1 ' and '0 2 ' (see Fig,'BI) are smaller by L::. F than the cor responding check lIIeasurelllents '0F l ' and '0F 2 ' on the crankshaft. (During machining the aVerJ ge tolerance is aiAled at.) Working Seguence - After fitting the two gear wheel halves as per po ints 1 to 7, the total le ngth ILl (see Fig. 'AI) of the waisted bolts must be I€ a sured with a V ernier call iper or a horseshoe lI1icrometer and rec orded (Note the bolt nUllbersl. o
o
Tighten the two bolts of one of the split faces with a spanner by hand (without the use of a hJmmer) until the gap on that split face is zero. Tighten the opposite two bolts in the salle lanner, whereby a gap jilin or j lax reAlains. (see I iy.'C ' ). '--../
- Should the gap be 1arger than j lax, the bores a f the gear wheel must be enl arged by an extremely sm.111 amount. Ihis can be done by careful scraping or grinding with elD~ry cloth arid J suitJlde piHe of \lood,
9.85
410/3d
"--'
RT
When the described initial position according to Fig. Ie' is reached in the measuring range for Fig. '0' (Gap = 0 and j rain. ~j ~ j max.)loosen the two waisted bolts of that gear wheel separating face si de havtng 0 _ clearance and tghten instead the waisted bolts of the gear wheel separating face side 1 having j clearance correspondingly more, so that finally in the measuring range for Fig. 10 (see Fig. 'BI) i.e. in the teeth region the clearance on both sides is equal. _ Tighten the waisted bolts crosswise with tightening device 94412 equally till their total length (see Fig. 'A') has increased by at least.o. L. _ In this condition between the teeth (in the measuring range for Fig. 10' in Fig. 'B' should the clea rance between the two separating faces by maximum 0.03 mm (Fig. '0'). _ In the measuring range for Fig. IE', Fig. 'B' i.e. on the outer edges between the shoulders the clea rance:should be practically zero. (Fig. IE').
1985
SULZER
RT
CAMSHAFT
Group:
420
Removing and Fitting a Camshaft Section
Sheet:
2
Too 1s: 1 Holding strap 1 Lifting device 2 Pi ns
1 Support 1 Clampng bolt 2 Holding straps 2 Supports 2 Special nuts 1 Set tools for cutting out an actuati ng pump Various spanners
94416 94417 94417 a 94418 94419 94422 94423 94423a 94430
2 3 4 5
Key to Drawings 6 Actuating gear housing 6a of the fuel and actua 7 tor pump B Camshaft (section) 9 Coupling 10 Reversing servomotor 11 Oil connecti ons
Inner beari ng shell Bearing saddle Bearing ring Bolts '0' rings '0' rings Feed shaft nut
The complete camshaft comprlslng several sections should never be fitted or removed in one piece.
The arrangement and use of the devices and tools for each individual section is the same as is shown on
illustration 'A'.
Valid only for engines with balancer Attention: The presence of a balancer (driven by the camshaft) must always be considered when fitting or removing a central or the last camshaft section at the free end of the engine. It is, therefore, absolu tely essential to follow the instructions in the supplement to Group 770/1 (there is otherwise the risk f an accident occurring).
gezeichnet fur RT 58 DRAWN FOR RT 58
1-107.197.0t.8
, 1
0
I
420/20
Removal of a Camshaft Section _ Remove the front and side casings from the fuel pump actuating gear housing. _ furn the engine with the turning gear and simultaneously raise the rollers together with their guides of III the fuel and actuator pumps from their cams. Refer to Group 551-26 of the Service instructions Manual for thi s. Make ready the cut-out devices for cutting out the actuator pumps (one tool 94430 for each actuator pump) • Slacken off and remove the tie rods with distance tubes which Jie vertically in front of the camshaft bearings to reinforce the fuel pump actuating gear housing. _ Release the shaft couplings which connect the camshaft section to be removed from its neighbouring units according to the instructions given on sheet 421/1g. The markings on the shafts and couplings make it possible to precisely reposition a~l the components during later re-assembly. _ Now slide the released couplings onto the camshaft sections which will not be removed _ Unscrew bolts 8 and pull down the oil connections 5 until there is no longer any connection between them and the bearing ring 7 of the reversing servomotor 4 (see Figs. 'A' and 'B'). _ As shown in Fig. 'A' attach a holding strap 94422 each on the front face of the drive housing; fhese prevent the camshaft accidentally slipping out of its bearings, while the bearing covers are being loo sened and removed. _ Slacken off both bearing caps and remove them. Replace them with the supports 94423 with the related special nuts 94423a on the now accessible bearing saddle 6a. _ Remove both the holding straps 94422 and rollout the camshaft section onto the supports 94423. Lift the unit from there with the aid of a crane. When removal will be carried out using the procedure whereby the cams will be pulled off the camshaft section, this can be prepared with the tool set according to Fig. 'e' and carried out there and then. Where the fuel cams, e.g. to the right of the reversing servomotor will be pulled off the shaft then the holding clamp 94416 has to be mounted on the left of the drive housing. Fit support 94418 at the same time. Lay the lifting device 94417 on the supp~rt 94418 and position this at the same time with the two pins 94417a which have to be inserted up in the drive housing. _ Clamp the bearing ring 7 of the reversing servomotor 4 with clamping bolt 94419 (see detail Section I I-Ill.
®
_ Use a screwdriver on the feed shaft nut 11 and thereby raise the camshaft section enough to unload a support 94423 which can then be removed. For further procedure, particularly for pulling off and on of a fuel and actuating cam, seee information in Group 421.
10 1
5 7
8
~.
B.
11 .84
420/2b
RT
@
J ~=.
c§l51~
I
_.....
I
-1
I I
-t·
I
=~ ~
1
111-111
1
9~419 (RT
62)
Gezeichnet fur Nocken demontage rechts DRAWN FOR DISMOUNTING THE CAMS ON THE RIGHT HAND SIDE OF THE REVER SING SERVO MOTOR
9~~23 0-107. 217. 136
1985
420/2.c
RT
Fitting a Camshaft Section Fitting follows in the reverse order or removal. Please not the follolling points: - The numbering of the individual parts IIhich belong together must concur. - The contact surfaces of the supports onto IIhich the camshaft section to be fitted lIill be placed
must be clean. The same applies to the camshaft bearing journal s and bearings.
- Shortly before rolling the shaft into its bearings lubricate the bearing surfaces liberally lIith
clean oil.
When fitting the camshaft bearing shells particular care has to be taken to ensure that the pin in
the bearing cap engages properly in the hole on the back of the outer bearing sh~ll half.
Furthermore, the inner bearing shell must be so placed in the axial direction that both its pins,
IIhich are in the butting faces, can engage properly in the relevant holes in the outer bearing
shell IIhen fitting the bearing cap.
The best thing is to put the bearing together provisionally before fitting the shaft, so long as
the inner bearing shells can still be slid sidellays.
Attention!
- The clamping bolt 94419 must be removed from the reversing servomotor and the three oil connec
tions 5 pulled up and led into the bearing ring 7 before the couplings 3 are pressed into the
shaft connections.
- When sliding on and positioning the couplings, check that the locating marks on the shaft ends to be connected concur. With regard to pressing on the shaft coupling lIith hydraulic fitting tools, see Sheet 421/2 and 421/3. Tightening the Studs of the Camshaft Bearings
Once the camshaft is in its bearings and their bearing caps are fitted, tighten down both the nuts
evenly lIith a spanner by hand until meta1-to-metal contact is obtained.
NOli tighten the nuts equally in little steps alternately, using the ring spanner and hammer.
Where a final check shows that the vertical bearing clearance of the camshaft bearings (see Table of
Clearances 012/10) is in order, the nuts can be secured with the locking plates.
I
0
"
0 I
SULZER
Steuer~elle/Camshaft
Demontage u. Montage der hydro Pressverbande Dismantling and Assembling of Hydraulically Fitted Components
RT
Gruppe: Blatt:
421 l:)
Steuerwel1enkupplung, Hubgebernocken und Brennstoff nocken werden mittels Hydraul ikwerkzeug montiert, ausgerichtet (eingestellt) und demontiert.
Coupling for camshaft, actuator cam and fuel cam are fixed with the oil injection method. They are mounted, adjusted and taken off with separate hydraulic tool.
(Details siehe 421/1 + 3)
(For details see 421/1 + 3) DemontagejDlsmantling
Motor schalten und Rol len abheben. Hydr. Werkzeug auf Kupplung montieren. Kupplung lasen und diese axial wegschieben. Lagerdeckel entfernen und Umsteueralanschlusse ab senken.
Turn engine and lift Hydraulic tool to be Coupl ings to be s1 id Bearing covers to be regulating oil to be
rollers. fixed to couplings. in axial direction. taken off and connections for lowered.
Hydr. Werkzeug HYDR. TOOL Steuerwelle aus dem Gehause rollen. Hydr. Werkzeug auf Hubgebernocken montieren.
Camshaft section to be rolled out of housing Hydraulic tool to be fixed to actuator cam.
Hydr. Werkzeug HYDR. TOOL Hubgebernocken entfernen und hydro Werkzeug auf ~rennstoffnocken montieren
Actuator cam to be taken off. Hydraulic tool to be fixed to fuel cam.
