WÄRTSILÄ RT-flex50-D Manuals

Manuals and User Guides for WÄRTSILÄ RT-flex50-D. We have 1 WÄRTSILÄ RT-flex50-D manual available for free PDF download: Maintenance Manual

WÄRTSILÄ RT-flex50-D Maintenance Manual

WÄRTSILÄ RT-flex50-D Maintenance Manual (523 pages)

Brand: WÄRTSILÄ | Category: Engine | Size: 19.67 MB

Table of Contents

Index
3
Table of Contents
5
General Information Contents
5
For Particular Attention
7
Preface
9
Table of Contents
11
General
17
- Engine Numbering and Designations
  17
- General Arrangement with One Turbocharger
  17
- General Arrangement with Two Turbochargers
  18
- Flex Parts
  19
- Overview
  21
- Safety Measures and Warnings
  21
- General Guidelines for Maintenance
  21
- Precautionary Measures before Beginning of Maintenance Work
  22
- Special Safety Measures
  23
- Recommendations for Performing Work
  23
- General Guidelines for Lifting Tools
  25
- Attachment Elements
  25
- RUD-Eye Bolts and RUD-Swivel Lugs
  26
- Lifting Capacity
  26
- Remarks on the Use of RUD-Eye Bolts
  27
- Remarks on the Use of RUD-Swivel Lugs
  28
- Shackles
  28
- Attaching and Disconnecting
  29
- Distribution of Load
  29
- Angle of Strand
  29
- Clearance Table
  31
Crankshaft and Thrust Bearing
32
- Crankshaft and Main Bearing
  34
- Crosshead Guide
  36
- Cylinder Liner
  38
- Piston Rod Gland
  40
- Exhaust Valve
  42
- Top and Bottom End Bearings to Connecting Rod
  44
- Piston Cooling and Crosshead Lubrication
  46
- Piston and Piston Rings
  48
- Driving Wheels for Supply Unit
  50
- Supply Unit
  52
- Fuel Pump
  54
- Tightening Values of Important Screwed Connections
  57
- Lifting Gear for Cylinder Liner
  63
- Engine Stay
  63
- Fuel Rail
  67
- Servo Oil Rail
  69
- Crank Angle Sensor Unit
  71
- Connecting Unit to Crank Angle Sensor Unit
  71
- Lifting Tool for Rail Unit
  72
- Arrangement of Blank Flanges
  72
- Tightening Values of Standard Screwed Connections
  73
- Standard Screws
  73
- Waisted Studs
  74
- Tightening Torque for Waisted Studs
  74
- Masses (Weights)
  75
- Individual Components Per Piece in Kg
  75
- O-Rings and Round Rubber Rings
  79
- Dimensions
  79
- Piston and Rod Seal Rings
  83
- Un-Slotted Back-Up Rings
  84
- Material Specification
  84
- Maintenance Schedule
  87
- Inspection and Overhaul Intervals
  87
- Engine Control System WECS
  93
- Engine Cross Section and Longitudinal Section
  95
- Bedplate and Tie Rod
  97
- Main Bearing
  97
- Thrust Bearing
  97
- Key to Illustrations
  99
- Tools
  99
- Checking the Foundation Bolts
  99
- Bedplate and Thrust Bearing
  99
- Checking the Pre-Tension
  100
- Loosening the Foundation Bolts
  101
- Tensioning the Foundation Bolts
  101
- Loosening and Tensioning of Waisted Studs
  103
- Set-Up of Double Pre-Tensioning Jacks
  103
- Loosening the Waisted Studs
  104
- Tensioning the Waisted Studs
  105
Crankshaft and Main Bearing
105
Cylinder Liner
143
Piston Rod Gland
167
- Removing, Dismantling and Assembling
  168
- Assembling a Gland
  170
- Cylinder Cover
  173
- Removal of Cylinder Cover
  173
- Fitting of Cylinder Cover
  173
- Removal of Water Guide Jacket
  175
- Fitting of Water Guide Jacket
  175
- Loosening and Tensioning of Cylinder Cover Waisted Studs
  177
- Set-Up of Pre-Tensioning Jacks
  177
- Possible Causes
  179
- Machining of Sealing Face for Injection Valve
  181
- Injection Valve Checking, Dismantling, Assembling and Adjusting
  183
- Physical Characteristics for Test and Calibration Fluid
  183
- Checking an Injection Valve
  184
- Judging an Injection Valve
  185
- Dismantling an Injection Valve
  186
- Assembling an Injection Valve
  186
- Adjusting the Opening Pressure
  188
- Determining of Total Shim Thickness ’H’
  188
- Replacing a Nozzle Tip
  189
- Protecting a Nozzle Tip
  189
- Screwing down the Injection Valve
  190
- Assembling a Spring Cage
  190
- Fitting an Injection Valve in Cylinder Cover
  190
- Starting Valve
  191