-Hydr. Werkzeug HYDR. TOOL BrennstotfnocKen entfernen.
Montage: Gleich wie Demontage, in umgekehrter Reihenfolge L.B.
Fue1 cam to be taken off.
Assembling: Same as dismantling but in reverse order
1984
SULZER
CAMSHAFT Removing the Fuel and Actuator Cams
RT
Group: Sheet:
421 1
'-'" Tools: 1 1 1 1 1 1 1 1 1 1 1 2 '-.../
Key to Drawings
Jacking tool Connecting piece Connection Connection Centering disc Hose pipe (1500 bar) Suspension strap Oi 1 pump Oi 1 pump SKF Oil pump High pressure ho se High pressure hoses
See Group 940/0a
94424 94425 94426 94427 94428 94429 94431 94931 94931a 94942 94935
1 Fuel cam 1a Actuator cam 2 Piston carrier section 3 Ring piece (2-part) 4 Bolts 5 Pi ston (total 6 off) 6 Camshaft 7 Sl eeve
8 Liner
8a Bush
9 Flange coupling
10 Guide plate
E Vents Connection from oil pump 94942 G) Connection from oil pump 94931 @ Connection from oil pump 94931 a
R Eye bolts
Q)
94935a
for tool detail s
Note: Three high pressure oil pumps of various designs are required when carrying out the work in Group 421, Sheets l-li described below. Fill up both pumps (Tool No. 94942 and 94931) before use with an oil of viscosity grade SAE 40. The non-return valve 94939a inserted between oil pump and jacking tool 94424 serves a special purpo se. When pumping, the non-return valve must always be closed. In this valve position oil can reach the jacks but cannot escape back. The lowering of existing pressure in the jacking tool can be very finely regulated by careful opening of the non-return valve. Removing the Cams Work Procedure: ~
Place the camshaft section in a clearly accessible and clean area.
- Slide tool 94424 over the shaft against the cam. - Screw in and tighten connecting pieces 94426 and 94425 to connection 'HI in the threaded hole M16 x 1.5 (with oil connection drilling 0 6 at the bottoml. - Screw in all the bolts 4 for mounting the tool, on the sleeve 7 and on the actuator cam itself, by hand but do not tighten them. - Connect up the oil pump 94931 with high pressure hoses and appertaining fittings to connections IWI and oil pump 94942 to connection 'H' as shown on the illustration. - Open both vent scre~s 'EI on tool 94424 and operate the high pressure pump until the oil escapes bubble-free. Shut the two vent screws. - Extend the piston and evenly tighten all bolts 4. - Oil may only be applied to connection 'HI after the oil pressure in the tool (connection 'WI) has been set at 30 to 50 bar. Pressure may only be built up at connection 'H' when the tool has been correctly fitted and is under pressure. Accident risk! - When oil appears around the full circumference of the jack seat, oil from the seam, the pressure in the tool can be slowly reduced, whereby the cam is loosened. - ATtach suspension strap to fuel injection- or actuating cam respectively as shown in illustration on sheet 421/1i. Lift cams with the aid of a hoist from the sleeve 7 or the camshaft 6 respective ly together with the bushes 8.
L. B.
1. 89
421/10
RT
Brennstoff- Nocken
Hubgeb er - Nocken
CAM TO FUEL PUMP
CAM TO ACTUA TOR PUMP '-"
I
H
5 6 7
3 -107. 197. 653
L.B.
1.88
SULZER
CAMSHAFT Pressing on the Fuel Pump Cam
RT ~
Tools:
Key to Drawi ngs
See Sheet
See Sheet 1
Group:
421
Sheet:
IB
E
Connecti on according to Sheet la
94424
1
,/ 4 - 107. 197. 367
Connection according to Sheet 1a
- Clean all seating surfaces before fitting. Slide the cam with liner onto the sleeve of the reversing servomotor. Ensure that the cam and liner are flush with each other. Slide the jacking tool along to the cam, screw connecting piece 94426 into connection 'H' (note drilling 0 6), then tighten all mounting bolts 4 evenly by hand. Connect pump 94931 to connections 'w' and pump 94942 to connection 'HI. -- - Open both vent screws' E' on tool 94424 and operate the hi gh pressure pump until the oil escapes bubble-free. Shut the two vent screws. Apply pressure to the taper with connection 'H' until oil escapes on both sides between reversing servomotor sleeve 7 and liner 8 around the full circumference. - By slowly increasing the oil pressure in the tool the cam will move slowly axially. The pressure at connection 'H' will rise continuously to about 550 bar. Oil must flow from both sides of the cam during the whole tightening procedure. - When the end position is reached, i.e. the cam and liner are at the limit stop, first release the oil pressure in connection 'HI and then, after about 30 seconds, the pressure in the tool. - Dismantle tool.
L.B.
1.89
SULZER
RT
Group:
CAMSHAFT Pressing on the Actuator Cam
Tools:
421 Ie
Sheet:
Key to Drawings
See Sheet 1
See Sheet Connection according to Sheet 1a
4 - 107. 197. 368
L @)
Connecting according to Sheet 1a
- Clean all seating surfaces before fitting. - Slide the cam and liner onto camshaft and position (note recess). Bolt on jacking tool whereby all the bolts 4 must be tightened evenly by hand. Connect pump 94931 to connections 'w' and pump 94942 to connection 'H'. - Open both vent screws 'E' on tool 94424 and operate the high pressure pump bubble-free. Shut the two vent'screws.
until the oil escapes
- Apply pressure to the taper with connection 'HI until oil escapes on both sides around the full circumference. - By slowly increasing the oil pressure in the tool the cam will move slowly axially. The pressure at connection 'HI will rise continuously to about 800 bar. Oil must flow from both sides of the cam during the whole tightening procedure. When the end position is reached, i.e. cam is flush with the liner, first release the oil pressure in connection 'HI and then, after about 30 seconds, the pressure in the tool. - Dismantle tool. - Attach suspension strap to fuel injection- or actuating cam respectively as shown in illustration on sheet 421/1i. Lift cams with the aid of a hoist from the sleeve 7 or the camshaft 6 respectively together with the bushes 8. Remark: When replacing an actuator cam la, its bush 8a must be replaced at the same time. Both parts form one unit and must not be interchanged. For spares orders bush and cam are always supplied together. L.B.
1.89
SULZER
CAMSHAFT Adjusting the Fuel and Actuator Cams
RT
Group:
421
Sheet:
1D
Key to Drawings
Tools: Gauge for setting cams High pressure oil pump Connecting piece Hose pipe (1500 bar)
94432 94942
94427
94429
See Sheet 1
.
M22xl,5
•
..
~--+-M22 X
7.5
10 0
I I
I I I
I
rr:
9"32
.. la
, - 107. 197. 378
1
Important Notes: - Before shifting cams, rollers with roller guides of a respective fuel injection pump group must be lifted above their cams. To adjust (move) the cams, the pump 94942 must be connected to connection 'HI. - Approximate pressure necessary to move cams: Fuel cams 600 bar Actuator cams 800 bar - Attention! Before applying pressure 10 the fuel cams ensure that the guide plates 10 (2 off) are bolted onto the side of the sleeve. These prevent the fuel cam from sliding sideways when adjust. ing it and it is therfore essential that they be in place.
L.B.
2.84
SULZER
RT
CAMSHAFT Removing and Fitting the Flange CouDling
Too 1s:
Group:
Sheet:
421 IE
Key to Drawings
See Sheet
2 3 4 5 6 9
E Vents Connecti on from pump 94942 G) Connection from pump 94931 R Eye bo It
Piston carrier plate Ring piece (2-piece) Bolts Pi ston (total 6 off) Camshaft Coupling flange
Q)
Removing the Flange Coupling Connection according to Sheet 1a
E
R
E
4 - 707. 797. 379
Connection according to Sheet 1a - Place the centering disc 94428 on the camshaft end.
- Bolt the jacking tool onto the coupling flange with bolts 4, only slightly tightening them by hand.
- Connect pump 94942 to connection 'H'.
- Open both vent screws IE' on tool 94424 and operate the high pressure pump until the oil escapes
bubble-free. Shut the two vent screws. - Extend the piston and evenly tighten all bolts. Oil pressure may onl y be applied to connection 'HI after the oil pressure in the tool (connection 'W') has been set to about 100 bar. Pressure may only be built up at connection 'H' when the tool has been correctly fitted and is under pressure. Accident risk! Once oil appears around the full circumference of the seam, the pressure in the tool can be slowly reduced, whereby the flange coupling is loosened. - Dismantle tool. Remove centering disc. L. B.
2.84
RT
421/1f Fitting the Flange Coupling
Connection according to Sheet la
3
2
---~ .~~
R
E\ \
\
94425
"'-MI6xl,5
4 - 107. 197. 380
Connection according to Sheet 1a
- Clean all seating surfaces before fitting.
- Position the flange with liner on the camshaft. Note marks on liner, flange and camshaft.
- Bolt on the jacking tool, whereby all bolts must be tightened evenly by hand. Connect pump 94931
to connecti ons I WI and pump,94942 to connecti on I HI. - Open both vent screws 'E' on tool 94424 and operate the high pressure pump until the oil escapes bubble-free. Shut the two vent screws. - Applly pressure to the taper with connection 'HI until oil escapes on both sides around the full ci rcumference. - By slowly increasing the oil pressure in the tool, the flange will move slowly axially. The pres sure at connection 'HI will ri se continuously to about 1000 bar. Oil must flow from both sides of the flange during the whole tightening procedure. When the end position is reached, i.e. flange flush with liner, first release the oil pressure in connection 'HI and then, after about 30 seconds, the pressure in the tool. - Dismantle tool.
L. B.
2.84
SULZER
CAMSHAFr
RT
Group:
Removing and Fitting the Camshaft Coupling
Sheet:
421 1G
Removing the Camshaft Coupling
9~931a
/ E
R
E
5
Connection according to Sheet 1a
- Bolt on the tool 1i ghtl y with bolts 4. Connect pump 94931 to connections' W' and pump 94931 a to con nection'S'. - Open both vent screws IE' on tool 94424 and operate the high pressure pump until the oil escapes bubble-free. Shut the two vent screws. - Extend piston and evenly tighten all bolts. - Set the pressure in the tool to 300 bar and then apply pressure at connection'S'. Pressure may onl y be bui lt up at connecti on IS' when the tool has been correctly fitted and is under pressure. Accident risk! When oil appears around the full circumference of the seam, the pressure in the tool can be slowly reduced, whereby the outer sleeve will slide slowly off the liner. - Dismantle tool.
L. B.
2.84
RT
421/1h Fitting the Camshaft Coupling
949310 i
/ I
'" -107. 197. 383
Connection according to Sheet la
- Clean all seating surfaces before fitting. - After mounting the shafts the axial gap between them may not exceed 1 mm. The two shaft ends must be exactly aligned. Check: Roller of fuel cams must be aligned. - Push coupling over the camshaft and place in correct position, dimension A. - The marks on the shaft ends must correspond. Position the coupling as illustrated. Bolt on the jacking tool, whereby all bolts must be tightened ~ by hand. Connect pump 94931 to connections 'II" and pump 94931a to connection'S'. - Open both v~nt screws 'E' on tool 94424 and operate the high pressure pump until the oil escapes
bubble-frQe. Shut the two vent screws.
Apply pressure to the taper with connection'S' until oil escapes on both sides around the full cir cumference. By slowly increasing the oil pressure in the jacking tool, the outer sleeve will slowly slide onto the inner sleeve. Oil must flow from both sides of the coupling during the whole tightening proce dure. - When the end position is reached, outer and inner sleeves are flush, first release the oil pressure in connection IS' and then, after about 30 seconds, the pressure in the tool. - Dismantle tool.
L. B.
2.87
421/1;
RT Aufhangelasche fur Brennstoff-und Hubgebernocken -Transport
LIFTING LUG FOR FUEL AND EXHAUST CAM TRANSPORT
94431
Brennstoff - Nocken
FUEL CAM
geze;chnet fur RT 58
DRAWN FOR RT 58
4-107. 240.075
L. B.
1986
SULZER
RT
CAMSHAFT
Group:
421
Removing and Fitting of SKF Shaft Coupling
Sheet:
3
Key to III ustrati ons
Tools: Hydr. hand pump Hand oi 1 pump SKF Pressure gauge High pressure hose
94931 94931 a 94932 94935
o
1 2 3 4 5 6 7
Cam sha ft Inner sleeve Outer sleeve Pressure oil pipe Valve screw Refl ux val ve Name plate
8 Nut 9 Seal ring 10 Threaded pin
P R "HPC" "LPC"
Fi tti ng cl earance Ring space HIGH PRESSURE CONNECTION LOW PRESSURE CONNECTION
Achtung ! ATTENTION! MAX. OIL PRESSURE 25MPa (250barJ
94932
L. B.
Anschluss CONNECTION
LPC-----J
Anschluss CONNECTION
HPC
----.J
,Entliiftungsbohrung VENT HOLE
1985
RT
421/3a
Removi nq an SKF Shaft Coupl i nq Working Sequence Connect pressure oil apparatur, consisting of hand pumps 94931 and 94931a and pressure oil pipe 4, to the coupling as shown on Fig. IA'. Bring oil pressure in the ring space at LPC with hand pump 94921 to about 200 bar (20 MPa) and keep this pressure constant. The pressure in this ring space may under nJW circumstance exceed 250 bar (25 MPa); the caption on the name plate 7 is meant to draw attention to t his! - With hand oil pump (SKF 94931a press oil at "HPC" into the fitting clearance 'pI till it issues along the whole circumference between the sleeves. On bigger cJup1ings thi~ ~ay take ~~veral minutes. - If the coupling is very cold and the oil from this pump only manageable with difficulty the heat the coupling up a little. Recommended temperature 20 - 30 0 C.
® 1
R
Open reflux valve 6 on the pump 94931 connected to ring space 'RI till the outer sleeve 3 slowly slides off the inner sleeve 2. Should the outer sleeve not get loose, press some more oil into the gap clearan ce 'pi between the sleeves with pump 94931a. Slight tapping on the inner sleeve can also assist the loo sening of the outer sleeve. - Clean the shafts on both ends of the coupling, shut connection bore "LPC" and the vent hole, whereby the shifting force is only transmitted by the oil enclosed in the ring space, thereby preventing a jamm ing of the seal ring 9. Now push the coupling fully onto one shaft end.
I
P
RT
421 3b
Fitting an SKF - Shaft Coupling Working Sequence Clean coupling seats and bores of the inner sleeve. Smear coupling seats slightly with thin oil. - Push shaft coupling onto camshaft. When joining the two shaft pieces the axial gap between them must be maximum 1 mmj the shaft ends there fore have to be very accurately aligned. - The marks on the shaft ends must correspond (Fig. '0'). Place shaft coupling according to Fig.
RT 58 RT68 RT76 RT81, RT 62
Rl/l,"
,R3/l,"
ill
'cr.
A
13{5 149
161,
177
140
Connect the pressure oil pipe 4 of oil hand pump 94931 to "LPC" for the ring space of the outer sleeve and open the vent hole nearby. Screw hand oil pump 94931a firmly into the connection bore G 3/4" of the outer sleeve and press oil (SAE 30) into the clearance gap 'pi until it flows out at the thicker end of the inner sleeve. With pump 94931 feed oil into the ring space until it flows from the vent hal e with out bubbling. Shut vent hole and by continual oil feeding drive the outer sleeve onto the inner sleeve, taking care that the pressure indicated on the pressure gauge never exceeds 250 bar (25'MPa). Continue pumping oil into the fitting clearance to maintain the oil film. The press fit is completed when the in ner sleeve protrudes by 10 mm. (Fig. '0').
®
Marken MARKS
Atteorl:i on! - Open the valve screw 5 of the oil pump 94931a to allow the oil from the fitting clearance 'pi to return to the oil container. Loosen the pressure oil pipe from "LPC" and remove with oil pump 94931. Shut the connection bore -LPC" with the corresponding threaded plug. The remaining oil is not drained from the ring space.
L.B.
? P7
RT
421/3c
After the first fitting, the nut 8 must be re-tightened; Loosen locking set screw and threaded pin 10 (Fig. lEI) to unlock the nut, tighten the nut 8, then lock the nut again by hard tightening threaded pin 10, lock threaded pin with set screw.
®
10
8
I. B.
9
1 n. R~
SULZER
CAMSHAFT
RT
Removing and Fitting the Gear 1 ,Theel to the Camshaft
Too 1s:
Group:
421
Sheet:
4
Key to Drawings
2 Holding straps 94420 2 Supports 94421 Var. spanners
1 Bearing housing 2 Camshaft 3 Coupling 4 Gear rim 4a Gearwheel hub 5 Adjusting screw 6 Inner bearing shell 6a Beari ng saddl e
7 Platform beam 8 Gearwheel for verti ca 1 dri ve
9 Distance ring S Bolt s * Threaded holes for taking the bolts lSI when tool is not being used
Valid only for engines with balancer Attention: The presence of a balancer (driven by the camshaft) must always be considered when fitting or removing the gearwheel on the camshaft. It is, therefore, absolutely es sential to follow the instructions in the supplement to Group 770/1 (there if otherwise the risk of an accident occurring).
o
gezeichnef fur RT58 DRAWN FOR RT 58
94421
•
1- 107. 197, 047
Removal Should it be necessary to remove the gearwheel on the camshaft, proceed as follows: - Bring the crankshaft of the first cylinder to T.D.C. (first cylinder at flywheel is cyl. No.1). Remove the casing hood above the gearwheel to be removed from bearing housing 1; the locating marks 1M' on the gear rim must line up with the outer edge lUI of the bearing housing (see Group 410/2). - For safety reasons take precautions to ensure that, while the work is being done, the turning gear remains en a ed but cannot be turned.
L.B.