- Removal from Cylinder Cover
  191
- Dismantling a Starting Valve
  191
- Grinding-In
  192
- Assembling
  192
- Fitting in Cylinder Cover
  192
- Relief Valve for Cylinder Cover
  195
- Checking Blow-Off Pressure
  195
- Fitting the Relief Valve
  196
Exhaust Valve
197
- Loosening of Waisted Studs
  198
- Transport of Exhaust Valve
  199
- Laying down the Exhaust Valve
  199
- Tensioning of Waisted Studs
  200
- Fitting of Expansion Piece
  201
- Replacement of Waisted Studs
  202
- Studs Fitted in Cylinder Jacket and Cylinder Cover
  202
- Recommended Jointing Compound and Adhesive Primers
  203
- Exhaust Valve Dismantling and Assembling
  205
- Dismantling of Exhaust Valve
  207
- Dismantling of Complete Valve Drive
  207
- Dismantling of Valve Spindle
  207
- Removal of Guide Bush
  208
- Fitting of Guide Bush
  208
- Assembling of Exhaust Valve
  209
- Fitting of Valve Spindle
  209
- Fitting of Valve Stroke Sensor
  210
- Assembling of Valve Drive
  210
- Setting of Damper
  211
- Determining of Total Thickness ’H’ of the Shims
  211
- Checking Filter
  212
- Checking Non-Return Valve
  212
- Blocking of Exhaust Valve
  213
- Replacing and Grinding the Valve Seat
  215
- Removing the Valve Seat
  215
- Fitting the Valve Seat
  216
- Checking the Valve Seat
  219
- Grinding the Seating Surface on the Valve Head
  221
- Crankshaft, Connecting Rod and Piston Contents
  223
- Conditions for Measuring
  225
- Crankshaft
  225
- Checking Crank Deflection
  225
- Measuring Crank Deflection
  225
- Setting the Checking Equipment
  226
- Judging the Measuring
  227
- Vibration Damper
  229
- Taking a Silicone Fluid Sample
  229
- Preparation for Taking a Silicone Fluid Sample
  230
- Taking the Sample
  230
- Sample Containers
  231
- Vibration Damper Inspection
  233
- Axial Damper Dismantling and Assembling
  235
- Turning Gear
  241
- Checking the Toothing
  241
- Recommended Suppliers
  242
- Application Instruction
  242
- Re-Lubrication Intervals
  242
- Crankcase
  243
- Utilization of Working Platform
  243
- Upper Platform
  245
- Arrangement of Lifting Tools
  245
- Continuous Crane Rail
  246
- Connecting Rod
  247
- Loosening and Tensioning the Connecting Rod Studs
  247
- Loosening the Stud of Bottom End Bearing
  248
- Tensioning the Stud of Bottom End Bearing
  249
- Pre-Tensioning Jack Placed for Tensioning
  250
- Pre-Tensioning Jack Placed for Loosening
  250
- Loosening the Stud of Top End Bearing
  250
- Tensioning the Stud of Top End Bearing
  251
- Inspection, Removal and Fitting of Bottom End Bearing
  253
- Lowering the Bearing Cover
  253
- Removal of Bearing Cover
  254
- Removal of Lower Bearing Shell
  254
- Inspection of Upper Bearing Shell
  255
- Removal of Upper Bearing Shell
  255
- Fitting the Bearing Shells
  256
- Inspection, Removal and Fitting of Top End Bearing
  257
- Inspection of Bearing Shell
  257
- Lifting the Crosshead with Piston in Situ
  258
- Lifting the Crosshead with Removed Piston
  260
- Removal of Bearing Shell
  261
- Fitting the Bearing Shell
  262
- Connecting Rod Removal and Fitting
  263
- Swiveling and Removal of Connecting Rod
  267
- Removal of Bearing Cover to Top End Bearing
  271
- Crosshead
  273
- Checking the Clearances
  274
- Fitting the Guide Shoes
  275
- Removal and Fitting of a Crosshead Pin
  277
- Removal of Guide Shoes
  282
- Piston Removal and Fitting
  285
- Loosening the Waisted Studs of Piston Foot Fastening
  285
- Tensioning the Waisted Studs of Piston Foot Fastening
  287
- Adjusting Suspension Device to Crane Hook
  288
- Removal of Piston
  288
- Fitting the Piston
  291
- Leak Test
  292
- Changing the Compression Shims
  293
- Fitting and Removing Compression Shim
  293
- Piston Dismantling and Assembling
  295
- Loosening Waisted Studs of Piston Crown
  296
- Loosening and Tensioning Sequenz
  296
- Tensioning Waisted Studs of Piston Crown
  297
- Dismantling of a Piston
  298
- Assembling of a Piston