2.84
421/4a Remove the 2-piece closing cover on the left and right side of tre bearing nousing as well as the hood (front). Release the shaft coupling 3 according to instructions on Sheet 42i/ 19 - Slide the now loosened coupling onto the neighbouring camshaft section. - The transmitter for the overspeed safety cut-out must also be removed from the drive side wall of the bearing housing. - Fit two holding straps 94420, one off per bearing saddle, sideways as shown on Fig. 'A'. These pre vent the gearwheel with its bearing journals from sliding out of its bearing by itself when the bearing caps are being slackened off and removed. - Slacken off and remove both the bearing caps and then bolt the supports 94421 onto the now acces si bl e bearing saddl e 6a. - Adjust the supports with the aid of the adjusting screws 5 so that they are solidly supported on the platform beams 7. - After removing both the holding straps 94420, the gearwheel, complete with camshaft 2, can be rolled out onto the supports 94421 and from there be lifted away by crane. - If the gear rim 4 with hub must be taken down for further dismantling of the camshaft, it is essen tial to check before any dismantling work is started if the gearwheel is marked together with its camshaft.
®
Markierung/DRIVING END
8 2
9
9
gezeichnet fur RT 58 DRAWN FOR RT58
3-107.197.339
L.B.
421 4b
RT
Fitting The gearwheel is fi tted to the camshaft in the reverse order or removal. Pl ease note the foll owi ng points when doing so: Note: During reassembly and later fitting of the gearwheel on the camshaft, ensure that gear rim 1 ap pears with its marking ~DRIVING END~ when looking at it from that end. The locating marks 'M' on the gear rim for the correct 'camshaft drive wheel position' are stamped on the same side (see Fig. 'B'l. - The identification numbers of the individual parts must correspond with each other. - All parts must be cl ean, undamaged, and lightl y oil ed before assembl y. - After the gearwheel on the camshaft has been rolled back into its bearings and both the holding straps have been fitted to stop it from rolling out by itself, a check has to be make if: 1) The locating marks 'M' on the gear rim correspond with the vertical outside edge lUI of the housing. 2) The gearwheel 8 for the vertical drive (bolted onto gearwheel hub 4a) is correctly engaged with the opposi ng gearwheel. Evenly tighten the bolts of the camshaft bearings using a ring spanner and hammer. When a final check shows that the vertical bearing clearance of the camshaft bearing (see Table of Clearances 012/10) is in order, the bolts can be secured with the locking pl ates. - When hydraulically tightening the shaft coupling 3, check that the marks on the shafts to be connected concur. With the oil pump running, check the oil supply to the bearings before finally fitting the hood.
Remarks for the Replacement of a split Design Gear Wheel on the Camshaft (Illustr. 'BI) - The removing and fitting is carried out as described above. - The replacement of a damaged split design gear wheel on the camshaft may only be done in exchange for a complete gear wheel i.e. the geared rim must be screw fastened to the hub and the bearing journal fitted. This is necessary as the final machining of the gear teeth has been carried out in this moun ted condition in the makers works and guarantees the required perfect true running of the complete gear wheel. For this reason a split design gear wheel may only be installed if the final machining of the teeth had been carried out with assembled hub/toothed gear rim. - After the final machining of the teeth the rim may not be separated
from the hub.
- Should the damage be limited to the toothing (gear rim), then the hub may be re-usedj provided a new
rim on which the teeth are not finishmachined is fitted to the hub, screw-fastened and dowelled to
which its teeth can be finished.
- The gear wheels for the auxiliary drives can be transferred to the replaced gear wheel. - After fitting a spare gear wheel it is strictly recommended to place an order for another spare.
L. B.
10.86
SULZER
RT
Removing anj Fitting the Pilot
Tools:
Valv~s
Group:
430
Sheet:
1
Key to Drawings
1 Extraction device 1 Feeler gauge
94451 94122 2 3 4 5 6 7 8 9
Upper shaft of the 10 Large holding pin lOa Small holding pin vertical drive Pilot valve sleeve 11 Cover Pilot valve 11a Screws Housing 12,12a Beari ng flange Starting timing cam ~ ~~}Beari ng bush Closing cover 14 Taper pin Pin for roller Ro 11 er 15 Dowel pin Tension spring 16 Taper pin
17
18 19 20 21 22 23 24 25 S SL
Support Bo It Locating pin I~ ut Threaded studs Extension pieces Jacking screws Oval fl ange Nut Clearance Bearing clearance
We recommend that during each 4-year survey a random check be made by removing two pilot valves 3 with sleeves 2 from housing 4 of the starting air control air distributor and to clean and examine them. (For reasons of safety, close the shut-off valve of the starting air receiver when carrying out this wo rk 1. The condition of the pilot valves removed will determine whether the remainder may be left in position or whether they all have to be removed. Should the pilot valves be very dirty, this means that the air supplied is not being cleaned sufficiently (poor condition air filters, etc. on the compressor). When pushed forward in their sleeves 2, the pilot valves 3 should move easily and be pulled back again by their spring 9. Roller 8 should turn easily on pin 7. Spring 9 must pull pilot valve 3 back until the latter rests against the large holding pin 10.
8 5
1~
19----, 110
11 3-------J
100
---J
2-------J '-107. 071. 730
2.84
430/1a
RT
Application fa extracting device 94451 for removal of pilot valve sleeves
c
®
23 20 25
24 22
a
b
.~.
1-107 073. 797
* When fitting the sleeve, place nut 20 under flange 24 if the sleeve cannot be pushed in by hand.
L.B.
2.84
430/1b
RT
Removal - Loosen screws 11 a and remove cover 11. - Bolt on device 94451 according to Fig. 'a' of I 11 us. 'B' and, by tightening nut 20, pull out sleeve 2 with the complete pilot valve 3 until it makes contact with the oval flange 24. It may then be possible to remove sleeve 2 by hand, using jacking screw 23. If not, screw the two extension pieces 22 onto the threaded studs 21, refit flange 24 and pull the sleeve out completely by turning nut 20 (Illus. 'B', Fig. 'c'). - For further dismantling, push the large holding pin 10 out sideways, thus allowing the pilot valve
with spring 9, roller 8 and pin 7 to be removed.
- The parts removed must be thoroughly cleaned. If possible, do not use emery cloth or else take care not to round off the edges of the sleeve and of the pilot valve. - Damaged components are to be replaced by new ones. - If spring 9 has to be replaced, the small holding pin lOa must be removed sideways by tapping it with a drift. Fitting If spring 9 was removed, refit it into the pilot valve 3 and also fit the small holding pin lOa. - Slide pilot valve 3, together with roller 8, pin 7 and spring 9 into sleeve 2 from the front. - Pull back spring 9 with a small wire hook and hook onto the large holding pin 10. - Carefully slide sleeve 2, with pilot valve 3 installed, into the bore of the housing (note numbering of the parts).
During fitting, make sure that locating pin 19 is at the top and comes to lie in the groove situated
at the front of the housing bore. - The sleeve can usually be inserted by hand if bore and sleeve 2 have been well cleaned. - If this cannot be done easily, use device 94451 according to Fig. 'a' of Illus. 'B'. Nut 20 must, however, be placed under the oval flange 24. By turning to the corresponding side, the sleeve is pushed into the bore until it seats. Attention! Never file or machine at the circumference of the sleeve for easier fitting as this might cause air leakage from one groove to another which, in turn, might impair the starting process. - With the pilot valves fitted, there should be a clearance of approx. 1 mm between the top of the starting pilot valve cam and each individual roller with n a air acting on the piston valve. This can be checked by dismantling closing cover 6 and bearing flange 12. - The total bearing clearance 'SL' should not exceed 0.3 mm.
L.B.
2.84
SULZER
Group:
432
Sheet:
1
STARTING AIR SHUT-OFF VALVE
RT
Cleaning and Function Check Too 1s:
Key to Drawings
Var. spanners
1 2 2a 3 4 5 6 7
Control valve Control piston Contra 1 valve body 10 1 ring Cover Guide bush Shut-off valve body Shut-off val ve housing 8 Shut-off valve seat
9 Non-return valve seat 10 Non-return valve body 11 Compression spring
12 10 1 ring 13 Allen screw 14 Non-return valve guide housing 15 Threaded bush 16 Piston sealing ri ng s 17
Compression spring
18 80 It
19 Rod sealing ri ng
20 21 22 23 24 25 26
Scraper ring
Spildle
Flange
80 It
80 It
Locking latch Handwheel
A Inner space 8 Annular space
AV 14
13 12 11 10
9
. ----.,
>.,.,c===l-I-I---t~.-
A B
C Stop D Equalizing hole E Drain valve K Check &water draining va1ve L Starting air distribution pipe AV Air to the starting air valves M. Ml Pressure gauge S Clearance (approx. 2 mm)
I
i
D • 6 ~;;+;;;;;~':#=~~=+S ,VAF',,~
-~--------
15
r
15
1~~~"J=-16
17
4 3
C
18
r
25
von Hand geschlossen
CLOSED BY HAND \.~--===---I-"*=f--Automat \... \-~===4 26 AUTOMATIC von Hand geoffnet /'*=--~--iI=:±:..::r--.. --=7
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r
p
,
I I
I
2~.
OPENED BY HAND
,, ,
0-107.197.033
,
gezeichnet fur RT58 DRAWN FOR RT58
432/1a
RT
The starting air shut-off valve r,as to be dismantled periodically for cleaning and inspection. When
necessary,regrind the valve seats of the non-return and shut-off valve. The threaded bush must first
be unscrewed if the shut-off valve body 6 is to be released from the spindle 21 to do this. Prior to
reassembly of the spindle, thoroughly degrease the thread in the shut-off valve body as well as that
in the threaded bush and smear them with LOCTITE HV 77. Insert the spindle and fully tighten down the
threaded bush.
Corroded springs have to be replaced.
During assembly, other parts have to be liberally coated with molybdinium sulphide. A function check has to be made after assembly and following safety precautions have to be taken: - The engine must be completely assembled, ready to start and the turning gear must be in (gear teeth
di sengaged.)
- No persons or obstacles whatsoever may be near the flywheel, the drive shaft or especially the pro
peller.
During the function check, the reversing lever in the control desk must remain in the 'STOP' position and the starting button must not be pushed. Initial Position Stop valves on starting air receivers are closed. Shut-off valve for starting air is in the position'closed by hand'. Checks a) Tightness Open stop valve of a starting air receiver and check whether the shut-off valve is tight, i.e. no pressure is shown on the pressure gauge 'M' or no air escapes from there with the discharge valve 'EI open. b) Openi ng by ,Hand Open shut-off valve by means of the hand wheel until the red mark on the spindle is at the position 'opened by hand'. Note wheter the spindle moves easily. When the valve opens, the pressure gauge 'M' shows approximately the same pressure as pressure gauge IM1'. c) Automatic Closing
-----------------
Turn the hand wheel (in closing direction) until the locking latch latches in position "Automatic". In this position, the shut-off valve should be closed automatically by the force of the spring. The pressure on pressure gauge 'M' must drop to zero when the discharge valve 'E' is opened. After closing same, no pressure may build up again. In this position, the valv.e closes positively only if there is a clearance'S' between spindle and val ve body (when new, approx. 2mm). By turning the spindle carefully (in opening direction), the contact with the valve body can be felt. The clearance'S' can thus be determined externally as the clearance of 2 mm corresponds to approximately 3/4 of a turn of the spindle. Should virtually no clearance exist after frequent re-cutting of valve seat and valve body, these parts will have to be replaced during the next overhaul. d) Automatic Opening Opening check valve 'K' has the same effect as opening pilot valve 1. The shut-off valve should open automatically at the same time, i.e. pressure gauge 'M' must show approximately the same pres sure as pressure gauge 'Ml'. Should this be the case, close check valve IKI and open discharge valve 'EI. The starting air distribution pipe 'LI must vent, i.e. the pressure on pressure gauge 1M' must fall to zero. After completion of the checks described, the shut-off valve is to be closed with the hand wheel (position 'closed by hand')
L.B.
2.84
~ ~
SULZER
RUNNING DIRECTION SAFEGUARD
RT
Group:
453
Sheet:
1
Inspection and Function Check
~ey
Tool s:
Various spanners
13
15 16
12
11 10
9 60 17
8
3
2
1 2 3 4 5 6,6a 7 8 9 lD 11 12 13 14 15 16 17 18 19 F Y
to Drawing
Special bolt Dr i vi ng disc Driving wheel Coupling element Housing Bolt bearing Sl eeve Rotary val ve Bo 1t Spring plate Cover Compression spring Spring plate Pointer Split pin Castellated nut Gasket Stop pin Bo lt Sliding faces Air gap
1
II
HI-HI
I
1- 107.195.548
L.B.
2.84
453/1a Oi smantl i nq procedure The running direction safeguard does not need any maintenance in service. HOllever, lie recommend that
it be dismantled during a major overhaul (every 4 years). The co~ponents should be cleaned and checked
for lIear, in particular the sliding faces 'F'.
Roughened sliding faces can possibly be reconditioned by careful polishing. By loosening the oil pipe
connections and the four bolts 19, the complete running direction safeguard can be removed.
For the inspection of the rotating parts proceed as follolls:
Remove the pointer after first knocking out the heavy type dowel pin. - Unscrew the bo 1ts 9 whi ch hol d dOlln the cover 11 and remove thi s along wi th gasket 17. - Pullout the split pin 15 which locates and secures the castellated nut 16 and unscrew the nut. - Remove spring plate 13 and 10 along lIith compression spring 12. - The special bolt 1 can now be knocked out with a couple of light taps on the head end and removed. - Driving disc 2 and coupling element 4 as well as the driving gearwheel 3 between, can nOli be pushed
down from the rotary valve 8.
This dismantled situation makes a complete inspection of the ball bearings 6 and 6a as well as the
coupling element possible.
Hints for Reassembly The parts prepared for reassembly should be oiled slightly, in particular the faces marked 'F'. With
sliding faces overhauled and any sharp edges removed, proceed for reassembly as for dismantling, but
in reverse order. The air gap 'VI must not be 1ess than 2 mm. If it is less, the driving di sc 2 and
the coupling element 4 must be machined to restore the original air gap of 4 mm.
- The two spring plates 13 and 10 are not interchangeable. Fit first the one named 'inner spring plate' 10. The compression spring 12 follows and finally the outer spring plate 13 which is compressed to
the dimension 'X' about 63 mm by tightening the castellated nut 16. Lock with split pin 15.
- Before fitting the cover 11 with gasket 17 on the housing 5, turn the rotary valve 8 with a spanner
(on the castellated nut) several times to and fro. This should be possible without much effort. The
0 rotary valve should allow turning by about 50 from one stop to the other, this can also be checked
on the cover 11 where the mark on the pointer must coincide with the marks on the cover in 'Forward'
and 'Reverse' during the function check.
Function Check After completing the assembly of the running direction safeguard its function should be checked as
fo 11 ows:
The engine (ready to start) has to be turned through one revolution 'Ahead' and 'Astern' with the
turning gear. When doing so, move the reversing lever on the control desk from 'Ahead' to 'Astern'
and back and observe if the shut-down servomotor reacts immediately and if the fuel regulating linka
ge is pulled in the '0' direction when the turning direction of the engine does RQi coincide with the
position of the reversing lever (watch the position of the setting plate positions on the fuel injec
ti on pumps).
If the cut-out servomotor does not immediately move to position '10' although the engine sense of ro tation corresponds to the position of reversing lever, the reasons for this may be that the control air pressure is too low to act against the spring force in the shut-down servomotor.
T •
R.
?,R.1
~
SULZER
SHUT-DOWN SERVOMOTOR
RT
Group:
455
Sheet:
1
Dismantling and Reassembly
Taa1s:
Key to Drawings
Various spanners
1 2 3 4 5 6 7 8 9
Cover Compression spring Cylinder Piston rod Piston Heavy type dowel pin 'Of ring Grooved ring Scraper ring
10 Pin 17 11 Cover 18 12 la' ring 19 20 13 Bolt 14, R'"'d r"bb'~f,r pi,t,o 21 ring sealing 22 l4b, Sliding ring l30x125x3.8 23 24 15 Stud bolt 16 Nut
Flange Tensioning bolt Bolt with lock nut Heavy type dowel pin 3/2-way valve Bo It Bolt Valve plate
II I
19 21
, 11__ 3
15
22
III
2
1
2' 16
1/ 2 Umg. frei
+111 Spannschraubensicherung V
HALF A TURN LOOSE
T
0
~
TENSION BOLT LOCKING r
455/1a
RT
Normally the shut-down servomotor does not need any maintenance. Should, however, considerable leakage
from the pressure chamber be detected, the grooved ring and/or the piston sealing rings must be re
placed. The servomotor piston 5 must be removed to do so.
An inspection of all the internal parts should be carried out during the 4-year survey in any case.
Di smantl i nq Procedure
Shut off control air and vent the piping system.
Release pipe connections to the valve plate 24 and, after removing the four bolts 22, remove the
complete shut-down servomotor from its mounting.
Remove piston 5 and cover 1 with spring 2 together as one unit after unscrewing the four nuts 16.
The spring tensioning bolt 18 remains secured by the tensioning bolt locking arrangement during re
moval of the piston.
Should the spring 2, loaded between piston 5 and cover 1, also have to be released from the latter,
it has to be unloaded with the aid of the tensioning bolt 18 after unscrewing the two bolts 23 and
removing the tensioning bolt locking arrangement.
Note: The bolt 19, predrilled and secured with heavy type dowel pin 20, should not be removed during dismantling. It serves only as a stop and limits the maximum engine power as determined during engine acceptance trials. - Inspect the individual parts after thoroughly cleaning them. - Damaged parts have to be replaced by new ones. Pay particular attention to the parts 7,8,9 and 14 which are subject to wear. Before finally reassembling the shut-down servomotor, lightly oil all its parts. Check without spring that piston with piston rod move freely in the cylinder. Reassembl y - Assembly follows in the same way as dismantling but in reverse order. - The piston is fitted with cover and spring outside the cylinder, the latter pre-tensioned and then pushed into the cylinder. Note: When tensioning the spring, screw in the tensioning bolt 18 up to the end of the thread and then turning it back through about half a turn. Now the tensioning bolt locking arrangement (hexago nal tubel can be fitted. - After connecting up the valve plate and control air pipes, check the function of the shut-down servo motor by filling and venting the control air system several times. - In the,vented condition the shut-down servomotor should bring the fuel pump regulating linkage to Pos. '0'.