  298
- Separating of Piston Crown
  299
- Separating of Piston Skirt
  299
- Causes of Heavy Burn Scars
  301
- Checking Piston Top Surface
  301
- Piston Rings
  303
- Checking Piston Ring Wear
  303
- Removing Piston Rings
  303
- Measuring Piston Rings and Grooves
  303
- Evaluation of Piston Ring Running Surface
  304
- Chrome-Ceramic (CC) Coated Piston Ring
  304
- Running-In Coated (RC) Piston Ring
  304
- Determining Wear of Piston Ring
  304
- Examples
  305
- Reuse of Piston Ring
  305
- Fitting Piston Rings
  306
- Storage and Handling of Piston Rings
  306
- Removal and Fitting of Inside Pipe
  307
Piston Cooling and Crosshead Lubrication
307
- Blank off Oil Inlet Pipe
  308
- Driving Wheels and Shut-Off Valve for Starting Air Contents
  311
- Driving Wheels
  313
- Checking the Running and Backlash Clearances and Condition of Teeth
  313
- Checking the Gear Tooth Backlash
  313
- With Feeler Gauge 94122
  313
- Checking the Running Performance
  314
- Measuring Tooth Backlash with Lead Wire
  314
- Replacing the Gear Wheel on the Crankshaft
  315
- Preparing Assembly of 2-Part Gear Wheel
  316
- Assembly of 2-Part Gear Wheel
  317
- Work Sequence
  317
- Cleaning and Function Check
  321
- Shut-Off Valve for Starting Air
  321
- Initial Position
  323
- Tightness
  323
- Manual Opening
  323
- Automatic Closing
  323
- Automatic Opening
  324
- Supply Unit, Injection and Exhaust Valve Control Contents
  325
- Removal of Servo Oil Pump
  327
Supply Unit
327
- Removal of Pinion
  328
- Removal of Shaft
  328
- Removal of Spray Nozzles
  329
- Removal and Fitting of Camshaft and Bearing Shells
  331
- Numbering of Bearings
  332
- Removal of Bearing Shells
  333
- Removal of Camshaft
  334
- Removal of Supports
  334
- Fitting of Bearings and Camshaft
  336
- Final Assembly
  337
- Application of Torque Amplifier
  338
- Torque Amplifier Applications
  339
- Removing and Fitting the Gear Wheel on Camshaft
  343
- Supply Unit Removal and Fitting
  345
- Lubrication of Supply Unit During Maintenance Works
  349
- Manual Lubrication
  349
- Fuel Pump Dismantling and Assembling
  351
- Removal of a Fuel Pump
  352
- Dismantling of a Fuel Pump
  353
- Removal of Guide Pin
  353
- Removal of Guide Piston
  353
- Removal of Roller
  353
- Removal of Pump Cylinder
  355
- Removal of Regulating Rack
  355
- Assembling of a Fuel Pump
  356
- Fitting the Pump Cover
  356
- Fitting the Pump Cylinder
  356
- Fitting the Pump Plunger and Lower Housing
  357
- Fitting the Regulating Rack
  357
- Fitting the Regulating Sleeve
  357
- Checking the Plunger Position
  358
- Fitting of a Fuel Pump
  359
- Preserving
  359
- Fuel Pressure Control Valve
  361
- Fitting the Fuel Pressure Control Valve
  362
- Removal of Fuel Pressure Control Valve
  362
- Cleaning the Filter
  363
- Storage on Board
  363
- Checking and Setting
  365
- Fuel Overpressure Safety Valve
  365
- Checking the Opening Pressure
  366
- Checking the Sealing Pressure
  366
- Injection Control Unit Removal and Fitting
  367
- Checking the Gas Pre-Charge Pressure
  371
- If Gas Pre-Charge Pressure Is Not Ok
  371
- If Gas Pre-Charge Pressure Is Ok
  371
- Pressure Reducing Valve 8.11−1
  371
- After Checking or Refilling Procedure
  372
- Refilling Procedure
  372
- Refilling the Accumulator
  372
- Arrangement of Equipment
  373
- Case with Measurement Set 94720C for CLU4−C and PRV 8.18−1
  373
- Details of Servo Oil Rail 4.11
  374
- Exhaust Valve Control Unit
  375
- Dismantling and Assembling of Exhaust Valve Control Unit
  377
- Storage and Handling of Exhaust Valve Control Unit
  377
- 5801−1/A1
  379
- Adjusting: with Heinzmann Stg 10-01 Actuator
  379
  - Regulating Linkage Adjusting
    379
  - Adjusting of Regulating Linkage
    380
  - Fitting of Connecting Element
    381
- 5801−1/A2
  383
- Group 6
  385
- Scavenge Air Receiver and Auxiliary Blower Contents
  385
- 6420−1/A1
  387