T
D
SULZER
Woodward Governor PGA 200
RT
Group:
Installing, Removing and Maintenance Sheet:
Tools:
Key to Illustrations
1 Screwdriver Var. spanners
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
510
1
Governor cover Pneumatic speed control Accumulator Connection / oil to cooler Oil drain plug Adjusting screw for needle valve Connection '2' / oil from booster Knob for manual speed setting Charge air connection Dip stick for checking oil level Governor output shaft Oil filter Cap for overspeed test device Oil filling connection Connection '1' / oil from booster Connection / oil from cooler Connection / oil to booster Oil drain plug Governor drive shaft
07813076-5
Installing and removing the governor on the engine When lifting off the governor or placing it on the engine, care has to be taken to ensure that the splines on the lower end of the governor '-.-/ drive shaft to not get damaged. Furthermore, it must be possible to insert the shaft without jam ming when fitting the governor onto the drive. Pipes and linkages must be connected up with out stressing them. When the governor, oil cooler and booster are separated from each other, care has to be ta ken to prevent any dirt from entering the oil pipes and their connections.
For checking The governor positions '0' and '8' must be checked immediately after connecting the fuel pump linkage to the governor; They must absolutely correspond to the positions on the control plate on the fuel injection pump. the V.LT. indicator must then stand in position '0'.
L.B.
7.86
510/1a
RT
Maintenance Information about maintenance work, mainte nance intervals and repairs can be gained from the WOODWARD bulletin which is supplied separately with the governor. Repairs on the governor should be carried out by WOODWARD experts only (or by specially trained personnel). It is, therefore, advisable to keep on board a complete spare governor, carefully adjusted to suit the engine, which al lows immediate replacement if necessary. The defective governor should be returned to a WOODWARD service agency for repair. It is imperative that a copy of the governor adjust ment records of the engine be handed to the agency as the governor will have to be re-ad justed according to these records.
18
19
0781 3076-7
Oil change Under favorable service conditions, the oil can remain in the governor for 6 months (approx. 3000 hours) or even more. Should, however, the oil become blackish or show signs of aging, it must be changed immediately. The used oil of the governor must be drained when hot by unscrewing the oil drain plugs 5 and 18 with the engine s top p e d. The oil in the oil cooler as well as in the booster must also be drained. Where an oil filter is fitted (governor with charging protection), remove the screw up on the housing 12 and withdraw the filter element. This should be sloshed about in paraffin or clean fuel and then gently blown out with compressed air. Replace the filter straight away since it is essential that it be in place when carrying out --- the following flushing procedure.
"'----'
iA
1986
510/1b
RT
Thereafter, make ready the same amount of clean flushing oil, of ~hich approx. 6 1/4 litres are poured in at oil filling connection 14. Now run the engine for 5-10 minutes at low revolutions.Since the oil can onl~ reach the cooler and booster when the governor is ~orking, the oil level will sink shortly after the engine has been star ted. The remaining oil must therefore be added in stages. At the same time, observe the level on the dip stick to see if the oil level is up to the mark 'Full '. Top up with more oil as necessary. During the short running time, the speed of the engine is to be changed frequently so that the gover nor is worked. Afterwards drain off the flushing oil in the same way as the old oil from the governor, oil cooler and booster. After flushing has been completed, fill the system with new, filtered oil (for oil specification, see WOODWARD bulletin 25007). Filling with new oil and putting the governor back into service is done the same way as described at the start of this section. Venting Oil System and Adjusting Needle Valve When starting up the governor for the first time and after every oil change, the oil system of the governor must be vented as follows: Start up the engine and run at low speed, at the same time unscrewing the adjusting screw of needle valve6 anti-clockwise by a few turns. This should cause the engine to hunt and thus force the go vernor to work. - Should opening the needle valve not cause the engine to hunt, this must be done by displacing the speed adjusting lever on the control desk. Slowly close the needle valve little by little until the point is reached where the engine ceases to hunt. The correct needle valve~position depends on engine characteristics. In principle, the needle valve should be open as far as possible to avoid sludge built-up. It should, however, not be opened by more than approx. 1/16 to 2 turns to ensure steady operation of the governor. Under no curcumstan ces may the needle valve be screwed completely tight; the governor could never work satisfactorily in this condition. Governor Maintenance Where a spare governor is kept for the installation, a check should be made at least annually to see that it is stored upright and that it is filled with rust protective oil to the mark on the dip stick.
(,
0
,
~
01
SULZER
DFVICE Maintenance, Function Check S~FETY CUT-OL~
RT
Group:
530
Sheet:
1
Key to Drawings Var. spanners
1 2 3a 3b 3c 3d 4 5 6 7 8 9
7
Cut-out yoke guide '0 1 rings Round rubber ring }fOr piston Sliding ring sealing Round rubber ring }fOr rod Sliding ring sealing Compression spring Castellated nut with split pin Cover Cover plate Screwed rod with nut Cylinder (upper)
10
Piston
11 12 13 14 15 16 17 18 19 K L St
3/2-way sol enoid val ve Valve plate Intermediate piece Cylinder (lower) Pull rod Fuel pump body Guide bush Cut-out yoke Piston underside Air supply chamber Control air pipe
~ush
8
10 K
11 12 13 St
14 L
:/'5 16
17
18
~s a rule the safety cut-out device requires no maintenance. Should, however, excessive air leakage from either the air supply chamber 'L' or from space 'K' (piston underside) be detected, the defective '0' rings, pi stan or rod sealing rings must be replaced by new ones. As opposed to the other parts of the air cylinder, the pull rod 16 can only be re moved from below. The fuel injection pump block must first be lifted. Before starting any maintenance work which may be necessary, fully release the control air pressure, vent the system and disconnect the control air pipe 'St' from the valve plate. When the air cylinder is being dismantled, all the parts of this unit have to be cleaned and their condition checked. If the compression spring is corroded it must be replaced.
Lightly oil the cleaned parts prior to assem bly. A function check has to be carried out after assembly and after putting the control air system under pressure. Operate the electri cal emergency stop button 5.25 (see the Sche matic Layout of the Engine Control System, Groups 400-20 and 530 of the Service Instruc tions Manual). As a result, the cut-out yoke will be pulled up to its stop on the under side of the fuel pump body, Warning! Never press the emergency stop but ton as long as work is being done with either the hands or tools on the underside of the fuel pump body.
1-107.195545
L. ~.
2.84
SULZER
RT
FUEL INJECTION PUMPS Setting and Checking the Control with V.I.T. (Variable Injection Timing)
551
Sheet:
1
Key to Illustrations
Too 1s:
94534 1 Tensioning tube 94552 1 Device for measuring 2 Devices for measuring 94554 94555 3 Special spanners 94557 2 Special spanners 94559 1 Torque wrench w.h~x.pl ug spanner and extension 94561 1 ~ithdrawing device 94564 1 Wi thdrawing devi ce 94571 1 Special spanner 94581 1 Ci rcul ar di sc 1 Grease gun
Important! Before starting preliminary measures to carry out chec king and setting work on the fuel injection pumps, the en gine must be changed over to Diesel fuel before shutting it down!
A) 0 ire c t ion san d
Group:
VIT indicator Clamp screw Pointer to setting shield Graduation to item 30 Load indicator Speed governor Regul ating linkage to suc tion valve Regulating linkage to spill va 1 ve Setting cam of curve seg men t Spacer Screws Spacer Nut Puller rod Disc Safety gri p Setting screw Fuel 1ever Shut-down servomotor Fuel inlet To the injection valves Fue 1 return Spill valve to pump 1 Spill valve to pump 2 Pressure valve to pump 1 Pressure valve to pump 2 Suction valve to pump 1 Suction valve to pump 2 K Hand 1ever
28a 1 Spill valve seat 29 2 Valve seats for suction/ 30 delivery valves 31 3 Relif valve 32 It Indicator to relief valve 33 5 Hand grip to manual shut-down 6/6a Pressure nipple (long) & (short) 34 8 Push rod with guide bush 35 9 Cover 10 Pin (short) 36 11 Pin (long) Compression spring 12 70 13 Compression spring 71 14 Plunger and 72 14a Pl unger gui de 73 15 Waisted screw 74 16 Speci a1 screw 74a 17 Stepped throttle 75 18 Connectors 19 Fue 1 pump body 76 20 Double nipple 3. 12 21 Orai n screw 6.03 E 22 Threaded pl ug P 23 Threaded plug 24 Regulating tappet R 25 . Shut-o ff valve Ul U2 26 Sh~t-off val ve 28 Injeciion start setting lever 01 02 Sl 52
perm iss i b1e
0 e v i a t ion s
The correct adjustment of the fuel injection pump control is extremely important. Cha~ges to the ef
fective delivery strokes may only be attempted when on occasion of checks, unadmissible deviations
from the recorded data of the timing records are established.
The timing records which will be often mentioned in this description are handed over to the customer
together with the test protocol.
a) Replacement of parts When parts of the fuel injection pumps (f.i.pumps for short) are being replaced, which influence the fuel injection control in any way, then the f.i. pump controls must be checked and if necessary re-set in compliance with the values of the timing records. b} Cut-out Checks In order to ensure that the engine can be shut-down at any time and 'can never' run away' respecti vely the various cut-out checks must be carried out after the engine has been set anew. (See para grap h 'E I ) • c) Setting Data in the Timing Records The decisive setting data of the fuel injection pumps and fuel cams are established for a speci
fied setting dial position and entered in the timing records.
These are: Idl e stroke. begin of injection/total stroke. end of injection
The effective plunger stroke entered in the timing records results by necessity from the idle
stroke and the total stroke.
L. B. L
551 /l a
RT
d) Effective delivery stroke (in mm) The effective delivery stroke is set by modifying the length of the regulatir,g tappet 24 for t~e suction and spill valves. In this manner shortening the regulati"g tappet produces an increase in the effective delivery stroke, and lengthening the regulating tappet produces a reduction in the effective del ivery stroke.
"-"
~~l~~!~~2=!~~=~~2~l~!~~2.!~~~~!=a~=~a~.~.~.2=a~~~~~!~S~=~~.!~~~~~~~~! Equal effecti ve del i very strokes on all f. i .pumps are necessary to obtai n bal anced power outputs on all the cyl i nders; For thi s reason the measured val ues of the i ndi vi dual f. i. pumps have to be com pared with each other. The maximum admissible deviation between the biggest and the smallest effective delivery stroke on individual cylinders is O,2mm, and the deviation of the effective delivery stroke to the values in the timing records should not exceed ~ O,lmm. e) Beqin of Injection The begin of injection (~ljJ II n---================-----
L.B.
2.84
660/1a
RT
The system required uses the spray nozzles built into the air duct 2 together with a cleaning plant.
The latter does not form part of the standard equipment of the engine. The plant consists of a
collecting tank for the cleaning agent, a circulating pump, a suction filter as well as the necessary
piping.
Cleaning Procedure
Open both the outer hinged covers 8 in the charge air receiver floor next to the air coolers and leave
them open throughout the cooler cleaning process.
- Fill the collecting tank of the cleaning plant with cleaning fluid.
- Close shut-off cocks 9 and 13 and open 12.
- Separate the fresh water supply pipe just after the shut-off cock from connectionQVand connect up
the pipe(Din its place. - Open shut-off cocks 5 and 4, 6 must be closed. Spray cleaning fluid with the cleaning plant's pump through the nozzle system (built into the air duct above the cooler). The spraying time depends on the degree to which the cooler is fouled. - The cleaning fluid flows through pipe~back into the collecting tank of the cleaning plant. - After stopping the circulating pump, separate the cleaning fluid supply pipe after the shut-off cock 5 and connect up the fresh water supply pipe(!)in its place. - Close shut-off cock 12 and open 13. - Open shut-off cock 5 and flush the cooler through with fresh water for a few minutes. - Put all the shut-offs which were set for the cleaning process back into their positions for normal service, i.e. close items 5,4 & 13 and open shut-off cock 9. - Before closing the hinged covers 8, check the degree of fouling of the water separating elements 14. Note: Should it no longer be possible to clean the charge air cooler by this method due to stubborn fouling it has to be removed (for removal see 660/3). Cooler Cleaning Plant Maintenance All the filters in the cleaning plant hoye to be cleaned periodically. The filter 3 must be cleaned after every "cleaning at standstill". The correct functioning of the spray nozzles can be checked when the engine is at a standstill by opening the inspection covers on the air duct before the cooler.
L ••
2.84
SULZER
CHARGE AIR COOLER Cleaning (Water Side) with Engine at Standstill
RT
Tools:
Group:
660
Sheet:
2
Key to Drawings
Compressed air Tube cleaning brushes
Various spanners
2 3
4 5 6 7 S/Sa 9 10 11 11 a
12
Cover with connections for water inlet and outlet Jo in t Round rubber Bolt
Sealing flange Cooler hausing Side wall Bolts for cover Cooler tubes Cooler tube fins Tube end plates Bolt
Joint
13 Flow-reversing cover
Joint
Air duct before cooler Inspection cover
Charge air receiver
14 15 16 17
A Cooling water outlet E Cooling water inlet G Drain connection l Vent connection M Measuring connection for pressure before/after cooler R Connection for chemical cleaning agent
The frequency with which the cooler tubes have to be cleaned, depends on the cleanliness of the cooling water used. The necessity for cleaning can be established by measuring either the differential pressure or the temperature difference between cooling water inlet and outlet (compare with figures for clean cooler). When using clean, neutralised cooling water, cleaning of the cooler tubes will rarely be necessary.
15 16
ur
I
1
4~
ii
lH
-
f-- - I - - .
j,,!~
b
/
E
M
L 13
H
1J7
\
1
G +-+
L
.
,.
3-107.197.036
17
gezeichnet fur RT 58 DRAWN FOR RT 58
G
1-107132. 796
tr Cleaning Methods 1--'....
10
2-t-~h~.
9
13
Cleaning can be done mechanically, hydrauli cally or chemically. a) Mechanical Cleaning with Cooler Installed
-----------------------------------------
B ---4_..J..I''o" '--It
After removing the covers 1 and 13, loosen the dirt with a special tube-cleaning brush and remove by flushing with water.
3 0-107. 073.344
4 5
L.B.
6
6 14 11
110
5.84
PeT
660/2a b) Hydraulic Cleaning with Cooler Installed
In case the deposits cannot be removed with brushing, use a high-pressure water-jet instead. Use spraying apparatus with special nozzles which can be ordered from the cooler manufacturers. c) ~~:~~:~~_~~:~~~~2_~~!~_~~~~:~_~!~:~_~:~~~:~ (for removal, see 550/3) Should the previous cleaning methods not have proved successful, chemical cleaning has to be adop ted. The tube stack is immersed into a bath of cleaning agent - immersion time depends on the degree of fouling - and then flushed with a powerful water-jet. The effect of the cleaning process can be increased and the cleaning time shortened by circulating the cleaning agent. The cleaning instructions from the cleaning agent manufacturers must be strictly followed. Regarding the choice of cleaning agent, we recommend that only products of reputable firms in this field be used, e.g. products from: DRW, VECOM, GAMLEN, HENKEL, etc. Locating and Plugging of Leaking Cooler whilst the Engine is Running In case of tube leakage due to corrosion or mechanical damage, cooling water (on board ship, usual ly sea-water) enters the charge air duct or even the charge air receiver, which is highly undesi rable. I
Leaking tubes can be located and plugged as follows:
~
0
0
- Reduce engine load until the air temperature after blower is approx. 65 _70 C. Close water shut off valves before and after the defective cooler and drain cooler. Remove side covers 1 and 13 and close the tube openings on one side of the cooler with cardboard or simi 1ar. On the opposite side of the cooler, pass a lit candle closely past the tube openings and observe the flame. - With a defective tube the flame will flicker or even go out. The cooler tube in question will then have to be plugged on both ends by driving in well-fitting, slightly tapered plugs (hard wood, copper, etc.). (I nstead of a candl e, hi ghl y concentrated soapy water may be used to locate 1eaki ng tubes. Brush the soapy water over the tube ends and watch for the formation of soap bubbles, which would indica te leakage). Cooler tubes thus plugged will have to be replaced at the next opportunity according to the cooler manufacturers' instructions. Transport of Cooler Inserts Th~
specially designed swivel-type lifting eyes "T" are always to be used for transport purposes. Suitable shackles are to be employed in such cases where holes only are provided. It is advisable that the finned tubes be covered during transport or storage in order to protect the cooling fins and to prevent damaging foreign matter from entering.
/ /
::".B.
A // \'\ /
/
." \ "'\
2.84
SULZER
RT76
SCAVENGE AIR COOLER Removing and fitting the Cooler Stack
Sheet:
3
Key to Illustrations
Tools: Shi Hi ng devi ce consi sti ng of: Roller plate Plate w. screws Support w. roller Eye screw
Group:660
1 2 3 4 5 6 7 8,8a 9 10 11 11a
94661 94662 94663/a 94664 94667
Cover Gasket Rubber ring Screw Sealing flange Cooler casing Side wall Screws f. cover Cooler tubes Cooling fins Tube plate Screw
12 Gasket 13 Flow reversing cover 14 Gasket K S T U
La tch Set screw Transport strap Flow reversal si de II' Water in- and outlet X Locking stop
The removal of a cooler stack has to be done always on the side opposite the water connections for inlet and outlet. The walk-way supports carry rails, on which the cooler stack can be rolled out. For the shifting of the cooler stack the shifting device 94661 has to be used. The sea water pumps have to be stopped and the coolers drained. Then proceed as follows:
w
1-~'
13
2 8--+--1
3
~~~~;j7 0-107. 073.344
5
6
6 14
110
Removal Loosen and remove all the screws fastening the cooling water inlet and outlet pipes to the cover 1. (Fig. 'AI). - Loosen and remove all the screws 4 and remove seal ing flange 5 and rubber ring 3 (Fig. IA'). - Loosen and remove all the screws
ill on the flow reversing side 'u' (see Fig. 'AI).
- Fit the roller plate 94662 to the flow reversing cover 13. The rollers must rest firmly on the rails, adjust the roller plate accordingly with the set screws'S' (see Fig. 'C'). - Using jack screws, loosen the tube plate 11 from the cooler casing 6. As soon as the cooler stack is free, i.e. has come off the gasket 14, adjust the set screws 'SI in such a way that the cooler stack in the casing. ,
0 I)
RT58,68,76
660/3a
- Fit the roller support 94664 in as shown on Fig. 'B' for the alternative which applies and attach a rope to the eye bolt in the roller plate, which is connected to the crane through the roller support. Pull the stack out of the housing with wire rope and crane until link 'K' contacts stop 'X' (Fig. 'C I).