- Checking the Air Flaps and Cleaning the Scavenge Air Receiver
  387
- Inspection of Air Flaps
  387
- Scavenge Air Receiver
  387
- 6545−1/A1
  389
- Auxiliary Blower Maintenance
  389
- 6606−1/A1
  391
- Scavenge Air Cooler Removal and Fitting
  391
- 6708−1/A1
  399
- Removal and Fitting of Water Separator
  399
- 6735−1/A1
  409
- Dismantling, Function Check
  409
- Scavenge Air Waste Gate Dismantling and Assembling
  409
- Cylinder Lubrication Contents
  411
- Lubrication Pump CLU4−C: Checking the Gas Pre-Charge Pressure
  411
- 7218−1/A2
  413
  - Lubricating Pump CLU4−C
    413
  - Case with Measurement Set 94720C for CLU4−C
    415
  - Lubricating Pump (CLU4−C)
    416
  - Piping Contents
    417
- Piping Group
  417
- 8447−1/A1
  419
- Servo Oil Piping Removing, Fitting and Regrinding
  419
  - Removal of Servo Oil Piping 2
    420
  - Removal of Servo Oil Piping 3
    420
  - Adjusting the Claws
    421
  - Regrinding the Sealing Faces ’DF’
    421
- Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding . . . . 8460−1/A1
  423
- 8733−1/A1
  427
- Fuel Pressure Piping
  427
- Removing, Fitting and Regrinding of Sealing Faces
  427
- 9223−1/A1
  443
- 9403−2/A1
  443
- Crank Angle Sensor Unit, Tools Contents
  443
- Crank Angle Sensor Unit: Dismantling, Assembling and Adjusting
  443
- Hydraulic Jacks and Pumps: Arrangement and Application
  443
- Tools: Explanation
  443
  - Crank Angle Sensor Unit Dismantling, Assembling and Adjusting
    445
  - Outer Shaft Encoder
    446
  - Removal of Shaft Encoder
    446
  - Fitting the Shaft Encoder
    447
  - Inner Shaft Encoder
    447
  - Shaft Encoder
    447
  - Fitting the Toothed Belt
    448
  - Toothed Belt Loose
    449
  - Toothed Belt Tension
    449
  - Final Works
    450
  - Rechecking of Toothed Belt Tension
    450
  - Toothed Belt Change
    450
  - Adjustment of Crank Angle Offset in WECS
    451
  - Removal of Crank Angle Sensor Drive
    452
  - Dismantling the Crank Angle Sensor Drive
    453
  - Parts to be Removed in the Following Sequence
    454
  - Assembling the Crank Angle Sensor Drive
    455
  - Determining of Thickness ’X’ of Distance Ring 33
    455
  - Completing of the Bearing Housing
    456
  - Sub-Assembly of Bearing Housing
    456
  - Fitting Gear Wheel 18
    457
  - Tightening the Shaft Nut
    457
  - Fitting the Crank Angle Sensor Drive
    458
  - Removal and Fitting of Compression Spring
    459
  - Fitting of the Lever
    460
  - Fitting the Compression Spring
    460
  - Removing the Compression Spring
    460
  - Adjusting the Compression Spring
    461
  - Fitting the Connecting Unit
    461
  - Checks
    462
  - Final Fitting the Crank Angle Sensor Unit
    462
  - Lubricating Oil Flow in the Crank Angle Sensor Drive
    462
  - Checking the Throttle
    463
  - Checking the Shaft Eccentricity
    464
  - Eccentricity Check
    464
  - Checking the Clearance between Shaft and Internal Bearing of the CAS
    465
  - Checking the Toothed Belt Condition
    465
  - Procedure for Measuring the Clearance
    465
  - Reasons for CAS Drive Replacement
    466
  - Replacement of the Toothed Belt
    466
  - Replacement of Toothed Belt or CAS Drive
    466
  - Recommended Special Tools
    467
  - Special Tools Available on Loan
    467
  - Standard Tools
    467
  - Tools Explanation
    467
  - Hydraulic Jacks and Pumps Arrangement and Application
    469
- 9403−3/A1
  473
- Hydraulic Pre-Tensioning Jacks Storing, Servicing and Maintenance
  473
- Storing, Servicing and Maintenance
  473
- General Application Instructions
  483
  - Hydraulic Pre-Tensioning Jacks
    483
  - Working Procedure for Loosening
    483
- 9403−4/A1
  484
- Working Procedure for Tensioning
  484
- Tool List
  485
- 9403−5/A1
  486
- Standard Tools
  487
- Recommended Special Tools
  518
- Special Tools Obtainable on Loan
  521
Special Tools Obtainable on Loan
522

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