- Flip up the four transport brackets 'T' of the stack, or, where not fitted, fit suitable shackles in the available lifting holes and use these to sling the cooler stack with wire ropes from the crane (Fig. 'BI). Loosen link completely.
'K'
and move the tube stack, which is hanging from the crane, out of the cooler housing
Fitting - Fix plate 94663 (a) onto cover 1 of the tube stack and screw eye bolt 94667 into the plate (Fig.
, C' ) •
- By means of the crane, place the cooler stack onto the rails.
- Fit roller support 94664 on the platform beam on the water connection side as shown - Loosen rope from the crane, flap down the transport-straps
on Fig. 'B'.
'T' or remove the shackles.
- Turn locating screws'S' to lift the tube stack slightly in the casing.
- Loosen latch 'K' from its catch and pull with the crane on the rope above the roller support until
the cooler tube stack is fully inserted. - Fit bolts lla (Fig. fu 11 y.
'A') and tighten lightly. Now remove roller plate 94662 and tighten the bolts
Remove plate 94663 (a) and fit rubber ring 3 as well as sealing flange 5 and fasten with the bolts
4 (Fig. 'A' and 'B').
- Connect pipes, shut drain cock on the cooler tube stack and open vent.
- Start up sea-water pumps and check cooler for possible leaks.
L.B.
12.84
"-"
660/3b
RT76
®
Ausbau 1,+7 Zyl. gezeichnet fur I, Zyl. DISMANTLING 1,+7 CYL. DRAWN FOR I, CYL.
-+-'1+: iI-'--'-'-'-'-'
.........
Ausbau 7+ 12 Zyl. gezeichnet fur 7 Zyl. DISMANTLING 7-:-12 CYL. DRAWN FOR 7 CYL.
~
tl~~.~~)-J~)~)~~<
In addition 8 pins (ex changeable) for interme diate gear wheel for the P.T.O.-transmission (if provided) Inside mic rometer, see 94l0la. 94412
1 Tightening device for the gear wheel on the crankshaft, consisting of:
944l2a
1 Socket spanner
X = 634 mm, AF70 X = 798 mm, AF80 X = 824 mm, AF85 X = 930 mm, AF95
944l2b
944l2c
1 Spanner
X = 235 X = 370 X = 405 X = 541
mm, mm, mm, mm,
1 Plate with X = 450 mm X = 507 mm X = 560 mm X = 584 mm
AF70 AFSO AF85 AF'35
(RT58)
(RT68)
(RT76) (RT84)
(RT58)
(RT68)
(RT76)
(RT84)
x
/'
/
....
X
2 pins
(RT58)
(RT68)
(RT76)
(RT84)
11.84
List of Tools for RT Engines (L.B.)
Code No.
Description and application
Sketch
940-27a
1 Device for removal and
fitting of a fuel cam
comprising:
94416
1 Retaining stirrup 740 mm (RT 58)
910 mm (RT 68)
890 mm (RT 76)
H2O mm (RT 84)
X X X X
X
94417
1 Lifting device X X X X
94417a
= 768 = 878 = 966 = 1060
mm mm mm mm
(RT (RT (RT (RT
58)
68)
76)
84)
In addi tion:
2 pins x
94418
1 Support X X X X
94419
= =
550 650 700 780
mm mm mm mm
(RT (RT (RT (RT
58) 68) 76) 84)
,
..II
/ X
1 Clamping bolt X X X X
=
55 55 65 65
mm mm mm mm
(RT (RT (RT (RT
58)
68)
76)
84)
1984
List of Tools for RT76 Engines Code No.
Description and application
Sketch
940-28
94420
2 Holding stirrups to block the camshaft driv ing gear wheel
94421
Mounting device for re moving and fitting the camshaft driving gear wheel on its shaft jour nals, consisting of: 2 Supports 2 Screws 'a' 2 Screws 'b'
94422
2 Holding straps for blocking a camshaft section
= cc cc
94423
Mounting device for re moving or fitting a cam shaft section, consistin of: 2 Supports 2 Nuts 'a'
1984
Tool List for RT Engines (L.B.)
Code No.
94424
Description and application
Sketch
940-29
1 Jack. Tool for pulling all the press fits into camshaft X
400 mm (RT58)
X
479 mm (RT68)
X
510 mm (RT76)
X
540 mm (RT84)
M14xl,5
94425
94425
94426
1 Connecting piece for pulling the press fits onto camshaft M 14xl,5 co
o
94426
1 Connecting piece for pulling the press fits onto camshaft X
= 210
M16xl,5
mm (RT58)
X
233 mm (RT68)
X
233 mm (RT76)
M14xl,5
94427
1 Connecting piece for settling the fuel and actuator cams
III 22xl,5
1. 1 . _ .
-
-
138
---41-1
5.84
Code No.
94428
Tool List Description and application
(L.B. )
Sketch
1 Centering disc for posi tioning the jacking tool 94424 on the camshaft when pulling on a flange coupling of the balancer or torsional vibration damper X 230 X 270 X = 300 330 X
mm mm mm mm
><
(RT58) (RT68) (RT76) (RT84)
,eOO 94429
1 Hose pipe (1500) bar
94430
1 Device for cutting out an actuating pump (1 off per pump)
94431
1 Suspension strap for the actuator cam and the fuel cam with 1 screw
94432
1 Gauge for setting the cams X 390 mm X = 450 mm 510 mm X 545 mm X
(RT58) (RT68) (RT76) (RT84)
I I
i
_ i
:d
I
I
I
1/ 11.84
Tool List for RT Engines (L.B.) Code No. 94451
Description and application
Sketch
940-30a
1 Extracting device for starting control pilot valve bush comprising:
c
a) 1 Flange b) 4 Threaded bolts M12 c) 1 Jacking screw
I
.
~
94461
1 Pressure Gauge applian ce Logic Box
114---....... ..,1
a
a) Pressure Gauge
63 0 + 10 bar
o
b) Minimess-Pressure Gauge Connection
b
c) Minimess-High Pressu re Hose L 400 d) Hex. Head Screw
Driver
1985
Tool List for RT Engines (L.B.) Code No.
94534
94551
Description and application
Sketch
940-31
1 Spacing tube to hold the shut-down servomo tor in its service po sition when adjusting the regulating linkage (when no control air is available)
190
1 Spanner for backing
union of the guide bush of the fuel injection pumps X X X X
94552
= 610 = 610 = 625 = 625
mm mm mm mm
(RT58)
(RT68)
(RT76)
(RT84)
1 Device for measuring the plunger stroke of the fuel injection pumps incl. 2 bolts
94554
2 Devices for measuring
the stroke of the fuel
injection pump suction and spill valves
\
:
l----330~
incl. 2 bolts each
5.85
Tool List for HT Engines (L.B.) Code No.
Description and application
940-32
94555
3 Special spanners for setting the fuel lnJec tion pump suction and spill valves
94556
1 Special ring spanner for
Sketch
fuel injection pump re lief valve L = 250 HT 76 a. 84
L = 350 RT 58 a. 68
94557
2 Special spanners for setting the fuel injec
tion pump suction and
spill valves
94558
3 Spacers for laying unde
1------ L
,
the push rode of the fuel injection pump suc tion valves (fuel charg reduction)
94559
94560
1 Torque wrench with hex. socket and extension fo tightening the bolts of the fuel injection pump valve covers
RI 'R =_.L....- - - 8
~lEo=====::r)I!iN:IOWl~s:Jee.fiiI'lJ]J
1 Blocking device for ec
centric shaft (1 off each per pump block, fo fitting and transport)
x
490 mm (RT58) 520 mm (RT68) 540 mm (RT76)
X= X= X = 580 mm (RT84)
x
11.84
Tool List for RT Engines (L.B.) Code No.
Description and application
940-33
94561
1 Withdrawing device for seats of fuel injection pump spill valves (for 7 mm bore)
94564
1 Withdrawing device for suction and delivery valve seats of fuel in jection pump (for 8 mm bore)
94565
1 Centering ring for lap ping cylinder tToor"'No.
Sketch
94567)
94566
1 Lapping cylinder for
108
sealing faces on fuel injection pump body (for valve covers)
94567
1 Lapping cylinder for
sealing faces of fuel injection pump valve covers
... 80
94571
1 Wrench for backing
union of fuel injec tion pump valves
94572
1 Adjusting device for the static pressure regulating valves
5.84
List of Tools for RT -Engines(L.B.) Code No.
94645
Description and application
940-34
Sketch
1 Plug spanner for dis-
mantling and assembling the valve groups in the scavenge air receiver
Cl Lr>
= = Lr> c.o
o-
0-
n:- c:::
.. ..
en
<
I
(RT58) (RT68) (RT76) (RT84)
~
~
;
><
~
X
I'""!" ~
"'-'
94185
1 Leaf spring for screw ing on the lower tie
rod nut
X X X X
= 720 = 815 = 760 =1025
mm mm mm mm
(RT58) (RT68) (RT76) (RT84)
,
,
-j L:
"
X
8.84
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